An Applied Guide to Water and Effluent Treatment Plant Design PDF
Preview An Applied Guide to Water and Effluent Treatment Plant Design
An Applied Guide to Water and Effluent Treatment Plant Design An Applied Guide to Water and Effluent Treatment Plant Design Sea´n Moran Elsevier Radarweg29,POBox211,1000AEAmsterdam,Netherlands TheBoulevard,LangfordLane,Kidlington,OxfordOX51GB,UnitedKingdom 50HampshireStreet,5thFloor,Cambridge,MA02139,UnitedStates Copyright©2018ElsevierInc.Allrightsreserved. Nopartofthispublicationmaybereproducedortransmittedinanyformorbyanymeans,electronicor mechanical,includingphotocopying,recording,oranyinformationstorageandretrievalsystem,without permissioninwritingfromthepublisher.Detailsonhowtoseekpermission,furtherinformationaboutthe Publisher’spermissionspoliciesandourarrangementswithorganizationssuchastheCopyrightClearance CenterandtheCopyrightLicensingAgency,canbefoundatourwebsite:www.elsevier.com/permissions. ThisbookandtheindividualcontributionscontainedinitareprotectedundercopyrightbythePublisher (otherthanasmaybenotedherein). Notices Knowledgeandbestpracticeinthisfieldareconstantlychanging.Asnewresearchandexperience broadenourunderstanding,changesinresearchmethods,professionalpractices,ormedicaltreatment maybecomenecessary. Practitionersandresearchersmustalwaysrelyontheirownexperienceandknowledgeinevaluatingand usinganyinformation,methods,compounds,orexperimentsdescribedherein.Inusingsuchinformation ormethodstheyshouldbemindfuloftheirownsafetyandthesafetyofothers,includingpartiesfor whomtheyhaveaprofessionalresponsibility. Tothefullestextentofthelaw,neitherthePublishernortheauthors,contributors,oreditors,assume anyliabilityforanyinjuryand/ordamagetopersonsorpropertyasamatterofproductsliability, negligenceorotherwise,orfromanyuseoroperationofanymethods,products,instructions,orideas containedinthematerialherein. BritishLibraryCataloguing-in-PublicationData AcataloguerecordforthisbookisavailablefromtheBritishLibrary LibraryofCongressCataloging-in-PublicationData AcatalogrecordforthisbookisavailablefromtheLibraryofCongress ISBN:978-0-12-811309-7 ForInformationonallElsevierpublications visitourwebsiteathttps://www.elsevier.com/books-and-journals Publisher:JoeHayton AcquisitionEditor:KostasMarinakis EditorialProjectManager:LeticiaLima ProductionProjectManager:KameshRamajogi CoverDesigner:MatthewLimbert TypesetbyMPSLimited,Chennai,India Preface INTRODUCTION What qualifies me to write yet another book on water process plant design, in a market seeminglysaturated with tomes on the subject? Well, firstly, there are myqualificationsandexperience asanengineer.Igrad- uated in 1991 with a Master’s degree in Biochemical Engineering and found myselfspecializing almost exclusively inwater and effluent treatmentplant. I worked for several specialist design and build contracting companies before becoming an independent consultant in 1996. Since then, my focus has been on water treatment plant design, commissioning, troubleshooting, and forensic engineering. This last activity—acting as an expert witness in many legal disputes and sev- eral court cases where plants do not work—has opened my eyes to many of the common mistakes made by plant designers, perhaps even more so than the plant commissioningprocessitself. These activities have given me a great insight into how not to go about designing water and effluent treatment plant. What is most surprising is how many of the errors I find as a forensic engineer in the design of water treatment plants appear repeatedly. Much of engineering knowledge is knowing what not to do, and that is the subject of this book: engineering know-how (and “know- how-not”). There are several ways in which process design can go wrong. The key way, in my experience, to guarantee a poorly operating plant is to dispense with the processengineer completely.Other ways include: (cid:129) Assumingthat anyone with a degree inengineeringis an engineer;fresh engineering graduates are notengineers yet and therefore require close supervision by a professional engineer (cid:129) Lack ofclarityon who is responsible for processdesign (cid:129) Failure tomanage the design process;active management andformal quality control are required toproduce agood design (cid:129) Failure tomanage the construction andcommissioning process; active management and formal quality control are also required tobuild a good plant (cid:129) Failure tomanage operation and maintenance properly The main source of my professional knowledge—other than learning from others’mistakes—hasbeenaccesstothedesignmanualsheldbythevarious com- panies I have worked for. While these are jealously guarded commercial secrets, they share many common features. They all contain a core of information that xix xx Preface may not be in the public domain, but is common