Sl d Sludge Handling Automation Sludge Handling Automation Sl d H - PowerPoint PPT Presentation

Sl d Sludge Handling Automation Sludge Handling Automation Sl d H H dli dli A t A t ti ti MECH/MECA 440 B– Senior Project Spring 2010 Final Design Presentation Tuesday, May 11 th , 2010 y, y ,

Design Team Members Design Team Members Mechatronic Mechanical Engineering Engineering Ahmad Aladdasi Ahmad Aladdasi Carlos Cabrera Carlos Cabrera Mechatronic Mechatronic Engineering Engineering Keith Lindauer Nik Tkachenko Faculty Advisor : Dr. Ramesh Varahamurti

Industry Sponsor Industry Sponsor USS POSCO INDUSTRIES “ “…To conduct business in a manner that provides T d t b i i th t id maximum value to our customers, owners, and employees. To be the Safest, Most Competitive Flat Rolled Steel Company” Flat Rolled Steel Company

Project Background Project Background � Water Water utilized at the facility is utilized at the facility is treated and treated and returned to San Joaquin ret rned to San Joaq in ret rned to San Joaq in ri er/ Ne returned to San Joaquin river/ New York river/ New York ri er/ Ne York York Slough. Slough. � Alum is introduced in the process to meet Alum is introduced in the process to meet state clarity state clarity requirements, creating sludge. requirements, creating sludge. � Sludge is sent to an Oil Separation Unit Sludge is sent to an Oil Separation Unit (OSU) (OSU) (OSU). (OSU).

OSU Clarifiers

Project Background Project Background Project Background Project Background S l Selector Valve t V l Clarifier Valve Flush Valve Flush Valve Pump Current Pumping System

Project Need Project Need Pump the sludge from the Pump the sludge from the clarifiers Pump the sludge from the Pump the sludge from the clarifiers clarifiers to the clarifiers to the to the to the Oil Separation Unit without human assistance Oil Separation Unit without human assistance Clarifiers OSU

Goal Statement Goal Statement Automate the existing procedure to pump the A t A t Automate the existing procedure to pump the t t th th i ti i ti d d t t th th correct consistency of sludge from the correct consistency of sludge from the Cl Clarifiers to the Oil Separation Unit (OSU). Clarifiers to the Oil Separation Unit (OSU). Cl ifi ifi t t th th Oil S Oil S ti ti U it (OSU) U it (OSU) Pneumatic Actuator PLC

Customer Requirements Customer Requirements Customer Requirements Customer Requirements • The Design Solution Must : • Automate the sludge pumping system • Automate the sludge pumping system • Switch between clarifiers • Utilize Emergency Switch • Back flush Back flush • The Design Solution Should : •Human Machine Interface • Would be Nice : Would be Nice : • Positive displacement pump analysis

Engineering Specifications & Engineering Specifications & Targets Targets Requirements Specification Metric Method/Device Target Range Conditions 50 ± 10 GPM Minimum Pump Sludge Flow Rate GPM Flow meter 100 ± 10 GPM Maximum 20% ± 5% solids Minimum % Solids in Water Regulate Sludge PPM Turbidity Meter Solution 60% ± 5% solids Maximum Pressure in Pipes Pressure PSI Pressure Gauge < 150 PSI Maximum

Design Solution Design Solution PLC

Design Solution Design Solution Design Solution Design Solution

Design Solution Design Solution Design Solution Design Solution

Design Solution Design Solution Design Solution Design Solution

Design Solution Design Solution PLC Interface With the System Nusonics Flow meter 115 VAC Power Supply Optical Turbidity Series 90 G.E Programmable Meter Logic Controller Rugged Pressure Centrifugal Pump Sensor Electro-Mechanical Actuator

Design Solution Design Solution Design Solution Design Solution PLC PLC Genius Blocks

Design Solution Design Solution Open South Open North Clarifier Clarifier Valve Valve Open Flush Valve Full Valve Full Close Stop Pump, Clarifier Close all Valve Valves

Design Solution Design Solution Close Flush Valve Close Clarifier Valve Stop Pump, Close all Valves

Design Solution Design Solution Stop Pump, Close all V l Valves

Fabrication Changes Fabrication Changes Fabrication Changes Fabrication Changes � Design Changes � Design Changes Design Changes Design Changes � Actuators Actuators – – Now Pneumatic Now Pneumatic � Valves Valves Valves Valves – Now Butterfly Now Butterfly Now Butterfly Now Butterfly � Pump Pump – – Only 1 Required Only 1 Required � Simulation of Turbidity Meter Si Si Simulation of Turbidity Meter l ti l ti f T f T bidit M t bidit M t

