Aeration control system design : a practical guide to energy and process optimization

Combining principles and practices from mechanical, electrical, and environmental engineering, this book enables you to analyze, design, implement, and test automatic wastewater aeration control systems and processes. It brings together all the process requirements, mechanical equipment operations, instrumentation and controls, carefully explaining how all of these elements are integrated into successful aeration control systems. Moreover, Aeration Control System Design features a host of practical, state-of-the-technology tools for determining energy and process improvements, payback calculations, system commissioning, and more.

Author Thomas E. Jenkins has three decades of hands-on experience in every phase of aeration control systems design and implementation. He presents not only the most current theory and technology, but also practical tips and techniques that can only be gained by many years of experience. Inside the book, readers will find:

Full integration of process, mechanical, and electrical engineering considerations Alternate control strategies and algorithms that provide better performance than conventional proportional-integral-derivative control Practical considerations and analytical techniques for system evaluation and design New feedforward control technologies and advanced process monitoring systems

Throughout the book, example problems based on field experience illustrate how the principles and techniques discussed in the book are used to create successful aeration control systems. Moreover, there are plenty of equations, charts, figures, and diagrams to support readers at every stage of the design and implementation process.

In summary, Aeration Control System Design makes it possible for engineering students and professionals to design systems that meet all mechanical, electrical, and process requirements in order to ensure effective and efficient operations.

Author Notes

Thomas E. Jenkins, PE, is an owner and President of JenTech Inc., where he provides consultation services to the wastewater treatment industry, including control systems, aeration systems, energy conservation, blower systems, and process equipment design. He also cofounded Energy Strategies Corporation in 1984. Mr. Jenkins is a Professor of Practice in the Department of Civil and Environmental Engineering at the University of Wisconsin-Madison. He also teaches water and wastewater treatment classes in the University's Department of Engineering Professional Development.