knowledge amongst experienced professional processdesign engineers. The second key qualification I have for writing this book is my experience in teaching and training engineers. I have been training other professional engineers around the world to understand water and effluent treatment plant design for morethan 20 years. Asaresult,Iknowhow(andhownot)togoaboutdesigningcosteffective,safe androbustwaterandeffluenttreatmentplants.Ialsoknowwhichpartsofthedisci- pline are most challenging for the various types of engineers and scientists in dif- ferentsectorswhoneedtounderstandorundertakethedesignofsuchplants. For example, many civil engineers have difficulty with chemistry, chemical engineers commonly flounder with biology, and scientists have trouble under- standing the difference between engineering and science. Process engineers from other industry sectors are often unfamiliar with water chemistry as well as open- channel hydraulics, far more important in water treatment than in other areas of processplantdesign. I have been teaching realistic process plant design in academia for some time, and most of my design examples have been water and effluent treatment plants. I know what beginners to process plant design find difficult; a subject I covered at a generic level in my first book, An Applied Guide to Process and Plant Design. Absolute beginners to water and effluent treatment plant design might find it use- ful to read both books, asI do notrepeat very much ofwhatis there inthis book. This book is not intended to cover every aspect of the discipline. Instead, I have focused on those aspects that I had to learn from more experienced engi- neers in order to design a working water treatment plant. There is not much in here thatyou can simply Google. As with both of my previous books I will not be following academic conven- tions of referencing. The text is based on my personal experience and that of my collaborators, on published codes and standards, and on those parts of in-house design manuals, which are too commonly replicated for anyone to reasonably consider them company-specific know-how. My sources for most of this material themselves came without formal attribution. I asked a more experienced engineer how to solve a problem, and they told me, or gave me a many times photocopied pieceof paper with a graph on it. Such is the nature ofknow how. I have not, therefore, reproduced very much in the parts of this book (beyond my explanation of engineering science), which is readily available in the public domain. I do, however, suggest texts and web resources in which such material can befound. This book isintended, likemy firstone,asa substitutefor aknowl- edgeable mentor, willing to freely disclose the core knowledge of the discipline that so many of us like to keep to ourselves. It is written in an informal style appropriate to interactions between mentor and mentee, but the informality does not imply lack of rigor. As with all my books the content has been validated by review byotherexperienced engineers. Inshort,thisisthebookIwishedIcouldhaveboughtwhenIstartedinthesector. Preface xxi STRUCTURE The first section of the book is an overview of practical process plant design, based largely on the consensus professional approach I have set out in my two previousbooks.Thisisfollowedbyasectiongivinganoverviewofrelevantengi- neering science. The book ends with sections on classic mistakes to avoid, trou- bleshootingand the specialistarea of large-scale water feature design. The main body of the book, between these sections, is split into water and sludge treatment. Water treatment is further split into clean, dirty, and industrial effluenttreatment. I have divided the unit operation design part of these chapters into physical, chemical, and biological processes. I could, alternatively, have split the processes by stage of treatment, but this involves as many compromises as the structure I ultimately chose. The absence of any perfect way to structure the material generated several orphan chapters, offered ina“Miscellany” sectionat the end. Finally, appendixes are provided to cover detailed consideration of some issues in engineering science, general process design, and specific design proce- dures which, though important and poorly covered in the existing literature, would interrupt the flow if placedinthe main body of the book. Sea´n Moran Derbyshire, United Kingdom 2017 Acknowledgments I would like to thank the many contributors who have helped with the production and planning of this book. Firstly, sincere thanks to the editorial and production team at Elsevier, particularly Fiona Geraghty, Kostas Marinakis, Edward Payne, and Leticia Lima who have all supported me throughout my book-writing ventures andsteered thisparticular project from