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TRANSCRIPT
City of Dayton Department of Water-Wastewater
Treatment Division
Process Control Program Overview
October 25, 2012
Session Outline
City of Dayton Water – One Source Brief History of Dayton’s WWTP Liquid/Solids Review Programs, Challenges, and Initiatives PMP Drivers, Contents, Benefits Review of Dayton’s PCP Conclusions Q&A
City of Dayton Water - One Source
http://daytonwater.org/
City of Dayton Water - One Source: Regional, Reliable, Renewable
Rebranding and Marketing Campaign
Designed to Retain and Attract LVWUs
Use Water to Attract Economic Growth
Regional Supplier of Water Services
Extensive PE/PO Campaign
Focus on Internal and External Customers
Water Trailer, New Website, Regional Leadership, and Outreach, Outreach, Outreach
Dayton WWTP Circa 1929
Dayton WWTP Circa 1936
Dayton WWTP Circa 1938
Dayton WWTP Circa 1938
Dayton WWTP Circa 1949
Dayton WWTP Circa 1992
City of Dayton WWTP Design @ 72 MGD - Peak @ 180 MGD
Dayton WWT Division Stats
Startup date: 1929
Service population: 340,000
Number of employees: 70
Design flow: 72 MGD
Average daily flow: 45 MGD
Peak flow: 180 MGD
Annual operating cost: $16M
18 Consecutive Months Without ANY Regulatory Violations!
(while maintaining some of the most competitive rates in the State)
Liquids Process Schematic
Solids Process Schematic
To Ensure Compliant, Efficient, Cost-Effective Operations…
I. Performance Measurement Program— • Program designed to define, promote, and track
Divisional progress as it relates to Departmental Goals • Areas of focus are: regulatory compliance, employee
development, customer service, fiscal responsibility, relation building/employee engagement, service capacity and delivery, innovation and sustainability, public education and outreach
II. Process Control Program— • Today’s featured program…
Challenges Facing Dayton WWT…
Facility Age and Capacity— Built in 1929 and at @ 50% Capacity
Regulatory Standards— Biosolids, Nutrients, etc.
Reduced Revenues— Economic downturn and loss of GM
Aging Workforce— Significant turnover across the coming years
Cultural Norms—
Need for ‘Change Movement’ Input/Investment from BUs
Path to Success…
Staff Development and Recruiting Develop tomorrow’s leaders and attract new talent
CIP Investment To meet Infrastructure and Regulatory needs
Sustainable Solutions Biosolids, Gas Recovery/Reuse, In-Sourcing
Aggressive Maintenance Program Designed to maximize equipment life and reduce
downtime Change Management
Aimed at assessing norms and fine-tuning, reenergizing staff
City of Dayton WWT-Process Control Program
Drivers for the Dayton PCP
I. NPDES COMPLIANCE
1. Maintain in Good Working Order the treatment works and sewerage system (ORC 6111.01) to achieve compliance. Ever Violated your NPDES?
2. Operate as Efficiently as Possible the treatment works and sewerage system (ORC 6111.01) to achieve compliance. Prove It !
3. Treatment Works obtain at least 85% removal of CBOD5 and Suspended Solids the treatment works and sewerage system (ORC 6111.01) to achieve compliance. Do you calculate this? Then how do you know?
II. PCP Content
1. Immediate Process Control Calculations showing all process daily performance
2. Networkable and secure 3. Data entry only one (1) time from either operations or
laboratory personnel 4. Assistance with plant diagnostics of both biological,
mechanical or electrical systems 5. Provides educational and current and design
performance of processes 6. Adaptability of software and alterations 7. Easily saved and stored for historical reference, and
easily cleared for current use.
III. PCP Benefits
1. Immediate Performance of all processes 2. Diagnostics help with standard and specific site
guidance 3. Graphing all Data and Process Control Analysis - good
visual trending etc. 4. Educational references of standard calculated
parameters and ranges for specific processes. 5. State Compliance of both solids and liquid processes.
(NPDES, RAPCA, etc.) 6. Theoretical vs. Applied approach of Calculation 7. Cost Effective Analysis etc. etc. 8. Operational and Laboratory Consistency
Future Compliance Using PCP
Proof to the public we are performing beyond expectations or “Just Compliance with the NPDES Permit”
Proof of compliance for “Certified Complaints” filed with OEPA or “Consent Decree”
How do we prove that operational strategies were correct/justified under specific conditions? Mass Loading Limits Calculated?
Operator of Record – Defense of actions
Who will we have to defend against tomorrow
Are we “running the show” the best we can?
Air Emissions Compliance Using PCP
More complicated concerns of Air Compliance with “Potential to Emit Strategies” and then evolution of PTI/O and Quarterly and Annual Reports.
Ongoing Compliance strategies with “Synthetic Minors”.
Nine (9) Point Source Emissions Calculating daily and
yearly totals Lbs of rolling 365-Day Total Particulate,
SO2, CO, NOx
Requires large amounts of calculations. AP-42 Table factors and Annual Reports.
Establish specific treatment Goals - NPDES & Operational
Establish process control guidelines
1) Types (Susp. Solids) & Methods of analysis (electronic
meter or EPA Approved ) used
2) Types and Methods of analysis (MCRT-5 ways), F/M, Solids
% capture, CBOD and/or COD factors, ????
Identify potential concerns, Organic and Hydraulic loadings
changing daily
Establish ranges of Operational Guidelines (MCRT 8-11 days)
Identify actions and reactions necessary to keep within process control guidelines
Necessary Development of a good PCP
Define monitoring frequency and times of data entry, data collection integrity by quality control measures
Develop written SOPs for sampling, record keeping, reporting and required communication of findings
Basically Who, What, When, Where are findings passed on
Software integrity
Necessary Development of a good
PCP (cont.)
The PCP is a viable daily updated real time Program.
All performance calculations on all treatment processes are calculated daily which includes reconfigurations of treatment processes.
Operator of Record has a daily tool to assure proper troubleshooting and/or process changes.
Optimization of treatment configurations can be reviewed and adjusted.
What-If analysis can be determined based on changing treatment strategies.
Conclusions
No data input into excel needed except copy – paste one time.
No cost of new software- the software exist on all Microsoft Office packages with training everywhere.
Configuration built for you, by you and once built there is only minimal maintenance up-keep.
All fields, spreadsheets and workbooks are secured with password protection and no alterations possible.
Historical data saved with workbook new name and two or three years of data contained in real time.
Conclusions (2)
Current PCP demonstration does not include advantages of Report writing in Excel and Visual Basic Applications,
What-if-analysis which includes Scenario Manager, Goal Seek and Data Table
Current PCP presentation not showing Operational Documentation of SOPs for plant, Optimization techniques and any vital information for sustainability of treatment plant operations.
Conclusions (3)
