IndWW-HW#1-FlowCalc-answers

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Your Name: ANSWER KEY IndWW HW#1 - Spring 2023 The below columns will auto-populate from the spreadsheets. pts In the spreadsheets, the yellow data is required. The light orange blocks are for showing work (and will be used for partial credit). 12 Q1 Water Meter Supply 6,194 gpd-cal Pts: 3 work 8,613 gpd-cal Pts: 3 subtract vol 7,357 gpd-cal Pts: 3 convert units 7,688 gpd-cal Pts: 3 divide days 12,464 gpd-cal 11,345 gpd-cal 10,034 gpd-cal 13,645 gpd-cal 13,393 gpd-cal 13,367 gpd-cal 15,656 gpd-cal 15,600 gpd-cal 3 Q2 Design Basis 14,332 gpd-cal (if quick avg Feb-June 14,358 exact Feb-June 15,628 gpd-cal (if quick avg May-Jun 15,629 exact May-June 3 Explanation/judgement: 5 Q3 Sanitary Flow 3,946 gpd-cal Would accept 3,946 gpd-cal or roundings to 3,900 gpd-cal (sig figure) or 4,000 gpd-cal (eng judgement of design basis). 4 Q4 WCT1 Evap Loss/Drift 504 gpd-cal 4 WCT1 Blowdown 576 gpd-cal 4 WCT4 Evap Loss/Drift 161 gpd-cal Evap Sewer Haul 5 Q5 Source 1 - Spray Station 66 gpd-cal 5 Source 2 - Parts Washer 154 gpd-cal 5 Source 3 - Dip Tank 30 9 gpd-cal 5 Source 4 - Scrubber 400 720 gpd-cal 30 Q6 Flow balance 6 - 2 each, outfalls totaled 5 Q7 Supply (upstream-metered) 13,694 Usage (dnstream-estimated) 15,902 Ratio: dnstream to upstrea 116% 5 Q8 Agree? Decent agreement, but would prefer tighter control to within 10%. What to adjust? 5 Q9 Meter agreement? 2 Q10A Bonus/Gas Meter Read 238,800 CF 2 Q10B Bonus/Gas Meter Read 2,388 CCF 2 Q10C Bonus/Gas BTU 1,030 BTU/CF 2 Q10D Bonus/Evap Hours 20.6 hrs/day 2 Q10E Bonus/Evap Flow 1,298 gpd 110 Total Because production is going up, neglect 2013 and 2012 data. Could justify Feb-Jun or May/Jun avg. Rounded: 14,500 to 16,000, w/matching explanation. Submit on sheet Q6-Q9; also submit a pdf of the flow balance Q6- Q9 sheet (fit to page) Adjust the sanitary flow. The other sources do not account for sufficient amounts of flow to cover a 15,902-13,694 = 2,208 gpd difference, when considered individually. Adjust sanitary from 25 to 20 gpd-person; decreases sanitary from 9,500 gpd to 7,600 gpd, or a 1,900 gpd difference. Balance would then be: 15902-1900=14002. Ratio 14002/13694 = 102% Conclusion: you did a very good job on your field measurements. Your field measurements showed 4,414 gpd and the meter is showing 4,387 gpd. Dnstream to upstream: 4414/4387 = 101%
IndWW HW#1 - Spring 2023 Question #1 & 2 Scenario: Your field visit is in July 2014 and you are preparing a flow balance for use in a WWTP upgrade because production has expanded. The following water meter data is available. Question 1: First, complete the table below (calculate yellow columns: TGL and gpd-cal). You may use the wh After reviewing the data in Question 1, answer Question 2 (see below this table). (if you use Column F for related calcs; label the header) 4/16/12 31 3449 3641 192 192,000 6,194 5/17/12 31 3641 3908 267 267,000 8,613 6/14/12 28 3908 4114 206 206,000 7,357 7/16/12 32 4114 4360 246 246,000 7,688 3/19/13 28 6649 6998 349 349,000 12,464 4/17/13 29 6998 7327 329 329,000 11,345 5/16/13 29 7327 7618 291 291,000 10,034 2/18/14 31 788 1211 423 423,000 13,645 3/18/14 28 1211 1586 375 375,000 13,393 4/17/14 30 1586 1987 401 401,000 13,367 5/19/14 32 1987 2488 501 501,000 15,656 6/18/14 30 2488 2956 468 468,000 15,600 Question 2: For the scenario described at top of page, and based on the data above, determine an appropriate Hint: Engineering judgement is required. Answer: 14,332 gpd-cal If avg Feb-June month 15,628 gpd-cal If avg May/June mont Explain your judgement: Because production is going up, neglect 2013 and 2012 data. Could justify Fe Read Date Elapsed Time (Days) Prior Reading (TGL) Current Reading (TGL) Consumption (TGL) Consump tion (gal) Water Usage (gpd-cal)
hite columns as needed for intermediate formulas. e design basis. hly 14,358 If correct/adjust for meter dates, the avg Feb-June thly 15,629 If correct/adjust for meter dates, the avg May-June eb-Jun or May/Jun avg. Rounded: 14,500 to 16,000, w/matching explanation.
