DC Water project: Constructing an ENRF system
DC Water’s $3.8 billion, 10-year capital investment program involved the construction of an ENRF system. KSB USA submersible motor pumps are central to the facility’s operation.
DC Water’s $3.8 billion, 10-year capital investment program involved the construction of an ENRF system. KSB USA submersible motor pumps are central to the facility’s operation.
The project:
Nitrogen removal with an ENRF system
Covering more than 150 acres and serving an area of 725 square miles, the Blue Plains Advanced Wastewater Treatment Plant (AWTP) is located in Washington DC. The latest ENRF process expansion of Blue Plains has been designed to reduce nitrogen levels to the limit of technology prior to being discharged into the Potomac River, a tributary of the Chesapeake Bay. The goal of the project was to meet or exceed the new U.S. Environmental Protection Agency (EPA) requirement to reduce effluent nitrogen production to four million pounds per year.
Nitrogen removal at Blue Plains is a two-stage process that involves nitrifying secondary effluent within the existing 12 nitrification/denitrification reactors. Essentially complete denitrification occurs in the newly constructed ENRF tanks.
A key element of the new ENRF process was the addition of a new high-capacity pump station. The design specifications mandated 24/7 operation, with a planned life span of at least 20 years. The selected pumps had to be robust and have a high degree of reliability.
The client:
DC Water
The Blue Plains Advanced Wastewater Treatment Plant (AWTP) in Washington DC is the largest advanced wastewater treatment plant in the world. Blue Plains has a design capacity to treat up to 370 million gallons every day, meeting the Metro-DC area’s wastewater and collection treatment needs. The treated effluent is discharged into the Potomac River, resulting in the plant having to meet some of the most stringent nitrogen standards in the world.
The challenge:
Delivering pumps that comply with stringent EPA requirements
Azir Khan, KSB’s project engineer takes up the story. “We had to demonstrate to DC Water that we had pumps with a proven track record. To this end, we were able to point to similar facilities in other parts of the world where the recommended pumps had given trouble-free operation for many years. The pumps that we recommended are our Amacan P submersible impeller pumps and Amarex KRT pumps. These are the largest submersible impeller pumps produced by any manufacturer.”
Not only was KSB able to demonstrate the effectiveness of these pumps, they were the only company that could factory-test pumps in accordance with operating conditions. It was a very stringent set of criteria that KSB had to pass in order to be accepted by DC Water.
Having specified these high capacity pumps DC Water also realized additional benefits from working with KSB, which included alternative configurations. Optimizing the configuration resulted in considerable power savings, as much as $200,000, in operating costs that could be achieved every year. KSB also had the engineering resources to assist engineers in optimizing the design of the pump station.
By reducing the number of pumps, the overall pump station footprint could also be reduced. Furthermore, extensive hydraulic calculations were performed to develop a pump curve required at various speeds.
Operating requirements and products supplied:
- 7 x Amacan P pumps. Maximum flow up to 179 mgd; maximum dead 12m.
- To satisfy the requirements of this project, the pitch angle of the propellers was adjusted, and the motors were specially wound.
- 4 x permanently installed submersible Amarex KRT pumps.
- Unknown number of portable Amarex KRT pumps.
The solution:
Optimized Amacan P and Amarex KRT pumps
KSB went to great lengths to demonstrate the capabilities of its pump technologies and understanding of the project.
“The pumps were optimized specifically for the project, using motors that were identified as being the most suitable and the hydraulics exactly matched the requirements of the project. The Amacan P and Amarex KRT pumps run at their optimum performance point at the peak flow, which is highly important both for the project and the longevity of the pumps,” continues Azir Khan.
KSB Amacan P and Amarex KRT pumps are true work horses for the wastewater treatment and water supply sectors and are to be found operating in many applications around the world where the most challenging water industry applications must be satisfied. At Blue Plains AWTP seven Amacan P pumps are located at various locations (Fig.1)in the denitrification return sludge gallery sumps and are used for pumping drainage, wash down and potentially sludge and chemicals if a pipe breaks. Four submersible Amarex KRT pumps are located at two dewatering pump stations in the denitrification return sludge gallery and are used for liquor pumping groundwater, pump/floor wash down drainage and wet weather run-off duties.
In the Alternate Carbon Building, two submersible Amarex KRT pumps are used for sump pumping eye wash station drainage, laboratory sink drainage, pump/floor wash down drainage and potentially carbon chemicals if a pipe or pump leaks. Portable submersible Amarex units have also been supplied and can be moved to various locations in the denitrification reactors and post-aeration tanks, their purpose being to handle mixed liquor. Their primary function is to dewater the denitrification reactors and post-aeration tanks if they are taken out of service.
The Amacan P series submersible motor denitrification pumps supplied to DC Water are typically used around the world for industrial and agricultural water supply, stormwater and flood prevention stations and the water and wastewater treatment industries. It is a close-coupled, wet-installed single-entry axial impeller pump where the propeller is in a tubular casing immersed in the water. Each of the pumps has a maximum flow capacity of up to 179 mgd and a maximum head of 12m and together they deliver a total of 895 mgd. Low vibration hydraulics and a vortex-free flow due to the inlet ribs and wide bellmouth ensure that the pump is hydraulically optimized. Operating efficiency is provided by the slim motor that minimizes discharge tube flow losses.
The Amarex KRT is a safe, reliable and energy-efficient solution for a wide range of pumping jobs in industrial and municipal wastewater processes (Fig 2). In order to provide maximum versatility/flexibility for applications, KSB offers this pump in a wide range of materials. A range of specially adapted hydraulic systems with high operational reliability, due to wide free passages, make for optimum economic transport of all types of liquids. The Amarex KRT submersible pumps are used for raw sewage pumping and on treatment plants. Unlike the water supply pumps, the pumps used in the handing of untreated and treated effluent have to operate all day long, which places them under a considerable workload.
“We were pre-selected for the project following a competitive procurement process,” reports Azir Kahn. “KSB has been able to equip Blue Plains with the most appropriate pumping technology designed to ensure reliable and long working life and enable our customer to benefit from reduced capital construction costs and lower yearly operating expenses.”
KSB Amarex KRT pump ready for factory testing
“We had to [show] DC Water that we had pumps with a proven track record. [...][W]e were able to point to similar facilities in other parts of the world where [our] [...] pumps had given trouble-free operation for many years. [...] [W]e recommended [...] our Amacan P [...] pumps and Amarex KRT pumps.”- Azir Khan, Project engineer, KSB.
Data | Facts | Figures
Location: Blue Plains, Washington DC, USA
Client: DC Water (District of Columbia Water and Sewer Authority), Washington DC, USA
Used Products
7 x Amacan P pumps. Maximum flow up to 179 mgd; maximum head 12m.
To satisfy the requirements of this project, the pitch angle of the impellers was adjusted, and the motors were specially wound.
4 x Amarex KRT permanently installed submersible pumps.
Unknown number of portable Amarex KRT pumps.
Used products
AmaCan P
Wet-installed submersible motor pump for installation in discharge tubes, with axial propeller in ECB design, single-stage, single-entry. ATEX-compliant version available.
Amarex KRT
Horizontal or vertical single-stage submersible motor pump in close-coupled design, with various next-generation impeller types, for wet or dry installation, stationary or transportable version, with energy-saving motor and models for use in potentially explosive atmospheres.