Green River Filtration Facility
Plant Overview
PNWS-AWWA Conference
Bellevue, WA
Gary Fox & Hilary Lorenz
April 29, 2015
IN THE BEGINNING…
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PILOT PLANT – OWNED AND OPERATED
BY TACOMA WATER STAFF
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ALL THAT HARD WORK PAID OFF
10 gpm/sf high rate
filtration approved by
Washington State DOH
April 2012.
Donating the trailer to
education – Green River
CC
GREEN RIVER
FILTRATION FACILITY
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OVERVIEW OF THE GRFF
The Big Chunks:
• Sources - Green River and North Fork Well field
• Capacity - 90 MGD Conventional / 150 MGD Direct
• Chemicals – Coagulant, coagulant aid, polymers…
• Filter Media – Dual media: Sand and anthracite
• Solids – Process flow, Basins, Screw Press, and Haul
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GRFF SITE PLAN – WEST VS. SOUTH LAYOUT
SOLIDS
FILTERED WATER
PROCESS FLOW DIAGRAMS
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MAY 15, 2012 - 0 MONTHS
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DECEMBER 21, 2012 – 7 MONTHS
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MAY 15, 2013 – 12 MONTHS
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DECEMBER 19, 2013 – 19 MONTHS
Upwards of 190 workers per day.
Pumping ~ 10 MGD Ground Water
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JUNE 17, 2014 – 26 MONTHS
~30,000 Cu/Yds of concrete poured site-wide
4464 Settling plates (304 SS material), pre-assembled in frames -per basin
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DECEMBER 2, 2014 – 33 MONTHS
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Substantial Completion – December 16!
Declare filtration 5-1-15
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APRIL 5, 2015
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MAIN WATER PROCESS FLOW
INTAKE STRUCTURE
IMPROVEMENTS
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GREEN RIVER INTAKE PROJECT
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GUIDE VANE ARRAY
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BRUSH SCREEN CLEANER
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BEHIND SCREEN-EDUCTOR BASIN
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THE GREEN RIVER SUPPLY CONDUITS
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PROJECT AREA 1: 736’ - 8’ Diam. Polyurethane lined Steel (2003)
PROJECT AREA 2: 1180’ – concrete lined tunnel (1912, lined 1966)
PROJECT AREA 3: 716’ – 8’ Diam. Coal Tar lined Steel (1979)
PROJECT AREA 4: 506’ – TWIN 5’ Diam. Coal Tar lined Steel (1930 & 1960)
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AREA 2- CONCRETE FINAL TUNNEL
Tunnel Before Repair Work Tunnel After Repair Work
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AREA 4: 1930’S 60” PIPELINE
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1930’s Pipe Before Repair Work 1930’s Pipe Pitting Before Repair Work
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AREA 4: 1930’S 60” PIPELINE
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1930’s Pipe After Repair Work 1930’s Pipe During Repair Work (prior to polyurea lining)
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AREA 4: 1960’S 60” PIPELINE
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1960’s Pipe Before Repair Work 1960’s Pipe After Repair Work
NORTH FORK
SUPPLY
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NORTH FORK SUPPLY
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Natural river bank filtration
Remote sites – 7 miles upstream of GRFF
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NORTH FORK TANK = 3MG
BACKWASH SUPPLY TANK = 10 MG
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Blending Valves
Existing 10 MG Tank (BW Supply)
NFW Tank
TANK PIPING
30 From NFW
Wellfield
BF-14-RW-101
Ozone Injector
Pump Station
BF-14-RW-103
BF-14-RW-102
NFW Tank
Existing 10 MG Tank
2-way
Isolation
Vault
3-way
Isolation
Vault
NEW NFW TANK VS. EXISTING 10 MG TANK
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From North
Fork Wellfield
NFW Tank 10 MG Tank
To Filter
Backwash
Overflow
To Blending
Facility
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INSIDE THE 10MG TANK
OZONE SYSTEM
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OZONE GENERATION AND SIDE-STREAM
INJECTION
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PRE-TREATMENT
AND FLASH MIX
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RAW WATER METERING STRUCTURE
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FLASH MIX INJECTION AT THE DECK
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CHEMICAL INJECTION GRID
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FLASH MIX ACROSS A CHANNEL
16’
CHEMICAL BUILDING
AND COMPONENTS
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NUMBER OF NEW TANKS: 20 INCLUDING NEW
HYPO TANKS
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COMPLEX CHEMICAL PIPING - REDUNDANCY
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POINT A TO POINT Z FLEXIBILITY
MANIFOLD ASSEMBLY
COMMISSIONING AND STARTUP
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PUMPS AND ACCESSORIES
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Polymer Blending
Units
EMULSIFIED POLYMER ACTIVATION
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CHEMICALS - FROM POINT A TO POINT B
CPB 1
CPB 2
CPB 3
CPB 4 CPB 5
CPB 6 CPB 7
CPB 8
CPB 12
CPB 11
CPB 15
CPB 9
CPB 10
CPB 13
CPB 14
RED = Acidic
PURPLE = Basic
LABELS, LABELS, LABELS- LEFT OR RIGHT?
