Project Details

Project Name: Upgrade of Textile Dyeing and Finishing WWTP
Country: USA
Description: The manufacturing plant discharged wastewater from its dyeing and finishing operation that processed lightweight cotton and cotton/polyester blend knitted fabrics for the apparel market. A design was provided for the expansion of the existing Wastewater Treatment Plant to increase the capacity from 3.0 MGD to 5.0 MGD. A complete evaluation of the facilities was performed resulting in a preliminary engineering report on which the design was based. This was accomplished through the addition of a third 80 ft diameter clarifier with a dedicated sludge pumping station. Sludge drying beds were upgraded to incorporate an innovative porous asphalt design. This design allowed the benefits of sand drainage and drying while allowing bed cleaning by lightweight mechanical equipment. Sludge conditioning chemical feed facilities were also provided. In addition to the third clarifier the completed WWTP design incorporated: a new return sludge splitter structure, modifications to existing flow control vault, a new flow control valve vault with air operated control valve and flow meter, a chemical feed system for combating filamentous bacteria utilizing hydrogen peroxide injection, and a new effluent flow measurement station with a Parshall flume element. The design incorporated extensive improvements to the monitoring and control aspects of the WWTP utilizing three programmable logic controllers configured in local area network and a PC-based graphical operator interface software package. Functions provided by the integrated alarm and control system included: level control and monitoring of the two aeration basins, dissolved oxygen monitoring and control of the two aeration basins via switching of floating aerators, flow control to the third clarifier as a ratio of plant influent flow, automatic batch control of waste sludge from the third clarifier, automatic switchover from main to standby return sludge pumps with failure alarms, automatic restart after power interruption of all WWTP equipment, and clarifier arm drive failure monitoring. Construction administration services were also performed,including: preparation of bid documents, prebid meetings, bid evaluation, shop drawing review, site inspections, approval of payment requests, and engineer's certification.

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