Facility Overview Plant-led Initiatives Identifying Energy-saving Measures Implementation

Transcription

1 Michigan Water Environment Association 2012 Annual Conference Boyne Mountain Resort June 25, 2012 Presented by: Dave Monette, City of Warren Lucy Pugh, AECOM Pete Cavagnaro, JCI Facility Overview Plant-led Initiatives Identifying Energy-saving Measures Implementation 1

2 IRON AIR CLARIFIERS RAW SEWAGE PUMPS GRIT REMOVAL PRIMARY SEDIMENTATON AERATION INTERMEDIATE PUMPS SAND FILTERS UV DISINFECTION RED RUN DRAIN TO CLINTON RIVER PRI SLDG WAS SLDG LANDFILL PRI & WAS BLENDING GBT THICKENING BFP DEWATERING INCINERATION ASH LAGOONS 1959 Original construction 1960s 1970s 1980s 1990s 2000s 2010s Plant expanded from 24 mgd to 36 mgd 50 mgal retention basin, secondary treatment, multiple hearth incinerator, SCADA State-of-the-art laboratory, aeration upgrades, dewatering Maintenance and upgrade projects; dechlorination and odor control Filtration and dewatering Disinfection and energy 2

3 Increased Costs Power was not expensive when most WWTPs were conceived and built Increase in power cost: Nat l Gas and Electric Increase in chemical cost Reduced Funding Budget constraints and reductions Training Licensing Problem solving Collaboration Recognition 3

4 Influent pumps rebuilt Blower modifications RAS Pump VFDs Automated RAS Control Monitor power use SCADA upgrade ORC engines September 2009 City of Warren received EECBG funding Committee formed within City to determine if and how to spend the money EECBG funds leveraged to develop RFP Proposals solicited from ESCOs Focus placed on wastewater treatment expertise Technical energy audit identified facility improvement measures (FIMs) 4

5 Request for Qualification/ Proposals ESCO Selection and Development Agreement Approvals & Contract High Level Preliminary Analysis Detailed Analysis Conceptual Design Detailed Analysis Plans & Specs Project Implementation Maintenance, Measurement and Verification Enjoy the full savings Utility Bill Payment for Efficiency Upgrades Customer Savings Before During After 5

6 Over $580k in annual savings will pay for the improvements Results guaranteed by Johnson Controls Guaranteed project cost - no change orders on contracted scope of work Reduces risk, aids in approval process Lighting retrofits Building control upgrade Boiler upgrade Building envelope improvements 6

7 Raw Sewage Pumps Improve operating efficiency Right-sized pump Intermediate Pump Station Replace motors Replace Eddy Current drives Modify controls 7

8 Three Allis-Chalmers single-stage centrifugal blowers One blower typically adequate for entire load Re-machined in 2003 along with ceramic diffuser retrofit Operating data analyzed to determine rightsized operating conditions Single blower sized to satisfy typical range of oxygen requirements Maximum daily maximum oxygen requirement Minimum mixing requirement Install in existing blower building 8

9 Continuous monitoring of dissolved oxygen and air flow rates Control air flow rates based on dissolved oxygen concentration Adjust blower output to maintain valve positions as open as possible Convert portion of aeration basins to anoxic and anaerobic zones for bio-p removal Reduce ferric chloride use Reduce sludge production/handling 9

10 The City of Warren was proactive in researching funding options and forming a multidiscipline team to collaboratively deliver these projects. Energy Performance Contracting provided an alternative method for project funding and delivery. PC works for facilities and process improvements. Improvements were made which would not have been possible otherwise. The authors wish to thank the following project team members for their contributions: Joe Kovalcik, City of Warren Bryan Clor, City of Warren Robert Dranberg, City of Warren Jason Tobolski, City of Warren Todd Schaedig, City of Warren Daniel R. Mack, Johnson Controls Christopher McNaughton, Johnson Controls Rao Chitikela, Johnson Controls 10

11 David Monette Division Head City of Warren Wastewater Treatment Plant (586) ext. 103 Lucy Pugh, P.E., BCEE Vice President AECOM Grand Rapids, MI (616) Peter V. Cavagnaro, P.E., BCEE Project Development Consultant Johnson Controls Ann Arbor, MI (734)