EPA-600/2-76-198
October 1976
INSTRUMENTATION AND AUTOMATION
EXPERIENCES IN WASTEWATER-TREATMENT FACILITIES
by
Allen E. Molvar
Raytheon Company
Portsmouth, Rhode Island 02871
Joseph F. Roesler
Robert H. Wise
Municipal Environmental Research Laboratory
Cincinnati, Ohio 45268
Russell H. Babcock
Charles A. Maguire Associates, Inc.
Waltham, Massachusetts 02154
Contract No. 68-03-0144
Project Officer
Joseph F. Roesler
Wastewater Research Division
Municipal Environmental Research Laooratory
Cincinnati, Ohio 45268
MUNICIPAL ENVIRONMENTAL RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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DISCLAIMER
This report has been reviewed by the Municipal Environmental
Research Laboratory, U.S. Environmental Protection Agency, and approved
for publication. Approval does not signify that the contents necessarily
reflect the views and policies of the U.S. Environmental Protection
Agency, nor does mention of trade names or commercial products constitute
endorsement or recommendation for use.
11
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FOREWORD
The Environmental Protection Agency was created because of
increasing public and government concern about the dangers of pollution
to the health and welfare of the American people. Noxious air, foul
water, and spoiled land are tragic testimony to the deterioration of
our natural environment. The complexity of that environment and the
interplay between its components require a concentrated and integrated
attack on the problem.
Research and development is that necessary first step in problem
solution and it involves defining the problem, measuring its impact,
and searching for solutions. The Municipal Environmental Research
Laboratory develops new and improved technology and systems for the
prevention, treatment, and management of wastewater and solid and
hazardous waste pollutant discharges from municipal and community
sources, for the preservation and treatment of public drinking water
supplies, and to minimize the adverse economic, social, health, and
aesthetic effects of pollution. This publication is one of the
products of that research; a most vital communications link between
the researcher and the user community.
This report describes a nationwide survey of instrumentation and
automation experiences collected from visits to fifty wet-and-dry-weather
wastewater-treatment facilities. The technical and economic benefits of
current monitoring and control practices are considered in the hope that
the results will assist design engineers, environmental planners, and
regulatory agencies in designing cost-effective instrumentation and
automatic control strategies to improve the quality and reliability of
wastewater treatment.
Francis T. Mayo, Director
Municipal Environmental Research
Laboratory
ill
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CONTENTS
Disclaimer
Foreword
List of Figures
List of Tables
Page
11
iii
vi
vii
I Introduction
II Summary and Recommendations
III The Survey
IV Instrument Cost Factors and Users' Attitudes
V Measuring Devices
VI Typical Control Strategies
VII Centralized Control
VIII Computer Control
IX Manpower Requirements for Instrument
Maintenance and Calibration
X References
Appendix A Definitions and Instrumentation Symbols
Appendix B Measuring Device Manufacturers
Appendix C Plant Survey Data and Instrumentation Schematic
Diagrams
1
5
15
22
32
54
72
78
83
86
88
98
125
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FIGURES
No. Page
1 Typical control-system components 3
2 Observed distribution of measuring instruments
8
3 Performance Summary of Measuring Devices in
Wastewater-Treatment Facilities 9
, Summary of Automatic Control EKperiences in ]i
Wastewater-Treatment Facilities
5 General Survey Questionnaire 17
6 Instrument Survey Form 18
7 Process-Control-Loop Survey Form 19
8 Flow-Proportional Chlorination Control 58
9 Compound, Residual Chlorine, Control System 60
10 Double Compound, Residual Chlorine, Control 62
System
11 Dissolved Oxygen Control Schemes 65
12 Sludge Pumping Control Strategies 67
13 Instrumented Scum-Pumping System 68
14 Chemical Addition Control Strategies 70
15 Example of Semi-Graphic Instrument Panels 73
16 Typical Outfall-Interceptor Control System 82
A-l Examples of Cascade Loops (Schematic) 89
A-2 ISA Symbols 95
VI
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TABLES
No. Page
1 Instrument Operating Experiences 7
2 Types of Facilities Surveyed 16
3 Regional Locations of Plants Surveyed 16
4A Background and Economic Data for Primary 23
Treatment Facilities Surveyed
4B Background and Economic Data for Secondary 24
Treatment Facilities Surveyed
4C Background and Economic Data for Various 26
Other Treatment Facilities Surveyed
5 Liquid-Level Measuring Instruments 33
6 Sewage and Sludge Flowrate Meters 35
7 Oxygen Transfer Equipment 64
8 Skill-Level Distribution 84
A-l Instrument Abbreviations 96
vn
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SECTION I
INTRODUCTION
BACKGROUND
Enactment of the Federal Water Pollution Control Act Amendments of 1972
clearly signaled an acceleration of the national commitment to implement
a series of corrective measures that will not only prevent further
pollution of our water resources but will chart a course for a long-term
water-quality-improvement program.-'- Instrumentation and automatic
control has the potential for increasing effluent quality, enhancing
treatment reliability and reducing the costs of achieving high degrees of
purification. Moreover, a review of cost-effective design alternatives
should include an examination of appropriate roles for instruments and
automatic control devices.
More than most manufacturing processes, municipal wastewater-treatment
facilities are continually exposed to changing inputs and ambient
conditions. With diurnal and seasonal variations in wastewater flowrates
and strengths, municipal plants must operate under widely varying loadings;
this situation tends to produce a variable quality effluent. For a typical,
25-MGD, dry-weather treatment plant, the ratio of maximum to minimum flowrate
is approximately 1.8, and the corresponding organic loading ratio is about
3 . Disturbances such as storm events, oils, grease, organic solvents,
or industrial chemical discharges also contribute to upsets commonly
experienced in most wastewater-treatment facilities. Combined sewer overflow
and stormwater-control technology is being implemented to meet more-
stringent water quality standards. These control facilities are also sub-
jected to variable load conditions, and they generate return flows to the
central wastewater-treatment plant which, again, cause effluent quality
variations. Sludge stabilization and thickening processes, while less
sensitive to diurnal and seasonal changes, generate recycle streams which
cause load changes in the primary and secondary treatment processes.
To minimize the adverse effects of influent variations, treatment plants
are often designed conservatively to meet peak loadings, and this incurs
higher-than-necessary capital and operating costs.
Based on successful applications of instruments and automatic control
devices in other industries, instrumentation of both wet- and dry-weather
wastewater-treatment plants offers the following potential advantages:
Improved wastewater-treatment reliability with corresponding
decreases in effluent-quality variability
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Increased water-quality-management capabilities
Reduced operating and maintenance costs
Smaller equipment and structure sizes because the treatment
processes are kept operating at their maximum efficiency.
3
A recent literature review indicates that the performance of most
wastewater-treatment unit operations and processes can be improved through
monitoring and control. Yet, on the basis of capital costs allocated to
plant construction, the majority of wastewater-treatment facilities
provide little instrumentation.
Elements essential to a general instrument or process-control scheme
(Figure 1) include the following components:
Measuring or sensing devices
Signal transmitting devices
Indicating elements for data display and inspection of
operating conditions
Controllers that implement the selected actions
Final control elements for executing the selected control strategy •
OBJECTIVES
To accumulate information needed for rational decisions governing the
type and degree of instrumentation that should be used in wastewater-
treatment facilities, the United States Environmental Protection Agency
sponsored a comprehensive study of current, and potential instrumentation
and automation applications in these facilities. As part of this project,
a team of engineers surveyed fifty, selected, municipal and industrial
wastewater-treatment facilities. These plants utilized a wide array of
treatment processes such as pretreatment, primary, secondary, and advanced
wastewater treatment. Although the majority of the surveyed facilities
were dry-weather or combined-treatment facilities, some stormwater-
treatment plants and control centers were also examined. The plant surveys
assessed instrument utilization and performance, and estimated special
manpower skills, training, and equipment necessary to operate and maintain
instrument systems properly. When available, total control-system costs
and economic or performance benefits derived were also noted.
The survey efforts concentrated on automatic on-line instruments and
computer systems; therefore, laboratory measuring devices (i.e., those
requiring a technician to transfer, prepare or condition a sample manually)
were excluded from this investigation.
If wastewater-treatment plant automation is to become more widely utilized,
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FINAL CONTROL
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comprehensive reports on the successes and shortcomings of observed
"field" instruments, automatic control devices, and wastewater-treatment
process-control strategies are essential. Such reports will provide
guidance to design engineers, municipal planners and regulatory officials;
they will also direct future research on equipment development and process-
control theory.
A glossary of terms is given in Appendix A-
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SECTION II
SUMMARY AND RECOMMENDATIONS
GENERAL
A nationwide survey of fifty wastewater-treatment facilities found that
most of these plants use fewer instruments and automatic control devices
than closely related, water supply and chemical processing plants.
Amassed cost data show that the average secondary treatment plant allocates
about 3% of construction costs for installed instruments; water supply
and chemical processing plants, however, allocate about 6% and 8%
respectively, for installed instruments. Remote satellite, wet-weather
treatment plants, which in theory should operate unattended or with a
minimal amount of operating man-power, allocated only about 2% for instru*-
mentation and automation. Central, computerized, stormwater-routing and
in-line storage systems, however, seemed to employ an adequate amount of
instruments and automatic control devices.
An explanation for this smaller utilization of instruments in most
wastewater-treatment facilities includes:
No profit incentive to produce high-quality effluent
No statutory penalty for poor-quality effluent, plus loosely
enforced effluent-discharge standards (or guidelines)
Lack of commercially available, field-proven instruments
that reliably measure important process parameters
Oversizing of plant capacity: Although this practice is
relatively expensive, it permits a more loosely controlled
operation
General lack of familiarity with on-line instrumentation
practices and needs.
Regulatory agencies can motivate wastewater-treatment plant authorities
to use more process-type analytical instruments by strictly enforcing
effluent guidelines and penalizing poor effluent quality. Furthermore,
instrument manufacturers and research agencies should demonstrate, under
actual field conditions, favorable cost/benefit ratios to stimulate on-line
instrument usage. To help assess an instrument's desirability, a uniform
easily-practiced record-keeping system is badly needed. Much misunder-
standing and confusion could be avoided if design engineers would use
standard symbols and standardized instrument drawings. Since instrument
purchasing and installation are becoming more complex, consideration should
be given to nationwide adoption of new contractual procedures to ensure
that the specified instruments and control systems are effective
when installed.
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Although collection of detailed capital, operating, and maintenance
costs for instrumentation was one of the prime survey objectives, only
30% of the surveyed plants had this information. If meaningful equipment
life-expectancies, mean time between failures, and operational cost infor-
mation are available, then the cost-effectiveness of instruments and auto-
matic control devices can be accurately estimated. Clearly such a need
exists, and wastewater-tteatment facilities should attempt to standardize
and improve their record-keeping practices.
MEASURING DEVICES
Unreliable sensors accounted for most of the difficulties experienced with
automatic measurement and control of wastewater-treatment processes.
