HomeMy WebLinkAboutII(A) Presentation – Innovative Idea Award to Don Smith, Wastewater Operator Class A Agenda 6-02-2004
Item IIA
Mayor ��e Center of d Liv. Commissioners
S. Scott Vandergrift ,...+!"'1-..�,,, .. Danny Howell, District 1
Scott Anderson, District 2
Acting City Manager Rusty Johnson, District 3
V. Eugene Williford, III --- Nancy J. Parker, District 4
STAFF REPORT
TO: The Honorable Mayor and City Commissioners
FROM: David Wheeler, P.E., Public Works Director
DATE: June 1, 2004
RE: Recognition for Don Smith, Wastewater Operator Class A
Innovative Idea Program
In October of 2003, Don Smith, Wastewater Operator Class A, formulated and implemented an
innovative process improvement at the City's Wastewater Treatment Plant which has resulted in
substantial energy savings as fully described in the enclosed document.
In short, Mr. Smith's modification enabled the City to decommission the pumps that
blow air into the digester, thus reducing the consumption of electricity for the operation
of the Wastewater Treatment Plant. In addition to cost savings, this modification
eliminates the noise and odor associated with the blower operation. While this
modification saves a substantial energy cost annually, it had no effect on the quality of
the sludge process.
The Public Works Department appreciates Mr. Smith's constant sprit of innovation to
save costs through process modifications.
Department of Public Works.301 Maguire Road.Ocoee.FL 34761
Phone:(407)905-3170.Fax:(407)905-3176.www.ci.ocoee.fl.us
e Center of Good L1
Mayor �b Og Commissioners
S. Scott \'anilergrifi '� t'� ' " Danny IIoweli District 1
Scott Anderson. District 2
City Manager ► 111-*; -' Rusty ,lohnson. District :3
Jim t fleason .. . . t Nancy J. Parker. District 4
MEMORANDUM
TO: David Wheeler, P.E., Director of Public Works
FROM: Robert Holland, Utilities Superintendent
DATE: October 13, 2003
RE: Innovative Committee Submission—Don Smith, Utilities Department
CC: Fred Ostrander,Chief Wastewater Operator
Attached you will find an innovative idea submitted by Don Smith wherein he made a
modification to the wasting process at the Utilities Plant. Don installed"T" fittings and an
isolation valve to facilitate the flow change, which is operating at this time.
This modification has permitted us to decommission the pumps that blow air into the digester.
The digester is no longer needed which, eliminates noise and offensive odors in and around the
Wastewater Treatment Plant. The sludge is now directly diverted to the sludge pressing
operation and an electrical cost savings of$36,963.46 per year will be recognized.
Please consider this"innovative idea"at your next meeting as we are seeing that the effect of the
modification has had no effect on the quality of the sludge process and has greatly reduced our
annual consumption of electricity.
The Citi of Ocoee• 150 N Lakeshore Drive•Ocoee. Florida 34761
phone (407)91)5-3100• fax: (407)656-8501•uunu.ci.ocoee fl ns
Modification to Ocoee Wastewater Treatment Facility
Waste Sludge Processing Procedure
Page 1
Overview of Wastewater Treatment
Incoming wastewater is treated by biomass(micro-organisms)that is nurtured in basins at
the wastewater facility. This biomass must be in balance with the strength of the incoming
waste. Because of the rapid reproduction of this biomass,some must be"wasted"each day to
maintain this balance.
The wasted biomass goes to a digester where it is retained for a number of days to
allow it to be reduced to its most stable form.
While in the digester,air must be supplied to keep it"fresh"and thereby eliminating
nuisance odors and provide oxygen for the living organisms. This air is supplied by centrifical
blowers powered by 150 hp motors.
After digestion,the biomass(now called"sludge")is sent to a belt press where the water
is removed and the sludge is formed into"cake." The cake is loaded into a semi-trailer
and taken to a processing facility.
The cake is taken to a processing facility where further treatment is accomplished.
The EPA(Environmental Protection Agency)classifies sludge into Classes. Class A sludge
requires no additional treatment after inplant processing and can be applied directly to land
applications such as orange groves,sod farms or landfills.
Our sludge is a class B and does require this additional treatment. This treatment has to
meet EPA standards for nutrient and pathogen(disease causing bacteria)reduction before
disposal.
The requirement for the additional treatment,makes on site digestion unnecessary at this
facility. Therefore,the expense of operating a digester can be eliminated. This is the basis
on which this modification has been put in place,tested and verified as viable method of operation
and a very significant cost saving procedure.
Page 2
Information Relating to the Modification
The original portion of the wastewater facility was put on line in December 1987.
Attachment 1 shows the original waste pump. I believe it has had no repairs since the
plant was put on line.
Attachment 2 shows 2 air blowers driven by 150 horsepower motors. Only one blower is
in use at a time. Each operates for one month and then are rotated. This allows time for
servicing and equalizing the run time. The blower that is in use runs for 24 hours a day, 7 days a
week. It provides air for odor control and a source of oxygen for the biomass.
The blowers have never been reconditioned since put in use. Only one of the motors has
been reconditioned.