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IndWW HW#1 - Spring 2023 Question #3 The HR department provides the following info: * 175 employees, split into 100 on 1st, 50 on 2nd, and 25 on 3rd shift. The 1st shift works M-F, and half also work on Saturdays. 10% of 2nd shift also comes on Saturdays. * In addition to employees, the plant relies on 25 temp workers on 1st shift and 10 temp workers on 2nd shi What is a reasonable initial estimate of sanitary flow? Show your steps below in peach box, and enter final answer in yellow box: 3,946 gpd-cal M-F: 175 + 35 = 210 people Saturday: 50 + 5 = 55 people 25 gpd (210 people x 5 d/wk) + 25 gpd (55 people x 1 d/wk)= 27,625 gal/wk 3,946 gpd-cal
ift, M-F
IndWW HW#1 - Spring 2023 Question #4 The site has two cooling towers. Here are your field notes. WCT1 WCT1 WCT4 WCT1 Evaporative Loss/Drift: Cooling tower 1 (WCT1) is used to cool a furnace that runs 24 hr/day, 7 d/wk. Open loop side is filled by a float. You have been unable to get info on temperature and pump rates. Tested by turning off make-up/blowdown and leaving the recirc pump (tower spray overpack) running. The base of cooling tower is 41" x 30" W. The water level dropped 1.25" in 19 minutes, and then you turned the make-up/blowdown back on. What is the evaporative+drift loss (gpd) to use in your flow balance? WCT1 Blowdown : The cooling tower blowdown rotameter reads 0.4 gpm. What is the blowdown (gpd) to use in your flow balance? WCT4 Evaporative Loss/Drift: Cooling tower 4 (WCT4) is used to cool a furnace that runs M-F, 12 hr/day. When the furnace is not running, the cooling tower is turned off. You have limited time on-site and cannot directly measure, but the set-up (tower size, equipment) is the same as a tower WCT3 that operates 24 hr/d, 7 d/wk and was estimated at 450 gpd evaporative+drift loss. What is the WCT4 evaporative + drift loss (gpd-cal).
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Define/Use as Needed For Calcs Show notes or work as needed CF gpm gpd Answer (gpd-ca 0.8897569 0.3502833 504.40789 504 GPD: 0.4 gpm x 60 min/hr x 24 hr/d = 576 gpd. 0.4 576 576 160.71429 161 Drop: 41" x 30" x 1.25" in 19 min. CF: (41"x30"x1.25")/(12in/ft x 12in/ft x 12in/ft) = 0.889757 CF. GPM: (0.889757 CF) x (7.48 gal/CF)/19 min = 0.35 gpm. GPD: 0.35 gpm x 60 min/hr x 24 hr/d = 504 GPD. WCT4 - assume same rate of loss as WCT3. Mental Math: For 12 hr/day instead of 24 hr/day, thus 225 gpd. Or, if more complicated and mental math not advised: 450 gpd WCT3 x d/24 hr = 18.75 gal/hr. Multiply by however many hours WCT4 runs: 18.75 gal/hr x 12 hr/day = 225 gpd WORK DAY basis. Weekly: 5 work days * 225 gpd-work = 1,125 gal/wk. Convert to calendar day basis: 1,125 gal/7 d = 160.7
al)
c6bcc2521885a94d4771305a25affc04127ebb3f.xlsx\Q5Misc Page 9 of 15 Question #5 Evaporative Losses Wastewater Generated Description Calc Notes Hrs/ Wk 7.71008 2.03701 3.78 462 1,080 30.5 400 0.50 IndWW HW#1 - Calculate the yellow Wastewater Source L (in) W (in) H (in) Vol (Gal) Evap (in) Evap Loss/Refill (GPD- work) Evap Loss/Refill (GPD-Cal) Flow (L/min) Flow (gpm) Vol (Gal/ Wk) Source 1 - Spray Station Spray Station: Hand held rinse spray gun (bucket/stopwatch measurement): 2L/16 sec, 2L/14 sec, 2L/17 sec. Gun is on a timer cycle, so big parts are rinsed 4 minutes, small parts are rinsed 1 minute. Interviews: 1st shift: 48 big parts/wk, 8 small parts/wk. 2nd shift: 6 big parts/wk, 3 small parts/wk. 3rd shift: 0. Spray station operates 6 d/wk. What is the gpd-cal? Flowrate: 60 sec/min * (2L/16 sec + 2L/14 sec + 2L/17 sec)/3 = 7.71 L/min. Also: 7.71 L/min x gal/3.785 L = 2.037 gpm. Total time running: (54 big parts/wk * 4 min/big parts + 11 small parts/wk * 1 min/small part)/(60 min/hr) = 3.78 hr/wk. Vol (Gal/Wk): 2.037 gpm * 60 min/hr x 3.78 hr/wk = 462 gal/wk. Flow GPD-CAL: (462 gal/wk)/7 days/wk = 66 gpd. The info that the operation is 6 d/wk is extraneous info, because you can get the minutes of operation directly from the parts and timer info. Source 2 - Parts Washer Parts washer: 6-7 cycles/day, 5 d/wk, 1st shift. 