Engineers' Society of Western Pennsylvania


337 Fourth Avenue
Pittsburgh, PA 15222

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Monday, November 13

Technical Sessions – 1:15-5:00 p.m.

Pre-Commissioning of Combined Cycle Plants

IWC Rep: Debbie Bloom, Wheaton, IL
Session Chair: Bob Bartholomew, Sheppard T. Powell Associates, LLC, Baltimore, MD
Discussion Leader: Doug Dewitt-Dick, Global Water Experts, Kemah, TX

This session presents an overview of the recently published Consensus on Pre-Commissioning Stages for Cogeneration and Combined Cycle Power Plants, developed by the Water Technology Subcommittee of the ASME Research and Technology Committee On Water and Steam in Thermal Systems. Other featured papers present experience and case studies on commissioning sample panels at combined cycle plants, condensate polishing systems for combined cycle power plants and specifications for combined cycle power plants.
Consider Attending: W01/A; W06; W09; W13

IWC 17-13: Consensus on Pre-Commissioning Stages for Cogeneration and Combined Cycle Power Plants
Edward (Ted) Beardwood, Solenis LLC, Wilmington, DE

The Combined Cycle Task Group for the Water Technology Subcommittee of the ASME Research and Technology Committee On Water and Steam in Thermal Systems have prepared this 90 page report (ISBN: 978-0-7918-6126-4) and is now available to the public. The presentation will introduce the elements of the consensus report and highlight some of its features.
This document provides guidance on design, procurement, and pre-commissioning activities that will result in the construction of a plant with steam/water-wetted surfaces that are as clean and corrosion-free as practical. Issues can surface during the commissioning of a combined cycle power plant that cause unintended delays, cost overruns, increased post start-up maintenance, and depreciation of equipment. Consensus recommendations have been developed to minimize these risks and improve long-term reliability. The material contained in the document is also transportable and transferable to other steam generation systems.

Discusser: Edward Sylvester, Jr., ChemTreat, Brentwood, TN

IWC 17-14: Commissioning New Sample Panels and Online Analyzers for HRSG Plants
Carl Feichtel and Robert Bartholomew, Sheppard T. Powell Associates, LLC, Baltimore, MD

Sample conditioning, online analysis and immediate corrective actions are essential during startup for protection of critical steam and water components. This paper presents past experiences of events and actions taken during startup and commissioning of sample conditioning and online chemistry monitoring panels for new combined cycle HRSGs. Proper programming, calibration, panel maintenance and continuous surveillance are needed. Risks from unit trips, condenser leaks, polisher exhaustion and other upsets also are addressed.

Discusser: David Daniels, M&M Engineering Associates, Leander, TX

IWC 17-15: Planning Ahead to Minimize Chemistry Challenges during Combined Cycle Power Plant
Colleen Layman, HDR, Inc., Whitewater, WI

This paper will explore the factors that should be considered when planning for commissioning of combined cycle power plants focusing on items related to the steam/water cycle chemistry. It will address items that should be considered during the design and construction phases of the project including equipment specification, design for testing and commissioning, shop inspections, and cycle chemistry process and procedure development. The discussion will include best industry practices and lessons learned from commissioning experiences.

Discusser: James Bellows, James Bellows and Associates, LLC, Maitland, FL

IWC 17-16: Selecting the Best Path Forward: Condensate Polisher Position Paper
Bryant Purse, Brad Buecker, Brian Clarke, and Steve Russell, Kiewit Engineering Group Inc., Lenexa, KS

When evaluating whether or not condensate polishers are essential for natural gas combined cycle plants, the primary factor has been the capital investment of the equipment. However, research has shown that in some cases the perceived high cost of condensate polishers is typically quite minimal compared to their benefits. This paper will present the life cycle cost of a condensate polisher and give justifications for when they are needed at new facilities.

