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Home My WebLink About1.06 Process description & flow diagramATTACHMENT to SPECIAL USE PERMIT APPLICATION Laramie Energy II, LLC Altela. Inc. Process Description & Flow Diagram Altela, Inc. Proprietary and Confidential Information ALTELA AL TELARAINs~1 SYSTEM PROCESS DESCRIPTION 1.0 General The Altela ARS-4000 System is a fully automated process designed to operate 24 hours per day with minimal shutdown time. In most cases, the system will be installed in relatively remote areas directly at a natural gas or oil well site. While a daily visit to each site will be normal procedure, the total time monitoring the system on site, once in operation, will be no more than I hour per day. In order to assure continuous operation of the Altela system, a reliable remote monitoring system is installed to provide a remote operator with a visual means of monitoring key system data. In addition, the remote monitoring system has an "auto-dial" capability, that is, it will notify the operator anytime an alarm situation occurs. The Ahela ARS-4000 system is cont ro lled via a Programmable Logic Controller or PLC. The PLC has built-in data logging capability. The PLC is programmed with a control logic that monitors many system variables continuously during operation. The logic is designed so that anytime a failure condition is sensed, the PLC will automatically shutdown the system through one of two shutdown modes. The standard, or "controlled shutdown" will automatically turn off each piece of process equipment in a methodical, controlled sequence. The "emergency shutdown" wi ll turn off all operating equipment immediately. In addition, the operator can trigger either shutdown mode, if required, at the push of a button. In general, the treatment process is relatively straight forward. The Altela system treats produced water by use of a di stillation process. In simple terms, the Altela system converts extremely dirty water into extremely clean water. As with all water treatment processes, the A Itela system is a waste reduction process, meaning the "bad" water is reduced by up to 80%. The remaining 20% must be disposed of through conventional methods. A simple explanation of the Altela process is as follows. The produced water is collected in a site holding tank. This water is transferred , via pump, into the Altela containerized system. Once inside the Altela system, the produced water is circulated continuously through twelve Altela Rain™ " towers." The towers are designed to evaporate pure water from the brackish produced water mixture. The evaporated water is subsequently condensed with in the same tower. The condensed water, which is distilled quality water, is collected and transferred from the towers into a "distilled water" holding tank. Periodically, the circulated produced water, at up to 8-times higher dissolved solids concentration, is pumped out of the Altela system, for eventual disposal. Likewise, the distilled water is also pumped from the system, either go ing down the drain or, where approved, used fo r local site irrigation or other productive use. Date: Feb. 20, 2008 Calculated By: T.N. Revi sion Level: A Revision Date: 02/20108 Allela, Inc. ProprielQly and Conjidenliallnformalion ALTELA AL TELARAINs~1 SYSTEM PROCESS DESCRIPTION 1.1 Detailed Process Description For a pictorial view of the Altela process, please reference Altela Process Flow Diagram, drawing number 400-4008, pages I through 4. I.I.A Page I -Produced Water (PW) Fill and Concentrate Water (CW) Transfer Process The process begins when the operator has confirmed the system is set in the operating mode and ready to begin treating produced water (PW.) To start the process, the operator presses the START PROCESS button on the control screen. When pushed, the PLC initiates system operation. The process proceeds as follows. I.I.A.I Blower I (B-1) turns on and begins transferring ambient air through the air-to-air heat exchanger (HEX) and into the bottom basin for Towers #1 through #6. 