FLOCCULATION /
SEDIMENTATION
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FLOCCULATION AND SEDIMENTATION
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• 4 flocculation trains • 32 flocculators • 44’x88’ floc trains • 20 minutes detention time @ 42
MGD
• 2 sedimentation basins with 90 MGD capacity winter 168 MGD summer (algae)
• 89’x89’ sed basins • Hybrid filtration plant
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FLOW THROUGH FLOCCULATION AND SEDIMENTATION BASIN
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PLATE SETTLERS
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SLUDGE SCRAPERS
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SOLIDS BUILDUP
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CONSIDER THE MATTER SETTLED
FILTERS
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FILTER SPECS: NUMBERS FOR THE NUMBERS
PEOPLE Plant Capacity: 150 mgd Initial
168 mgd Ultimate
Filter Type : Constant Level & Rate
Number of Filters: 8
Cell Dimensions: 42 ft x 20 ft
Cells per Filter: 2
Filter Area (each): 1,680 sf
Filter Area (total): 13,440 sf
Filtration Rate (Nominal – not including recycle):
-All 8 Filters 7.7 gpm/sf (150 mgd)
8.7 gpm/sf (168 mgd)
-One Off-Line 8.9 gpm/sf (150 mgd)
9.9 gpm/sf (168 mgd)
FILTER MEDIA SPECS:
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Criterion Value
Anthracite Media
-Depth 50 in
-Effective Size 1.32 ± 0.05
-Uniformity Coefficient <1.4
-Specific Gravity 1.65
Number of super sacks (2500 lbs) 1360
Sand Media
-Depth 20 in
-Effective Size 0.66 ± 0.03
-Uniformity Coefficient <1.4
-Specific Gravity 2.63
Number of super sacks (4000 lbs) 688
STAINLESS STEEL UNDERDRAINS
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Filtration
Low Rate Backwash
with Air Scour
LOADING FILTER MEDIA
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FILTERING SOLIDS
SETTLED WATER INTO FILTERS
BACKWASH WATER OUT OF FILTERS
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FILTER PIPE GALLERY
FINISHED WATER
PUMP STATION
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5 PUMPS – 200 HP EACH – 73 MGD CAPACITY
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FILTER OUTLET WEIR STRUCTURE
Filtered unchlorinated
SHC, CS, F- added
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108” BUTTERFLY VALVE
CLEARWELLS
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CLEARWELLS
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6.6 MG Capacity
1.3 MG Capacity
285’D x 15’H
80’D x 35’H
Total Volume
Operational Volume
Max. Design Flow of Served Pipeline
Emergency Supply Duration at Peak Flow
P1 Clearwell 1.3 MG 0.45 MG 73 MGD 25 min (3 hour with 10 MG tank supply)
P5 Clearwell 6.6 MG 6.2 MG 95 MGD 1.6 hour
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BACKGROUND – WHAT IS CLEARWELL USED FOR?