4-5 cycles/day, 5 d/wk, 2nd shift. 0 on 3rd. Triggered a cycle, no water came out till end of cycle. Drain sump: 3 ft x 3 ft sump, water level raised 3.5" from one cycle. What is the gpd-cal? 10-12 cycles/day, 5 d/wk. Use 11 cycles/day x 5 d/wk = 55 cycles/wk. Flow: 3 ft x 3 ft x 3.5"/12" = 2.625 CF/cycle x 7.48 gal/CF = 19.635 gal/cycle. Vol (gal/wk): 19.365 gal/cycle x 55 cyles/wk = 1,080 gal/wk. Note: I used 11 cycles/day because that is the midpt of the interviews. When doing a flow balance, if you always pick max from interviews, you will normally not get a good balance with the flow meter. It is better to get a flow balance that is in agreement, and then apply safety factors (as/if needed) to your balance as far as a design basis. That way, you can use your balance for multiple purposes (e.g., permit, reporting, etc. as well as designs). Therefore, suggest using 11 cycles. However, I also accepted answers that used max cycles (12 cycles). Source 3 - Dip Tank Hot dip tank. 3.5'Wx3'Lx4'H sidewall (6" freeboard; freeboard = distance from operating water level to top of sidewall). Once/mo hauled. Daily top-offs with tap water to make-up for evaporative loss. Operator snap-shots of top-offs: 11/21/14 3" water added Friday morning, 11/21/14 2" added Friday afternoon, 11/22/14 2" added Saturday morning. Provide estimates of evap loss and hauled volumes. EVAP (GPD-CAL): 3+2+2=7 inches/1.5 days = 4.66 inch/day. (3.5'x3'x4.66"/day)/(12 in/ft)= 4.08 CF @ 7.48 gal/CF = 30.5 gal/day. Hauled: 3.5'x3'x(4-0.5')x 7.48 gal/CF x 12 hauls/yr = 3,299 gal/yr hauled. GPD hauled: 3,299 gal/yr x (yr/365 day) = 9 gpd-cal. Tip: the tanks were topped off in morning, afternoon, morning. That first morning, the topoff was due to evap loss overnight. So, these 3 refills really represented 1.5 days of evap time. Source 4 - Scrubber Scrubber info: 14,000 cfm air flow; 30 gpm recirc rate (pump recirculation from scrubber sump to scrubber packing); 0.5 gpm blowdown; assume 400 gpd evap loss; 7 d/wk, 24 hr/d operation. The 14,000 cfm and the 30 gpm are extraneous info. They could be used to estimate if no other info was available, but info is directly given. Given 400 gpd evap loss (directly enters, as this is shown as a 7 d/wk operation). Flow: 0.5 gpm x 60 min/hr x 24 hr/d = 720 gpd
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c6bcc2521885a94d4771305a25affc04127ebb3f.xlsx\Q5Misc Page 10 of 15 d Off-Site Haul 66 154 3,299 9 720 GPD- Calendar Haul (Gal/ Yr) Haul (GPD - Cal)
ANSWER KEY SOURCES FLOW GPD (CALENDAR) FINAL DISPOSAL Water Meter Data gpd Water Use Evap/Loss Discharge 13,694 gpd Supply (upstream-metered) 13,694 4,716 gpd Process WW Sources Usage (dnstream-estimated) 15,902 to on-site WWTP Ratio: dnstream to upstream 116% Clean/Strip Acid Line 2,530 0 2,530 X-Ray Room 115 0 115 Washing Area 512 0 512 Scrubber System 1,022 302 720 Wet Tumblers 537 0 537 4,414 gpd Subtotal WWTP = 4,716 302 4,414 WWTP Outfall 001 823 gpd RO Reject 823 gpd 823 0 823 RO Reject 5,237 gpd WWTP+RO Flow 9,500 gpd Restrooms 9,500 gpd 15,160 gpd 9,500 0 9,500 Restrooms Outfall 003 to City 863 gpd Cooling Towers 423 gpd 