CORNELL ENGRI 113 - Water Treatment Plant Design

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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 WellSedimentationOverviewOverviewSafetyCompetition guidelinesTrouble shooting guideHydraulic challengesSurface tensionStartup requirementsRapid Mix/Flocculation/SedimentationParting PointersLaboratory SafetyLaboratory SafetySafety hazardsElectricalChemicalAluminum Sulfate (alum)Buddy SystemDon’t go into any other areas of the environmental laboratoryProfessional behaviorPPE: Safety glasses, lab coatProject 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!)Team WorkTeam WorkThink efficiencyYou 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 scheduleWater Treatment Plant GoalsWater Treatment Plant GoalsBest value (meets EPA turbidity standard with lowest annual cost of production for NYC)Longest continuous operation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 modificationsEPA 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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!TAs will measure the flow rates and the turbidity several times per day and email results to the classEconomicsEconomics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 competitionCompetition 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 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 NYCCalculate the cost of your plantAssign 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 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 NYCWhen it doesn’t work!When it doesn’t work!You are creating a complex systemAny component that fails can lead to failure in the systemHow 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 TroubleshootingThe Scientific method:Clearly identify the problemCreate hypothesesDesign experiments to test the hypothesesDraw conclusions based on the dataHow can you choose which components to test first?Intuition?Ask which component could cause the observed symptomsRequires an understanding of how the system works!Modular ApproachModular ApproachHow can you build a complex system with the greatest probability of ultimate success?Break a system down into its components and test individual piecesOnly add components to the system after the components have been testedBegin with the system as simple as possibleWhat would the simplest operating rules be?Add unit processes one by oneState MachinesState MachinesWhat are the potential states for your water filtration plant?OffDown flowBackwashMedia settleFilter to WastePlant 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 pointTime greater than min set point and Above filter turbidity less than set pointClear well emptyOutput Device ControlOutput Device ControlSome of the controls are either on or off depending on the stateCentrifugal backwash pumpFilter to waste valveSome of the controls have variable settingsAlum pump


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CORNELL ENGRI 113 - Water Treatment Plant Design

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