• Clearwells provide operational storage to accommodate short-term variations between plant
production and plant outflow, to allow for a controlled shutdown and to maintain hydraulic grade
lines in P1 and P5 pipelines.
• CT is achieved in P1 and P5 pipelines, not in the clearwells.
M
NaO
H
SH
C
NaO
H
SH
C
SHC
HF
A
HF
A
NaO
H
SH
C PEG
10 MG Tank
From Filter Effluent
Filter Outlet
Weir Structure
Finished Water
Pump Station
Backwash
Pump Station
P1 Clearwell
P5 Clearwell
P1
P5
M
SA18
SA19
SA20
SA21
Existing
Sample
Station #5
Stormwater
Wetpond
Max WSE 905’
Min Service EL 893’
Max WSE 876’
Min Service EL 860’
Max WSE 957.5’
Min Service EL 922’
Energy
Dissipation
structure
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M
M
M
P1 CLEARWELL & STAND PIPE
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BF-07-FW-101
BF-07-FW-102
BF-07-FW-103
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P1 CLEARWELL – 10’ STAND PIPE
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SCHEMATIC OF BACKWASH SUPPLY – FIGURE
13-1
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P5 CLEARWELL
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EL 874.00
INSIDE P5 CLEARWELL
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SOLIDS
PRODUCTION
FACILITY
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SOLIDS HANDLING – MAIN PROCESS FLOW
SOLIDS PROCESS FLOW DAIGRAM
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FWW
From
Filters
Washwater
Equalization
Basins
Washwater
Equalization
Basins
Pump
Station PE
G
M
Sludge From
Flocculation/
Sedimentatio
n Basins
M
M
Washwater
Clarifiers Solids Metering
Vault
PE
G
Thickener Sludge
Blending Tank
Sludge
Thickener
Decant
Screw Press No. 1
Screw Press No. 2
PE
G
PE
G
Hauled Offsite
Hauled Offsite
Hauled Offsite Pressate
Pressate
Thickened
Sludge Pump
Station
Return Water To
Ozone Reactors
Return Water To
Rapid Mix Channel
Decant Structure
Return
Equalizatio
n Basin
Sludge Storage Basin
Geobags
From
FTW
Floc/Sed Drain
and Sludge
Bypass
Decant
Overflow
Ove
rflo
w
Sludge Storage
Basin
Pump Station
SH
C
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EAST PLANT SOLIDS PRODUCTION
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RETURN WATER PS
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THICKENER
WASHWATER CLARIFIERS
• 2 BASINS (20’X42’ EACH)
• SIDE WATER DEPTH =
15 FEET
• DESIGN FLOW:
o 3,200 gpm (Normal)
o 6,400 gpm (Max)
• SURFACE LOADING
RATE =
3.8 GPM/SF
• EFFECTIVE PLATE
LOADING RATE =
0.35 GPM/SF
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Inflow pipes from Washwater
EQ Basins Pump Station
INCLINED PLATE SETTLERS
DESIGN CRITERIA: DESIGN CAPACITY: 6,400 GPM (9.22 MGD); 3,200 GPM / BASIN DESIGN EFFECTIVE LOADING RATE: 0.35 GPM/SF HYDRAULIC CAPACITY: 6,400 GPM / BASIN 0.7 GPM/SF
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SLUDGE BLENDING 3-5% SOLIDS
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THICKENED SLUDGE PUMP STATION – PROGRESSIVE
CAVITY PUMPS
MECHANICAL
DEWATERING
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SCREW PRESS CROSS SECTION
STEAM INLET
http://www.fkcscrewpress.com/spintro.html
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SCREW PRESSES - 24 DRY TONS / DAY
3.3’
18’
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SCREW PRESS FLOCCULATION TANK
-SNF Polydyne Chemical A-6320 (Anionic polymer) -Dosing 7 lbs active polymer per dry ton of solids
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PRESSATE
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CAKE- 25% SOLIDS
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CONTAINER BAYS
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AWAY THEY GO