Preface	p. xi
Acknowledgments	p. xiii
List of Figures	p. xv
List of Tables	p. xxi
1 Introduction	p. 1
1.1 Basic Concepts and Objectives	p. 2
1.2 Safety	p. 9
1.3 The Importance of an Integrated Approach	p. 10
1.4 Importance of Operator Involvement	p. 13
1.5 The Benefits of Successful Aeration Process Automation	p. 14
1.5.1 Energy Cost Reduction	p. 14
1.5.2 Treatment Performance	p. 18
1.5.3 Improved Equipment Life	p. 18
ExampleProblems	p. 19
2 Initial System Assessment	p. 21
2.1 Define Current Operations	p. 24
2.1.1 Energy Cost	p. 25
2.1.2 Energy Consumption Patterns	p. 29
2.1.3 Influent and Effluent Process Parameters	p. 35
2.1.4 Treatment Performance	p. 36
2.2 Evaluate Process and Equipment	p. 37
2.3 Benchmark Performance	p. 40
2.4 Estimate Potential Energy Savings and Performance Improvement	p. 42
2.5 Prepare Report	p. 45
ExampleProblems	p. 47
3 Aeration Processes	p. 49
3.1 Process Fundamentals	p. 49
3.1.1 Peripheral Equipment and Processes	p. 55
3.1.2 BOD Removal	p. 62
3.1.3 Nitrification	p. 66
3.1.4 Denitrification	p. 67
3.2 Loading Variations and Their Implications	p. 68
3.3 Process Limitations and Their Impact on Control Systems	p. 70
ExampleProblems	p. 74
4 Mechanical and Diffused Aeration Systems	p. 77
4.1 Oxygen Transfer Basics	p. 78
4.2 Types of Aerators	p. 87
4.2.1 Mechanical Aerators	p. 88
4.2.2 Mechanical Aeration Control Techniques	p. 90
4.2.3 Diffused Aeration	p. 95
4.2.4 Diffused Aeration Control Techniques	p. 103
4.3 Savings Determinations	p. 106
ExampleProblems	p. 111
5 Blowers and Blower Control	p. 113
5.1 Common Application and Selection Concerns	p. 114
5.1.1 Properties of Air	p. 114
5.1.2 Effect of Humidity	p. 119
5.1.3 Pressure Effects	p. 123
5.1.4 Common Performance Characteristics	p. 125
5.2 Positive Displacement Blowers and Control Characteristics	p. 134
5.2.1 Types and Characteristics	p. 134
5.2.2 Lobe Type PD Blowers	p. 134
5.2.3 Screw Blowers	p. 138
5.2.4 Control and Equipment Protection Considerations	p. 141
5.3 Dynamic Blowers	p. 143
5.3.1 Types and Characteristics	p. 144
5.3.2 Multistage Centrifugal Blowers	p. 150
5.3.3 Geared Single Stage Centrifugal Blowers	p. 152
5.3.4 Turbo Blowers	p. 154
5.3.5 Control and Protection Considerations	p. 155
ExampleProblems	p. 157
6 Piping Systems	p. 161
6.1 Design Considerations	p. 162
6.1.1 Layout	p. 162
6.1.2 Pipe Size	p. 172
6.1.3 Pipe Material	p. 174
6.2 Pressure Drop	p. 178
6.3 Control Valve Selection	p. 182
ExampleProblems	p. 187
7 Instrumentation	p. 191
7.1 Common Characteristics and Electrical Design Considerations	p. 192
7.2 Pressure	p. 202
7.3 Temperature	p. 205
7.4 Flow	p. 209
7.5 Analytic Instruments	p. 216
7.5.1 Dissolved Oxygen	p. 217
7.5.2 Offgas Analysis	p. 221
7.5.3 pH and ORP	p. 224
7.6 Motor Monitoring and Electrical Measurements	p. 224
7.7 Miscellaneous	p. 226
ExampleProblems	p. 230
8 Final Control Elements	p. 233
8.1 Valve Operators	p. 234
8.2 Guide Vanes	p. 238
8.3 Motor Basics	p. 239
8.4 Motor Control	p. 247
8.5 Variable Frequency Drives	p. 251
ExampleProblems	p. 259
9 Control Loops and Algorithms	p. 261
9.1 Control Fundamentals	p. 264
9.1.1 Discrete Controls	p. 264
9.1.2 Analog Control	p. 267
9.1.3 Proportional-Integral-Derivative	p. 271
9.1.4 Deadband Controllers	p. 274
9.1.5 Floating Control	p. 276
9.2 Dissolved Oxygen Control	p. 280
9.3 Aeration Basin Air Flow Control	p. 287
9.4 Pressure Control	p. 288
9.5 Most-Open-Valve Control	p. 291
9.6 Blower Control and Coordination	p. 293
9.7 Control Loop Timing Considerations	p. 302
9.8 Miscellaneous Controls	p. 303
ExampleProblems	p. 305
10 Control Components	p. 309
10.1 Programmable Logic Controllers	p. 310
10.1.1 System Architecture	p. 314
10.1.2 Program Structure	p. 315
10.1.3 Communications Networks	p. 318
10.1.4 Accommodating Instrument Inaccuracy and Failure	p. 322
10.2 Distributed Control Systems	p. 323
10.3 Human Machine Interfaces	p. 323
10.3.1 Supervisory Control and Data Acquisition	p. 325
10.3.2 Touchscreens	p. 327
10.4 Control Panel Design Considerations	p. 328
ExampleProblems	p. 330
11 Documentation	p. 333
11.1 Specification Considerations	p. 335
11.2 Data Lists	p. 338
11.3 Process and Instrumentation Diagrams	p. 341
11.4 Ladder and Loop Diagrams	p. 342
11.5 One-Line Diagrams	p. 344
11.6 Installation Drawings	p. 345
11.7 Loop Descriptions	p. 347
11.8 Operation and Maintenance Manuals	p. 348
ExampleProblems	p. 349
12 Commissioning	p. 351
12.1 Inspection	p. 354
12.2 Testing	p. 357
12.3 Tuning	p. 361
12.4 Training	p. 365
12.5 Measurement and Verification of Results	p. 368
ExampleProblems	p. 369
13 Summary	p. 371
13.1 Review of Integrated Design Procedure	p. 371
13.2 Potential Problem Areas	p. 374
13.3 Benefits	p. 375
ExampleProblems	p. 375
Appendix A Example Problem Solutions	p. 377
Appendix B List of Equations and Variables	p. 447
Bibliography	p. 485
Index	p. 487

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