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Pumping Technology into Sewage Pumping Stations
Clarence Walters
Greater Toronto Airports Authority
September 24, 2018
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Toronto Pearson Growth Stats
• Number of flights in 2014: 432,000 / 2017 : 465,555
• Number of passengers 2014 : 38.6m / 2017: 47.1m an increase of 2.8m over 2016.
• Current projected growth percentage: 7% - 8%.
• Projected Growth numbers: 64 million passengers by 2033.
• Number of Restaurants in Terminals 1 and 3: 2014 -69 and at end of 2017 – 91 dining venues.
• Number of washrooms across both terminals 384
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Prematurely failing Drainage
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Root Cause Analysis
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Revision of Design Standards
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New Drainage Piping Material
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New FOG removal Technology
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Our Problems did not end there !!
• Increased number of passengers, employees not only translated to the need for more food establishments but also increased use of facilities
• We do not have separate main drain lines for washrooms and restaurants
• Branch drain lines from both washrooms and restaurants connect to the main drains.
• There are over 380 washrooms between both terminals – 1200 toilets
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Drainage System Structure
• Elevation of the Terminals are well below the regions sanitary drain lines
• Drain lines in the terminals empty into sump pits in the service levels of the terminals.
• Pumps in the pits pump this sewage out of the terminals into our main sewage lift stations
• From there they are pumped out to the sanitary sewer lines.
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Root Cause Analysis
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Problems encountered1. Excessive amounts of toilet paper and long lengths of paper
towel being used as seat liners which were not breaking down and causing blockages in the trunk lines and pumps
2. Needles and sanitary products disposed down the drains floating at the top and not being ejected by the pumps
3. High build up of paper on the surface and sediment at the bottom of the pits (needed further investigation)
4. Residual FOG floating on the surface, causing build up on the
sides and floats, also decaying and causing bad odours
5. Sewage Sump pits in the terminals were not designed for this capacity, increased growth, lack of additional space for new pit is putting a strain on the system.
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High Priority Trunk Line - Terminals to SLS
• Back up caused flooding into the terminal service level
• Our first priority was to install back water valves and monitoring equipment to detect levels of the roadside manhole pits
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Back Water Valve T-1 Service Roadway
Control Panel Receiving Antenna
Inner Roadway
Transmitter
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Exploring & Developing Solutions
• 1st issue - Paper towel Elimination
-Explored option of using hand dryers
-Noise levels
-Slip and falls
-Cleaning frequency(ASQ)
Customer surveys, preference was and
leaned towards paper towel and so we
agreed on size of the sheet dispensed
on the cut.Faucet+Dryer
Hand Dryers
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Exploring & Developing Solutions
• 2nd issue - Needles and Sanitary product
- Provide / increase number and location of sharps
containers and bins washrooms washroom stalls
- Incorporated as part of the
washroom redevelopment plan
Sharps Containers
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Evaluation of the terminal pump stations
• Some terminal pits comprising of grinders
• Most terminal pits had 2 pumps
• Always an exception - some pits were sectioned off elevator / escalator pits and too small and shallow
• High build up of paper on surface (location) and sediment at the bottom of the pits
• Residual FOG floating on the surface, decaying and causing bad odor
• Every pit had a different manufacturer of pump
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Sewage pit problems
Grinder E-142 Sectioned – Converted Sump Pit
FOG Floating on Surface FOG Sticking to Floats
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Remedying the problem of paper, FOG and sediment buildupStep 1
• Looked at style of pumps and type of impellers on the pumps
• We have the 3000 series Flygt Sanitation pumps, units come with interchangeable impellers depending on the application
• We upgraded to the N-technology
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Remedying the problem of paper, FOG and sediment buildupStep 2
• 3000 series submersible pumps can be fitted with a 'Flush Valve’
• Where we can not install the flush valve we have added mixers
• This breaks down the tissue paper, keeps the sediment and FOG suspended and helps it get ejected by the pump (incl. syringes)
• We also added an ultrasonic level detector (all tied to our BMS)
Flush Valve Mixer / Agitator
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Flush Valve Flow Diagram
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How the flush valve
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Pictures of our installations – Flush Valves
3085 Pump c/wFlush valve E142 Paper in the Pit E142 Surface buildup
E142 After Pump Cycle
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Pictures of our installations - Mixers
T-3 HBS Pit Mixer on a Pole Mounting
Surface Build Up Mixer in Operation
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Sewage Lift Station Terminal 1• Comprises of a wet well and dry chamber
• Wet well has 2 chambers / sections connected by a sluice gate
• 2 grinders on the inlet channels, each inlet has a sluice gate
• 4 Flygt 3301 pumps in the dry chamber
• Each wet well is served by 2 pumps (back up / redundancy)
• PLC controlled, all controls are on the dry side
• Station has cameras, full monitored remotely by our BMS
• PLC program software is very basic, hardware was extremely old and the company who did the programming holds rights to software and programming. We are reliant on them for troubleshooting and system changes, which have not been done since its inception
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Terminal 1 SLS – Pump Level
Wet Well 1
Lifting Davit Arm4 – Sewage Pumps
Wet Well 2 & Spare Sewage Pump Header Valves
Opening & Header Valve
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Terminal 1 SLS – Dry Side – Controls Level
Entrance to Contol Room Control Panel
Monitoring CamerasChannel Grinder
Air Analyzers & other Controls
Controls and Exhaust Fans
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Terminal 1 SLS – Wet Well
Surface Buildup in Wet Well 1
Surface Build up in Wet Well 2
Grinder in inlet ChannelsExhaust Plenum Sluice Gates
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Terminal 3 Sewage Lift Station• Terminal 3 has its own sewage lift station (6A)
• Station has a wet well and contains 3 Flygt 3153 submersible pumps.
