Headline goes here Second line Fiber length Solids Rags Probability for a 3 -in solids handling...
Transcript of Headline goes here Second line Fiber length Solids Rags Probability for a 3 -in solids handling...
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
1
“The New Wastewater: Impact of Modern Trash
on Wastewater Collection and Treatment”
Bob Domkowski Engineering Consultant
Xylem, Inc. – Flygt Products
October 20, 2015 Modern Trash: Current wastewater utility choices
2
Grind it Pump it Screen it
TODAY’s NEWS Wet Wipes and Grease Make for a Mess in Charleston Sewers
Disposable Wipes Not For Toilets Warns BV
Utilities Grapple with Flushables
City Plagued by Flushable Wipes
NY: Class action lawsuit filed against wipes mfgs.
Flushable Wipes Problematic for Rhode Island WWTPs
Flushable Wipes Clogging Sewers says Halifax Water
Flushable Wipes Blamed for Clogging City Sewers
How many of you recognize photos like
these?
Flushable does not mean ‘Flow-able’!
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
2
Recent News Quotes:
• “85% to 90% of all backups seen today are preventable
and are caused by non-flushables”
• Jerry Ledbetter, Environmental Dept.. City of Claremore, OK
• “We take out 2 to 3, 5-gallon buckets of wipes every week
from each (sewage) pump station”
• Pete Jones, Ocean City, MD
• “Wipes are clogging up sewers like nothing else sewer
workers have ever seen!”
• Anne Heyden, San Antonio (TX) River Authority
• “It’s good news for me but bad news for the public”
• Scott Levin, Levin Pipe Cleaning Services
5
What To Flush Quiz… What were collection systems designed to convey?
• Toilet paper
• Flushable wipes
• Poop
• Paper hand towels
• Facial tissue
• Dental floss
• Toilet wand pads
• Pee
• Feminine hygiene items
• Cleaning wipes 6
What To Flush Quiz… What were collection systems designed to convey?
• Toilet paper
• Flushable wipes
• Poop
• Paper hand towels
• Facial tissue
• Dental floss
• Toilet wand pads
• Pee
• Feminine hygiene items
• Cleaning wipes 7
Only
3!
Modern collection system headaches
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
3
New Wipes TV Advertising Campaign Ad co-mingles dry and wet products
9
Typical “Modern Trash” Non-woven sheet goods
Typical manufacturing process: Needle punch
Thermal bonding
Spunlace (Plastic-based substrate)
Wet layup
New short fibers / mineral binders
Typical commercial products Baby / personal wipes
‘Swiffer’ wiping sheets
Dryer sheets
Toilet bowl cleaning wand pads
Personal cooling wipes (New)
3-4 new products monthly!
Wipes: 2004 – 2014 Market Sales
11
($11Bn)
Overview of Current Actions
• Legal actions • Armstrong vs Costco Wholesale (NicePak)
• Honigman vs Kimberly-Clark
• Kurtz vs Kimberly-Clark (Class Action suit in NY)
• Palmer vs CVS (NicePak)
• Federal Trade Commission • FTC – NicePak Settlement (May 2015)
• NicePak has agreed to stop advertising wet wipes as flushable
• Unless it can substantiate claims that the product is safe to flush
in the ‘real world’ 1. Safe for sewer systems
2. Safe for septic systems
3. Break apart in a sufficiently short amount of time after flushing
NicePak manufactures wipes for: Costco, CVS, Target, BJ’s (etc)
12
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
4
Kohler Ad: Toilet as a Trash Can…
13
Typical WWTP (Diurnal) Flow Duration Curve
Sewage flow duration pattern for a typical municipality
Tre
atm
en
t ca
pa
city (
mg
d)
Portland Water District (PWD), Portland, ME ‘Awareness campaign’
10-in
Pump
16-in
Suction line
PWD Spent $3.8M installing (2) Screens
PWD: “Wipes cost us $800 per pound for removal and disposal”
KOIN-TV: Vancouver, WA Collection System ‘Flushable’ Problems
16
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
5
Anderson P.S. - Vancouver, WA P.S. Modifications
Video capture Current status
Studies Show Today’s Reality: Probability of solids and fibers distribution / passage
18
5-in 4-in 3-in 2-in ½ -in 2-in 3-in 4-in 8-in >12-in
Size of solid,
spherical objects
Size of soft,
stringy objects
Diameter Fiber length
Solids Rags
Probability for a 3-in solids-handling impeller to pass modern trash
Complications of ‘Modern Trash’ “Environment 1992 Conference”
“Flushability, Transportation and Decomposition of Non-woven Products”
Foretold challenges due to:
Reduced water flow - EPAct (’94) regulation reduced toilet flush volume to 1.6 gallons
- Low flow shower heads
- Now… Even waterless urinals
Explosive growth of flushable product sales
- Confusing packaging
- Hidden ‘Do not flush’ symbols
Laboratory and field studies predicted difficulties in
developing non-flushables that met both:
- Possible regulations (Dispersability)
- Consumer expectations (Push-through)
INDA - Industry of Non-woven Mfg. The industry’s take on wipes…
20
Wipes usage increasing at a healthy 10% per year
Only 5% of wipes are marketed as ‘flushable’ (<1% in N.A.)
