Water Treatment System Training
Summary
We recommend ongoing engineering support for environmental processes (air, water, remediation) that are affected by continuous downtime resulting from process malfunction, process upsets, and inadequate or failing instrumentation and control. The engineering support services are used to identify points of failure, identify opportunities for process improvement, right-sizing of process equipment, process redesign, and operator training among others.
Our experience is that many environmental processes have remained unsupported, which increases operating costs (e.g., operating labor and chemicals) and reduces process resiliency. Vulnerabilities are exposed when there is a change in operations management or operators. An environmental process that is susceptible to upsets can expose a company to significant fines or disruption in manufacturing operations.
The activities listed below describe the scope of work applied to environmental processes.
Field Assessment
A preliminary field assessment is used to identify if a water treatment system (wastewater, water, stormwater) is operating within normal operating values (e.g., chemical dosing, hydraulic retention times, etc.). The assessment consists of gathering and reviewing the available information including the following: (a) The water process, equipment, layout, and technical information describing process equipment; (b) process flow diagrams and process instrumentation diagrams; (c) operation and maintenance manuals or technical information containing equipment manuals and dimensions (e.g., mixers, motors, pumps); (d) specifications of chemicals added (e.g., pH control and coagulation), (e) analytical reports and discharge reports prepared for the regulatory agency; and (f) If available, source emission reports that provide information on discharges of unitary processes. The information will be used to estimate hydraulic retention times throughout the process, process loads (e.g., COD, TSS, BOD, metals), and understand which specific sources may be creating the process exceedances in discharge limits. If there are multiple points of potential failure or vulnerabilities, several preliminary field assessments may be required around the different unit processes.
Assessment Report
After performing a field assessment, a preliminary assessment letter report is prepared. The report will identify the following:
- Possible Causes for Process Upsets or Underperformance – We will summarize essential technical data and describe the process parameters that are key for process control and performance.
- Initial Recommendations – We will provide initial opinions on how to improve process performance in the short term.
- Identify Other Technologies to be Evaluated – We will provide an opinion on which technologies should be evaluated to enhance solids removal (i.e., coagulants, pH control, baffles, screening, dissolved air flotation, solids screening, and solids skimming.
- Recommend Additional Action – We will recommend additional actions to determine how to evaluate process improvements. These additional actions may include additional bench scale testing, pilot testing, or recommendations on performing continuous process improvements.
An assessment report is prepared when sufficient information is available to recommend specific process improvements and to specify process modifications or upgrades (see below).
Cost Estimate
When process improvements require a change in unitary processes, or if process modifications require an investment (e.g., new tanks or control panels) I will prepare a feasibility study. During the feasibility study I will size process equipment and obtain costs. With those costs, I will prepare an order of magnitude cost for the project, such that the client can budget or decide to move forward with the process improvements. An order of magnitude cost will be based on equipment and skid mounted or prepackaged systems.
Specify Process Modifications or Upgrades
As part of this task, I will prepare block diagrams, process flow diagrams (PFDs), process and instrumentation diagrams (PIDs), control narratives, basic technical specifications, detailed technical specifications (when required for bid packages), and preliminary cost estimates.
- Block Diagram – I will use a block diagram to provide a high-level conceptual approach to process understanding and process improvements.
- Process Flow Diagram – A process flow diagram is to describe unitary processes, including basic permit information, and flows.
- Process and Instrumentation Diagram (PID) – The PID will indicate what process equipment will be used, how process equipment is interconnected, flow direction, process safety and control systems, piping, pressure ratings, and provide mechanical and instrumentation details (field and panel mounted).
- Control Narrative – A control narrative will be written to support the electrical engineers and/or electrical contractors with wiring diagrams, control panel diagrams, and to program the human machine interface/programmable logic controller (when applicable).
- Basic Technical Specifications – Basic technical specifications written supporting mechanical and electrical diagrams. A preliminary process design document is prepared to support construction, and the contractor may select final equipment. For most commercial and industrial processes, basic technical specifications provide sufficient information for on-site construction.
- Detailed Technical Specifications – Detailed technical specifications are prepared whenever a client requires a document package for construction. Generally, this applies to municipalities that are required to bid construction projects
- Preliminary Cost Estimate – A preliminary cost estimate will consider final dimensions of process equipment, the mechanical layout, and a detailed understanding of instrumentation and control requirements. This estimate is normally sufficient to fund the project.
Instrumentation, Control and Remote Monitoring
To improve and maintain process uptime, we identify process issues that may lead to shutdown events and develop strategies to manage those issues. We specify changes to programmable logic controllers, process control system redesign, sensor installation to monitor process variables, process automation and installation of remote monitoring systems or pagers designed to alert operators of a shutdown event. Process upgrades are identified based on client requirements and budgets. We use e-mail to notify operators of errors and operating conditions using PLCs or chart recorders.
Operations Management
When we design and operate processes, we use operations data to identify areas of improvement. We have taken-over management of many water treatment and remediation processes after the client experienced many years of reduced process performance. We continuously identify process improvement alternatives.
Operation and Maintenance Manuals
Operation and maintenance manuals are prepared for new and existing processes to support technical knowledge at several skill levels. These manuals offer technicians and operators a technical reference, describe standard operating procedures, and support mechanical and electrical subcontractors. The manuals are prepared with the intent of complying with quality systems and supporting quality control. I recommend continuously revising and augmenting manuals, documenting changes in equipment and procedures to support changes in staffing, while maintaining process performance. Generally, we include the following information as appendices to the manuals: applicable permits, templates for sample chain of custody forms, operations schedules, material safety data sheets, specifications of chemicals to be used, standard operating procedures not described in the manual, parts lists, equipment specifications, and mechanical drawings.
Operator Training
I will provide on-site training of technicians on compliance sampling, operating of process equipment, understansing process functionality, and troubleshooting.
Web Based Project Support
We prepare web pages in your intranet, as a one stop location for operation manuals, MSDS sheets, health and safety plans, contingency plans, equipment manuals. The same page can be used to support operation and maintenance using posted schedules, and reference materials such as parts lists, specifications, manuals, standard operating procedures, health and safety plans. Web based documents support training, coordination and help share information to keep our projects moving forward.