Norton KS WWTP Expansion 2007
City of Norton KS contracted with their consulting engineering firm to design the .45 mgd average day flow treatment plant in the early 2002 calendar year. Funding request applications and other delays had provided expired preliminary cost estimates. But the decision was to bid the project as designed and determine how the contractor cost compared to the original budget. Cost escalation in the 4 years was signficicant.
Contractor bids were $1.8-2.2 million more than the original estimate and consequently the project could not be built. Some negotiations were done but the cost reduction was still inadequate. The contractor suggested a modified design build concept with KDHE and the city for consideration. A design meeting was arranged and within the single day, a new alternate concept was determined that the budget was now within reach. A council meeting presentation was provided and a contract was accepted on a price and a contingency funds of <5% of the project.
The consulting engineer finalized construction drawings concurrently with the construction.
The reason for the project is that the existing 50 year old trickling filter wwtp failed to consistently meet the NPDES permit requried by KDHE. An activated sludge project was required by the BNR level of total nitrogen and phosphorus reduction.
Equipment and Process Technology Provided
Project Cost $3.3 Million
Influent Pump Station
VFD control pumps with fiberoptic networkDedicated PLC controls in A/C buildingHeadworks - Indoors
2 MGD peak flow automatic screw screen with override2 MGD peak flow grit chamber with Stainless steel classifierSpliter box for forward flow and RAS flowTreatment Plant
Dual GR Schreiber oxidation ditch, concentric ring designThree Kaeser blowers with acoustical enclousures. Blowers located indoors for easier maintenance.Three RAS pumps with automatic wasting through magnetic flow meters and pneumatic operated valves to WAS tanksWEDECO Self Cleaning UV system with Stainless Steel channel sized for 2.2 MGD peak flowTwo Sludge digestion tanks with two floating aerator per tank and a telescoping valve for decanting.Controls
Plant wide SCADA system with desktop recordingFIber Optic network Local Area Network SystemDissolved Oxygen Control system conserve energy by turning on/off the blowers for each basinFactory prewired MCC with VFD, Soft Starters, and regular starters. PLC is prewired into the MCC section; all the MCC sections are prewired elminating contractor field wiring - reducing project cost and allowing factory inspection of MCC.New control room with local sink area.New Automatic Generator for line power backupStructure
New area for equipment storage inside the equipment buildingNew lavatory and shower facilitiesNew Plant Drain lift station 
Old plant being demolished and ground leveled for easier grass maintenance.
John, Joyce, Dick and Pat say "HI" from the new treatment plant aeration bridge
Influent Pump Station
Submersible pumps, quantity two with a shelf spare are used in the wetwell. The local control panel is install in the FRP building with a dedicated air conditioner for temperature control. Stainless steel junction boxes provide connect the pumps to the control panel.
A manual hoist lifts the pumps and basket screen in the wetwell provide access to the incoming flow stream. A city dumpster is provided for removal of material on a regular basis.
The purpose for the screen is simply to protect the Myers VFD pumps from large inorganic trash in the collectoin system.
The influent pumps are sized to provide alternation every hour and up to a low flow of 80 gpm and a peak flow of 900 gpm. An influent magnetic flow meter records the data and provides data recording of the incoming water volumes.
Headworks Room
Wastewater is pumped up to the IPEC screen which removes material to 6 mm perforated screen opening. The screen is operated on a timer basis with an override of the float switch. If all else fails, then the notch in the concrete will provde an overflow to the splitter box arrangement.
Material is conveyed, compacted, and deposited in the plastic "baggie" for disposal down the slide.
Grit Chamber and Dewatering
Grit chamber after the screening system allows the heavy material drop to the bottom of the grit chamber. Water and material is pumped to the grit classifier for dewatering.
Water from the dewatering classifier overflows back to the grit chamber.
Dewatered grit is collected in the plastic baggie for disposal.
Water the discharges to the splitter box and mix with the RAS flow, shown below
Biological Process - Schreiber
Blowers and RAS Pumps
Based on several other facilities in KS, this plant is designed with a concentric ring design and a common area for field equipment storage as well as wwtp equipment such as blowers, pumps and UV
The treatment is .45 mgd with a peak flow of 1.35 mgd. Performance is as follows:
InfluentEffluentBOD300<10 ppmTSS 300<10 ppmTKN30 Ammonia30 <1.0 ppmPhos5 <1.5 ppm
WAS & RAS Automatic valve with magmeter
Inside blower with RAS pumps on pedestal
Headworks building on top of equipment room
West Aeration basin and treatment building
Equipment Room under Headworks Area
Dissolved Oxygen Probe in aeration basin
UV Disinfection - WEDECO
A Stainless steel prefabricated channel was provided to assist the constrution costs as compared to a concrete channel. A fixed weir was provided for the contract value.
Sleeves are self cleaning with a pneumatic wiper and effective to minimize operator manual cleaning requirements.
Joyce provides some training to John on how the controls function. Picture below.
Controls & SCADA system
SCADA System and Examples of Screens
Sludge Digestion & Loadout System
Wasted sludge is generated and wasted to the digestion tanks, two, by the operator. The floating aerators provide mixing and aeration on a cycle timer basins. Two basins allow for operator control and decant of clear water into the plant pump drain.
The load out pump cycle is operator controlled from out at the tanker loadout system. Operator pushed button and then pump runs for operator selected the proper amount of time.
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