Monroe L. Weber-Shirk

School of Civil and

Environmental Engineering

WTP ProjectWTP

Project

Safety, Expectations, Economics, LogicSafety, Expectations, Economics, Logic

Raw water To wasteF1

F1

S1

Manual flow control valve

Solenoid valve

Clearwell

To wasteOverflow to waste

S1 S2

S3 S4

S5

F2

Preassembled module

Laboratory SafetyLaboratory Safety

Safety hazardsElectricalChemical

Aluminum Sulfate (alum)

Buddy System Don’t go into any other areas of the environmental

laboratory Professional behavior PPE: Safety glasses, lab coat

Safety hazardsElectricalChemical

Aluminum Sulfate (alum)

Buddy System Don’t go into any other areas of the environmental

laboratory Professional behavior PPE: Safety glasses, lab coat

Project ExpectationsProject Expectations

Spend at least 4 hours per week working on WTP outside of class

Keep an Excel time sheet (time in, time out, task, and weekly totals) for each of you (email weekly on Thursday to Jeff)

Work together as a team and divide up tasks Spend time teaching each other what you are

learning Professional Play! (Have fun!)

Spend at least 4 hours per week working on WTP outside of class

Keep an Excel time sheet (time in, time out, task, and weekly totals) for each of you (email weekly on Thursday to Jeff)

Work together as a team and divide up tasks Spend time teaching each other what you are

learning Professional Play! (Have fun!)

Team WorkTeam Work

Think efficiencyYou can’t all work on the same thing!

Compare your team work to soccer players Don’t bunch up!Give each other permission to experiment with

the plant

Make a project schedule

Think efficiencyYou can’t all work on the same thing!

Compare your team work to soccer players Don’t bunch up!Give each other permission to experiment with

the plant

Make a project schedule

Office HoursOffice Hours

Office hours will be in HO 150 for the rest of the semester

Monday 6:30-8:30 pm (Dale Meck) Tuesday 6:30-8:30 pm (Stephanie Wedekind) Wednesday 6:30-8:30 pm (Jeffrey Shore) Thursday 8:00-10:00 pm (Laura Mar)

Office hours will be in HO 150 for the rest of the semester

Monday 6:30-8:30 pm (Dale Meck) Tuesday 6:30-8:30 pm (Stephanie Wedekind) Wednesday 6:30-8:30 pm (Jeffrey Shore) Thursday 8:00-10:00 pm (Laura Mar)

Water Treatment Plant GoalsWater Treatment Plant Goals

Best value (meets EPA turbidity standard with lowest annual cost of production for NYC)

Longest continuous operation Best user interface (HMI or GUI) Best plant control logic Best plant design Best maintenance plan for cleaning sedimentation

tank and flocculation tank Documentation of experimentation, data analysis,

and appropriate plant modifications

Best value (meets EPA turbidity standard with lowest annual cost of production for NYC)

Longest continuous operation Best user interface (HMI or GUI) Best plant control logic Best plant design Best maintenance plan for cleaning sedimentation

tank and flocculation tank Documentation of experimentation, data analysis,

and appropriate plant modifications

EPA Turbidity StandardsEPA Turbidity Standards

As of January 1, 2002, turbidity may never exceed 1 NTU, and must not exceed 0.3 NTU in 95% of daily samples in any month.

Our requirement will be that the turbidity be less than or equal to 0.3 NTU at all times

Samples will be collected from the clear well several times per day

The [(flow rate at the time of a turbidity violation) x (12 hours)] will be deducted as a penalty from the total plant production Note that if the TAs collect more than 2 samples per day it will be

possible for the penalties to exceed the production!

As of January 1, 2002, turbidity may never exceed 1 NTU, and must not exceed 0.3 NTU in 95% of daily samples in any month.

Our requirement will be that the turbidity be less than or equal to 0.3 NTU at all times

Samples will be collected from the clear well several times per day

The [(flow rate at the time of a turbidity violation) x (12 hours)] will be deducted as a penalty from the total plant production Note that if the TAs collect more than 2 samples per day it will be

possible for the penalties to exceed the production!

EconomicsEconomics

Capital costs Cost of building the various components building Controls and sensors

Operation and Maintenance costs (O&M) Chemicals (alum) Electricity Labor

Both capital and O&M costs contribute to the cost of the water produced

We will only include the capital costs for this competition

Capital costs Cost of building the various components building Controls and sensors

Operation and Maintenance costs (O&M) Chemicals (alum) Electricity Labor

Both capital and O&M costs contribute to the cost of the water produced

We will only include the capital costs for this competition

Competition EconomicsCompetition Economics

We will only include the costs for the processes that you can control

The costs will be scaled as if your plant were full scale

Otherwise the computer, data acquisition system, and control hardware would completely dominate the cost!

The clear well and the flow accumulator will not be included in the economics

We will only include the costs for the processes that you can control

The costs will be scaled as if your plant were full scale

Otherwise the computer, data acquisition system, and control hardware would completely dominate the cost!

