Wastewater Treatment Consulting Engineering: P&IDs, Startups & Other Considerations William Marten, P.E., BCEE December 6, 2010 UW-Madison CEE 426 ®

What We’ll Cover (in a roundabout way): P&IDs Plant Startups Some Personal Career Experiences Some Things to Consider as You Start Your Careers

So What’s a P&ID? Process & Instrumentation Diagram Detailed Process Flow Diagram –Includes Information on Tanks, Equipment & Instrumentation to Monitor & Control –Sometimes Includes More Detailed Information Serves as “Roadmap” of the Treatment Systems Serves as Communication Tool (of How the System is Intended to Work) for –Designers –Contractors –Owners/Operators –Regulators

P&IDs Are Developed as a Project Progresses Planning Preliminary Design Final Design Construction Startup Process Flow Diagram Unit Process Interface/Preliminary P&IDs Finalize P&IDs/Write Loop Descriptions/Control Narratives Revise P&IDs & Controls Based on Constructability Revise P&IDs & Controls Based on Operability/Functionality

Process Flow Diagrams

Several Important P&ID Sheets Legend Sheets –Help Define What Abbreviations & Symbols Mean Unit Process Interface Summary –Shows How Unit Processes Are Interrelated –Tells What PID Sheet(s) Cover Specific Unit Processes

PID Legend Sheet

PID Legend Sheet 2

Unit Process Interface

Example P&ID

P&IDs Need Loop Descriptions (Control Narratives) for Detail Typically Part of I&C Specifications Verbal Descriptions of Control System Functions at Each “Control Level” –Local –Remote Panel Manual –Remote Panel Automatic –PLC/Computer OIU (Operator Interface Unit) Used to Program Controls & Displays at PLCs & OIUs

Another Example P&ID

Related Loop Description

What’s Up With Startups? Critical Time in any Project –Where the “Rubber Meets the Road” –Where the Owner/Operator(s) Finally Find Out What They’re REALLY GETTING Startups Need to be Planned & Executed Effectively Startups Can Determine Success/Failure of Any Project

What’s Involved in a Startup? Inspection – Startup Punchlist –List of What Needs to be Done (Process & Non- Process) –Assigns Responsible Party –Defines Priority –Tracks Status Facility/Equipment/System Checkouts –Continuity Testing –Performance Testing –Control System Testing Actual Startup Activities

Example Startup Punchlist

Startups Must Be Planned For… Development of Startup Plan –Defines Startup Roles & Personnel Assignments –Defines Communications Protocol  Owner, Designer, Contractor, Inspection Staff –Outlines the Startup Activities (Sequence)  Pre-Startup  Startup  Post-Startup –Develops Process Control Targets & Tools

Examples of Pre-Startup Activities System Checkouts –Manufacturer –Unloaded –Clear Water Training –Vendor/Manufacturer –Designer Arrange for Chemical Deliveries/Seed Sludge Define Data Collection/Testing Needs Define/Provide Process Analysis/Control Tools

Startup Activities Process Setup – Set Valves and Equipment for Process Flow Train Startup Sequence & Procedures Staff Assignments Initiate Process Sampling/Testing Log Book to Track All Activities

Successful Projects Require Effective Communications Owner Understanding –Process Expectations vs. Reality Contractor Understanding –Control of Change Orders Design Team –Design Meets Intent Effective Communications (Written, Verbal) Starts At Planning and Never Ends

A Little Bit About Consulting Career Paths Project Delivery –Project Management –Production (Doing the Work) –Technical Expert Business Development/Marketing –Client Manager –Sales Manager Administrative –Supervisory –Office Management –Corporate Management

What Should You Be Looking For? OJT (On the Job Training) Opportunities –Project Opportunities (Cradle to Grave) –Mentors –Furthering Your Education Ability to “Know Yourself” & Grow into Yourself –Career Path Flexibility Does The Firms Business Goals Match Your Interests? What are the Time/Travel Opportunities & Demands? Does the Firm Support Professional Society Activities?

What Background Do You Need? Sound Understanding of Engineering, Hydraulics & Process Fundamentals Knowledge of Complementary Disciplines –Civil, Structural, Mechanical, Electrical Power, Instrumentation & Control Computer Skills a Must –Including CADD Skills Good Writing & Interpersonal Skills a Plus

What Are Employers Looking For? Sound Educational Foundation Hard Workers –Willing to Try New Things –Willing to Get Involved in “Outside” Activities Communicators – Written and Verbal People Skills Organization Skills

What to Look Out For…. Firms trying to serve markets outside their area of expertise. Firms only interested in making a buck. –(versus serving client’s needs most effectively) Firms overly dependent on market conditions –“Hire & Fire” versus conservative growth

Final Words of Encouragement Work Hard Have Fun Try to Learn New Things Get Involved in Professional Societies Look For Mentors