1.I.A.2 Blower 2 (B-2) turns on and begins transferring ambient air through the air-to-air heat exchanger (H EX) and into the bottom basin for Towers #7 through # 12. 1.I.A.3 Blower 3 (B-3) turns on and beginning exhausting hot, water laden vapor from all 12 towers through the air-to-air heat exchanger, HEX. Note: Blowers I, 2 and 3 are always ON when the system is initialized. All three blowers remain ON until the system operation is stopped. Note: The Air-to-Air Heat Exchanger HEX is used to pre-heat the outside, ambient temperature air before it is introduced into the towers. This process helps minimize temperature swings within the tower that would otherwise be caused by introducing cold air into the towers. I.I.AA The PLC checks level status in the CW Tank, tank T-I. If the PLC registers a tank level above the Lo Level sensor and below the Hi Level sensor, the PLC will open automated valve PA V-I and start the PW Pump, pump P-I. I.I.A.S P-I will transfer PW into the CW Tank, tank T-1. As liquid enters T-I, the PLC will monitor the level status. 1. I.A.6 When the liquid level reaches the tank Lo Level sensor, the PLC will open PAV-2 and start the CW Pump, pump P-2, and begin transferring PW to the towers. This operation will continue unless the system is manually shutdown by the operator or automatically shutdown due to an alarm condition. 1.I.A.7 When the level rises to the Hi Level sensor, the PLC will stop P-I and close PAVI. 1.I.A.8 Once P-2 is ON, the PLC will monitor the liquid level in T-I. When the liquid level falls below the Lo Level sensor, the PLC will initiate P-I and transfer PW into T-I until the liquid level rises above the Hi Level sensor. This process will cycle as long as the system is operating automatically. I.I.A.9 As PW is transferred into T -I, a conductivity sensor will continuously measure the Total Dissolved Solids (TDS) of the incoming PW. The instantaneous TDS value will be displayed at the operator control panel. In addition, whenever P-I is Date: Feb. 20, 2008 Calculated By: T.N. 2 Revision Level: A Revision Date: 02/20108 Allela, Inc. Proprielary and Confidenliallnformalion A LTE LA ' AL TELARAINs\l SYSTEM PROCESS DESCRIPTION initiated, the TDS value wi ll be averaged and stored in the system data logger table. I . I.A.IO As PW is tran sferred into T-I , a flow sensor wi ll continuously measure the flow of the PW going into T-1. The PLC wi ll totalize the flow, and the total flow will be displayed at the operator control panel. In addition, whenever P-I is initiated, the total flow va lue will be stored in the system data logger table. I.I .B Page 2 -Concentrate Water (CW) Transfer Process and Tower Flow Control As stated earlier, once the process is started, the CW Pump, P-2, will continuously transfer PW to the towers until the process is stopped. The process operates automatically and is controlled via the PLC according to the following. I . I.B .I Once P-2 is started, automated valve PAV-2 is opened and PW is transferred at a total flow of approximately 12 gallons per minute to the towers. 1.I.B.2 The towers are installed within the container in two rows or Tower Banks. Bank I holds towers I through 6, bank 2 holds towers 7 through 12. 1. I.B.3 The PW flow must split and be transferred to each bank of towers. 1.I.B.4 Before flowing to a tower bank, the PW is passed through a 200 micronbag filter. The bag filter is required to continuously remove heavy particles from the PW water that may plug the flow meters ot tower inlet piping. The filter will be cleaned periodically by opening the filter chamber, removing the dirty filter, and replacing with a clean filter. Note there is an air blowdown on each filter that allows the operator to purge the water from the filter chamber prior to removing the top from the chamber. The purge process is conducted as follows : 1.I .B.4.a Close the 1-1 /2" ball valve at the inlet to the filter chamber. 1.I.B.4 .b Close the I" ball va lve transferring water to the flow meters. 1.I .B .4.c Open the I" ball valve that transfers water back to the CW Basin tank located beneath towers 1-6. 1.I .B.4.d Open the Y2" ball located above the air coupler. 