Accumulated instrument operating experiences, summarized in Table 1,
clearly show that wastewater-treatment instruments require more maintenance
than their industrial counterparts. Since most measuring devices in
wastewater applications interface directly with raw sewage, mixed liquors
or thickened sludge, these devices are subject to continued fouling from
solids deposition, slime buildup, and chemical precipitation; accordingly,
they need more frequent cleaning and calibration. Poor mechanical
reliability, interferences due to extraneous parameters, and lack of
established measuring principles are also responsible for the unsatisfactory
performance of some analytical sensors.
The distribution of measuring devices (Figure 2) indicates that flow and
level devices account for nearly half the instrumentation employed in
wastewater-treatment facilities; analytical instruments (e.g., on-line
colorimetric instruments) represent approximately one quarter of the
instruments observed; position, speed, weight and other mechanical-type
measurements add up to another 15%. Based on actual field experiences
in the surveyed facilities (Figure 3), the following measuring instruments
are commercially available with sufficient reliability for on-line use in
wastewater-treatment applications:
level, flow, temperature, pressure, speed, weight, position,
conductivity, rainfall, turbidity, pH, residual chlorine, free
chlorine gas, and free flammable gases.
Sludge density meters, sludge blanket level detectors, on-line
respirometers, dissolved oxygen probes, and many automatic sampling
systems use well-established principles which are suitable for wastewater
monitoring and control activities, but some of these require a large
amount of maintenance. Such instruments, accordingly, need lower
maintenance requirements before they will become widely used.
In spite of the many successful flow-measuring devices observed in
treatment plants, accurate and reliable flowrate monitoring for
stormwater poses special problems. Highly transient flows, large
operating ranges, high concentrations of suspended solids, and frequent
collisions with large debris are only some of the obstacles that an
acceptable in-sewer flowmeter for stormwater must overcome.
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* AUTOMATIC ANALYSIS
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Figure2. Observed distribution of measuring instruments
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1972-3 NO. OF CASES
10 15 20 25 30 35 40
BUBBLERHTYPE LEVEL DETECTORS
DIFFERENTIAL-PRESSURE LEVEL DETECTORS
FLOATS
ALL OTHER LEVEL DETECTORS
I WEIRS AND FLUMES
VENTURIS, ORIFICES, NOZZLES
MAGNETIC FLOWRATE
OTHER FLOWRATE METERS
NUCLEAR RADIATION DENSITY METERS
TRANSMITTING RAIN GAUGES
J TEMPERATURE
PRESSURE
ROTATIONAL SPEED
WEIGHT
POSITION
TURBIDITY
CONDUCTIVITY
PH AND ORP
] THALLIUM DO PROBE
J MEMBRANE DO PROBE
I RESIDUAL CHLORINE
OTHER ANALYTICAL ANALYZERS
I GAS MONITORS
1 SAMPLING SYSTEMS
UNSATISFACTORY FAIR SATISFACTORY
Figures. Performance summary of measuring devices in wastewater- treatment facilities
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Consequently, a suitable stormwater flow meter needs to be developed for
producing the accurate flowrate data required for sewer regulation.
AUTOMATIC CONTROL
As shown in the summary of automatic control devices (Figure 4) , most
facilities successfully practice automatic liquid-level, liquid-flowrate,
and air-flowrate control since fluid regulation is important for proper
operation and since satisfactory flow meters are readily available.
Presently available, flow-control systems that use established designs
are entirely adequate for wastewater-treatment activities.
Automatic process control, however, is only occasionally utilized in
wastewater treatment. The nationwide survey, summarized in Figure ,
found that control systems for flow-ratio chemical addition, feedback
residual chlorine, and digester temperature worked well and caused no
difficulties. Most plant managers considered these automatic control
systems cost-effective since they save energy and chemicals, and improve
plant operation. Automatic feedback control systems for dissolved oxygen
effectively reduce oxygenation power consumption, but some users reported
that these systems required considerable probe maintenance. The
turbidity and pH control systems observed in this survey gave
unsatisfactory performance because of faulty system design and instal-
lation. Some of the most potentially useful process-control parameters
(such as substrate concentration, MLVSS, food/microorganism ratio) have
not been successfully practiced in wastewater-treatment plants.
The small number of automatic control loops observed in the present plant
survey attests to the low level of automation that is characteristic of
most wastewater-treatment plants. The survey's observations indicate that
lack of sufficiently reliable analytical sensors has impeded process-
control efforts. Other commercially available, process-control
components (transmitters, display devices, controllers, and final
control elements) have proven their ability to provide reliable service
in wastewater-treatment plants.
Intensive application of elaborate and novel logic schemes, computers,
displays, and recorders will not improve wastewater-treatment
effectiveness. Instead, well-documented field-evaluation programs are
needed to help ferret-out desirable control systems from the
numerous potentially viable ones.
CENTRAL CONTROL
Central control organizes the plant operation in such a manner that all
treatment information, important events, and alarms are displayed,
indicated and recorded in a centralized location, usually referred to as
the control room. In addition, most central facilities practice
automatic, or remote manual, actuation of final control elements. The
success of central control is assured by the commercial availability
of reliable transmitters, displays, indicators, and recording equipment.
Virtually all the large successfully surveyed facilities utilized
10
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1972-3 NO. OF CASES
10 15 20 25 30 35
LIQUID LEVEL CONTROL I
LIQUID FLOWRATE CONTROL
SLUDGE PUMPING
AIR FLOWRATE |
CHEMICAL ADDITION |
RESIDUAL CHLORINE |
DISSOLVED OXYGEN
1LJ PH
TURBIDITY
AUTOMATIC SCUM REMOVAL
AUTOMATIC DATA ACQUISITION
SUPERVISORY COMPUTERS
DIRECT PROCESS CONTROL BY DIGITAL COMPUTER
LiiiJ UNSATISFACTORY KfflW FAIR SATISFACTORY
D
Figure4. Summary of automatic control experiences in wastewater- treatment facilities
11
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a high degree of centralized control, Since it reduces the number of
men required to operate a large treatment plant, centralized control
is one of the few forms of instrumentation readily justifiable on an economic
basis.
COMPUTERS
Modern data-logging systems accumulate, format, record and display large
quantities of data effectively; consequently, most new plants have
automatic data-acquisition systems. Approximately twenty percent of
the visited facilities used data-logging computers, and ninety percent
were satisfied with them.
Although direct digital, and digital supervisory, process-control computers
have demonstrated their merits in many industries, they are not well
established in dry-weather treatment plants: Only two of the surveyed
facilities had process-control computers; on the other hand, three
stormwater-control centers used computerized supervisory control, and all
of these computer systems worked well.
Computerized supervisory control of large storm and combined sewer
systems is cost-effective because the vast number of variables and
control points exceeds human computational and decision-making abilities
within corrective time limits.
MAINTENANCE
In spite of inadequate amounts of installed instrumentation, wastewater-
treatment personnel exhibited a good attitude towards instrumentation, as
measured by their willingness to use and maintain those instruments
actually present. The survey team found that the treatment plants
supplied approximately ninety percent of the maintenance resources
needed. Small abandonment rates also attested to their favorable acceptance.
Individual plant managers' disposition towards instrumentation, however,
ranged from poor to excellent. As a group, satellite stormwater-
treatment facilities supplied less-than-adequate maintenance; possibly
because of their newness, maintenance of stormwater instruments is not well
understood. Since none of these satellite facilities could start up or
shut down automatically, it would behoove individuals concerned with
stormwater-treatment facilities to direct sore attention to development
of automatic instruments and devices, as well as to improving the
maintenance of existing devices. On the other hand, stormwater-control
centers, which typically receive stormwater and combined sewer network
information, were well maintained and operated satisfactorily.
Although most plants have reasonably well-qualified instrument-maintenance
staffs, any plans for installing sophisticated instruments and automatic
control devices must be accompanied by appropriate provisions for
upgrading the qualifications of instrument-maintenance personnel.
12
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TRENDS
The survey results show that many instruments provide useful services
to enhance a treatment plant's efficiency and operational reliability. Most
of these field-proven devices measure and control the important physical
variables, such as flowrate and liquid level. A limited number of
process analyzers and miscellaneous control devices have also
demonstrated their desirability, but some of the most important process
parameters (organic loading, for instance) have never been successfully
monitored on an automatic basis in wastewater-treatment plants at least
not without excessive amounts of maintenance. If treatment-process
efficiency and reliability are to improve, suitable measuring devices
must be available to permit real-time control. Continuous or semi-
continuous monitoring devices must also be available to document compliance
with discharge standards. In light of increasingly stringent discharge
standards, the potential rewards of process control appear sufficiently
large to justify development of the necessary automatic measuring
devices.
As a guide for future research and development, the following list of
sensors, control loops, software and hardware represents the important
needs for wastewater-treatment instrumentation and automation:
Sensors
Rapid, on-line, automatic monitoring devices for organic
contaminants
In-situ suspended solids meters for the 500- to 5,000-mg/l
range
On-line wet-chemical analyzers for ammonia, total phosphate
and total hydrolyzable phosphate
Stormwater flowmeters
Control Loops
Organic load equalization
Food-to-microorganism ratio
Breakpoint chlorination
Phosphate removal
Feed-forward DO control
13
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Computer Hardware and Software
User-oriented language
Uniform data formating and reporting
Standardized input/output requirements
Centralized software library, with program routines useful
for wastewater-treatment-plant operation, control, and
management
To control treatment processes successfully, the design engineer must
have quantitative knowledge about each process' behavior under
time-varying loads. Although most treatment processes are well
understood in the static sense, the dynamic characteristics are not
always known; accordingly, useful models that describe time-varying
behavior are needed to advance wastewater-treatment process control.
14
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SECTION III
THE SURVEY
BASIS OF FACILITY SELECTION
To satisfy the previously mentioned survey objectives, 50 treatment
facilities were selected for field visits. Selection was based on the
variety of instrumentation used, the size and type of treatment processes
employed, and plant location. Because of the need for actual field data,
only acceptably functioning wastewater-treatment facilities with good
record-keeping practices were considered as suitable candidates. Consistent
with these criteria, the survey team visited three pilot plants which had
gathered a large amount of pertinent experience with full-size control
systems. Unfortunately, several new and highly automated plants, such as
Bridgeport (Connecticut), Garland (Texas), Wantau (New York) and the
stormwater facility at Syracuse (New York), were inappropriate candidates
because of insufficient operating data.
Because most of the selected plants employ a higher degree of instrumentation
and automation than is usual in wastewater-treatment facilities, some typical
treatment plants were also surveyed to establish base-line information.
As shown in Table 2, the 50 treatment facilities examined during the
nationwide survey utilized a wide array of treatment processes.
Geographical locations, summarized in Table 3, are grouped according to
USEPA regions.
