Design and Operaon of Advanced Aeraon Control Systems · ABAC Controller M M Conclusions NEWEA –...

NEWEA–2018AnnualConference&Exhibit

January22,2018

DesignandOperaAonofAdvancedAeraAonControlSystems

Session10

MaureenD.Neville


WhatisAdvancedAeraAonControl?

Useofprocesssensors,automatedcontrolvalves,andflowmeterstocontrolbloweroutputinanaera7onsystem

2

Blowers

PIT

DO NH3

Aera7onTanks

MFIT


WhyAdvancedAeraAonControl?

§  WhenpermitlimitsdictateaccuratecontrolforopAmalBNRoperaAon

§  WhenenergyandothercostsavingsofadvancedcontrolcanjusAfycostofcontrolequipment

3

Source:StenstromandRosso(2010)www.seas.ucla.edu/stenstro/Aera7on.pdf


OutcomesfromaWell-DesignedAeraAonControlSystem

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1.  Achieveprocesssetpoint(DOtypically)quicklyandmaintainsetpointundervariableloadingcondiAons

2.  Maintainsetpointswithasfewactuatorstarts/stopsaspossible

3.  OpAmizeenergyusebyminimizingairflowneededforprocessneedsandbyreducingpressureloss

ModulaAngControlValveComparison


BuXerflyValves(BFVs)

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§  ThestandardchoiceforMOVcontrolinU.S.

§  NotallBFVsarecreatedequal….

§  AWWATypevs.HighPerformanceType


DiaphragmControlValves

§  IrisDiaphragmControlValve§  Sixsegmentsformcentralaperture,

creaAngcentralflowaxis§  HundredsofinstallaAonsworldwide§  5installaAonsintheU.S.

§  SquareDiaphragmControlValve(SDCV)§  Slidinggatewithsquare-

shapedaperture§  Fallingflowaxis§  InstallaAonsworldwide

daAngbacktoearly2000s§  1installaAonintheU.S.

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Source:EggerTuroPumpsSource:BinderGroup


JetControlValves

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Source:BinderGroup

§  Engineeredforpreciseairflowcontrol§  Venturi-shapedvalvebody§  Centralcontrolelement(“bullet”)moves

paralleltotheflow§  Annularorificearoundcontrolelement

§  16installaAonsworldwide

§  NoneinstalledtodateintheU.S.


Motor-OperatedActuatorsforMOVApplicaAons

§  ModulaAngduty=capableofupto1,200start/stopsperhour

§  SomevalvemanufacturersrequireaminimumposiAoningaccuracy(±0.2%),whichonlysomedigitalstyleactuatorscanachieve

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Source:Limitorque

Source:Rotork

Source:Auma


FactorstoConsiderforValveComparison

§  StableRangeforControl§  ValveSizeSelecAon+FlowMeterInstallaAonàInstalledCost§  PressureLossàOperaAonalCost

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Source:TheBinderGroup

StableRangeforControl

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BFVs:50-80%

Diaphragm:20-90%

JetValve:0-95%

%stroke

%flow


ValveSizeSelecAonsforUpperBlackstoneUpgrade(28Valves)

12

Exis7ngPipe

Size

DeZurikHighPerformance

BFVs

EggerIrisDiaphragmValves

BinderSquare

DiaphragmValves

BinderJetControlValves

FirstGrid 12-inch 10-inch 10-inch 12-inch 12-inch

Middle4Grids 8-inch 5-inch 4-inch 6-inch 10-inch

SixthGrid 8-inch 5-inch 5-inch 6-inch 10-inch

SeventhGrid 8-inch 5-inch 5-inch 8-inch 10-inch

Es7matedInstalledCost:$1.3M$1.5M$1.7M$1.9M


FlowMeterInstallaAonRequirements

§  Ideally…..§  10straightpipediametersupstream§  5straightpipediametersdownstreambeforecontrolvalve

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FlowMeterInstallaAonRequirements

§  IrisDiaphragmValve§  Canbeinstalledonly1pipediameter

downstreamofthermalmassflowmeter

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§  JetControlValve§  Canbeinstalledonly0.5pipediameter

downstreamofthermalmassflowmeter


PressureLossComparisonatVariousValveStrokes

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0.00 0.20 0.40 0.60 0.80 1.00 1.20

BFV

IrisValve

SDCV

JetValve

psig

Qavg,h50 Qavg,h70 Qmax,hmax Est.AnnualCostSavings:

$34,000$34,000$26,000$16,000

$47,000$34,000$17,000$8,000

$87,000$31,000$9,000$9,000

MostOpenValveControlStrategiesforDOControl

NEWEA–2018AnnualConference&Exhibit17

Pressure-basedMOVControlwithDOPIDLoops

1.   DOPIDàairflowSP2.   Flow/valvePIDàvalveposi7onSP3.   BlowerpressurePIDàblowermodulatestomeetfloa7ngpressureSP


DisadvantagesofPIDLoops

P=Propor7onalTermPointssystemintherightdirecAontomeetDOsetpoint,assumingairflowislinearlyrelatedtoDOconcentraAonI=IntegralTermForcessystemtobalanceAmeoverversusundersetpointD=Deriva7veTermAppliessomefricAontotheresponse,butinmanycasesnotused