• PLC controls are in a weather proof cabinet onsite
• Remotely monitored by our BMS
• PLC program software is very basic, hardware was extremely old and the company who did the programming holds rights to software and programming. We are reliant on them for troubleshooting and system changes, which have not been done since its inception
• Aggressive Quarterly PM Program and monthly visual checks for both stations
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Terminal 3 – SLS Controls Sewage Pit & Exhaust Fan
Control Valves View of the Pit
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Control Panel
PLC controls
Spare Submersible Pump
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Quarterly PM Program
• Check Coolant
• Megger the pumps
• Current Draw
• Check Flow Rates
• System Pressure
• Run hours
• Inspect impellers
• Check of the station
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Assessment of our Pump Controllers T1 / T3
• PLC from different manufacturers
• Programming and support from 2 different vendors
• We do not take care of programming or changes
• Response time in case of failure is of concern
• Flexibility in programming limited
• High costs for programming, retrieving data
• Size and location of the vendors of concern
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Assessment of our Pump Controllers
Terminal 1 Terminal 3
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Options for Upgrading
• Approached current vendors who proposed upgrading hardware and using the same software
• Researched the market for sewage pumping station controllers
• Heard of ‘Pump Station Managers’ specifically designed for sewage lift stations.
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What are Pump Station Managers
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Pump Station ManagerWeather Resistant for Outdoor Environments
Touch Pad for indoor Environments
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Pump Station Manager
• Next generation of technology for water and wastewater pump stations
• Combines the best of PLC’s, RTU’s and pump controllers into a comprehensive & intuitive package
• Integrates numerous control panel components, lowering control panel costs
• Pre-programmed logic designed to significantly reduce operating costs
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Benefits …• Reduces control panel costs – smaller enclosure size,
lower design costs, less wiring, fewer internal devices, lower deployment and commissioning costs, lower fabrication and installation costs
• Easy to configure via ‘Setup Wizard’
• Built in local SCADA without added cost of HMI hardware and software
• Remote control programming – minimizes site visits
• Cuts maintenance troubleshooting costs
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Benefits… cont.• Establishes pump efficiency
• Measures energy used by each pump
• Decreases pump station electrical consumption
• Pump reversal feature
• Trending pump efficiency
• Determines ROI for maintenance procedures
• Valuable pre programmed functions ...(Odor reduction, max run time, max pumps to start per hour, minimize
excessive start, blocked pump detection & predictive alarming)
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Features of Pump station Manager
• Max run time and run most efficient pump
• Clean the well out and have multiple set points
• Generator Profile and Locked level
• Optional VFD module and VFD settings
• Mixer / Agitator control
• Security key and Predictive Critical Alarms
• Flow without a flowmeter
• Save / copy configurations , Data logger
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Features of Pump station Manager .. Cont.
• History page / 620 tags / remote monitoring
• Connects to any modern SCADA
• Rapid hardware changeout
• Quick programming recovery
• Odor reduction
• Blocked pump detection
• Pump fault detection
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Demonstration to our team
• Carried out information sessions, for our engineering and maintenance teams
• Site tours to various sites
• We wanted to try and match
something similar to and Airport
• What better than a ….
University campus + housing Demonstration Unit
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Pictures from our site tour
WesternUniversity
Sewage Pit with Davit Arm
No Smells
Opening
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Pictures from our site tour
Sewage Pit with Dual Pumps
Opening Guarding
Optional Connection
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Pictures from our site tour
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Our Ultimate Goal
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Conclusion• Our root cause analysis and research proved to be
very beneficial to us to determine solutions to make our system more reliable.
• We have moved forward and have started to upgrade our sewage pits with the addition of new mechanical equipment and controllers for the pumping stations.
Questions ?