SURVEY METHODOLOGY
Prior to on-site inspections, the survey engineers attended a two-day
orientation session for intensive training in the type of measuring and
sensing devices which might be encountered. This training also encompassed
the standardizing of all surveying protocol, including the collecting
of data and the preparation of reports and drawings. Extensive question-
naire forms (see Figures 5, 6, and 7), detailing background information,
instrumentation performance and cost, and control-loop experiences, were
prepared in advance.
At the start of each facility visitation, the survey engineer met with the
plant management and those persons responsible for instrumentation. Plant
histories, design flowrates, and operational characteristics were discussed,
with special emphasis placed on the overall benefits or liabilities of the
installed instrumentation; this information was documented on the General
Survey Questionnaire (Figure 5).
A plant tour, with the facility's instrument engineer (or equivalent)
functioning as the guide, permitted the survey engineer to examine the
operating instruments and control loops, item-by-item. During the tour,
15
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Table 2. TYPES OF FACILITIES SURVEYED
Type of Facility Number Visited
Primary treatment plants 9
Secondary treatment plants 25
Tertiary treatment plants 3
Wet-weather treatment facilities 4
Computer data center 5
Industrial waste treatment plants 2
Pilot plants 2
Table 3. REGIONAL LOCATIONS OF PLANTS SURVEYED
EPA Region Number Visited
1 2
2 4
3 4
4 5
5 16
6 2
8 1
9 10
10 6
16
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GENERAL SURVEY QUESTIONNAIRE
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measuring devices were inspected, and pertinent data (manufacturer,
model number, maintenance characteristics, accuracy, and application) were
recorded on the Instrument Survey Form (Figure 6). In addition, the survey
engineer examined control techniques, costs, benefits derived, and
operating experiences; these observations were recorded on the Loop and
Process Control Survey Form (Figure 7). To coordinate the accumulated
information with respect to in-plant applications, instrument diagrams
were constructed using standard ISA symbols (see Figure A-2 of Appendix A).
These schematics, which ignore parallel duplicate instrumentation,
pictorially describe the control instrumentation, strategies, and configur-
ations practiced in the surveyed facilities.
Although instruments utilized in wastewater-treatment works are arrangements
of mechanical, pneumatic, electronic, and electrical devices, their
performance is undoubtedly affected by human factors, particularly the
attitude of plant personnel and the proficiency of the available instrument-
maintenance staff. The survey team assessed the capability of each plant's
instrument staff on the basis of personal interviews, organizational
structure, and the condition of the observed instruments. The available
level of skill (see Appendix A) was used to characterize the overall
existing capabilities of each facility's instrumentation group; whereas,
the desired level of skill represents the degree of instrument-technology
proficiency actually required to operate and maintain the facility's
instruments and automatic-control systems properly. The attitude of plant
personnel toward instrumentation is usually illustrated by the importance
attached to maintaining their equipment, by the degree of reliance on
monitoring data for plant operation, and by their opinion of the benefits
of automation. Attitudes and opinions on instrumentation were paraphrased
in the Estimate of Overall Benefits section of the General Survey
Questionnaire. Notwithstanding the subjective nature of evaluating human
attitudes, the reporting of experienced survey teams produced useful in-
formation that has led to greater understanding of the human aspects of
instrumentation usage.
This survey, which limited its investigation to on-line process instruments,
omitted some routine control systems, such as those supplied with package
incinerators, lift stations and pumps, if their success was well-documented
in other applications.
SURVEY RESULTS
Survey data from the visited wastewater-treatment facilities were documented
on the survey forms (Figures 5, 6, and 7) and instrument diagrams
(Appendix C). This information was condensed into a series of tables and
figures (see Conclusions and Recommendations) which summarize background,
cost, and maintenance data associated with the observed instrumentation.
With these tables and figures the reader can quickly assess the number of
instruments observed, find the percent acceptance based on interviews with
the plant's instrument staff, and gain an overview of instrument costs
and associated maintainance requirements. Those readers interested in
20
-------
studying the instrumentation details of each facility are referred to
Appendix C for the complete survey forms and instrument diagrams. A
numeric code permits linking the summarized results with the actual
survey data in Appendix C. Also, this code preserved the anonymity of
the surveyed facilities.
Although collection of detailed operating and maintenance-cost information
was one of the prime survey objectives, only a few treatment plants had
collected or preserved such data. As a result, the survey placed more
emphasis on documenting instrument-operating experience and performance.
21
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SECTION IV
INSTRUMENT COST FACTORS AND USERS' ATTITUDES
INTRODUCTION
Meaningful data on the success and shortcomings of instrumentation
employed in wastewater-treatment facilities includes more than a simple
statement about the ability of the instrument to function in the observed
environment. Applicability of principles, amount of resources committed,
and level of skill, motivation and attitude of the operating personnel are
also important items in a rational evaluation of an instrument's success
or failure. Our discussion begins with an overview of pertinent background
data that concentrates mostly on the non-technical aspects, such as economic
data and users' attitudes and motivations. Subsequent sections discuss
measuring devices, automatic control loops, central control, computers, and
skill levels - both applied and required.
OVERVIEW OF MOTIVATION, ECONOMICS, USERS' ATTITUDES AND MAINTENANCE SKILLS
Some reasons for installing instruments are:
They may be essential to operate the plant
They may save money
They may improve the reliability of plant operation
Their usage may be mandated by regulatory agencies
All of these reasons, with the possible exception of regulatory requirements,
imply that a user purchases an instrument and maintains it because he hopes
to realize a net gain. More simply, he spends to save, to improve, or to
comply with regulations. The necessity and cost savings for some additional
instruments, namely flowrate and liquid-level measuring devices, are
readily apparent. The desirability of other instruments, such as respiro-
meters and total organic carbon analyzers, is relatively unknown. A
significant number of successful trial applications usually precedes,
frequently by several years, widespread employment of the instrument.
In Tables 4-A, 4-B, and 4-C the surveyed facilities are grouped as primary,
secondary, tertiary, stormwater, industrial, control center, or pilot plant.
The first items denote background information such as flowrate data, BOD,, and
suspended solids removed, and the year built. Substantiating the reason-
ableness of these data, a summary of the performance (measured by BOD and
suspended solids removals) compares favorably with generally recognized
values. For example, in their 1968 survey of municipal wastewater plants,
the EPA reported that primary treatment removes 37% of the BOD, secondary
treatment removes 81 to 85% of the BOD, and advanced wastewater treatment
22
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(AWT) removes 94% of the BOD. The mean BOD removals for the currently
surveyed facilities were 37 percent by primary treatment, 86 percent by
secondary treatment, and 98 percent by AWT. The ratio of present average
flow to design flow measures the degree of loading. If the ratio is
significantly higher than 100%, design capacity has been exceeded and over-
loading is severe. Although secondary plant number B-21 was somewhat
overloaded, the majority of the surveyed facilities operated within their
design limits. Thus, these facilities have BOD and suspended solids
removals which are in harmony with literature values.
INSTRUMENT COST DATA
Although the percentage of installed plant cost allocated to instrumentation
has several shortcomings* as an effective yardstick of the degree of a
plant's instrumentation, the scarcity and non-specific nature of available
economic data necessitate the use of this measure.
Calculations showing percentage of total plant cost have been successfully
used for many years in the chemical processing industry for preliminary
instrumentation-cost estimates. Out of the 50 facilities surveyed, only
eighteen had instrumentation-cost data. This was expected, since instrument
expenses are usually imbedded in the overall construction contract. In some
recent projects, however, the instrumentation has been awarded as a
separate contract. With only 35 percent of the facilities having sufficient
cost data, straightforward conclusions from a statistical summary must be
tempered by the limited sample size and good judgment.
Mean values for installed instrument costs: indicate that primary plants
spend 6%, stormwater-treatment facilities 2.5%, secondary plants 3.3%, and
AWT plants 6% of their construction costs on instruments. However, only
three primary facilities and one AWT plant had instrument-cost data; on the
other hand, instrument-cost data are available for ten secondary plants.
Accordingly, the survey results show that 3.3% of secondary plant costs are
allocated to instrumentation; no statistical conclusions can be made about
the instrumentation costs for primary, stormwater and industrial plants, or
for data centers. Based on annual product-shipment data published by the
U.S. Department of Commerce,7 Smith^ reasoned that about 1.5% of the munici-
pal wastewater-treatment plant's cost is allocated for meters and control-
equipment purchases before installation. As a rule of practice, 0.5% of
plant cost is dedicated to instrument installation; thus, the nationwide
product shipment data indicate that about 2% of the plant's cost is allocated
to instrumentation. Because secondary plants typically spend more on
instruments than primary, the estimated 3% of plant costs spent on
instrumenting secondary plants seems reasonable. Previous data' show that
industrial wastewater-treatment facilities spend slightly more on instru-
ments than do municipalities.
*The estimate, based on percent of plant cost, includes several sub-costs
(such as the site and its development, buildings, and aesthetic improvements)
that are not related to instruments. Also, linear scale-up of the measure
is not strictly valid. For example, a. plant twice as large usually does not
require the same percent of installed plant cost for instrumentation as
does the smaller plant.
28
-------
Notwithstanding the scarcity of economic data, all the information indicates
that secondary treatment plants purchase considerably fewer instruments
than do continuous chemical-processing plants, a related application.
Surprisingly, stormwater plants (operational only during storm events) spend
even less on new instrumentation then do secondary plants. This appears
contradictory to the goal of automatic, unattended operation usually
associated with auxiliary wet-weather facilities. One would think that
unmanned operation would necessarily require a large amount of automation.
An inspection of the stormwater-plant surveys (Appendix C) discloses that
most of these facilities do not operate properly when unattended. In short,
these plants rerely start up, treat, and shut down without human inter-
vention and control.
Typically, the chemical industry allocates anywhere from 6 to 10% of a
plant's cost for instruments". Water supply facilities, moreover, allo-
cate about 5 to 7% of plant cost on instruments. A partial explanation for
this observation is that water supply and chemical plants must keep effluent
(product) quality within certain narrow limits, whereas most municipal
plants are not penalized for poor quality effluent. If effluent guide-
lines were strictly enforced, motivation to employ instrumentation would
increase by virtue of the "compliance stimulus." Alternatively, clear
demonstrations of significant cost-benefits would naturally encourage
instrument usage.
MAINTENANCE-COST DATA
In some instances, insufficient 0 & M funds precluded good maintenance
practices. The amount of funds and manpower dedicated to instrument
maintenance reflects not only the attitude of management, but also the
entire community's attitude toward effective operation of their treatment
facility. Table 4 (A, B and C) illustrates the annual manhours expended
on instrument maintenance, including outside contract maintenance. In order
to normalize the maintenance manpower, the ratio of manhours to thousands
of dollars of installed instrument costs are reported in Table 4 (A, B and C)
High ratios show that adequate (or perhaps excessive) manhours are allocated
for maintenance; low ratios indicate poor maintenance practices. On the
average, primary plants spent 7 manhours per year for every thousand dollars
worth of instrumentation; similarly, secondary and stormwater facilities
allocated 5.8 and 4.9 manhours per year per thousand dollars of instrument
cost, respectively. This maintenance manpower is comparable to industry's
maintenance schedule for non-fouling instrument applications. An alternate
basis for ascertaining the adequacy of maintenance resources is the percent
of instrument cost spent on maintenance for a period of one year. If
maintainance labor costs ten dollars an hour, then the manhours per
thousand dollars of installed instrumentation are equivalent to the percent
of instrument cost spent on maintainance:
annual manhours X $10 = % instrument cost for maintainance.
