Clarifier Studies - NEWEA
Transcript of Clarifier Studies - NEWEA
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Clarifier Studies Target Process and Mechanical Improvements at LRWWU NEWEA Spring Meeting - June 7, 2016
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LRWWU Duck-Island WWTF
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§ 35 year old primary and secondary clarifiers § Generally perform well § Robust construction § Mechanical issues with corner sweeps § Parts nearing the end of their useful lives § Opportunity to incorporate new technology § Optimizing wet-weather performance § Minimize down-time § Prioritize limited funds
Project Motivation
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§ Clarifier Process Performance Study § Structural Evaluation § Corner Sweep Alternatives Evaluation § Drive Mechanical Assessment
Methods of Assessment
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Test Purpose Results
Dye Identify flow
regime & short circuiting
Moderately severe short circuiting, esp. corners.
Drog
ues
Locate currents Strong density currents at bottom of clarifiers
Clarifier Process Study
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Clarifier Process Study
Test Purpose Results
Blan
ket D
epth
s
Confirm solids removal capacity
No increase in blanket solids over range of test conditions. RAS not limiting
Solid
s Performance indicator
Near-ideal performance up to 26 mgd.
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Clarifier Process Study
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Energy Dissipating Inlet § Standard practice for optimal clarification § Impinged flow performs better § LA-EDI appears to be the
best performer, esp. at high flows
Clarifier Process Recommendations
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Clarifier Structural Evaluation
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Clarifier Structural Evaluation
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Clarifier Structural Evaluation
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Clarifier Structural Evaluation
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Clarifier Structural Evaluation
§ Tank Floor Repair: $600,000 § Common Wall Repair & Coating: $1,100,000 § Other Concrete Repair: $3,000,000
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1) Elimate sweeps with larger fillets 2) Elimate sweeps by filling corners 3) Keep but improve sweeps
Corner Sweep Alternatives
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29º 36º
Alternative 1: Larger Fillets
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Existing Octagonal Circular
Primary Surface Area, Each (sqft) 6,400 5,300 5,000 Peak Capacity, All (mgd)
115
95
90 Secondary
Surface Area, Each (sqft) 13,225 11,000 10,400 Critical Capacity, All (mgd) 77 64 60
Capacity Remaining 100% 83% 79%
Alternative 2: Fill Corners
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Corner Alternative 3: Improved Sweeps
New Corner Sweeps
§ Maximize Flow § Reduce emergency shutdowns § Offline only once a year
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Corner Alternative 3: Improved Sweeps
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Delete
bullets,make
pictures
larger.Wheel
picture
Insertaslide
beforewitha
picofthe
wholesweep
Corner Alternative 3: Improved Sweeps
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Corner Alternative 3: Linkage
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Corner Alternative 3: Plastic Chain and Improved Wheel
Existing Design Improvements
§ Chain and Sprocket Design § Ultra High Molecular Weight
Polyethylene Wheels § Reduced counter weight § Sealed Wheel Bearing § Metal track
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§ Keep the existing corner sweep design Ø Maintain Existing Capacity Ø Less expensive
§ Careful specification: Ø Plastic chain & sprocket Ø Sealed bearing UHMW polyethylene wheel Ø Full-circumference steel rail Ø Submit load ratings for components Ø Warranty, references
Corner Sweep Recommendation
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Drive Mechanical Assessment
Replace or Refurbish § Existing Drives are 35 year old
FMC/Link-Belt model SB-G/-SU § Originally designed for the
mining industry § .04 RPM § Evaluation by Interstate Water
and Wastewater Specialist, LLC
Primary Gear Reducer 30:1
Output Spur Gear 9.75:1
Intermediate Worm Reducer 150:1
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Drive Mechanical Assessment
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Drive Mechanical Evaluation
Required Peak Torque (ft-lbs)
Drive Operating Torque (ft-lbs)
Drive Peak Torque (ft-lbs)
Primary 29,800 23,830 57,200
Secondary 43,000 34,430 96,300
Evaluation and Findings
§ Overall good shape with a rated life of 48 years § Main Bearing wear is at 40% to 60% of remaining design life § Worm Gear may need to be replaced on some units § Intermediate (worm & pinion) bearings and seals need to be
replaced
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§ Replacement cost is $90k versus $30k to $50k § Rehab estimated at $10k to $25k per drive § Mating plates required for new mechanisms § Minimize risk, best quality § Still requires crane, bridge removal, freight, painting § Bridges can also be retained
Drive Mechanical Recommendations
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Next Steps and Choices
Capital Improvement Plan - $11M Budgeted Estimated Cost
Complete Rehab and Structural Repair $12,500,000
Secondary Clarifiers Only with Structural Repair $7,500,000
All Clarifiers with Priority Structural Repair Only $7,300,000
Secondary Clarifiers and Priority Structural Repair $4,510,000
Construction to begin May 2017
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Questions/Discussion NEWEA Spring Meeting - June 7, 2016
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Clarifier Structural Evaluation
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Clarifier Process Recommendations
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Clarifier Process Recommendations