inception through topublication. Rosie Fernyhough and Alun Rees both assisted with the tedious but crucial task of proofreading and also made helpful suggestions during the writing of this book. Many thanks to all those individuals and companies who have kindly supplied images and information, including Tim Allen at Durapipe, Adriaan van der Beek at JWC Environmental, Denise Bennett and Jeremy Dudley at WRc plc, Piotr Brozda at PCI Membranes, Linda Dingley at Grundfos, Ken Edwards at LMNO Engineering, Nazir Haji at EEMUA, Professor Simon Judd, Razib Khan, Tosh Singh at Lutz-Jesco (GB) Ltd, Vicky West at CIWEM, Kim Woochan at ROplant.org and Murphy Yuan at the Shanghai Xunhui Environment Technology Co.,Ltd. Special thanks to Geoffrey Blumber at Hexagon PPM for supplying another striking frontcover image fromone oftheir client projects. Finally, thank you to my wife Annemarie for all her work on preparing and checkingthe manuscript and managing the project. xxiii CHAPTER 1 Introduction: the nature of water and effluent treatment plant design CHAPTER OUTLINE WhatisthisBookAbout?.............................................................................................1 ABriefHistoryofWaterTreatmentPlantDesign...........................................................2 TheLiteratureofWaterTreatmentPlantDesign............................................................3 InteractionwithOtherEngineeringDisciplines..............................................................3 HydraulicCalculations................................................................................................4 WaterChemistry.........................................................................................................4 WaterBiology.............................................................................................................4 Economics..................................................................................................................4 MaterialsSelection.....................................................................................................5 TheImportanceofStatisticsinWaterandEffluentTreatment........................................5 StatisticsinSewageTreatmentPlantDesignandPerformance...........................6 StatisticsandDischargeConsents...................................................................7 ContractualArrangementsinWaterandEffluentTreatment............................................8 MisconceptionsinWaterandEffluentTreatmentPlantDesign.....................................10 Chemical/ProcessEngineeringMisconceptions................................................10 AcademicMisconceptions.............................................................................10 SalesMisconceptions...................................................................................11 FurtherReading........................................................................................................12 WHAT IS THIS BOOK ABOUT? This is a book about designing water and effluent treatment plants. These plants are groups of machines (plus ancillary machines) which process relatively dirty water into relatively cleanwater over aseries oflinked stages. In professional practice, the design of water and effluent treatment plants is largely based on longstanding heuristics, supported to some extent nowadays by engineering science and mathematics. This book is based upon some of the most elusive parts of the body of design knowledge which I have amassed over my 25 years of professional practice; the sort of knowledge which rarely makes it into the public domain, which I would pass on tosomeone I was mentoring. AnAppliedGuidetoWaterandEffluentTreatmentPlantDesign.DOI:https://doi.org/10.1016/B978-0-12-811309-7.00001-1 1 ©2018ElsevierInc.Allrightsreserved. 2 CHAPTER 1 Introduction FIGURE1.1 BronzeRomanhydraulicpump.1 Courtesy:Lalupa. I have gone to great pains to make sure that this book is as close as possible to current consensus best practice. It is however general in nature (though I have offered limits on applicability where I am aware of them), and only offered for guidance. A BRIEF HISTORY OF WATER TREATMENT PLANT DESIGN Water engineering has a long pedigree. Fig. 1.1 shows a Bronze Roman hydraulic pump and adjustable nozzle dating from 1 to 200AD, found in a mine in Huelva province, Spain. While the Romans were impressivewater engineers, the modern forms of both dirtyand clean water engineeringwere pioneered inthe United Kingdom. Historically, civil engineers tended to be responsible for the design of munici- pal water treatmentplants, with assistance from chemists for process development 1LicensedunderCCBY-SA3.0:https://creativecommons.org/licenses/by-sa/3.0/deed.en
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