Process audit and asset assessment using on-line instrumentation
The traditional approach to assessing the performance of an Activated Sludge Plant (ASP) is to conduct an expensive and often labour intensive through-plant sampling survey. The results from this kind of survey do not give an accurate picture of the plant performance in real time, and often can be ruined by inaccurate or spoilt analytical results. A new approach to Process Audits has been developed based on on-line instrumentation and remote monitoring. The key equipment required to dynamically monitor the ASP performance is the MSL Respirometer which is used to measure organic loading, required retention time and aeration system requirements. Auto-cleaning, auto-calibrating Dissolved Oxygen sensors are used in conjunction with a Respirometer to assess the aeration system efficiency (actual Kla value) and the maximum oxygen demand (OUR) which can be sustained by the plant. Ultrasonic flow meters are used to determine flow splits and actual plant retention time which is compared to the required retention time measured by the Respirometer. Mixed Liquor Suspended Solids (MLSS) profiles are monitored continuously using a self-cleaning optical sensor, which is used along with Respirometric readings to measure the effect of poor wastage regimes and ingress of inert solids. On-line ammonia, phosphate and nitrate monitors can be used to give information on the diurnal variation of nutrients, related to the loading on the plant. As well as the normal plant operation, the effect of shock loads, storm conditions and sludge liquor returns can all be assessed. All instruments are linked via a serial communications loop to a modern and telephone line. The plant is monitored remotely, making it an unobtrusive survey allowing operations to continue as normal and giving a true picture of the plant performance. This approach has been used on several UK sewage treatment works and has proven to be a cost-effective method. In one case a proposed capital spend on final settlement tanks was shown to be unnecessary; in another case the plant was shown to be unable to support a nitrifying biomass.