Attachment 3 shows the Digester sludge pump(3)and flow pattern to the belt press. The
flow from the digester comes through a 90 degree fitting(2) into the sludge pump(3)and as
indicated by the arrows, it then flows to the belt press. Fitting(1)a 90 degree fitting is used only
when transferring sludge from one side of the digester to the other side.
NOTE: The digester sludge pump was replaced with a new one approx. 1 year ago.
Attachment 4 shows the wasting modification completed. Fittings 1 and 2 shown on
attachment 3 were removed and"T"fittings were installed in their place. The"T"fittings are
shown as 4 and 5 on attachment 4. The fittings 1 and 2 that were removed on attachment 3 were
reinstalled to the"T"s as shown on attachment 4.
An isolation valve(6)on attachment 4 was installed to facilitate a flow change that is in
the works at this time.
When wasting with this modification,the waste flow comes into T(4). With isolation
valve(7)closed,the flow follows the arrows to the inlet side of the sludge pump through T(5),
then through the pump and as the arrows indicate,the sludge is pumped to the belt press.
Several positive things happened with this modification. They are noted on page 3.
Page 3
Results of This Modification
Several positive things happened from this modification.
1. The original waste pump shown on attachment l is not in operation. This saves
electricity cost,although it may be minimal.The pump is in need of repair,also. Previously,
when pressing from the digester the sludge pump was utilized,and the waste pump was used for
the wasting process. Now,wasting and pressing are done at the same time and with the same
pump!!
2. The amount of biomass per gallon of water determines how many gallons you have to
waste to maintain the balance between the incoming wastewater and the biomass. The more
biomass per gallon,the less gallons need to be wasted. Wasting with the original waste pump,
our biomass concentration usually was around.75%. Wasting with the modification,our
biomass concentration averaged 1.38%for the month of July!! Instead of operating the press for
7 hours a day 5 days a week,we now operate it approx 3-4 hours a day for 7 days. Asa result,
our cake hauling has decreased from 4-5 loads a week to3-4,saving at least the cost of one truck
load a week!!
3. We now have the option of two different pumps that can waste directly to the press.
If one pump is out of service,another can be utilized.
4. Our neighbors will not be subject to nuisance odors from the digester,nor the sound of
the operating air blowers. The city will not have to respond to odor complaints because of a
poorly operating digester!
5. Some of the equipment that has been taken out of service still needs preventative
maintenance and some need corrective maintenance. This does not eliminate the need but it will
defer any monetary outlay at this time. It is well to note,all equipment taken out of service as a
result of this modification is still very much operational and can be put in service at a moments
notice.
6. All of the above are perks!! The driving force behind this modification was the
thought of saving US for our city. Operating the air blower with the 150 hp motor 24 hrs a day,
7 days a week cost money. Progress Energy estimated the cost of running this motor as stated,at
its full capacity would cost$75,489.30 a year. ( See attachment). We did not need to run at full
capacity. We do have proof of actual savings at this time!!
Page 4
7. For the month of August, Utility Dept used 208,610 kw of electricity compared to
173,420 kw for the month of September.GOOD NEWS!! This is a reduction of 35,190 kw!!
Bad news....our electric bill was$12,718.30 for the month of August. GOOD NEWS!! Our
electric bill went down to$9,638.01. This is a reduction of$3080.29!!! This equates to a
savings of$36,963.48 per year!!
On the negative side of this modification,was the cost of the materials to install it.
Although the cost to effect the modification was minimal,it is included below for your
information.
ITEM QUANTITY COST
6 inch valve 1 $292.67
"T"fitting 2 $199.90
Flange adapters/seals 4 $168.56
6 inch PVC pipe 8 ft (From stock)
TOTAL COST $661.13
One supervisor and 6 technicians within the Utility Dept performed the modification
within approx two hours.The modification was completed during time when there was no
outstanding"public work"to be completed. The modification was completed in an outstanding
manner and has been in operation for more than a month!! KUDOS!!!
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Page 1 of I
Cornell, Pat
From: Gleason, James
Sent: Tuesday, October 07,2003 2:19 PM
To: Cornell, Pat
Cc: Wheeler, David; Holland, Robert; Diedrich, Fran; Horton,Wanda
Subject: RE: Innovative Idea Committee
Importance: High
The committee is in place-we are waiting on David Wheeler to rule on the submitted application!
Jim Gleason
Ocoee City Manager
150 North Lakeshore Drive
Ocoee,Fl. 34761
jgleason@ci.ocoee.fl.us
Work: 407-905-3111
Fax: 407-656-6885
Cell: 407-509-2770
"The ignorance of one voter in a democracy impairs the security of all."
-John F. Kennedy-
Original Message
From: Cornell, Pat
Sent:Tuesday, October 07, 2003 10:56 AM
To: Gleason, James
Cc: Wheeler, David; Holland, Robert
Subject: Innovative Idea Committee
At the Supervisor's meeting on this date,we discussed the Innovative Idea program. It
was determined that at the time that this program was active, the committee members
were comprised of: the Human Resources Director, City Engineer, City Manager, Finance
Director and a City Commissioner. I would like to assist in re-establishing this committee
as an active entity; as we have some very cost saving and progressive ideas that are ready
for submission to the committee members. I will be happy to assist you in any way that I
can to re-active this committee with whomever you choose to make up the committee
group. Please let me know what direction you would like to go with this and what steps
you would have me take to assist you.
10/13/2003