29
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Thus, in the aggregate, wastewater-treatment facilities earmark about
6% of their installed instrument cost for annual maintenance, Chemical
processing and other related industries spend about the same amount
for instrument maintenance. In short, a favorable comparison of the
resources allocated to instrument maintenance among wastewater-treatment
works, chemical plants, and water-supply plants shows that most municipal
wastewater plants satisfy their maintenance requirements as far as manpower
is concerned. Those readers interested in comments from individual plant
managers may refer to the completed General Questionnaires in Appendix C.
MAINTENANCE SKILLS
The level of skill applied also significantly affects the instruments"s
operational success or failure. Comparisons of levels of skill applied
versus those required provide a measure of competency of the instrument-
maintenance group. The surveying engineers found that primary plants employ-
ed a 2.5 level of skill*, while a 3.1 level of skill was required; this
corresponds to an 80% compliance. In other words the majority of primary
plants need Level 3 instrument technicians, while only a small number need
Level 2 or Level 4 technicians. Since most of these primary facilities
employ Level 2 and 3 instrument technicians, they tend to use under-
qualified maintenance personnel. Secondary treatment plants satisfy about
94% of the required skill; therefore, their maintenance staffs are adequately
qualified. Industrial facilities, control centers and data centers similarly
utilize amply trained instrument-maintenance staffs. Stormwater facilities,
however, supplied less than half the required level of skill; their poor
performance can partially be attributed to a lack of sufficiently trained
ins trument-maintenance personnel.
PROCESS KNOWLEDGE
Successful process instrumentation and automation must consider process
behavior and the availability of essential instrumentation components.
Although most processes employed in wastewater treatment are well under-
stood in the static sense, dynamic characteristics are not thoroughly
known. Useful mathematical models that describe unsteady-state behavior
simply do not exist for most wastewater-treatment processes. This
shortcoming makes selections of appropriate control strategies and
manipulated variables somewhat difficult, but a combination of good
engineering judgment and experience should produce workable control
strategies.
SUMMARY
The lack of appropriate measuring devices, as well as improper maintenance
of available devices, have greatly impeded the optimum instrumentation
of wastewater-treatment facilities.
*See Appendix A for level of skill definitions. Although the meaning of a
2.5 skill level is not precisely defined there (i.e., Appendix A defines
only integer levels, not fractional levels), it denotes the average value
of the plant's skill levels.
30
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After identifying measuring devices as a problem area, the survey team
expended considerable effort investigating existing measuring equipment.
A comprehensive discussion addresses measurement principles, practices
and performance. On the other hand, transmitters., indicators, controllers
and final control elements utilize well-established technology, and numerous
mechanical, electrical, or pneumatic devices are commercially available;
consequently, very little attention was devoted to them. In short, the
user survey concentrated on the most serious problems — measurement of
wastewater variables, and control-loop performance.
31
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SECTION \
MEASURING DEVICES
INTRODUCTION
Analytical sensors, transducers, and measuring systems pose special prob-
lems in wastewater applications because these devices often are in contact
with a potentially fouling or damaging fluid. During the plant survey,
many types of measuring devices were observed, and users'experiences were
recorded. The reliability (that is, the dependability of obtaining an
accurate answer from the sensor over a given period of time) and the amount
of maintenance required were also determined. Most of the instruments that
measure physical variables, such as level, flow, pressure, speed and
position, performed well in wastewater-treatment plants; whereas, some of
the analytical sensors were judged as unsatisfactory by the interviewed
users. The forthcoming discussion examines measurement principles, poten-
tial applications, operating characteristics, maintenance requirements
and users' experiences for each measuring device observed during this
survey.
LEVEL-MEASURING DEVICES
Because wastewater treatment involves liquid flow and storage, level
measurement is an important parameter. Level-measuring instruments for waste-
water facilities should be (in order of importance) accurate, reliable,
easily serviced, and inexpensive.
Applications
Level-measuring devices are almost always used for wet-well control. The
level instrument sends information to an automatic controller or plant
operator, and pumps, gates or other final control elements are adjusted
accordingly. In auxiliary excess-stormwater facilities, liquid level was
frequently used to automatically start up and shut down these plants.
Principles
Liquid level is determined by measuring the relative height of the air-
liquid interface or by measuring thp hydrostatic pressure at. some fixed
point below the minimum operating level. Bouyant floats can gauge air-
water interface locations of clean liquids, but fouling and high maintenance
makes floats a generally poor choice for the hostile environment of a
wastewater-treatment plant. Slack diaphragm pressure-sensing elements also
perform satisfactorily and have become widely adopted for special appli-
cations such as determining sludge levels in digesters. However, bubble
tubes, which measure the back pressure of an air stream being slowly forced
into a liquid at a predetermined level, are the most common (and usually
the most successful) liquid-level detectors.
32
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Other level-monitoring devices, such as ultrasonic, thermal, conductance,
or capacitance probes, cannot compete with the bubble-tube or differential-
pressure sensor in cost or reliability, although two successful ultra--
sonic liquid-level probes were encountered.
Diaphragm-box pressure-sensing level detectors are often used in small
standby wastewater-treatment stations, such as those for stora water;
diaphragm boxes require no compressed air or power and are quite- reliable,
but they need occasional servicing to replace any air that may have escaped.
Field Experiences
Numerous types of satisfactory liquid-level detectors, using established
designs, are commercially available in the $200 to $1500 cost range. The
interested reader may refer to Appendix D for a representive list of
supplies and product-performance specifications. During the user survey,
all the types of liquid-level sensors encountered, except conductivity,
demonstrated a ninety-percent-plus field acceptance. The small number of
dissatisfied users cited corrosion and fouling as the culprits. Most users
reported bubble-tube level detectors as the preferred primary elements;
other devices are usually more expensive and require careful application.
The liquid-level performance data, shown in Table 5, contain no mean-time-
between-failures, and only scant maintenance data, since level-measuring
devices in most plants require only modest amounts of maintenance and are
often virtually ignored. It is apparent that, when properly installed,
liquid-level detectors should cause no difficulties in wastewater-treatment
facilities.
Table 5. LIQUID-LEVEL MEASURING INSTRUMENTS
Type
c D , Bubble
Survey Results _ ,
Number of Not Acceptable
Number of Fair
Number of Successful
% Acceptance
Median Labor (MH/yr)
Median Frequency (no/yr)
1
0
39
98
8
2
Diff .
Press.
1
0
9
90
5
0.6
Float
1
3
2
93
60
24
Diaphragm Ultra-
Box sonic
0 0
0 0
0 2
100
-
_ _
Conduc-
tivity
2
0
1
33
33
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FLOW METERS
Applications
Flowrate is probably the most important measurement required in waste-
water treatment since it is the basis for hydraulic and mass loadings and for
material balances. For example, the product of flowrate and organic
strength (i.e., BOD concentration) determines the plant's organic loading;
also, throughput rates indicate how near the plant is operating relative to
its hydraulic capacity, paces chemical-addition systems (i.e., the
chlorinator at most plants), and is the basis for controlling many treatment
processes. Moreover, flowrate measurements are used to monitor sewer through-
put, to activate sewer flow diverters (or regulators), to calculate
hydraulic and material balances for storm events, and to control (i.e., auto-
matic start-up or shut-down) stormwater-treatment facilities. In most
wastewater-treatment plants, influent, sludge recycle, sludge wasting, air
flow, chemical flows, and utility flowrates are continuously metered. To be
useful, flow meters must measure reliably, require only occasional and
simple maintenance, must resist damage by momentum exchange with high-
energy fluids, must not impede flow (i.e., must be non-intrusive), and should
be competitively priced. Some wastewater applications, such as stormwater
monitoring, require flow-measuring instruments with 50:1 rangeability.
Principles
The large-scale flow-measuring devices commonly used for liquids are
weirs, flumes, Venturis, nozzles and magnetic flow meters. Weirs and
flumes, which operate in accordance with Bernoulli's Theorem since they
develop a differential head that is related to flowrate, are employed in
open channels and for other non-pressurized service. Venturis and flow
nozzles, which also operate according to Bernoulli's Theorem, measure
flows in pressurized pipes.
Magnetic flow meters, based on Faraday's law (EMF generation is propor-
tional to the velocity of a flowing conductor), are suitable for pressurized
full-pipe fluid-transport monitoring. These well-known methods are
discussed in the literaturelO.
Other methods, such as mechanical propellers and other positive-displacement
mechanisms, pitot tubes, rotameters, and thermal or ultrasonic flow meters,
are either too expensive, too sensitive to process conditions, or too in-
trusive to be suitable for many wastewater applications. One ultrasonic flow-
meter, however, was observed working fairly well during the user survey.
A few propeller-type flow meters, common in smaller water plants, were
successfully working in several of the surveyed treatment plants. Orifices
and positive-displacement meters, in addition to nozzles and Venturis, are
commonly used for gas- and air-flow monitoring.
Field Experiences
Wastewater-treatment plant operators reported serious sensing-line plugging
problems with their flumes, weirs, and Venturis. Magnetic flow-meter users
34
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frequently cited the accumulation of a non-conductive film as a principal
source of failures. Ultrasonic and thermal electrode cleaners are being
evaluated by many plants to eliminate such fouling difficulties.
The principal advantage of flumes, Venturis, and the like is that they are
simple, well proven, and so well understood that for almost any plant, they
can be installed with good assurance that they will perform with reasonable
accuracy (approx. 1 to 5% of full scale) [see reference 11]. Their prin-
cipal disadvantage lies in measuring the generated differential pressure.
Techniques for connecting the primary element (or sensing lines) to the
differential-pressure instrument are well established, but a certain amount
of frequent and concientious maintenance is required to assure continuing
operation. Magnetic flow meters have gained wide acceptance because of their
low maintenance requirements, and they have proven to be about as reliable as
the venturi or flume when properly installed. They also do not obstruct the
flowing streams, and have no small passages or liquid connecting lines to
plug or foul. Magnetic flow meters, however, are fairly expensive.
Flow-meter experiences, displayed in Table 6, indicate that propeller-type
meters may not be well suited for wastewater service. Venturi meters had
the highest degree of acceptance among the surveyed plants, but also
required the largest amount of maintenance manpower (necessary to keep the
differential-pressure sensing lines clear). Both flumes and magnetic flow
meters had a moderately high degree of acceptance. Flumes, which require
only a small amount of maintenance manpower, are only applicable to open-
channel flow.
