Water Treatment Plant DesignOverviewLaboratory SafetyProject ExpectationsTeam WorkWater Treatment Plant GoalsEPA Turbidity StandardsEconomicsCompetition EconomicsCapital Cost Estimates Used for the CompetitionCalculating the cost of water from your plant if applied to NYCWhen it doesn’t work!Scientific Method of TroubleshootingModular ApproachState MachinesPlant State LogicOutput Device ControlAlum pump rpmFlow Control ValveHydraulic Challenges (getting the water to go where you want it to go)Simplified WTP SchematicImproved WTPRelative Strength of ForcesOpen Channel Flows: Water and AirLeak and Overflow PreventionPlant LayoutStartup RequirementsPointersOperating CriteriaRapid MixingFlocculation DesignGiven Gq, Q and d, Find Floc Tube LengthTurbidity after Sedimentation Increases with Maximum ShearSedimentation TankHow will your Team Win?Good Engineering?Competition SubmissionParting PointersMonroe L. Weber-Shirk School of Civil and Environmental EngineeringWater Treatment Plant DesignWater Treatment Plant DesignalumalumFlocculationClear WellSedimentationOverviewOverviewSafetyCompetition guidelinesTrouble shooting guideHydraulic challengesSurface tensionStartup requirementsRapid Mix/Flocculation/SedimentationParting PointersLaboratory SafetyLaboratory SafetySafety hazardsElectricalChemicalAluminum Sulfate (alum)Buddy SystemDon’t go into any other areas of the environmental laboratoryProfessional behaviorPPE: Safety glasses, lab coatProject ExpectationsProject ExpectationsSpend at least 4 hours per week working on WTP outside of classKeep 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 tasksSpend time teaching each other what you are learningProfessional Play! (Have fun!)Team WorkTeam WorkThink 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 plantMake a project scheduleWater Treatment Plant GoalsWater Treatment Plant GoalsBest value (meets EPA turbidity standard with lowest annual cost of production for NYC)Longest continuous operationBest plant control logicBest plant designBest maintenance plan for cleaning sedimentation tank and flocculation tankDocumentation of experimentation, data analysis, and appropriate plant modificationsEPA Turbidity StandardsEPA Turbidity StandardsAs 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 timesThe [(flow rate at the time of a turbidity violation) x (12 hours)] will be deducted as a penalty from the total plant productionNote that if the TAs collect more than 2 samples per day it will be possible for the penalties to exceed the production!TAs will measure the flow rates and the turbidity several times per day and email results to the classEconomicsEconomicsCapital costsCost of building the various componentsbuilding Controls and sensorsOperation and Maintenance costs (O&M)Chemicals (alum)ElectricityLaborBoth capital and O&M costs contribute to the cost of the water produced We will only include the capital costs for this competitionCompetition EconomicsCompetition EconomicsWe will only include the costs for the processes that you can controlThe costs will be scaled as if your plant were full scaleOtherwise 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 economicsCapital Cost Estimates Used for the CompetitionCapital Cost Estimates Used for the CompetitionItem cost unitfilters 8000 $/m2surface area of filtergarnet 90 $/m3volume of garnetsand 20 $/m3volume of sandanthracite 30 $/m3volume of anthraciterapid mix tank 5000 $/m3volume of rapid mix tankflocculation tank 2500 $/m3volume of flocculation tanksedimentation 2000 $/m3volume of sedimentation tanklamella 20 $/m2total surface area of lamellaCalculating the cost of water from your plant if applied to NYCCalculating the cost of water from your plant if applied to NYCCalculate the cost of your plantAssign cost for 1 week of operation assuming 25 year life (1/1300th of total capital cost)Calculate the amount of water produced in the week of the competitionSubtract any water that was produced within 12 hours of a turbidity standard violationCalculate the cost per m3 of water producedCalculate the annual cost for using your process to provide 60 m3/s to NYCWhen it doesn’t work!When it doesn’t work!You are creating a complex systemAny component that fails can lead to failure in the systemHow do you identify the source of a problem?Attempt to identify the events that could cause a failure in advanceScientific Method of TroubleshootingScientific Method of TroubleshootingThe Scientific method:Clearly identify the problemCreate hypothesesDesign experiments to test the hypothesesDraw conclusions based on the dataHow can you choose which components to test first?Intuition?Ask which component could cause the observed symptomsRequires an understanding of how the system works!Modular ApproachModular ApproachHow can you build a complex system with the greatest probability of ultimate success?Break a system down into its components and test individual piecesOnly add components to the system after the components have been testedBegin with the system as simple as possibleWhat would the simplest operating rules be?Add unit processes one by oneState MachinesState MachinesWhat are the potential states for your water filtration plant?OffDown flowBackwashMedia settleFilter to WastePlant State LogicPlant State LogicAssume 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 emptyOutput Device ControlOutput Device ControlSome of the controls are either on or off depending on the stateCentrifugal backwash pumpFilter to waste valveSome of the controls have variable settingsAlum pump
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