Testing Overview Testing Overview Testing Overview Testing Overview � Tests/Checks � Tests/Checks Tests/Checks Tests/Checks � Assembly/Wiring Check Assembly/Wiring Check � Engineering Requirements Test Engineering Requirements Test Engineering Requirements Test Engineering Requirements Test • System Isolation Test System Isolation Test • Emergency Stop Test Emergency Stop Test Emergency Stop Test Emergency Stop Test • Automatic Test Automatic Test • Semi Semi- -Automatic Test Automatic Test

Test Results Test Results Test Results Test Results � Assembly/Wiring � Assembly/Wiring Assembly/Wiring Assembly/Wiring � PASS PASS � System Isolation � System Isolation System Isolation System Isolation � PASS PASS � Emergency Stop Emergency Stop � PASS PASS

Test Results Test Results Test Results Test Results Test Results Test Results Requirements Specification Metric Method/Device (Semi- Conditions (Automatic) Automatic) 18 GPM 18 G 16 GPM 16 G Mi i Minimum Pump Sludge Flow Rate GPM Flow meter 65 GPM 49 GPM Maximum Target Range Minimum N/A N/A % Solids in Regulate Sludge PPM Turbidity Meter Water Solution Maximum N/A N/A Pressure in Pipes Pressure PSI Pressure Gauge 60 PSI 53 PSI Maximum

Discussion of Results Discussion of Results Discussion of Results Discussion of Results Test Results Method/ Test Results Requirements Specification Metric Target Range (Semi- Conditions Device (Automatic) Automatic) 50 ± 10 GPM Flow Fl 50 10 GPM 18 G 18 GPM 16 G 16 GPM Minimum Mi i Pump Sludge Flow Rate GPM meter 100 ± 10 GPM 65 GPM 49 GPM Maximum 20% ± 5% solids Minimum N/A N/A Regulate % Solids in Turbidity PPM Sludge Water Solution Meter 60% ± 5% solids Maximum N/A N/A Pressure in Pressure Pressure PSI < 150 PSI Maximum 60 PSI 53 PSI Pipes Gauge

Budget Budget Final Unit Price Unit Price Quantity Quantity Price Centrifugal Pumps $1,125 2 $2,500 4” - #150 Pipe $5/ft 100 $500 G.E. PLC + 2 Blocks $5,000 1 $5,000 Available to Use, 2” Actuated butterfly flow screw $2301 1 $2,301 (Already 4” pneumatic Actuated Butterfly valve $2301 3 $6,903 Purchased Parts) 2” Gate valve $1000 2 $2,000 4” WCB check Gate 4 WCB check Gate $500 $ 3 $1,500 $ , Nusonics inc. Flow meter $10,000 1 $10,000 4” Butterfly gate valve $500 2 $1000 4” Garloc expansion joints $550 1 $550 Parts Needed Viatran 548 Pressure Gauge $200 1 $200 Turbidity Meter and Assembly $8,000 1 $8,000 Labor Mech. Eng. $ 34.97/hour 100 $ 3,497 Design Design Meca. Eng. $ 36.8/hour 400 $ 14,720 Manufacturing $ 50/hour 25 $1,250 Overhead @ 40% per labor hour $8,980 Benefits @ 37% per labor hour $8,307 Total Cost = $77,208 Parts on Hand = $32,254 Donated Labor + Expenses = $21,200 + 17,287 = $36,754 Final Cost = $77,208 – $69,008 = $ 8,200

Additional Content Additional Content Additional Content Additional Content � Unique problems encountered � Unique problems encountered Unique problems encountered Unique problems encountered � Turbidity Meter(Shipping Times) Turbidity Meter(Shipping Times) • Simulate using current supply • Simulate using current supply Simulate using current supply Simulate using current supply � Suggestions for the future Suggestions for the future � Change injection valve to variable position Change injection valve to variable position Change injection valve to variable position Change injection valve to variable position � Revise Specifications Revise Specifications � Refine % Solids once turbidity meter is Refine % Solids once turbidity meter is installed installed

Conclusion Conclusion Conclusion Conclusion � All the design specifications are met � All the design specifications are met All the design specifications are met All the design specifications are met

Acknowledgements Acknowledgements � USS � USS USS-Posco USS Posco Posco Posco � Frank Frank Martucci Martucci � Mike Atwood Mike Atwood Mike Atwood Mike Atwood � Natalie Natalie Tkachenko Tkachenko � Todd McHugh Todd McHugh Todd McHugh Todd McHugh � Ron Hatchel Ron Hatchel

QUESTIONS ? QUESTIONS ? QUESTIONS ? QUESTIONS ? OSU Clarifiers