863 440 423 Cooling Towers 9,923 gpd Sewer Outfall 002 ANSWER KEY (ANOTHER OPTION) SOURCES FLOW GPD (CALENDAR) FINAL DISPOSAL Water Meter Data gpd Water Use Evap/Loss Discharge 13,694 gpd Supply (upstream-metered) 13,694 4,716 gpd Process WW Sources Usage (dnstream-estimated) 15,902 to on-site WWTP Ratio: dnstream to upstream 116% Clean/Strip Acid Line 2,530 0 2,530 X-Ray Room 115 0 115 Washing Area 512 0 512 Scrubber System 1,022 302 720 Wet Tumblers 537 0 537 4,414 gpd Subtotal WWTP = 4,716 302 4,414 WWTP Outfall 001 823 gpd RO Reject 823 gpd 823 0 823 RO Reject 5,237 gpd WWTP+RO Flow Points 10,363 gpd Restrooms & 9 9 pt - recognizable flow balance Cooling Towers 4 4 pt - meter data, supply, usage, ratio Restrooms 9,500 0 9,500 4 4 pt - group WWTP flows in one category; omit RO from WWTP Cooling Towers 863 440 423 9,923 gpd 3 3 pt - correctly depict the water use as the use not the discharge #s Subtotal RR/WCT = 10,363 440 9,923 Sewer Outfall 002 3 3 pt - Outfall 001 depicted & with correct flow 3 3 pt - Outfall 002 depicted & with correct flow 15,160 gpd 3 3 pt - Outfall 003 depicted & with correct flow Outfall 003 to City
IndWW HW#1 - Spring 2023 For use in answering Questions #6-9 (for preparation of your flow balance on Q6-Q9FlowBalance sheet). Given the below plan view and field notes (line 27-43 below), construct a flow balance (this flow balance is not related to questions Q1-Q5 on the homework; all info for the flow balance is on this sheet). Transparent facility background is generic/solely for pictorial purposes. Meter Info * The site's water bill shows a base supply of water charged at $2 per CCF, which has an avg of 11,238 gpd-cal. Additional water is charged at $4 per CCF, and shows 2,456 gpd-cal supplied at that rate. * This site operates 7 d/wk. From interviews and a field visit, you have gathered the following initial info. Item Description Flow info (all gpd-cal) WW Source 1 RO Reject 823 WW Source 2 Clean/Strip Acid Line 2,530 WW Source 3 X-ray room 115 WW Source 4 Washing Area 512 WW Source 5 Scrubber System 302 gpd evaporative/drift loss, 720 gpd blowdown to WWTP WW Source 6 Wet Tumblers 537 Restrooms 380 people @ 25 gpd = 9,500 Cooling Towers WCT to sanitary sewer 440 gpd evaporative/drift loss, 423 gpd blowdown to WWTP When your purchases were > downstream use, check what sanitary adjustments would do: People GPD Flow (gpd) 380 24 9,120 380 23 8,740 380 22 8,360 380 21 7,980 380 20 7,600 realistic adjustment 380 19 7,220 can justify others as well
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A copy of Client B flow balance, with notes removed for clarity is provided below. Provide a similar format (sum upstream vs. downstream, and calculate the ratio) when completing your balance on question 6 (see the question 6 sheet). Tip: Place your cursor on the green fields below to see how they are calculated. Simplified Version of Client B Flow Balance WATER SUPPLY SOURCES WATER DEMAND/USAGE FLOW GPD (CALENDAR) FINAL DISPOSAL Sprinklers 563 gpd (calendar) Lawn Irrigation WATER USE EVAP/LOSS DISCHARGE Meter # 12345678 563 563 0 Lost to Atmosphere Sprinkler Meter data based on dd-mm-yy to dd-mm-yy records. Subtotal Irrigation = 563 563 0 or Irrigation gpd (cal) Main Water Supply Supply (upstream-metered) 28,196 13,842 gpd (calendar) Non-Process WW Meter # 101010101 28,196 gpd (calendar) Usage (dnstream-estimated) 26,227 Sources to 001 mm/yyyy to mm/yyyy Ratio: dnstream to upstream 93% Sanitary & Cooling WW Includes: Sanitary RR (Front, South, Middle) 6,188 0 6,188 Main Plant RO Reject/Backwash 2,353 0 2,353 Drinking Water