The clear well and the flow accumulator will not be included in the economics

Capital Cost Estimates Used for the Competition

Capital Cost Estimates Used for the Competition

Item cost unitfilters 8000 $/m2 surface area of filtergarnet 90 $/m3 volume of garnetsand 20 $/m3 volume of sandanthracite 30 $/m3 volume of anthraciterapid mix tank 5000 $/m3 volume of rapid mix tankflocculation tank 2500 $/m3 volume of flocculation tanksedimentation 2000 $/m3 volume of sedimentation tanklamella 20 $/m2 total surface area of lamella

Item cost unitfilters 8000 $/m2 surface area of filtergarnet 90 $/m3 volume of garnetsand 20 $/m3 volume of sandanthracite 30 $/m3 volume of anthraciterapid mix tank 5000 $/m3 volume of rapid mix tankflocculation tank 2500 $/m3 volume of flocculation tanksedimentation 2000 $/m3 volume of sedimentation tanklamella 20 $/m2 total surface area of lamella

Calculating the cost of water from your plant if applied to NYC

Calculating the cost of water from your plant if applied to NYC

Calculate the cost of your plant Assign cost for 1 week of operation assuming 25

year life Calculate the amount of water produced in the

week of the competition Subtract any water that was produced within 12

hours of a turbidity standard violation Calculate the cost per m3 of water produced Calculate the annual cost for using your process to

provide 60 m3/s to NYC

Calculate the cost of your plant Assign cost for 1 week of operation assuming 25

year life Calculate the amount of water produced in the

week of the competition Subtract any water that was produced within 12

hours of a turbidity standard violation Calculate the cost per m3 of water produced Calculate the annual cost for using your process to

provide 60 m3/s to NYC

Data Collection and ReportingData Collection and Reporting

The process method file must be stored in your folder on the Enviro server

A copy of the process method file must be submitted to mw24 at the beginning of the competition week

Any changes to the process method file during the competition must be submitted to mw24

TAs will measure the flow rates and the turbidity several times per day and email results to the class

Backwash and Filter to waste water may be subtracted to obtain the net production of each plant

The process method file must be stored in your folder on the Enviro server

A copy of the process method file must be submitted to mw24 at the beginning of the competition week

Any changes to the process method file during the competition must be submitted to mw24

TAs will measure the flow rates and the turbidity several times per day and email results to the class

Backwash and Filter to waste water may be subtracted to obtain the net production of each plant

How will your Team Win?How will your Team Win?

Produce the most clean water Keep costs down Efficient use of flocculation/sedimentation tanks Judicious use of filter to waste Only backwash when needed Well designed filter media (donated by US Filter) Document your design process Get your plant running ASAP so you can improve

it before the competition begins.

Produce the most clean water Keep costs down Efficient use of flocculation/sedimentation tanks Judicious use of filter to waste Only backwash when needed Well designed filter media (donated by US Filter) Document your design process Get your plant running ASAP so you can improve

it before the competition begins.

Turbidity SensorsTurbidity Sensors

Turbidity sensors are probably not able to measure less than 1 NTU

They can be used as a guide to help understand how the plant is performing

Use the Hach Turbidimeter to measure effluent samples to see if your water is meeting EPA standards

Turbidity sensors are probably not able to measure less than 1 NTU

They can be used as a guide to help understand how the plant is performing

Use the Hach Turbidimeter to measure effluent samples to see if your water is meeting EPA standards

State MachinesState Machines

What are the potential states for your water filtration plant?OffDown flowBackwashMedia settleFilter to Waste

What are the potential states for your water filtration plant?OffDown flowBackwashMedia settleFilter to Waste

Plant State LogicPlant State Logic

Assume your water treatment plant is currently backwashing.

Under what conditions will the plant switch to a different state?Time greater than max set pointTime greater than min set point and

Above filter turbidity less than set pointClear well empty

Assume your water treatment plant is currently backwashing.

Under what conditions will the plant switch to a different state?Time greater than max set pointTime greater than min set point and

Above filter turbidity less than set pointClear well empty

Output Device ControlOutput Device Control

Some of the controls are either on or off depending on the stateCentrifugal backwash pumpFilter to waste valve

Some of the controls have variable settingsAlum pump rpmFlow control valve

Some of the controls are either on or off depending on the stateCentrifugal backwash pumpFilter to waste valve

Some of the controls have variable settingsAlum pump rpmFlow control valve

Alum pump rpmAlum pump rpm

How might a plant operator want to control the alum pump?Pump rpmAlum stock flow rateAlum mass rateAlum concentration after mixingFully automatic

What inputs are required?

How might a plant operator want to control the alum pump?Pump rpmAlum stock flow rateAlum mass rateAlum concentration after mixingFully automatic

What inputs are required?

Flow Control ValveFlow Control Valve

How should the solenoid valve be controlled?

What role does the flow accumulator play?

What will happen to the flow rate if the valve is opened for a short period of time?

How should the solenoid valve be controlled?

What role does the flow accumulator play?

What will happen to the flow rate if the valve is opened for a short period of time?

Closed loop control logic

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Parting PointersParting Pointers

Hydraulics: water flows from higher potential energy to lower potential energy

Leaks: fix them right away, clean up all spills immediately, keep bench dry, sensors and controls die when wet!

Save configuration files often and keep old versionsSensor configuration (inside calibrator)Rules (inside rule editor)Overall process method (make sure it refers to current

sensor and rules files)

Hydraulics: water flows from higher potential energy to lower potential energy

Leaks: fix them right away, clean up all spills immediately, keep bench dry, sensors and controls die when wet!

Save configuration files often and keep old versionsSensor configuration (inside calibrator)Rules (inside rule editor)Overall process method (make sure it refers to current

sensor and rules files)