Discusser: John Kelly, United Water Consultants, Chicago, IL


Wastewater Membranes: Advancing Municipal and Industrial Recycling and Reuse

IWC Rep: Scott Quinlan, GAI Consultants, Cranberry Township, PA
Session Chair: Dan Sampson, HDR, Vallejo, CA
Discussion Leader: David Weakley II, GAI, Homestead, PA

Membrane technology plays an increasingly critical role in wastewater recycling and reuse. While straightforward in theory, practical applications require attention to detail. This session provides detail by focusing on case studies, beginning with the use of municipal tertiary treatment water to replace drinking water. The discussion then shifts to industrial processes with a case study of a high recovery secondary RO at a refinery and then a case study of ceramic membranes to treat and reuse metal- and oil-contaminated wastewater. The session closes with a novel wastewater membrane design that may provide benefit to a variety of industries.
Consider Attending: W01/A; W03/A; W09; W11; W18

IWC 17-17: Switching from Drinking Water to Municipal Tertiary Wastewater for Industrial Plant Makeup: Design Progression through Installation and Operation
Mitch Mueller, Black & Veatch, Overland Park, KS; Melanie Blake, Koch Membrane Systems, Inc., Wilmington, MA

Tertiary wastewater is being used at industrial facilities to deal with water scarcity issues. This paper describes steps leading to selecting tertiary wastewater as makeup for an industrial facility, selecting a treatment approach, pilot testing, system design, startup and operation and other considerations when using tertiary wastewater. Final design consisted of ultrafiltration and reverse osmosis treatment for cooling tower and boiler makeup, and a phosphate reduction system to meet wastewater discharge permit limits.

Discusser: Brittany Hohman, P.E., Veolia Water Technologies, Moon Township, PA

IWC 17-18: A Unique High Recovery Secondary RO to Resolve Refinery Source Water and Brine Disposal Issues
Ed Greenwood, Amec Foster Wheeler, Cambridge, ON, Canada; John Christiansen, P.E., Amec Foster Wheeler, Houston, TX; Dan Kwiecinski, P.E., Amec Foster Wheeler, Albuquerque, NM; Scott Denton, The HollyFrontier Companies, Artesia, NM; Robert Kimball, Amec Foster Wheeler, Denver, CO

Amec Foster Wheeler designed and constructed a unique high recovery Secondary RO system at a Refinery in New Mexico to resolve source water and wastewater disposal limitations. The new system is directly coupled to the Primary RO System and operates beyond the solubility limits for Silica and Calcium Sulfate by using a unique high recovery three stage array with both permeate and concentrate recycle loops to optimize performance.

Discusser: Michael Bluemle, Solenis LLC, Wilmington, DE

IWC 17-19: The Use of Ceramic Membranes to Reuse Waste Water Contaminated with Cr VI and O&G and to Allow for Production Capacity Expansion
Benoit Tranape, Tracey Williams, and Chris Sakorafos, Veolia Water Technologies, Waltham, MA

A Midwest aerospace components manufacturer generates waste rinse waters from over 1,500 finishing processes containing Chromium VI, Oil and Grease, Total Suspended Solids, and surfactants. This paper discusses the successful application of a ceramic based membrane process to effectively process these pretreated contaminated waste waters in a single step process, removing Cr, TSS, O&G, and a portion of the surfactants, allowing for more than 80% of the wastewater to be recycled through RO treatment.

Discusser: Holly Churman, GHD, Houston, TX

IWC 17-20: Use of a Novel Membrane Technology to Treat Industrial Process and Waste Waters
James Peters, PPG Industries, Monroeville, PA

This paper will review a novel composite single layer membrane that provides high flux, excellent separation capabilities and durability. The presentation will review intrinsic membrane properties that create a durable, fouling resistant and high flux membrane. Lab scale and pilot field tests will be reviewed in a variety of industries. The case studies will focus on how the new filtration technology met real world customer needs allowing scale-up to larger field tests or commercial units.