RO Reject/Backwash 103 0 103 LEGEND: gpd = gallons per day FIC Furnace #1 and #2 Cooling Water 5,193 0 5,193 calendar = calendar day basis (average over 7 calendar days) FIC Furnace #2 Heat Exchanger (neglible) 0 0 0 Handwash Sink 5 0 5 13,872 gpd HVAC Condensate (nominal) 0 0 30 To Outfall 1 Subtotal Sanitary/Cooling Water = 13,842 0 13,872 8,311 gpd (calendar) Non-Process WW Sources to 002 Sanitary RR (NE Upstairs/Downstairs) 2,063 0 2,063 Exercise Area Showers (NE Upstairs) 200 0 200 5,317 + Vacuum Furnace #2 Hoses (negligible) 0 0 0 604 = HVAC Condensate (nominal) 0 0 30 5,921 gpd WCT-1, -2, -3, -4, -5 Cooling Towers 6,048 3,024 3,024 To Outfall 2 Subtotal Sanitary/Cooling Water = 8,311 3,024 5,317 Local Sewer Ordinance Pt of Compliance 1,662 gpd (calendar) Metals WWTP Categorical to 003 Process Wastewater Includes: FIC Scrubbers 1 - 2 see below 40 see below Tumblers, Met Lab see below 0 see below Chem Line Acids & Rinses see below 48 see below Etch/Titration Hood/Sink see below 0 see below Coating Furnace Scrubbers 1 - 4 see below 400 approx 71 Chem Line C/S Scrubber see below 400 288 to 432 Platinum Line Scrubber see below 20 approx 4 Sludge Dryer Scrubber see below 150 approx 192 Treated via Metals Precipitation. Lime, Polymer Solutions see below 0 see below Through Outfall 3 Subtotal of Metals WWTP (T11/T12) = 1,662 1,058 604 Categorical Pt of Compliance. 48 gpd (calendar) Series 700 Evaporator Metal /Chloride WW Includes: Mop Buckets, Barrel Tumbler, Chem Line Alkalines X-Ray Wastewater Typical 0 gpd (optional route here; typical to Series 800 Evaporator) T11/T12 Final Hold WW Typical 0 gpd (optional here; typical to 003 City Discharge) Water Lost to Evaporation. Furnace Scrubbers Typical 0 gpd (optional here; typical to Metals WWTP) Residues Disposed Off-Site. Subtotal of Series 700 Evaporator = 48 48 0 Zero Discharge to Sewer. 1,602 gpd (calendar) Series 800 Evaporator Dilute Oily/X-Ray WW Air Compressor Blowdown 0 80 0 Parts Washers, FPI Lines, X-Ray WW 1,602 1,602 0 Water Lost to Evaporation. Subtotal of Series 800 Evaporator = 1,602 1,682 0 Residues Disposed Off-Site. Zero Discharge to Sewer. 650 gpd (calendar) Non-Process WW Cafeteria to 005 Cafeteria - sink, food vats, tray washing 650 0 650 660 gpd HVAC Condensate (nominal) 0 0 10 To Outfall 5 Subtotal Cafeteria = 650 0 660 Grease Trap 112 gpd (calendar) Equipment Refills 112 112 0 Water for Equipment Top-Offs & & Hauled Wastes 112 112 0 Residues Disposed Off-Site. Sewer Tee
IndWW HW#1 - Spring 2023 Question #10 (BONUS) Q10A. Read this gas meter. Neglect the dials labeled 1/2 and 2. Provide answer in CF and CCF. 238,800 CF Remember - gas meters arrows both clockwise and CCW Read whatever # you have crossed; do not read next # up. 2388 for the #s. Then, how many 0s? Look at far R dial. One full rev is 1,000. You are at 8 on that dial. Note that the dial itself says: 1,000 per REV So, that 8 is 800. Meter reading is: 238800. Q10B 2,388 CCF CCF is 100 CF Q10C. What BTU content per CF can I use for natural gas (hint: lecture slide 50) 1,030 BTU/CF Q10D. I installed an evaporator 30 days ago. The gas meter was installed at same time (started at 0) and now reads 450,000 CF. The evaporator is rated at 63 gph and 750,000 BTU/hr. How many hours per day has the evaporator been running on average? Show Work: 450,000 CF x 1030 BTU x hr = 618 hrs CF 750,000 BTU Answer: 20.6 hrs/day =618 hrs/30 days ago installation Q10E. What is the average gpd of wastewater processed by this evaporator? Show Work: 20.6 hr/d x 63 gph = Answer: 1,298 gpd
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