Table 6. SEWAGE AND SLUDGE FLOWRATE METERS
Survey Results Venturis Flumes Magnetic Propeller
Number of Not Acceptable 116 2
Number of Fair 1 12 1 1
Number of Successful 34 14 28 5
% Acceptable 94 82 80 63
Median Maintenance
Labor (MH/yr) 20 2 12 10
Median Maintenance
Frequency (MH/yr) 4 1.4 12 7
35
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The survey results clearly demonstrate that Venturis,, flumes, and
magnetic flow meters can successfully monitor sewage flowrates within
acceptable limits of reliability, accuracy and maintenance requirements.
However, pulsating flow can not be monitored by these devices. During
the plant survey, BIF venturi meters and Brooks, Fisher & Porter, and
Foxboro magnetic meters were all found to provide acceptable service.
A representative list of flow-measuring instrument suppliers is contained
in Appendix B.
Obviously flow-meter cost will vary as a function of size, accuracy and
range. As an approximate guide, flumes, weirs, flow tubes and nozzles
are the least expensive devices, often costing within the $500 to $5,000
range. Venturis and magnetic flow meters (often used for sludge streams)
are more expensive.
Storm and combined sewage flow monitoring poses special difficulties due to
large operating ranges, debris, flooding, etc.; suitable flow-measuring
devices that have demonstrated their usefulness in wastewater-treatment
facilities are not readily adaptable to use in stormwater flow monitoring.
oo
Presently, sonic flow-monitoring demonstration projects and open-
channel magnetic-flowmeter development programs^ are underway to
find satisfactory devices for storm-related flowrate monitoring. Moreover,
Hydrospace Challenger Inc. has reported on an assessment of devices for
storm flow measurement^.
DISSOLVED OXYGEN MONITORING
App1ications
Most secondary wastewater-treatment processes involve aerobic biological
destruction of soluble organics. Intensive secondary processes, such as
activated sludge, contact stabilization and extended aeration, require
aerating the wastewater-microorganism mixture. If the dissolved oxygen con-
centration (DO) drops below a critical level (usually 0.5 mg/1), oxygen
becomes rate limiting. On the other hand, toe high a dissolved oxygen
concentration represents needless power consumption and can cause sludge
bulking
Principles
In spite of the many techniques available for DO measurement, only the
electrochemical DO sensors are compatible with in situ monitoring service.
Three types of DO sensors are commercially available, and they operate on
the following principles:
36
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, A galvanic sensor in which molecular oxygen diffuses through
a membrane and reacts with the lead/silver electrode system to pro-
duce a current proportional to the DO concentration.
. A similar polarographic cell that requires oxygen to diffuse
through a membrane; after which, the oxygen is reduced by a small
polarizing voltage applied across two noble metal electrodes.
This cell produces a current proportional to the DO concentration.
A thallium cell in which oxygen reacts with thallium metal thus pro-
ducing thallous ions in portion to the DO concentration. The
potential developed is a function of thallous ions at the surface
of the metallic electrode; hence, this type of electrode needs no
membrane.
All of the electrochemical DO sensors are affected by temperature, sample-
stream velocity, and other environmental factors such as ionic strength.
Field Experiences
23 out of 50 visited facilities practiced continuous DO monitoring. Only
six plants used automatic DO-control systems; the other facilities used
their DO measurements to indicate trends. Seventy-nine percent of the
users considered their DO-monitoring probes acceptable; whereas, the other
21% of the facilities judged their DO-measuring probes unsatisfactory or only
fair. Most of the dissatisfied users reported that probe fouling, drift and
"noisy" data are the principle problems with DO probes. Discussions with
successful users suggest that daily-to-weekly probe inspections are
advisable, depending upon the service requirements. Moreover, in-place
weekly calibrations, such as zero and span adjustments and cross-checks
with portable (laboratory) DO meters, ensure continued accuracy. Membrane
fouling was cited as the chief maintenance problem, and mean-time-between-
failures ranged from 1 to 9 months. When the membranes are changed, the
instrument should be thoroughly recalibrated by a Level 3 technician.
Galvanic, polarographic and thallium DO probes worked equally well in the
surveyed wastewater-treatment plants.
All in situ DO-monitoring systems (except perhaps the thallium cell) require
a considerable amount of maintenance because the probes for these systems
are in direct contact with wastewater, usually under conditions conducive to
sensor fouling. Partial membrane plugging, poisoning of sensor or membrane
surface by toxic chemicals, and bacteriological growth lead to errors and
noisy data. Choosing measuring devices equipped with jet cleaners, ultra-
sonic agitators, or stirring-type agitators should minimize fouling problems.
Ionics, Weston and Stack, and Beckman DO probes were found to work well in
several of the facilities visited. Although DO analyzers require frequent
inspection and maintenance, accurate and reliable galvanic, polarographic, and
thallium DO-measuring systems that are suitable for continuous duty in
wastewater-treatment plants are available from the above, and other manu-
facturers within the $1,000 to $2,000 price range (see Appendix D for a
partial list).
37
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TOC, TOD, AND COD MONITORS
Applications
Monitoring influent loads (the product of flowrate and organic strength)
and subsequent treatment efficiencies requires on-line organics-measuring
instruments. Historically, BOD^ data were used to estimate the wastewater's
organic content, but this test takes five days to complete. The amassed
information consequently would have little impact on daily operation.
Clearly, the need exists for real-time data that permit operational control.
Instruments such as total organic carbon (TOC) analyzers, total oxygen
demand (TOD) monitors, and automated chemical oxygen demand (COD) devices
have been developed for rapidly measuring the organic content of wastewater.
Potential streams for on-line organic monitoring operations, and potential
control functions addressable by any of these rapid organic analyzers in a
typical activated sludge plant, include:
Influent or head works(such as grit chamber) to assess incoming
load
Sludge thickener return to ascertain load on primary settlers
Primary sedimentation effluent to measure clarifier efficiency
and to provide feed-forward control of subsequent biological pro-
cesses.
Aeration tank liquor to furnish feed-back control (e.g., measure-
ment of TOC in order to maintain proper food-to-microorganism ratios
through cascaded control of RAS)
Secondary clarifier effluent to indicate removal efficiency
Chlorination chamber effluent to assess organic load to receiving
waters.
Principles
Breifly, TOC and TOD analyzers oxidize wastewater samples at high temper-
atures, usually 950°C. In TOC systems, the concentration of carbon
dioxide produced by oxidation of the sample's organic matter is measured
in an infrared analyzer, or that same carbon dioxide is quantitatively
reduced to methane and subsequently analyzed with a hydrogen-flame
ionization detector. TOD instruments, on the other hand, measure the oxygen
deficit of the instrument's carefully-controlled, carrier-gas, oxygen
concentration after sample combustion. Automated COD devices oxidize
organics in the liquid phase, usually by a modification of the classical,
acidic dichromate, oxidation method; the instrument's colorimeter then
measures the resulting color change which is proportional to the initial COD con-
centration. To date, TOC instruments employing infrared detectors appear to be
the most-promising on-line organic monitors.
38
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During the user survey, one facility (an industrial wastewater plant)
utilized several on-line, automatic, TOG analyzers. This plant's
management believed, however, that their TOC instruments required an excessive
amount of maintenance since the mean-time-between-failures ranged from
3 to 30 days and since a Level 5 instrument technician was necessary for
proper calibration and maintenance. For these reasons, the plant managers
characterized their TOC analyzers as unacceptable.
Currently, five manufacturers supply continuous on-line organic analyzers.
Appendix B contains their names and the important specifications. Most
of these instruments cost between $7,000 to $12,000. Although commer-
cially available, rapid, organic monitors use known analytical techniques,
their adaptability to continuous service in wastewater monitoring has not
been established. The fact that only one treatment plant (industrial)
practiced on-line organic monitoring attests to current low-level
utilization of these instruments. Attempts to adapt the then-current models
to this application illustrate that improvements and refinements are needed.
The propensity of most organic analyzers to fail by plugging and corrosion
shows that special consideration should be given to sample conditioning
(see samplers on page 41) and construction materials. Design engineers and
plant managers will expect to see clear-cut demonstrations of workable
on-line organic analyzers prior to their widespread usage.
Field Experiences: (NONE)
WET-CHEMICAL ANALYZERS
Applications
With the increased emphasis placed on nutrient removal, a need developed
for continuously monitoring and controlling the efficiency of nutrient-
removal processes, such as ammonia stripping, phosphorus precipitation and
breakpoint chlorination. Nutrient addition for the effective biological
treatment of industrial wastewaters may also make on-line nutrient analyses
advisable.
Consider an activated sludge plant that is practicing phosphate removal
by chemical addition to the primary clarifier; the phosphate concentration
of raw sewage, in conjunction with the flowrate (mass loading), can be used
to pace chemical additions. Subsequent monitoring of the primary clarified
effluent for its phosphate concentration permits the assessing of phosphate-
removal efficiency, as well as the trimming of feed-forward control with
feedback information. Other potential areas for phosphate monitoring
include final effluent and digester supernatant.
Principles
To date, automated wet-chemistry procedures are the only reliable methods
for on-line phosphate and ammonia analyses. These devices utilize a color-
imetric reaction under temperature-controlled conditions.
39
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Two surveyed facilities attempted on-line phosphate monitoring, and one
pilot plant measured ammonia using wet-chemistry analyzers. All three
analyzers performed unsatisfactorily because of extremely poor reliability,
sample-line plugging and pump failure. Mo.st users commented that adequate
sample pretreatment may alleviate plugging problems.
Field Experiences
Several manufacturers provide continuous on-line wet-chemical analyzers
in the $3,500 to $5,000 price range (see Appendix B for a partial List),
The more-promising wet-chemical analyzers have fail-safe alarms and status
indicators. In spite of the use of standard chemical procedures, mechanical
difficulties and reliability problems make most commercially available wet-
chemical analyzers unsuitable for continuous unattended operation in many
wastewater-treatment projects (especially where suspended solids are present
in the sample). Additional development work is needed to improve sample
pretreatment and increase analyzer reliability before unattended wet-chemical
sensors can provide reliable continuous information on nutrient concentrations.
SLUDGE DENSITY
Applications
Since the bulk of pollutants are settled as solids in wastewater-treatment
plants, continuous automatic density meters are almost indispensible for
the measurement and control of solids concentration in modern treatment
facilities. Sludge densities range from 1% to 15% solids (10 to 150 g/I),
but the density of pumpable sludge rarely exceeds 10% solids (100 g/1).
Most treatment plants measure the sludge density of the primary clarifier
underflow in order to regulate sludge pumping. If the primary clarifier
removes sludge with too low a density, an undue load is placed on downstream
thickeners, digesters or incinerators. Underflow solids-concentration data,
in tandem with flowrate information, also permits calculation of sludge loads
sent to digesters and dewatering facilities.
Principles
Slurry densities can be determined directly by weighing a known volume.