Discusser: Adhiraj Joshi, Aquatech International, LLC, Canonsburg, PA


Making Connections: Wastewater Fundamentals Across Industries

IWC Rep: Brad Wolf, Berkeley Research Group, LLC, Pittsburgh, PA
Session Chair: Jane Kucera, NALCO Water, an ECOLAB Company, Naperville, IL

The objective of this session is to introduce the audience to the fundamentals of wastewater laying the groundwork for active participation in the more detailed presentations in the other technical sessions of the conference. Wastewater is the final step of water treatment in any facility and is absolutely critical to the ultimate sustainable operations of that facility. Cooling towers, boiler systems (pretreatment and blowdown), desalters, tank drainings, cleaning, and other operations generate wastewater in almost every industry. Prior to its final disposition, this wastewater must be treated rather than directly discharged. The session will begin with a discussion of water analytics. Correctly analyzing and characterizing wastewater is critical to understanding and managing a waste treatment plant and successfully controlling the effluent quality. The session will then discuss three typical types of wastewater from key industries including: refineries, power plants, and produced water. The papers will help the attendees understand the fundamental aspects of each of these wastewaters from the 10,000 foot level, including where the waste comes from, issues related to various sources, how to treat it, and various options for discharge or reuse.
Consider Attending: W01/A; W08; W09; W15; W21

IWC 17-21: Analyzing a Water Analysis
Dennis McBride, Burns & McDonnell, Kansas City, MO

The process of designing, operating, and troubleshooting a water treatment system almost always begins with a water analysis. This analysis may be performed in a specialty laboratory, in a plant lab, or by personnel in the field. Each method has its advantages as well as disadvantages. Unfortunately, many times the analysis may be flawed (e.g. does not balance ionically), reported poorly (e.g. reported units not included in the report), or misunderstood by the recipient charged with its use (e.g. recipient does not consider the units reported, critical species may change in transport to the lab). This paper will talk about the differences between a potable and an industrial water analysis, which chemical species may be critical in an industrial water analysis, the importance of reporting and understanding the units, normal variability in various samples (i.e. well water versus surface water), as well as some tricks in evaluating the analysis for balance and completeness.

IWC 17-22: Water and Wastewater Fundamentals: Petroleum Refineries
Harley Schreiber and Floyd Griffiths, WesTech Engineering, Inc., Salt Lake City, UT

Wastewater generated in refineries can present challenging treatment problems. The wide range of constituents can include suspended solids, dissolved metals and organics as well as oils and grease. Pretreatment of raw water and processing of plant wastewater requires fundamental knowledge of physical, chemical and biological separations methods and associated equipment. Although general in nature, this paper will form a sound foundation by which the reader can build their knowledge base and apply this to other wastewater treatment challenges.

IWC 17-23: Power Plant Wastewater Treatment – A Fundamentals Introduction
Jeff Easton and Jaron Stanley, WesTech, Salt Lake City, UT

Power plants use large amounts of water for cooling, material handling, cleaning and waste removal. Significant amounts of wastewater are produced requiring treatment prior to reuse or discharge. Understanding the basic flowsheets and treatment methods can be quite useful for those new to the industry or those who would like a better understanding of power plant wastewater needs. This presentation discusses wastewater sources and waste constituents including effluent requirements, treatment methods and basic flow sheets.

IWC 17-24: Wastewater Fundamentals: Produced Water
Jason Burney, Ph.D., Carol Batton, Michael Weberski, and Michelle Samuels, Nalco Champion, an Ecolab Company, Naperville, IL

Produced water refers to water returned as a byproduct associated with oil and gas extraction processes and is an industrial waste stream. The quality varies widely depending upon geography, well age, and hydrocarbon type of the producing site. Produced water management is key to protecting the environment, reducing future fresh water demands and helping control production costs. This paper presents a produced water overview identifying components, handling challenges, and treatment strategies for different end uses.