1. I.B .4.e Insert the air line into the air coupler. 1. I.B.4.f Open the ball valve on the air line SLOWL Y. I.I.B.4.g Allow the air to purge the water from the filter. This should take about one minute, and the purge is complete when the operator hears air entering the CW basin tank. 1.I.B.4.h Repeat the process with the second filter chamber. 1. I .B.4.i Remove and replace the filter bags. 1. I.B.4 .j Reverse the process to place the va lve back into the normal operating position. 1. I.B.5 After the filter operation, the PW flows into a distribution manifold to feed PW into each tower. Each leg of the distribution manifold is plumbed with a visual flow indicator and a flow control valve. The flow control valve should be set to allow fromO .8 to 1.2 gallon per minute of PW flow to each tower. Date: Feb. 20, 2008 Calculated By: T.N. 3 Revision Level: A Revision Date: 02/20108 Altela, Inc. Proprietary and Confidential Information A LTELA " AL TELARAINs~1 SYSTEM PROCESS DESCRIPTION 1.I.B.6 After passing through the now control valve, the PW is transferred to the tower inlet piping located at the bottom and back of each tower basin. I.I.C Page 3 -Tower Operation The standard Altela Rain™ system is designed to hold 12 operational towers. Each tower nows PW at a now rate of approximately I gallon per minute. The process operates automatically and is controlled via the PLC according to the following. I. I.e. I PW enters the tower through the piping connected to the bottom of the tower. The PW nows into the tower and up the Tower PW Manifold, where the liquid is preheated to the appropriate operating temperature range, between 182 F and 192 F. 1.1.e.2 Once the PW reaches the top of the tower, it nows out the top of the PW drip strips and is distributed evenly throughout the tower. I. I .C.3 Each tower is fitted with a thermocouple device to monitor tower PW temperature. The tower PW temperature is displayed on a digital meter located on the front of the PLC control panel. I. I .C.4 Each tower is fitted with a thermocouple device to monitor tower top IT air temperature. The tower TT temperature is displayed on a digital meter located on the front of the PLC control panel. I .1.e.S The air blowers, B-1 and B-2, blow warm air through each of the towers at a nominal rate of20 CFM. Air flow to each tower is measured with a handheld flow meter. Each lower air inlet pipe is fitted with a manual flow control valve, which is adjusted to allow the required air flow to the tower. The air enters the bottom of the tower and flows up to the top, where it is mixed with steam entering the top of the tower. I. I .e.6 The hot PW flows down through the tower, coming in contact with the air entering the tower. The air facilitates evaporation of pure water from the PW stream within the tower. As water is evaporated from the PW, the TDS concentration in the remaining water increases, thus concentrating the salts in the PW. The concentrate water, or CW, falls to the bottom of the tower where it is collected in the tower bottom basin. As the basin fills, the CW exits the tower through several drain tubes and flows into the CW Basin Tanks, TAl and T-42. See following section for a detailed explanation of the CW Drain Tank process. I . I.e. 7 The air/water vapor mixture flows to the top of the tower. Steam is introduced into the tower to further heat the air/water vapor mixture. The top of the tower is fitted with a thermocouple to monitor the tower top temperature. The tower top temperature is displayed on a digital meter located on the front of the PLC control panel. The steam rate into the tower is determined by the steam manifold pressure. Each tower has an identical internal steam "bar" with holes designed to now steam at a given rate dependent upon steam manifold pressure. The steam rate is set to maintain the tower top temperature at the appropriate operating temperature. Date: Feb. 20, 2008 Calculated By: T.N. 4 Revision Level: A Revi sion Date: 02/20/08 Allela, Inc. Pl'opl'ielwy and Conjidenliallnjormalion ALTELA" AL TELARAINsM SYSTEM PROCESS DESCRIPTION 1. 