Fully automatic process instruments, based on this principle, are used in
several industries for slurry density measurements, but not in waste treat-
ment. Nuclear and ultrasonic instruments that measure radiation or sound-
level attenuation, respectively, can be calibrated to report density directly.
Nuclear devices are the most popular sludge-density instruments used in the
wastewater field. Nuclear sources for sludge density meters are licensed
and controlled by Federal arid State authorities; none of these sources has
been involved in any radiation accidents to the best of the authors'
knowledge.
Field Experiences
Nuclear density meters require frequent recalibration to ensure accuracy
since the nature of sewage solids is continually changing and since
40
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sewage solids tend to adhere tenaciously to the inner walls of most types
of piping and thus produce calibration errors. Correct installation is
also essential for reliable operation. Many instruments, however, were
installed without simple provisions for isolation (i.e., to permit easy
standardization and flushing) and sampling.
The major problems with nuclear density meters is the unreasonably long time
usually required to repair the meter because it must be returned to the
manufacturer. As one plant superintendent put it, "We have two density
meters, one to work with while the other's at the factory."
The survey found that nuclear density meters were unsatisfactory in 7
instances, fair in 4, and successful in 8, for an acceptance rating of
only 42%. Mean-time-between-failures is estimated as typically 1 to 3
years; typical (median) maintenance required in order to keep such
instruments working is 51 man-hours per year, with a servicing frequency of
48 times per year. Only a portion of radiation instrument servicing is
within a Level 4 instrument technician's capabilities.
Because of their newness, no ultrasonic sludge-density instruments were
observed during the user survey.
As might be expected, sensor fouling was mentioned as the main disadvantage
of available sludge-density instruments. Since the sensing surfaces
are directly in contact with the sludge, fouling occurs rapidly. Although
glass or ceramic liners and high-velocity scouring tend to minimize solids
accumulation, a significant amount of required maintenance should be
anticipated. Several commercial suppliers offer sludge-density measuring
instruments which cost from $2,500 to $4,000 (see Appendix B for a partial
list). During this survey, devices manufactured by Ohmart and Nuclear
Chicago performed satisfactorily in several wastewater-treatment plants.
Inasmuch as commercially-available sludge-density measuring devices use
well-established technology, they should provide fairly reasonable service
with proper installation and maintenance.
SAMPLING SYSTEMS
Applications
Because of liquid and solid phases present in sewage, taking a represen-
tative sample is a difficult task. Analytical data on unrepresentative
samples are totally useless, and frequently less desirable than no data at
all. Correct sampling is so essential to wastewater instrumentation that it
was investigated as a separate item. A real-time on-line sampling system
takes a representative sample, preconditions it, and transports it to a final
destination; then, this sample must be suitably conditioned for subsequent
analyses without causing any unacceptable changes in the parameters 01
interest. Most sampling systems can be categorized as either off-line, or
real-time on-line.
41
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With off-line systems, the sample must be transported to a preservation
module, typically a refrigerated compartment maintained at 4°C. The col-
lected samples can be stored as separate grab samples, or they can be com-
posited on a timed or flow-proportional basis. Occasionally some modified
samplers make it possible to bring the sample into the control room and
thus greatly reduce sample-collecting labor. Since off-line samplers allow
the plant's chemist to make periodic tests on accumulated grab samples or
composites, they effectively satisfy the need for cumulative historical in-
fluent and effluent data.
Real-time samplers macerate, transport, and suitably condition samples for
continuous analyses. Principle advantages of real-time sample systems over
in situ monitoring include:
Immunity from main-stream flow variations
Ability to pre-condition samples
Instrument economy through time-shared use of analytical devices
Centralized location for better servicing and calibrating of
analytical instruments
Opportunity to maintain special temperature and humidity conditions
for delicate instruments at a central location.
Principles
Since many articles report on the details of successful sample systems, only
a brief discussion - limited to the important components and practices of con-
tinuous samplers - is justified here:
Sampling intake probes should be located in a well-mixed turbulent
region—at least fifty pipe diameters downstream of process-stream
junction points. The velocity of sample entering the probe should
have the same speed and direction as the main flow (isokinetic samp-
ling) .
Special attention should be directed towards suspended solids pre-
cipitation, biological growth, corrosion, and sample stability in
the delivery system.
When applied to raw sewage, fluids with high suspended solids con-
centrations, and mixed liquors, the sample must be macerated prior
to transmission; otherwise, the transmission lines will plug.
Pumps are available that grind and macerate the sample, as well as
provide sufficient head and flow to prevent settling-out of most
suspended material.
Rugged, non-clogging, 1 to S-horsepower pumps should be utili2:ed
with 1-in, to 2-in. sample-conducting pipe. These pumps must deliver
enough flow to maintain a velocity of at least two feet per second.
42
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All sample lines must be of uniform and smooth bore, and also be
easily cleanable; stagnant regions must be avoided to prevent
septicity and solids deposition.
Adherence to these practices should provide a reliable system capable of
delivering samples in most municipal plants. Virtually any process stream
may be a candidate for continuous real-time sampling; the accumulated
sample information documents treatment efficiencies and provides data for
process control. When used for control purposes, consideration must be given
to the effects of transportation delay; allowance must also be made for
automatic analyzer delay, if significant.
Field Experiences
Sampling systems were observed in fifteen treatment facilities during the
plant survey. Eleven out of the twelve high-flow continuous samplers per-
formed satisfactorily according to the interviewed personnel; this repre-
sents a 92% acceptance. All three non-high-flow samplers were judged un-
satisfactory. None of the visited plants practiced real-time data sampling.
With regard to failure modes, all of the surveyed plants which possessed
continuous samplers cited plugging. It also should be noted that very
few plants seriously questioned the representative nature of the delivered
sample. Frequent inspections are essential to ensure proper operation;
most of such repair and inspection efforts are within the capabilities of
Level 1 technicians.
With careful design and faithful maintenance, mechanically reliable, con-
tinuous sampling systems are obtainable with current technology and equip-
ment. Representative sample transport, conditioning, and (real-time)
analysis have all been relatively unexplored. In fact, the USEPA spon-
sored a contract to develop a wastewater sample transport and conditioning
system; this project was recently completed, and a final report is presently
being prepared for public release. That project's mission was to develop and
field-evaluate the necessary hardware to transport sewage, primary effluent,
aeration basin mixed liquor, secondary effluent, primary sludge and secondary
sludge; moreover, these samples had to be conditioned to make them
compatible with existing analytical devices for TOG, orthophosphate, hydro-
lyz.able phosphate, ammonia, nitrite, and nitrate. The developed system had
to be able to run unattended and require only a reasonable amount of
maintt-•'.T-,l-e effort.
Chicago Pump, N-CON, and Sonford off-line samplers use established designs,
and these worked well in the visited plants. Many automatic samplers are
commercially available in the $2,000 to $6,000 price range, and a recent
EPA report-^ reviewed all these presently available sampling systems.
Experience to date suggests that more field demonstrations are advisable
prior to widespread application to streams with high concentrations of
suspended solids. Sampling systems, however, can be readily applied
to primary and secondary clarifier effluents.
43
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RESIDUAL CHLORINE
Applications
Public health protection (i.e., preventing the spread of water-borne disease)
makes it essential that municipal wastewater-treatment facilities eliminate
pathogenic organisms. Maintaining a prescribed residual chlorine level
after a minimum contact period provides effective destruction of most harm-
ful microorganisms. Accordingly, most wastewater-treatment facilities must,
under current laws, monitor the residual chlorine concentrations of final
effluents to assure adequate disinfection.
Fully automatic, residual chlorine analyzers are well proven for ensuring
proper chlorination and for providing a continuous record of residual
chlorine levels; moreover, when incorporated into a feedback system to opti-
mize adjustment of the chlorine/wastewater ratio, residual chlorine analyzers
can often pay for themselves in chlorine savings. When a plant effluent
with extremely low chlorine residual is required, a fully automatic residual
chlorine analyzer-controller with an auxiliary dechlorinator system may
be the only practical means for achieving compliance.
Principles
The operation of commercially available residual chlorine analyzers is
based on the ability of chlorine, as a strong oxidizing agent, to depolarize
one of the two electrodes in an amperometric cell, thus permitting electric
current to flow in proportion to the concentration of oxidizerl6.
All, commonly used, residual chlorine analyzers measure total residual
chlorine by adjusting the sample pH, reacting the sample with potassium
iodide or similar reagent, and measuring the resulting depolarizing effect.
If only the free uncombined chlorine is to be measured (as might be desired
to monitor breakpoint chlorination), replacement of the potassium iodide by
potassium bromide usually permits only free chlorine to be detected.
However, automatic free chlorine measurements are not commonly practiced,
and interferences from excessive concentrations of chloramines may be a
significant problem.
Successful operation of the analyzer for wastewater depends on the sampling
system because the sample must be treated with a pH-adjusting reagent, as
well as a KI (or KBr) solution, before measurement. A successful sampling
system must function quite reliably, eliminate dirt from the sample stream,
and then bring the sample to the titration cell within a reasonable elapsed
time. Most residual chlorine analyzer failures are caused by the inability
of the analyzer installation's designer to appreciate these problems.
Field Experiences
Out of the 19 residual chlorine analyzers observed during the user survey, 3
were rated only fair, and the other 16 seemed to work well; this represents an
44
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acceptance of 85%. Thirteen of the residual chlorine analyzers supplied
information to automatic control systems, On the average, residual chlorine
analyzers required 140 man-hours per year for maintenance, with 365 checks
per year. In the course of this survey, Fischer and Porter and Wallace and
Tiernan residual chlorine analyzers worked well and provided their users
with reliable service, Several other manufacturers also supply residual
chlorine analyzers (see Appendix B). Presently available residual chlorine
analyzers employ well-known designs and should be suitable for continuous
duty in wastewater-treatment plants.
CHLORINE-GAS DETECTORS
Applications
Chlorine is the most common disinfectant used in American water and waste-
water plants, but it is also a hazardous material. Methods and procedures
for handling chlorine are well developed; when these are carefully observed,
accidents caused by chlorine are infrequent. For better protection from
accidental release of chlorine to the atmosphere, automatic analyzers capable
of detecting free chlorine in personnel-occupied areas are often specified.
The allowable chlorine concentration (threshold limit value, or TLV ) is
commonly 1 part per million; detector ranges are often 0-5 ppm.
Principles
The common chlorine-gas detector consists of a polarized amperometric cell,
identical in principal to the residual chlorine detector cell. Ambient air
is introduced into the cell, either by diffusion through a porous cell wall
or by pumping a small stream of air through the electrolyte. Traces of
chlorine depolarize the cell, producing a current porportional to chlorine
concentration. Sampling systems can be readily fitted to the analyzer
inlet to filter and condition the sample; such systems can also collect and
transport samples to the analyzer from adjacent areas.
Chlorine-gas monitors are built to be self-checking and to alarm on certain
internal failures, but routine and competent maintenance is crucial.