INDA members see baby wipes as very different from
‘flushable’ wipes
INDA members are not so willing to put ‘Do Not Flush’ logo
on valuable ‘real estate’ on front of packaging
INDA’s new ‘Flushability Assessment Tool’ is voluntary, it
contains some vague language
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
6
INDA - Flushability project
Flushability Project… What is flushable?
• ‘Flushability’ has been left up to individual manufacturers
• High risk:
- Non-woven products can harm homeowners and municipalities
- INDA develops standardized product pump test rig
- Products can be compliance tested
- Flygt 4-in model 3085/3-hp pump is basis of test
• INDA external experts help develop a test program
• Flygt is one such ‘external expert’ consultant for:
- INDA
- A major U.S. manufacturer
Original Flushability Test… Will flushables make it through the ‘S’ bend?
22
Toilet ‘S’ Bend
Closet elbow
23
Flushability Assessment Decision Tree Product labeling to comply with Code of Practice
“Flushability” – Current Definition:
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
7
Flushability - Modern Trash Quest to become unrecognizable…
25
Toilet paper Spunlace (Current wipes) Hydraspun™ substrate
(<1-min) (24-hours) (20 min to1-hour)
Today’s reality: MWWCA Membership A Recent Collection System Operations Survey
87.5% experienced problems with “flushable’ products.
61.4% experienced >10 incidents with “flushable” items
84.4% clogging problems in small lift stations due to “flushables”
51.1% clogging problems in large lift stations due to “flushables”
59.6% Costs due to ‘flushables’ is up to $1,000 per incident
12.8% Costs due to ‘flushables’ of up to $2,000 per incident
88.9% Report that problems with “flushables” are increasing
Average annual cost for each Maine city = $37,500
Collection System Headaches: 2012
Orange County (Ca.) Sanitary District
27
(2) WWTP with total capacity of 210MGD
Collection system size: (2.3M people) 587 miles of conveying lines (OCSD)
4,513 miles of satellite lines (Others)
OCSD owns 22 pumping stations
In 2011-2012 OCSD: Conducted 971 corrective de-ragging actions ( 971 / 15 = 65 )
Spend $320,000 de-ragging pumps
Worst single day recorded:
10 employees took 8-hours to clear 5 P.S.
(40) 35-gal contractor trash bags of debris were removed
from the (20) pump units
Collection System Headaches: 2012
Orange County (Ca.) Sanitary District
28
(2) WWTP with total capacity of 210MGD
Collection system size: 587 miles of conveying lines (OCSD)
4,513 miles of satellite lines (Others)
OCSD owns15 pumping stations
In 2011-2012 OCSD: Conducted 971 corrective de-ragging actions
Spend $320,000 de-ragging pumps
Worst single day recorded:
10 employees took 8-hours to clear 5 P.S.