1.e.8 The air/water vapor mixture flows down through the tower, cooling along the way. As the mixture cools, the distilled water (DW) condenses from the air and falls to the bottom of the tower, where it is collected in the side DW troughs. As the water collects, it exits the tower from each side and flows into the DW Drain Tank, T-S I. See next section for a detailed explanation of the DW Drain Tank process. 1.1.e.9 In addition to DW, the air/water vapor mixture also exits the tower through the DW troughs. This mixture is sti ll hot and contains a relatively high level of water vapor. This hot air/water vapor mixture is exhausted from the towers through a piping system plumbed to a blower, B-3, that provides positive purge of all hot exhaust and sends the vapor through the Air-to-Air heat exchanger. . I.I .D Page 4 -Distilled Water (DW) Transfer Process and Boiler Operation As stated in the previous section, the DW exits the towers and flows into the DW Drain Tank located beneath the towers. In addition, steam is generated by a boiler and supplied to each tower to control the tower top temperature. Both processes are controlled automatically via the PLC according to the following . I . I.D.I The DW flows by gravity into the DW Drain Tank, T-SI. 1. I.D.2 Tank T-SI contains a 3-position level sensor that monitors the liquid level within the two basins. When the level rises above the Hi or Pump On level sensor, the PLC in itiates the DW Drain Pump, P-S, and transfers the DW into the DW Tank, T-2. 1.1.D.3 P-S pumps for a timed duration, lowering the liquid level in T-SI. At the end of the timed cycle, the PLC turns the pump off. 1.I.D.4 The DW Basin Tank level control also consists of a Lo level sensor. This sensor is installed to protect against a loss-of-prime situation. When the tank level drops below the Lo sensor, the PLC receives a signal and the program turns the pump off. In addition, if the tank level remains below the Lo level sensor for timed duration during normal system operation, the PLC program will initiate an alarm shutdown mode. I . I.D.S In addition to the Pump On and Lo level sensors, T-SI is fitted with a Hi Level sensor to detect a high level condition in the tank. If the liquid level rises above this sensor, the PLC will again initiate P-S and transfer the DW into the DW Tank. In addition, if the level does not fall within a timed duration, the PLC will actuate a System Shutdown Alarm and begin a system shutdown to prevent a potential tank overflow situation. 1.I.D.6 T-SI is also fitted with a thermocouple device and transmits a signal to the PLC. The PLC monitors the signal and displays the DW Drain Tank temperature at the operator panel. 1. I.D.7 Before the DW enters the DW Tank, it flows past a conductivity sensor that measure the TDS level of the DW liquid. The TDS value is monitored by the PLC Date: Feb. 20, 2008 Calculated By: T.N. S Revision Level: A Revision Date: 02/20/08 Altela. Inc. Proprietary and Conjidenliallnjormation ALTELA' AL TELARAINs~1 SYSTEM PROCESS DESCRIPTION to ensure the DW liquid stays within compliance before discharge outside the container. If the TDS level rises beyond the established set point, the system will automatically begin the System Shutdown process to ensure that no failed DW enters the DW Tank. I.I.D.S After passing the TDS sensor, the DW enters the DW tank. As the liquid level rises within the tank, it is monitored by several level sensors which send a signal to the PLC. As long as the liquid level is above the Low Alarm sensor, the DW pump will, on demand, open the automatic valve and transfer DW to the boiler. This transfer process is controlled by the Boiler level sensors. 1.I.D.S.a When the liquid level within the boiler falls below the Fill On sensor, the boiler sends a signal to the PLC to initiate the DW pump and transfer water to the boiler. This signal remains ON until the liquid level within the boiler rises above the Fill Off sensor, at which time the signal is off and the PLC turns the DW Pump off. I.I.D.S.b If the liquid level within the boiler should fall below the Lo Alarm sensor, the boiler will shutdown and send a signal to the PLC. The PLC will then automatically begin the System Shutdown process. 