David Hux, City of Shelby;

David Hux, City of Shelby; David Hux, City of Shelby; - Start

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David Hux, City of Shelby; - Description

Will Shull, . Mary Knosby, and Christopher Crotwell, HDR. Construction . OF AMMONIA REMOVAL UPGRADES FOR FIRST BROAD RIVER . WWTP . 2015 . NC AWWA WEA Annual . Conference. November . 17, . 2015, Raleigh. ID: 512023 Download Presentation

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David Hux, City of Shelby;




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Presentations text content in David Hux, City of Shelby;

Slide1

David Hux, City of Shelby;

Will Shull, Mary Knosby, and Christopher Crotwell, HDR

Construction

OF AMMONIA REMOVAL UPGRADES FOR FIRST BROAD RIVER WWTP

2015

NC AWWA WEA Annual

ConferenceNovember 17, 2015, Raleigh

Slide2

04

Construction Sequencing

05

Summary and Conclusions

01

Overview of Existing Plant

02

Revised Ammonia Permit Limits

03

Ammonia Removal Upgrades Project

Topics for Today’s Presentation

Slide3

01

Overview of Existing Plant

Slide4

Permitted for 6 mgd

Current avg flows

2.75 mgd prior to new industry (2009-2012)

Approx. 3.5 mgd with new industry Originally constructed in 1960’sTrickling Filter PlantUpgraded in 1993Added polishing activated sludge aeration basinsTwo 0.75 MG aeration basinsJet pod aeration systemNot sized for nitrification

First Broad River WWTP

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First Broad River WWTP

Process Flow Diagram

Polishing Aeration Basin

Slide6

02

Revised Ammonia Permit Limits

Slide7

2010 Permit Renewal included revised ammonia permit limitsSummer Monthly average NH3-NFrom 18.5 mg/L to 4.7 mg/LSummer Weekly average NH3-NFrom 35 mg/L to 14.1 mg/LBased on DWR’s current ammonia policy1 mg/L summer in-stream NH3-NPermit notes “EPA’s recent proposal have the potential to lower ammonia criteria further”6-year compliance schedule provided

Revised Ammonia Permit Limit

YAD1391A

Slide8

WWTP upgrades required to meet revised ammonia limit

Current Effluent NH3-N Performance

Slide9

ParameterMonthly AverageWeekly AverageDaily MaxFlow (mgd)6.0--BOD5 (mg/L)2537.5-TSS (mg/L)3045-Ammonia-N (Summer)(mg/L)4.714.1-Ammonia-N (Winter)(mg/L)18.535-Fecal Coliform200/100 mL400/100 mL-TRC (mg/L)--28 µg/LpH>6.0 pH < 9.0 standard unitsTotal Nickel261 µg/L 

NPDES Permit Limit

Summary

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03

Ammonia Removal Upgrades Project

Slide11

Upgrade biological treatment process Enhance nitrification to meet more stringent ammonia limitsRepair and replace several deficient treatment componentsImprove treatment reliability Accommodate flows up to the permitted capacity of 6.0 mgd. Meet project schedule requirements for Clean Water State Revolving Fund (CWSRF) program

Project Goals

Slide12

Convert existing process to conventional activated sludge system

Decommission trickling filtersAdd third 0.75 MG aeration basinReplace jet pods with fine bubble diffusers Provide additional blower capacityAdd baffles / mixers for pre-anoxic zone For denitrification and alkalinity recovery

Biological Treatment Process Upgrades

Slide13

August 2014

October 2014

March 2015

September 2015

Construction of Aeration Basin 3

Slide14

Replace Existing DIP Air Header with Stainless Steel

Construction of Aeration Basin 3

Route Stainless Steel Air Header under Walkway

Slide15

Zone 1, Cell A

Zone 2

Zone 3

Zones 4 & 5

New MLE Process

FLOW

Anoxic /

Internal Recycle Discharge / Mixers

Aerobic

(Fine Bubble)

Aerobic

(Fine Bubble)

Aerobic (Fine Bubble)

Internal Recycle Suction

IR

Slide16

04

Construction Sequencing

Slide17

Maintenance of Plant Operation

Identity threats to operationDurationCoordinationContingency PlanCommunication is vital to success

Construction Sequencing

Slide18

How to install while continuing plant operation?

AB Splitter Box Phasing

PC2

PC1

Slide19

How to install while continuing plant operation?

Put trickling filters back into serviceHow is the plant going to react

AB Splitter Box Phasing

PC2

PC1

TF2

TF1

Slide20

How to install while continuing plant operation?

Put trickling filters back into serviceHow is the plant going to react

AB Splitter Box Phasing

PC2

PC1

ABSB

Slide21

Conversion

Self-priming centrifugal to non-clog submersibleSelective demolition of structureValve vault installation

WAS Pump Station Conversion

Slide22

Phasing Challenges

How can we waste?Temporary bypass?Conflicts with trickling filterSolutionPump to existing thickener with new pumpsSimilar heads and flow rates to existing system

WAS Pump Station Conversion

Slide23

Positive displacement to Turblex variable diffuser

More control

More efficientReplace ductile iron with stainless steel piping

Blower Upgrades

Slide24

Phasing challenges

Existing room full of blowersKeep plant operationalPhasing SolutionsRoute new piping overheadShort coordinated shutdown

Blower Upgrades

Slide25

Startup challenges

Lower flows (less I&I)One AB in operation during retrofitTrouble meeting low air demandProposed SolutionsWaste to atm. via header blow-off valveIncomplete blower functionWaste to atm. via AB2 header Noise pollutionWaste to AB3 via AB2 header Introduce coarse Bubble but little effect on DO

Blower Upgrades

Slide26

Replace Influent Screen

Recondition Clarifiers No. 1 and 2 and replace drive units, weirs, bridges and scrapers

Replace and upgrade RAS

pumps

Rehab Primary Clarifiers

Repair and Replacement Upgrades

Slide27

Install new 40-ft Gravity Thickener

Install new Thickened WAS Pump Station

Rehab 26-ft Gravity Thickeners and convert to Belt Filter Press Filtrate EQ

Rehab Sludge Holding Tank

Repair and Replacement Upgrades, Cont’d

Slide28

05

Summary and Conclusions

Slide29

Ammonia upgrades provide future flexibilityAccounts for future industrial changesPositioned for potentially more stringent effluent NH3-N limitOther upgrades will improve overall process reliabilityBetter process control (ie, RAS / WAS pumping)Equalize side stream flows (filtrate EQ)Communication is vital to a projects success

Summary and Conclusions

Slide30

Questions?

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