ZLD Industrial Applications

IWC Rep: Jonathan Shimko, Tetra Tech, Pittsburgh, PA
Session Chair: Mike Preston, Black & Veatch Corporation, Oakland Park, KS
Discussion Leader: Lanny Weimer, GE Power, Water & Process Technologies, Ormond Beach, FL

Zero liquid discharge is goal that is being pursued across a variety of industrial applications.  The application of ZLD water management and treatment systems in various settings can be informative and stimulate cost effective applications from one industry to another.  This Session will consider ZLD approaches in refining, electronics, mining, and power.  Hear how they applied different ZLD approaches and what they learned in the process.
Consider Attending: W01/A; W04/A; W09; W16

IWC 17-25: Refinery Wastewater Treatment: From API to Evaporator
Americus Mitchell, Sunil Sajja, and Joseph Guida, Fluor, Sugar Land, TX

The design of refinery wastewater treatment plants is an engineering task, which requires experience in refinery operations and knowledge of wastewater treatment systems and equipment. This knowledge and experience was tested in the design of a Zero Liquid Discharge System for a refinery in the Middle East. Normal design issues such as removal of free/emulsified oil and residual organics are compounded by requirements of downstream units. These issues along with other details will be discussed.

Discusser: Jim Beninati, HDR Engineering, Inc., Pittsburgh, PA

IWC 17-26: Three Years of Full Scale Operational Experience from a Zero Liquid Waste (ZLW) Treatment Facility
Srikanth Muddasani, Kashi Banerjee, and Keith Benson, Veolia Water Technologies, Moon Township, PA

A ZLW plant was built in 2013 in a remote area in the mountains of WV to treat mine water collected from six different locations. The objective of this treatment plant was to meet a strict regulatory limitation imposed by DEP for chlorides (<218 mg/l) discharged to surface water. The mine water is treated using advanced treatment technology to produce clean water for reuse or discharge. Paper will describe treatment steps and operating data.

Discusser: Craig Van Dyke, GE Water, Bellevue, WA

IWC 17-27: Zero Liquid Discharge in Thin Film Transistor Manufacturing
Bruce Bishkin, GE Water & Process Technologies, Bellevue, WA; Arthur Lin, Chunghwa Picture Tubes, LTD, Taoyuan City, Taiwan

Case study of a Taiwanese thin film transistor manufacturer having wastewater with high levels of fluoride and ammonia implementing a zero liquid discharge solution. Technologies employed included forced circulation crystallizer, falling film evaporator, mechanical vapor recompression, and indexing pressure filter.

Discusser: Jeffery Preece, EPRI, Charlotte, NC

IWC 17-28: Thermal Evaporative Systems for Volume Reduction and Water Balance
Todd Whiting, Purestream Services, a Swire Company, Salt Lake City, UT

Maintaining balance and levels in cooling tower evaporation ponds is a challenge for many power plants. Long-term water balance studies and plans to effectively manage water flows from cooling towers, wastewater storage and re-use help for overall understanding of balance and historical data can help forecast for future challenges. However, unseen variables, including fluctuating power demand, logistics, regulatory, construction costs of additional ponds, company zero-liquid discharge policies, fresh water sourcing, and operations contribute to the complicated process of discovering a practical and cost effective solution for the over-abundance of wastewater and available storage. In some cases, thermal evaporative technologies may provide an economic and effective alternative solution for volume reduction, re-cycling or other disposal methods such as trucking and offsite disposal. This presentation will review case studies of two water imbalance scenarios and provide a narrative of how power plants may implement thermal evaporative modular systems to resolve water imbalance in plant evaporation ponds.

The presentation will include an overview of mechanical vapor recompression submerged-core technology. Data on volume, estimated energy requirements, chemistry requirements, operational perimeters, and R&M will also be included. Cost comparisons with other volume reduction technologies and disposal methods will be reviewed.

Discusser: Christian Haussmann, P.E., Water Systems Specialists, Inc., Seattle, WA