1. I.D.S.c In addition, the boiler is fitted with a pressure sensor that monitors boiler pressure. If the boiler pressure rises above the Hi Pressure level, the boiler will shutdown and send a signal to the PLC. The PLC will then automatically begin the System Shutdown process. 1. I.D.S.d As DW is transferred to the boiler, a flow sensor will continuously measure the flow of the DW flowing to the boiler. The PLC will totalize the flow, and the total flow will be displayed at the operator control panel. In addition, whenever P-3 is initiated, the total flow value will be stored in the system data logger table. I.I.D.9 If the level within the DW Tank rises above the Tank High sensor, the PLC will open PAY-4 and initiate the DW Pump to begin transferring the DW liquid out of T-2. I.I.D.IO Before the DW is di scharged from the system, it flows past a conductivity sensor that measure the TDS level of the DW liquid. The TDS value is monitored by the PLC to ensure the DW liquid stays within compliance before discharge outside the container. If the TDS level rises beyond the established set point, the system will automatically begin the System Shutdown process to ensure that no failed DW leaves the Altela system. I. I.D.I I As DW is transferred out, a flow sensor will continuously measure the flow of the DW leaving the system. The PLC will totalize the flow, and the total flow will be displayed at the operator control panel. In addition, whenever P-3 is initiated, the total flow value will be stored in the system data logger table. I . I.E Page I -Concentrate Water (CW) Transfer Process Date: Feb. 20, 200S Calculated By: T.N. 6 Revision Level: A Revision Date: 02120/0S Altela, Inc. Proprietary and Confidential Information ALTELA" AL TELARAINS\' SYSTEM PROCESS DESCRIPTION As stated in the previous section, the CW exits the towers and flows into the CW Drain Tanks located beneath the towers. This process is controlled automatically via the PLC according to the following. I.I. E. I The CW flows by gravity into the CW Drain Tanks, T-41 and T-42. 1.I.E.2 The tanks are interconnected so that the liquid level is the same in both tanks, 1.I .E.3 Tank T-41 contains a 3-position level sensor that monitors the liquid level within the two bas ins. When the level rises above the Hi or Pump On level sensor, the PLC initi ates the CW Drain Pump, P-4, and transfers the CW into the CW Tank, T-2. I.I .EA P-4 pumps until the liquid level in T-41 drops below the Lo or Pump Off level sensor, at which point the PLC turns the pump off. I.I.E.S In addition to the Pump On and Pump Off level sensors, T-41 and T-42 are both fitted with a Hi Level sensor to detect a high level condition on either tank, If the liquid level rises above either sensor, the PLC will again initiate P-4 and transfer the DW into the DW Tank. In addition, if the level does not fall within a few seconds, the PLC will actuate a System Shutdown Alarm and begin a system shutdown due to a potential tank overflow situation. 1.I .E.6 T-41 is also fitted with a thermocouple device and transmits a signal to the PLC. The PLC monitors the signal and displays the CW Drain Tank temperature at the operator panel. 1.2 Critical System Shut Down Alarms and Logic The system will automatically shutdown ifany of the following alarm conditions occur. 1.2.A Tank I CW Tank Hi Hi Level -if the liquid level in the CW tank reaches the HIHI liquid level switch, and HIHI level condition remains active for the timed duration, the system should proceed with an orderly system shutdown, 1.2.B Tank I CW Tank Lo Lo Level -if the liquid level in the CW tank reaches the LOLO liquid level switch, and LOLO level condition remains active for the timed duration, the system should proceed with an orderly system shutdown. 1.2.C Tank 2 DW Tank Hi Hi Level -if the liquid level in the DW tank reaches the HIHI liquid level switch, and HIHI level condition remains active for the timed duration, the system should proceed with an orderly system shutdown. 