(40) 35-gal contractor trash bags of debris were removed
from the (20) pump units
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
8
Collection System Headaches: 2012 Orange County (Ca.) Sanitary District
29
(2) WWTP with total capacity of 210MGD
Collection system size: 587 miles of conveying lines (OCSD)
4,513 miles of satellite lines (Others)
OCSD owns15 pumping stations
In 2011-2012 OCSD: Conducted 971 corrective de-ragging actions ( 971 / 15 = 65 )
Spend $320,000 de-ragging pumps
Worst single day recorded:
10 employees took 8-hours to clear just 5 pump stations
(40) 35-gal contractor trash bags of debris were removed
NYC DEP – Wastewater Treatment Non-flushable problems
30
DEP has spent $18M over past 6 years manually removing
wipes from their collection system
DEP carts away 110,000 yd3/month from WWTPs
Waste volume has doubled in past 5 years
NYC DEP claims wipes account for 55,000 yd3/month!
Ward’s Island WWTP 275-mgd
INDA Case Study: Town of Moraga, Central Costra County, CA
• Significant number of pump clog incidents per month
• 3” bar screen replaced with 1.5” bar screen
• Case study results:
- Increased frequency of bar screen cleaning
- Bar screen blinding by ‘pan-caking’ of brown towel sheets
- While reduced, 6-in pumps each still clogged 3-4 times /mo.
Town of Moraga, Costra County, CA Recorded wastewater trash distribution
32
54%
70%
16%
13%
17%
19%
11%
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
9
Case Study: Town of Moraga, Costra County, CA
Pump clogs mainly consisted of:
- Long, twisted, knotted, rope-like formations
- Strong non-woven materials
- Long fibrous products:
- Personal hygiene products
- Household cleaning wipes
- Personal wipes
Town of Moraga, Costra County, CA Typical pump clog sample
Washed pump clog debris
Decomposed debris clog
Modern Wastewater: Wastewater pumping is a tough application!
Courtesy of Jacksonville Electric Auth.
(~1,200 Pump stations)
Courtesy of San Antonio River Auth.
(Collection system:189 mi.)
Modern Wastewater: Wastewater pumping is a tough application!
36
Courtesy of City of Peoria, AZ
(24 Pump stations)
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
10
Costs of Leading Edge Disturbance Air and water being fluids…
37
NASA: Just keeping aircraft wing leading edge bug-free:
Would yield a fuel savings of 0.5% = $240 M / year
Solids-handling Pumps – The Issue An historical overview
Mr. A. Baldwin Wood – 1915 - New Orleans S & WB
• “Father of the ‘non-clog’ wastewater pump” - developed the
Wood “Trash Pump”
• Typical 2-channel solids-handling impeller…
• Large throughlets, blunt vertical vane leading edges
• Complies w/1947-developed “10-States Standard”
Impeller rotation
Wipes
Wip
e
Wip
e
Descendants of the “Wood Trash Pump” 2-channel impeller with blunt leading edges
39
Reduced hydraulic efficiency Mechanical failures
Significant Plant Maintenance Issues
40
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
11
41 42
“While public education is important, ultimately we need to invest in improved, modern
equipment that can handle this material” Public Works Director – Andy LaFond
Innovative Technology The answer is not larger impeller throughlet size!
(3) 16-in. dia. pumps are equipped with impellers having
2 x 4.5-in. dia. throughlets… each clog regularly!
Innovative Technology
Self-cleaning hydraulics providing
Sustained high hydraulic efficiency
Horizontal vane edges are wiped clean
during each rotation
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
12
Innovative Technology Laboratory pump-clog test rig
Innovative technology
Laboratory test protocol
• Test objects, 50 pieces of each:
- 10 mil plastic strips
- ‘Wettex’ dish cloths
- Reinforced textile rags
• The 8” to 10” square test objects were fed into each pump,
- One piece at a time, in 15 sec. intervals.
