James S. McMillen, P.E. Perkins Engineering Consultants, Inc., Arlington, Texas. May 25, 2012

Transcription

1 James S. McMillen, P.E. Perkins Engineering Consultants, Inc., Arlington, Texas May 25, 2012

2 Why are we here? Project Background Blower Technology Owner s Perspective System Integration Wrap Up

3 HST Blowers offer several advantages over MSC Blowers Better Efficiency Wide operating range Ease of installation 3

4 HST Blowers offer several advantages over MSC Blowers Better Efficiency Wide operating range Ease of installation 4

5 HST Blowers offer several advantages over MSC Blowers Better Efficiency Wide operating range Ease of installation Lower noise Highly integrated Lots of unknowns One Owner s experience 5

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7 Grit/Snail Basin to intercept snails from Trickling Filters 7

8 Grit/Snail Basin to intercept snails from Trickling Filters 8

9 Grit/Snail Basin to intercept snails from Trickling Filters 9

10 Grit/Snail Basin to intercept snails from Trickling Filters 10

11 Grit/Snail Basin to intercept snails from Trickling Filters New diffusers & piping for Aeration Basins and Reaeration Basins. 11

12 Grit/Snail Basin to intercept snails from Trickling Filters New diffusers & piping for Aeration Basins and Reaeration Basins. Two new blowers 12

13 Grit/Snail Basin to intercept snails from Trickling Filters New diffusers & piping for Aeration Basins and Reaeration Basins. Two new blowers Fiber optic loop and HMI system integration $2.56M Construction 13

14 Two new blowers Each 5, psig Operate in conjunction with four existing 2,900 cfm blowers which were prone to surge Integrate into plant control system 14

15 Multistage Centrifugal Multiple impellers on a rotating shaft Wide* range of airflows Narrow* range of pressures 50-70% eff. Positive Displacement Lobes mounted on counter-rotating shafts Constant airflow Wide* range of pressures 45-65% eff. *Relatively speaking 15

16 High Speed Turbo Single turbine impeller on a rotating shaft Wide range of airflows (up to 50% turndown) Airfoil bearings (or magnetic) Integral liquid cooling Integral PLC Integral VFD Integral blow off valve Integral controls Integral everything 16

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18 Optimize DO in activated sludge process Reduce energy usage and electrical costs Preserve or reduce current levels of maintenance 18

19 Before: DO read locally at the basins Operator had to manually adjust valve or start second blower Ammonia concerns due to low DO Now: DO feedback ramps blower up or down and adjusts valves Second blower can be brought online automatically No surge 19

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21 QTY Capital 20-Yr Energy NPV High Speed Turbo Blower 2 $352,950 $1,831,486 $2,184,436 MSC Blower A 2 $242,930 $2,990,181 $3,233,111 MSC Blower B 2 $227,500 $2,803,295 $3,030,795 21

22 Before: Clean air filters Rebuild blowers 20 year intervals) Now: Change air filters Replace 2 year intervals Clean hose at pneumatic blow off valve Ask me again in five years 22

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24 Master PLC Individual Aeration Basin Air Valve PID Control HST Blower Speed PID Control based on Air Header Pressure Starting / Stopping of Blowers (HST & MSC) Blower PLC Internal Blower Control Individual Surge Protection Other Safety Devices 24

25 Mode Warm Cold Lead (Primary) Blower Higher Capacity HST Lower Capacity HST Lag 1 (Secondary) Blower First Available MSC Higher Capacity HST Lag 2 (Next) Blower Last Available MSC First Available MSC Operator chooses Warm Mode or Cold Mode Lag 3 (Final) Blower N/A Last Available MSC The two HST blowers are not to run at the same time Cold Mode just sets the starting point in the sequence MSC Blowers can run in parallel with the Higher Capacity HST Blower if needed 25

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28 Noise level of HST blowers is significantly lower than MSC blower HOWEVER, efficient sizing of aeration piping causes it s own set of noise issues Consider noise insulation on air piping or oversizing air piping Duty point can be easily modified by changing out blower core (impeller). Early coordination is key! 28

29 Close coordination with the manufacturer during the design phase is needed Close coordination with the Operator during startup and initial operations is critical Control logic in a hybrid system can take unexpected paths 29

30 James S. McMillen, PE