Field Experiences
Six of the seven chlorine-gas monitors encountered were working well, for an
acceptance rating of 86%. Median maintenance was found to be 50 man-hours
per year with checks twice a month. The Fischer & Porter and Wallace and
Tiernan chlorine-gas detectors embodied established designs and provided
good service.
TURBIDITY MEASUREMENTS
Applications and Principles
Historically, turbidity refers to the tendency of small suspended particles
45
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to obscure light transmission through a liquid; it is an optical property
of the sample that causes light to be scattered and absorbed rather than
merely transmitted in a straight line, Turbidity in water is usually caused
by the presence of clay or silt, bacteria, and other finely divided materials.
Although turbidity measurements do not rigorously correlate with the weight
concentration of suspended matter, in-plant turbidity data indicate suspended
solids removal trends. As the suspended solids concentration increases from
zero to about 200 mg/1, the turbidity also increases (and conversely).
Frequently, wastewater-treatment facilities monitor effluent turbidity to
appraise its effects on receiving waters and to denote suspended solids
removal efficiency. Turbidity measurements of secondary effluent also serve
as early warning devices for sludge bulking or clarifier malfunction,
similarly, turbidity measurements of filtrates can be used to signal filter
breakthrough. Most of the time, unacceptable turbidity levels alert plant
operators to initiate corrective actions, such as adding coagulants to a
bulking sludge, adjusting food/microorganism ratio, or backwashing a filter.
Turbidity data are occasionally used to regulate coagulant additions.
Continuous turbidity-measurement devices measure the fraction of a light beam
that is either transmitted by a turbid sample fluid or scattered from the
fluid's surface. Some devices measure turbidity levels by determining the
intensity of light scattered at small angles (15-degree surface scatter) or
at large angles (90-degree, or "right-angle", scatter). Other devices relate
a sample's percent optical transmission to the sample's turbidity. Light-
scattering devices are referred to as nephelometers, while those devices
utilizing optical transmission measurements are called transmissometers;
the former are best suited for measuring low turbidities, while the latter
should only be applied to water of relatively high turbidity. A temperature-
controlled photodetection system is desirable since the device's output
is temperature sensitive.
Field Experiences
Aside from sample-line plugging, optical window fouling represents the most
common failure mode. Some manufacturers minimize this problem by including
self-cleaning devices that periodically flush the optical surface with a
cleansing fluid, but such methods have not proven practical for wastewater
service. Light-scattering instruments that involve no contact between the
optical surfaces and the sample also performed well. During the plant
survey, 11 facilities practiced turbidity monitoring; 8 out of these
11 users were satisfied with their turbidity-meter performance.
Principal complaints cited interferences from sample color and optical
surface fouling. Depending upon the type of sensor utilized, weekly-to-
monthly inspections are necessary to ensure proper operation. After optical
component servicing (such as cleaning and changing light sources), the
meters were found to work well in several of the wastewater-treatment plants
visited during this survey. Reliable turbidity instruments are available
from commercial sources within the $1,000 to $3,000 cost range (Appendix
B), and with proper maintenance they can successfully monitor secondary
effluent turbidities.
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RESPIROMETERS
Applications
Respirometers measure the rate of oxygen consumption as the microorganisms
metabolize substrates (food); for on-line respirometers, the output is
usually reported as a time-related oxygen demand (OD) (e.g., a 15 minute
OD). Because a wastewater's aerobic biological activity correlates with its
OD, many investigators have attempted to correlate on-line (i.e., short-
term) OD measurements with 5-day BOD's. Unlike TOC, TOD, and COD analyzers,
respirometers utilize a biological technique to assess soluble organic concen-
tration; they can thus estimate organic loading for a plant's raw sewage,
primary clarifier effluent, aeration tank liquor, and secondary clarifier
effluent. (The reader should be forewarned that considerable effort is
necessary to determine correlation coefficients or graphs predicting process
behavior). In addition, respirometers can allow estimation of the viability
of return activated sludge by furnishing measurements of the sludge's
endogenous respiration rate. Monitoring aerator influent TOC and sludge
respiration rate permits a rapid estimation of the optimum food-to-
microorganism ratio on a biological basis; this is a more-reliable control
measurement for the secondary treatment process than are chemical and/or
physical measurements.
Principles
The numerous respirometer designs which have been developed in the last
half-century are all batch instruments. Automatic on-line devices take a
sample and subject it to intense aeration for a prescribed time, then the
resultant oxygen decay is measured over an adjustable time interval. The
difference between the initial DO and the terminal DO yields the oxygen
demand. Some instruments measure the oxygen consumed by coulometry (electro-
lytic replacement of the oxygen consumed), differential pressure techniques,
or electrochemical DO determinations via DO probes. Respirometers may be
operated isothermally or adiabatically. Principal drawbacks of most respiro-
meters are their tendency toward inlet clogging and the high amount of
maintenance necessary to ensure proper operation.
Field Experiences
During the user survey, the investigators encountered only one on-line
respirometer. The plant manager commented that his staff was disenchanted
with this instrument because of its high maintenance requirements and poor
reliability. Only two manufacturers supply automatic on-line respirometers
(see Appendix B), and these instruments cost between $4,000 and $6,000,
Notwithstanding fifty years of respirometer experiences, additional develop-
ment and demonstration efforts may be necessary prior to general use of
automatic respirometers in wastewater-treatment plants.
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SLUDGE LEVEL
Applications
Liquid-solid separation is a fundamental unit operation of wastewater-
treatment technology. Solids are usually collected by gravity settlers
where the solids with a specific gravity of about 1.05 collect as a
"sludge blanket" in the lower regions of the settling tank. Once accumu-
lated, this sludge can be segregated from the upper layer by keeping track
of the phase boundary or interface. Detecting sludge interface is not easy,
since it may be 2 to 12 feet below the surface and since the upper layer is
often too dirty to see through.
Principles
For wastewater treatment, several promising sludge-level detectors use optical
sensors to determine the sludge interface at: fixed levels in a settling
tank. Although such instruments measure only at single points and have an
on-off output, the devices are quite useful for controlling sludge withdrawal
from a clarifier. Rising sludge attenuates the light beam sufficiently to
actuate an on-off switch that controls the sludge pumping cycle.
Field Experiences
Three manufacturers (Kay-Ray, Keene and National Sonics) offer sludge-level
detectors in the commercial market place, and these units typically cost from
$800 to $1,400. Biospherics, Inc., is another manufacturer of these devices;
however, as of the time the survey was initiated, Biospherics analyzers were
too new to be found in established plants. Only three plants out of the fifty
surveyed measured sludge level, and all of them used optical probes.
Although all the users were satisfied with their initial results, it has been
reported that the life expectancy may be as short as six months because of
poor-quality assemblies.
pH
Applications
pH measurements in biological treatment systems are useful for monitoring
industrial spills (i.e., toxic loads of acidic wastes entering the treatment
plant); also, pH values for anaerobic digesters should be monitored to permit
the maintenance of an optimum acid/base balance. pH measurement and control,
moreover, is an integral part of most physical-chemical waste-treatment
processes.
Principles
pH measurements in water- and wastewater-treatment plants utilize a glass and
reference electrode pair; the glass electrode is specific for hydrogen ion,
while the reference electrode provides a stable and reliable means of
completing the circuit and of furnishing a reference EMF.
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Both electrodes may become inoperative when coated by oil or slime, but
the reference electrode has the additional problem of plugging, which
disrupts electrical continuity of the porous-media salt bridge, The majui
problem in wastewater pH measurements is to make the probes easily service-
able so that they can be quickly cleaned and recalibrated.
FieJ_d Experiences
In the last few years, the development of preamplifiers that mount either on
top of or within the electrode holders, coupled with special electrode
housings and mountings (or other systems) to make probe installations
easily serviceable, has resulted in reasonable acceptance of on-line pH
instrumentation. In the survey, pH-measuring installations were found
satisfactory in 11 of 13 cases, for an acceptance of 85%. The median
maintenance requirement for domestic sewage applications was 50 man-hours
in 96 checks per year. Beckman, Foxboro, Leeds and Northrup, and Universal
Interlock Instruments supply well-designed units that performed well in
several of the surveyed wastewater-treatment facilities. Numerous commer-
cial sources sell pH probes in the $1,200 to $2,000 price range (see Appendix
B). Most, commercially available, pH probes use well-established designs
that are suitable for continuous duty in wastewater activities if properly
installed and maintained.
ORP
Applications
Oxidation-reduction potential devices measure the ratio of oxidants to
re,ductants in aqueous solutions. The measurement itself is non-specific
and does not yield concentration data; however, it is useful in monitoring
the progression of such oxidation-reduction reactions as aerobic oxidation
and anaerobic sludge digestion. For aerobic oxidation processes, dissolved
oxygen measurements are more meaningful and thus eliminate the need for ORP
data; whereas, in anaerobic sludge stabilization, ORP monitoring frequently
can be useful for process control. ORP is also useful for measuring
reduction of hexavalent chromium and oxidation of cyanide in the treatment
of plating wastes.
Principles and Field Experiences
ORP measurements are usually made by employing either a platinum or gold
indicating electrode in conjunction with a reference electrode. Like many
other in situ electrochemical methods used for sewage samples (pH and DO),
oil and slime quickly foul the probe and thus cause a large amount of
maintenance. When reliable methods have been established to reduce fouling
problems, ORP may become more useful in domestic waste-treatment facilities.
Only three ORP installations were encountered in the survey; two were
unsatisfactory and one was only marginally acceptable. Numerous
commercial sources supply ORP analyzers within the cost range of $1,000 to
49
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$2,000 (see Appendix B). Since ORP probes foul so easily, they are not
suitable for continuous monitoring in a wastewater environment unless users
make a commitment to clean the electrode surface frequently.
FLAMMABLE GAS DETECTORS
Applications
Wastewater-treatment plants are routinely required to continuously monitor
the atmosphere in certain areas for the presence of combustible or explosive
gases. This type of gas detector typicall/ sounds an alarm when gas concen-
tration exceeds a predetermined fraction of the lower explosive limit (LEL).
Common hazardous areas are near the digesters, where methane may be leaking
to the atmosphere, and possibly at the plant headworks where sewer gases or
incoming gasoline can cause hazards.
Principles
Commonly used gas detectors are nonspecific. They pass a constant flow of
warm sample over a hot filament, the temperature of which is continuously
monitored. Combustible material in the sample burns at the filament, thus
raising its temperature and triggering an alarm. A monitor consists of a
sampling system, detector, and measuring and alarm circuitry. The sampling
systems and detectors are the parts requiring the most maintenance, but the
entire system must be checked frequently on a fixed schedule if the
instrument is to remain reliable.
Gas monitors in industry have often been neglected until an accident
occurs. The sample system plugs or the detector becomes insensitive; in
either case, the instrument cannot detect a hazardous situation. Gas
monitors are usually provided with self-checking circuitry for filament
and alarm systems, but routine system checks (preferably using hazardous
gas samples) are also necessary.