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Source:BioChemTechnology

COMMONRESULTS:à Oscilla7onaroundsetpoint

à Poorresponsetodiurnalrangeà Seasonalre-tuningneeded


Flow-basedMOVStrategiesthatDon’tUsePIDs

Floa7ngDOControl§  Usesaproprietary,nonlinear

alternaAvetoPIDloopsforvalveandairflowcontrol

§  Operator-adjustable“responsedelays”tominimizeoscillaAons

Predic7veDOControl§  DOandvalvecontrolbasedona

wastewaterprocessalgorithm

§  Calculatesairflowbasedonreal-Ameoxygenuptakerates(OUR)

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GenerallytheblowersarealsomodulatedtotargetairFLOWsetpoint,althoughPRESSUREcontrolcouldbeused

Ammonia-BasedAeraAonControl(ABAC)


AmmoniaInstrumentTypes

Type IonSelec7veElectrodeProbes WetChemistryAnalyzers

Range Nominally0–1,000mg/LNTypcalibratedaround1–20mg/LN

Nominally0.02–1,000mg/LNTypcalibratedaround0.05–20mg/LN

Accuracy ±5%ofmVsignal+0.2mg/L ±3%+0.05mg/L

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Source:HachCompanySource:UpperBlackstone


AmmoniaInstrumentsforABAC:LessonsLearned

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IonSelec7veElectrodeProbes WetChemistryAnalyzers

LowAmmonia

Openstrugglesinlowammoniaenvironments(<1mg/LNH4-N)

BeXerchoiceforlocaAonswith<1mg/LNH4-N

Loca7on

Mostcommoninfirsthalfoftank(anaerobic/anoxicorheadofaerobic)Mixedsuccessforprimaryeffluent(due

togrease)

Mostcommonatendofaerobiczone,secondaryeffluent,finaleffluent

MixedsuccessinupstreamlocaAons(smalltubingturnsblack)

AccuracyChecks

Requirefrequentaccuracychecksandre-calibraAon

AccuracychecksrecommendedtoidenAfywhenmaintenancerequiredontubingorflow

cells

O&M ReplacementcartridgeheadscanbecostlyifrequiredmulApleAmes/year

ReagentcostcanbereducedbyincreasingAmeinterval(balancedwithprocesscontrol

needs)


ABACExample1:NansemondWRRF(114ML/d5-stgBardenpho) Suffolk,VA

ABACControlScheme

AmmoniaSetPoint

AmmoniaResult

AmmoniaPIDcontrollersoutputAutoDOsetpointsforeach

controlzone

@effluent=3.5mg/L

Typically2.8–4.0mg/L

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à 12%reducedenergyà 47%reducedsupplemental

carbonà Reducedsupplemental

ammoniaforchloraminaAon

Formorereading:Upretyetal,WEFTEC2015

AerobicAnoxicAnaerobic

NH3ISE

ABACControllers(x5)

M M M

Blowers

PIT

Anoxic Re-Aera7on

NH3WCADO DODO

AutoDOSetPoint(x15)


ABACExample2: SouthPlant(87ML/dA/O)GrandRapids,MI

ControlScheme AmmoniaSetPoint AmmoniaResult

ProprietarycontrolleroutputsAutoDOsetpoint

foreachtrain

@effluent=4-5mg/L

<1mg/Lduetoblowerturndown

limitaAons

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à 15%reducedenergy

Formorereading:Lunnetal,WEFTEC2014

AerobicAnaerobicBlowers

NH3ISE

PIT

ABACController

M

DONH3WCAMLSS

AutoDOSetPoint(x3)


ABACEx3:RobertW.HiteTreatmentFacility(300ML/dMLE)Denver,CO

25 Formorereading:Grayetal,WEFTEC2012

ControlSchemeAmmoniaSetPoint

AmmoniaResult

ProprietarycontrolleroutputsAutoDOSetPoint

foreachdropleg

@effluent:1.0–1.5mg/L

~1mg/L à 13%reducedenergy

AerobicAnoxicBlowers

NH3ISE

PIT

ABACController

M M MDO DO DO

Disinfec7on

NH3WCAMLSS

AutoDOSetPoint(x36)


ABACExample4:J.D.PhillipsWRF(75ML/dA2/O)ColoradoSprings,CO

26 Formorereading:Lagrangeetal,WEFEnergyandWaterConference2011

ControlSchemeAmmoniaSetPoint

EffluentAmmonia

AmmoniacontrollerdirectlymodifiesvalveposiAon(no

DOcontrolloops)

@secondaerobicgrid:3-4mg/L

~1mg/LduringthedayAme

à 20%reducedenergyà ImproveddetecAonof

nitrificaAonupsetsà Lowershearonbiofloc

AerobicAnoxicAnaerobic Blowers

NH3ISE

PIT

ABACController

M M M

Conclusions


RecommendaAonsforDesignersandOperators

1.  Definethedesiredoutcomes(COSTSAVINGS,TIGHTERPROCESSCONTROL)

2.  Carefullydefinedesigncriteriaforvalvesandactuators

3.  Pilotprocesssensorsonatrialbasis

4.  Partnerwithexperiencedblowermanufacturersand/orintegratorswhocandeliver:§  Tightcontrolthatmaintainssetpointswithminimalwearandtearonequipment§  HighlevelofserviceoverAme

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Contactus!

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[email protected]

Findmoreinsightsthroughourwaterpartnershipatcdmsmith.com/waterand@CDMSmith

[email protected]

NEWEA–2018AnnualConference&Exhibit30

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