1.2.0 Tank 2 DW Tank Lo Lo Level -if the liquid level in the DW tank reaches the LOLO liquid level switch, and LOLO level condition remains active for the timed duration, the system should proceed with an orderly system shutdown. 1.2.E Container Fire Alarm ON -if the Fire Alarm is actuated, the system should immediately proceed to an emergency system shutdown. Date: Feb. 20,2008 Calculated By: T.N. 7 Revision Level : A Revision Date: 02/20108 Altela, Inc. Proprietmy and Confidential Information ALTELA" AL TELARAINS\! SYSTEM PROCESS DESCRIPTION 1.2.F CW Basin Hi Hi Level -if the liquid level in the CW Drain Basin reaches the HIHI liquid level switch, the system should proceed to an emergency system shutdown. ALARM: CW Drain Basin HI HI Level -Pump or Level Switch Failure. 1.2.G CW Basin Lo Level -if the liquid level in the CW Drain Basin reaches the Lo liquid level switch, and Lo level condition remains active for 60 seconds while the PW transfer pump is operating, the system should proceed to an emergency system shutdown. ALARM: CW Drain Basin LO Level -Pump or Level Switch Failure. 1.2.H DW Basin Hi Hi Level -if the liquid level in the CW Drain Basin reaches the HIHI liquid level switch, the system should proceed to an emergency system shutdown. ALARM: DW Drain Basin HI HI Level -Pump or Level Switch Failure. 1.2.1 DW Basin Lo Level -if the liquid level in the DW Drain Basin reaches the Lo liquid level switch, and Lo level condition remains active for 5 minutes while the PW transfer pump is operating, the system should proceed to an emergency system shutdown. ALARM: DW Drain Basin LO Level -Pump or Level Switch Failure. 1.2 .1 Boiler Lo Lo Water Level -if the liquid level in the boiler triggers the LOLO water shutdown alarm in the boiler controller, the system should immediately proceed with an orderly system shutdown. ALARM: Boiler LO LO Water Level -Boiler Shutdown, DW Tank Empty, DW Pump or Valve Failure, or feed line leak. Take corrective action. Manual reset of boiler required to restart. 1. 2. K Boiler Hi Hi Pressure Level -if the pressure in the boiler triggers the HIHI pressure shutdown alarm in the boiler controller, the system should immediately proceed with an orderly system shutdown. ALARM: Boiler HI HI pressure -Boiler Shutdown due to excessive pressure, check steam lines for blockage. Take corrective action. Manual reset of boiler required to restart. 1.3 Other Non-critical System Alarms and Logic The following non-critical alarm conditions are monitored by the PLC for automatic corrective action to avoid a system shutdown if the situation can be corrected through automatic adjustment via the PLC controller. 1.3.A CW Tank LO Level -CW tank LO liquid level, tank fill in progress. 1.3.B DW Tank LO Level -DW tank LO liquid level, monitor to assure boiler feed water ava ilable. 1.3.C CW Tank HI Level -CW tank HI liquid level, tanks transfer in progress. IJ.D DW Tank HI Level -DW tank HI liquid level, tank transfer in progress. 1.3.E Boiler LO Level -Boiler LO liquid level, boiler fill in progress. 1.3 .F Boiler LO LO Level -Boiler LO LO Liquid level, boiler flame off until fill process is complete. Date: Feb. 20, 2008 Ca lcu lated By: T.N. 8 Revision Level: A Revision Date: 02/20108 Allela, Inc. Proprietary and Confidential Informal ion ALTELA ' ALTELARAINSM SYSTEM PROCESS DESCRIPTION 1.3 .G Boiler HI Pressure -Boi ler HI pressure, boiler fl ame off until HI pressure condition clears. ************END OF DOCUMENT************ Date: Feb. 20, 2008 Calculated By: T.N. 9 Revision Level: A Rev ision Date: 02/20/08 ~~ ~~ ~~ 1 ~~ ~~ " S1£N,I IN f'ROW BOIlER Y Y uy f"JIQM PJrG{ • 8\1-221 811-22 'H"~ 8\1-224 .'-=~ 8V-226 1 ~ Ir . ~ . -~ ~ ~ r i""'-r i"<-i-"'i""-i-"'i""-r= i"'-I "-YNR >-nH)t,j PJIG[ 1 " ElOWJST .. ) TO PACE 1 I -< I" 'I" I" f€J ~ }<® ~ ~O5 ~ re-"" r:l rC-202 C--J FC-2Q.l J rC-204 r. J f C-2O& ~ ~ ..J 16 J ~ "-"-"-"-"-"-. ~ "-~ "-. ~ t,. :'t i . ,.:t: . "t , .1-1-. . 1-1-. ,l: • 1-: :1-CW OIWN TANK T-41) 1'O'IIER 1 PW .... TO\llER2PW ..... 1'O'IIER 3 PW ~ ,..,.. 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