• Tests were performed at flows of 900 gpm and 1,250 gpm
• (7) type hydraulic designs were tested
• (6) Pump manufacturers
• All test program pumps were 4-in pumps
Laboratory Impeller Clog Testing
47
Closed 1-V Vortex Screw Semi-open 1-V N-Technology
Innovative Technology
In solids-handling pump design
0
10
20
30
40
50
60
70
80
90
Closed 1-V 2-V Vortex Screw Open 1-V Chopper N-Hydraulics
Hydraulic efficiency in clean water
Hydraulic efficiency recorded during repeated clog tests
Pump efficiency comparison by impeller type
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
13
Consortium for Energy Efficiency
Municipal water and wastewater systems
• Consumes 4% of all U.S. energy
• 52,000 water systems produce 51Bn gallons of water per day
• 16,320 wastewater treatment facilities treat 34.8Bn gallons per day
• Greatest energy consumer in water treatment: Pumps
• Greatest energy consumers in wastewater treatment are:
- 1. Blowers
- 2. Pumps
- 3. Sludge handling equipment
National Municipal Water and Wastewater Facility
Initiative
Potential WWTP Energy Savings: By motor hp and application (Source: WEF)
Pump savings Motor upgrades
Air compressor savings
Other savings
Fan savings
Downsize savings
Rewind savings
1-5
HP
5-2
0 H
P
25-5
0 h
p
51-1
00 H
P
101-2
00 H
P
201-5
00 H
P
501-1
000 H
P
> 1
,000 H
P
Energy savings: Life cycle cost for a pumping system (Source: EPA)
Downtime
Maintenance
InstallationPump
Energy
Operating
Environmental
25%
40%
10% 7%
5% 10%
3%
Energy savings: Life cycle cost for a pumping system (Source: EPA)
Downtime
Maintenance
InstallationPump
Energy
Operating
Environmental
25%
40%
10% 7%
5% 10%
3%
Innovative
technology
Innovative
technology
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
14
End-user Savings Operations budget / Maintenance budget
The following is a review of a few of the numerous
successful projects where:
Pump clogging issues were eliminated
Significant operational savings were realized
Significant maintenance savings were realized
53
Lumberton, TX – Municipal Utility District Recorded Energy Savings 2003 to 2010
Service area: 63 mi2 Population: 20,400
Energy Saving Project: City of Andalusia, AL
Riverside WWTP (3) 45-hp modern technology pumps
48.1% Engineer-recorded svgs
Central Lift Station (3) 85-hp modern technology pumps
(2) 45-hp modern technology pumps
56.1% Engineer recorded svgs
55
U.S. DOE Block Grant – Dept. of Economic Affairs Project spec.: 25% energy savings is required of the contractor Failure to achieve: Reimburse $240,000 State of AL funding
Energy Saving Project Ypsilanti Communities Utility Authority (YCUA)
• Upgrading several large wastewater pump stations - Solve clogging issues / Improve hydraulic efficiency / Install ASDs
- Martz Road P.S. = > 30% energy savings
- Willow Run P.S. = > 30% energy savings
- Snow Road P.S. = > 40% energy savings
• Snow Road Pump Station - (5) 12-in, NT-3312 / 470-hp pumps Result: > 40% Energy Savings
- DTE Energy Savings Rebate Program awards YCUA: $65,378!
56
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
15
Modern Trash: Current wastewater utility choices
57
Grind it Pump it Screen it
Grind It!
Current state
New tooth designs
Cuts to small squares
Minimizes rat tailing
Municipal quandary
If you grind it
Wipes removed with sludge
Ground apply issues
58
Pump It!
Current state
Innovative technology designs
Horizontal leading edge
Self-cleaning hydraulics
Sustains hydraulic efficiency
Proven results
Manufacturer’s non-clog guarantee
59
Screen It!
Current state
Perforated plate
0.25-in dia. holes
Continuous cleaning
Brush
Water jet
Bar screen
6-mm (0.25-in) space
Automatic cleaning
60
“Modern Collection System Headaches - Handling Modern Trash” – R. Domkowski
10/16/2015
16
Putting It All Together
‘Modern trash’ / non-woven sheet goods have became
the No. 1 enemy of collection and treatment systems
Public education so far seems to have a limited benefit 18%-20% reduction in mass of materials
Must maintain public awareness campaigns
Maintenance budgets are strained due to needs of
dealing with repeated equipment stoppages
Problem is getting worse each month
Proven solutions exist that delivers sustained
operational efficiency and greatly minimize maintenance
spending
61
“The New Wastewater: Impact of Modern Trash
on Wastewater Collection and Treatment”
Bob Domkowski Engineering Consultant
Xylem, Inc. – Flygt Products
October 20, 2015