Filter Surveillance PSW Rocky Mountain Summit April 5, Advanced Process Control and Optimization
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1 Filter Surveillance PSW Rocky Mountain Summit April 5, 2016 Advanced Process Control and Optimization
2 Partnership for Safe Water Partnership for Safe Water mission: To improve the quality of drinking water delivered to customers by optimizing water system operations.
3 Learning objectives Overview Why should operators optimize filtration? How to Optimize Filter Performance How to measure the progress of optimization? What tools and techniques are needed? Necessary skills to assess filter performance/health Parameters used for comparison 3
4 Optimize Filters? Optimize filter performance Minimize filter turbidities/particle counts (not just adding more chemical) Optimize Upstream Processes Develop Standard Operating Procedure for Filtration Optimize filter backwash Ripening time Minimize initial spike Maximize filter run length Perform Filter Surveillance 4
5 Key to Good Filter Surveillance Program On-going Filter Log review Backwash Observations Unit Filter Run Volume (UFRV) Review filter profiles as operational team Once per quarter (per season) Adjust high flow rate for temperature Check media expansion make adjustments Once per year Visual observation of filter surface and components Probing media Solids retention analyses Core sampling Sieve analyses / media assessments 5
6 How is Progress Measured? Develop Filter Log DATA / TRENDS (On-going) Individual filter turbidity/particle Counts (On-going) Filter run times (On-going) Uniform filter run volume (UFRV) 6
7 Filter Log BWPF ONLINE FILTER VERIFICATION FILTER 1 AR FILTERTRAK 660 SC Serial No DATE ON RESTART Y/N TIME ON OPER ON FTW TIME FTW SPIKE FLOW RATE 1 FLOW RATE 2 FLOW RATE 3 FLOW RATE 4 NTU ON H.L. ON BENCH NTU SCADA TIME NTU NTU DIFF DATE OFF OFF OPER OFF NTU OFF H.L. OFF RUN TIME MG Total UFRV ENDING PT. CTS. BW Y/N BW BW NTU VOLUME 7
8 Tools and Techniques for Inspection HEALTH & SAFETY REQUIREMENTS Review AWWA Standard B100 Measurement Tools Shovel, level, 3/8 inch steel rod, tape measure Coring Tool 11/2 inch electrical conduit, 5 foot length, baggies Expansion Tool One-inch interval tubes or cups Laboratory Instruments and Tests Turbidimeter, glassware, balance, sample bottles, baggies COMMUNICATIONS 8
9 Safety Considerations Is your filter a confined space? Do your filters require fall protection? Safe atmosphere down inside the filter box? Always use a ladder and practice ladder safety Make sure filter is drained before placing a piece of plywood down to step on the media surface. Wear a hard hat and stay out from underneath the bucket
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11 Filter Inspection Tools 11
12 Media Assessment Bed Depth Measurement (Drained Bed) Know original specs Effective size - Uniformity Coefficient - Depth - L/D ratio Use a 3/8 inch steel rod to poke into media, or dig into it to measure depth If filter is dual or mixed bed, note depth of each strata, and depth of mixed interface Check to see if troughs are level, then measure distance from trough to bed - check for mounding Calculate L/D ratio - should be >1100 for low NTU production 12
13 Core Sampling for Solids Retention Solids retention analysis best way to determine backwash effectiveness Use core sampling tool and baggies to obtain depth samples Take samples at 0-2 inches, 2-6, 6-12, 12-18, 18-24, etc., until all bed strata are sampled Sample before and after backwash Wash 50 grams of each sample with 5 successive 100 ml washes of lab water Measure turbidity of each X 2- plot on graph as NTU/100 grams media 13
14 Lab Setup for Core Samples Turbidimeter Pan balance Baggies before and after Glassware Lab water Weigh boats or other plastic cups 14
15 Guidelines After Backwash < 30 NTU Bed is too clean - examine wash rate and length - this bed will not ripen quickly NTU Well cleaned and ripened bed - no need for action NTU Slightly dirty bed - reschedule retention analysis soon > 120 NTU Dirty bed - evaluate filter wash system and procedures > 300 NTU Mudball problem - rehab bed 15
16 Solids Retention Measures the effectiveness of 160 backwash 140 Can show too little or 120 too much backwash 100 Change in historical 80 solids retention is 60 cause for concern 40 Graph results for 20 database 0 NTU/100 grams of media 0-2 in 2-6 in 6-12 in in in in Before After 16
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21 Backwash Waste Turbidity Analyses Too little / too much washing is a common problem After the first coring, and before the bed expansion measurement and second coring, the washwater turbidity should be measured for duration of wash Sample at 1 minute intervals and analyze Graph results as NTU vs. time Record all data Volume of backwash, rates, Ramping intervals, operator habits 21
22 Washwater Turbidity Plot Turbidity vs. Time Helps prevent Excessive washing Wastes washwater Strips ripening AWWA goal of 10 NTU This filter washed too long NTU of Wash AWWA Standard 1 min 2 min 3 min 4 min 5 min 6 min 7 min 8 min 9 min 22
23 Bottles Ready for Backwash NTU Sampling 23
24 Operators Sampling Backwash Water 24
25 Bed Expansion Measurement with Expansion Tool Check high flow wash rate (seasonally adjusted) Desire 20 30% expansion Position and tie down the expansion tool so that it rests on top of the bed at the start of high rate backwash Wash bed under normal conditions and observe amount of expansion 25
26 Use of Expansion Tool 26
27 27
28 Calculation of ES & UC from sieve analysis Sieve pans used for media size analysis ES = D 10 90% larger, 10% smaller UC = D 60 / D 10 Example sieve analysis for anthracite ES= 1.2 UC = better than
29 Customize Your Filter Surveillance Visually check underdrain Filter Valve confirmation Acid solubility Biofiltration Considerations Plant and filter specific considerations. Concrete condition of filter box 29
30 Filter Profile Graphical summary of filter performance for entire run Filter Profile Usually done with turbidity measurements - particles counts can be used Turbidity, ntu Minutes into Filter Run 30
31 TURBDITY (NTU) FLOW (MGD) & HEADLOSS (FT) BWPF WORST FILTER RUN PROFILE - November 2014 Filter #1(Full Profile) See Detail 1 Mini Backwash Flow Filter-to-Waste (FTW) Turbidity Highest Turbidity NTU See Detail 2 Backwash Flow See Detail Turbidity Flow Headloss /1/14 21:36 11/2/14 21:36 11/3/14 21:36 11/4/14 21:36 11/5/14 21:36 11/6/14 21:36 11/7/14 21:36 11/8/14 21: FTW TURBIDITY SERVICE TURBIDITY FLOW BW FLOW HEADLOSS Series5 31
32 Worst Filter Run Report 32
33 Take Away Messages The Key to Operational Excellence is in the understanding of the smallest details of the plant. The Most Important Component to Any Optimization Effort is a tenacious, engaged Operator. 33
34 NO COMPLACENCY 34
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