Field Experiences
Flammable gas monitors were found at 10 sites; 6 performed satisfactorily
and 4 did not, for an acceptance of 60%. Typical maintenance for only one
monitor is estimated at 12 man-hours per year with 12 checks; 8 additional
man-hours are required for each additional sample point in the same vicinity.
During the plant survey, flammable gas detectors manufactured by Davis and
by Mine Safety Appliance worked best. Most flammable detectors cost
$2,000 to $4,000 per unit.
RAINFALL
Rainfall measurements are important in anticipating loads to stormwater
facilities and sewer-regulation networks because they permit stormwater-
treatment facilities to take immediate steps to anticipate the arrival of
the stormwater. Either the tilting bucket or the accumulative rain gauge
50
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can be successfully tied into telemetering systems for data transmission
to a control location.
Rain gauges have proven quite practical, especially when the output signal
is well designed and when the system is properly protected from surges.
Rain gauges were found to be working successfully at 5 sites. Maintenance
for the typical instrument may be estimated at 50 man-hours, (i.e., 24 checks)
per year. Adequate rain gauges are commercially available in the $500 to
$2,000 range.
TEMPERATURE
Most sewage-treatment facilities generally obtain process-temperature
measurement only for digesters and incinerators. The well-developed gas-
filled systems, resistance thermometers, or thermocouples are quite suit-
able. In a waste-treatment facility, the objective is to make the
instrument sufficiently rugged, accessible, and corrorion-proof.
Commercially-available resistance thermometers are sufficiently sensitive
(even when protected by heavy, stainless steel, thermometer wells) to indi-
cate changes as small as 0.1 degree Fahrenheit in plant influent temperature.
Such sensitivity can occasionally be useful in detecting changes in wastewater
characteristics arising from slugs of industrial waste. Good-quality plat-
inum resistance bulbs (or a proven and certified equivalent) are recommended,
especially since few facilities have temperature-calibration capabilities
adequate for temperature instruments. Suitable temperature-measuring
devices are commercially available from several suppliers; types appropriate
for wastewater duty usually cost from $400 to $1,600 for a complete
instrument (see Appendix B).
Temperature measurement instruments worked well in 18 locations, and only
one plant reported marginal performance, for an acceptance of 95%. Mainten-
ance requirements are estimated at 8 man-hours per instrument with one
check per year for a well-designed system; note, however, that these
maintenance estimates do not include incinerator applications or high-
corrosion environments.
WEIGHT
Common applications for scales in a waste-treatment plant include inventory
control of chlorine, lime, and other chemicals. A newer use is the con-
tinuous weighing of dewatered sludge on belt scales to monitor sludge-
filter and centrifuge performance and to indicate incinerator charge rates.
The mechanical, lever-type, floor scale is being challenged by hydraulic
systems which are cheaper to install, relatively corrosion resistant, and
waterproof. Belt scales are more apt to be hydraulic or electric (i.e.,
strain-gauge type) than mechanical; all weight-measuring instruments,
however, require regular and competent maintenance. A radiation-type belt
scale was installed at one plant, but operational experience was unavail-
able. Belt scales are usually furnished as a part of moving-belt conveyor
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systems. Weighing systems (belt scales) were successful at 5 locations,
for a 100% acceptance; maintenance data and more detailed performance
figures were not available.
CONDUCTIVITY
Wastewater conductivity denotes the presence of ionized substances. In
some domestic waste-treatment facilities, high conductivity values indicate
sea-water intrusion, either through open tide gates or flooded inlet/
outlet structures. Sometimes increases in conductivity can be correlated
to industrial waste spills or salt runoff from highways.
On-line conductivity monitoring requires inert probes (as resistant as
possible to corrosion and fouling), alternating current to prevent
polarization, and sensitive (but stable) electronics. At seven plants the
survey team found all conductivity installations working well for monitoring
either influent or effluent streams; i.e., acceptance was 100 percent. The
personnel responsible for obtaining these continuous conductivity measure-
ments were apparently willing to give this equipment the proper care because
average maintenance was 60 man-hours in 200 checks, annually. Most:
commercially-available conductivity instruments are priced in the $1,000
to $1,500 range, use good designs, and are suitable (when properly main-
tained) for continuous duty in wastewater activities (see Appendix B).
SPEED
Rotational speed measurements in wastewater treatment are usually confined
to centrifugal pumps, variable-speed centrifugal blowers, small positive-
displacement pumps used for chemical addition, and clarifier sludge flights.
The older common method for speed measurement utilized a dc tachometer-
generator that feed a special meter in a calibrated loop. This method is
simple and practical, but is subject to wear and requires considerable
maintenance. A newer method utilizes a magnetic pick-up and an electronic
converter to produce a digital pulse or pneumatic analog signal. Although
slightly more expensive to buy and install, it is cheaper and easier to
apply because it has no moving parts and, therefore, requires little
maintenance.
Speed-measuring instruments are usually designed and furnished as sub-
systems with pumps or pump drives. Meaningful maintenance and failure-
rate data are unavailable, but speed-measuring systems were noted at 8
locations, and all of them worked well.
POS IT ION
Remote position indicators are essential for those wastewater-treatment
plants that automatically direct and control flow. Large valves, sluice
gates and the like are already routinely controlled from a remote location,
even when such control is manual; in most cases, a position signal must be
sent back to let the instrument or operator know that the control system is
indeed functioning acceptably. Industrial-type limit switches are simple
and adequate devices for detecting extreme positions (full open or full
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closed). More-sophisticated devices, however, are needed to detect the
position of modulating gates and valves. There is little difficulty
when an electric positioner drives the gate if the position sensor (usually
a slidewire) is installed as part of the actuator drive, but the later
addition of position sensors to hydraulic and pneumatic operator install-
ations is difficult; such sensors should be furnished with the operators
at the time these latter are installed.
Position-monitoring measurement was found at 11
factory, one was fair, and nine were successful.
cations, however, were electric. The difficulty
sensors lies not in the sensor itself, but in th<
for connecting the sensor to an appropriate tran
Tapes and pulley systems are usually unsuccessfu
position indicators usually sell for $300 to $1,
dtes: one was unsatis-
All successful appli-
in practical position
: lack of suitable devices
emitter or readout device.
Commercially available
.00.
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SECTION VI
TYPICAL CONTROL STRATEGIES
INTRODUCTION
A large number of processes are utilized in industrial and municipal
wastewater purification, and an even larger number of potentially viable
automatic control strategies exist. This report, however, discusses only the
automatic control processes observed during the plant survey. All manual
control methods have been excluded because they add little in appraising
the state-of-the-art of instruments and automatic devices. For the reader's
convenience, the subject matter is divided into two sections:
Level and flow control.
Treatment-process control.
With this format, the similarities regarding control philosophies, imple-
mentation, and performance become more apparent. Control systems can be
classified, in order of increasing complexity, as shown in the following
paragraphs.
Fixed Program Control
Fixed program controllers follow a pre-set command to activate devices
regardless of surrounding conditions; they are open loop controllers.
Remote Manual Control
This is not automatic control, but it involves signal generation by a
sensor, signal transmission, then actuation of a final control element by
the operator. Such a system cannot, of itself, modify its action; it is
also open loop control.
Two-Position Control
This is the simplest variety of closed loop control because it contains all
of the essential components. Two-position control, by definition, means
that the final element is either fully open or closed. Two-position control
includes on-off and differential gap as special cases; on-off control,
however, is the most common. In general, as soon as the measured variable
exceeds the control point, the final control element travels to its extreme
position.
Modulating Control
Any type of control system that intentionally maintains a final control
element in some intermediate position is modulating control. Although most
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modulating systems are analog feedback types, modulating control also
includes open loop and feed-forward which are implemented either by
analog or digital methods. Modulating control may also be combined with
programmed responses.
Multiloop Control
This unites several open and closed loops (synthesized either by digital or
analog techniques) into a control strategy appropriate for the process
requirements; loops can be linked in ratio, feed-forward feedback,
cascade and adaptive combinations. Present-day wastewater facilities
were found to use all five degrees of control.
Control System^Hardware
Although signal transmission and final control devices are not emphasized
in this discussion, they play an important part in wastewater-control-
system performance. Final control elements in wastewater plants are almost
always pumps or large valves. Large valves and sluice gates are usually
operated as two-position, full-open or full-closed devices; occasionally,
however, they are used to modulate flows. Small variable-speed positive-
displacement pumps and dry-feeders are also quite common, but the variety of
valves frequently employed in other process industries is rarely used as
final control elements in wastewater-treatment plants. Pneumatic sensors
and sensing transmitters have become fairly common, utilizing the standard
3-15 psi signal and sometimes a vacuum signal (20 to 70 inches of water).
Comparable success has been obtained with electronic transmission systems,
usually standardized at 4 to 20 milliamperes dc.
Switches, proportional controllers, and proportional-plus-reset (PI) con-
trollers, developed for the process industries, are used with considerable
success in wastewater treatment; however, derivative (or "anticipatory")
controllers are very rarely encountered in a waste-treatment plant.
The latest trends in instrument miniaturization and modularity have been
incorporated into controller and recorder designs for most new plants; for
example, the latest improvements in controller design (e.g., standardized
transmission signals and good process-control interfacing devices) were
evident in most of the newer plants.
In summary, transmitting devices, controllers, and final control elements
for waste-treatment processes employ well-established technology. Most of
the observed commercial devices performed satisfactorily in the surveyed
wastewater-treatment facilities.
LEVEL AND FLOW CONTROL
Liquid Level Control
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Principles and Applications
In any process involving the flow and storage of liquids, such as those in
wastewater treatment, level control becomes essential for plant operation.
Since the actual level itself is not important (so long as it is between
acceptable limits in most wastewater-treatirent facilities), highly accurate
level control can often be sacrificed for stability and simplicity. With the
typical wet-well arrangement, automatic level control keeps the plant's
throughput approximately equal to the influent rate by adjusting pump speeds
or throttling the pump discharge. On-off controllers with adjustable
differential gaps, or proportional-only controllers, are the most frequently
used control devices for wastewater-treatment level-control applications
since they are stable, simple, and relatively cheap. Single-mode (i.e., pro-
portional only) level-modulating controllers are usually preferable because
supplementary derivative action is unnecessary and can even be a disadvantage
due to noisy level signals. A slow integral (reset) action can help drive
the working level toward the mid-range of the wet-well, thus providing
maximum capability for coping with sudden changes; however., reset is rarely
used for wet-well level control.
There are two philosophies regarding wet-well size: a generously sized
wet-well results in simpler pump drives and may even allow flow equal-
ization; whereas, more-sophisticated level control permits using a smaller
and less expensive wet-well. Although sewers and other in-line storage
structures smooth out some of the flowrate variations, flow ratios of 10 to
-1 i '
1 at the headworks are not unusual. ^ For smaller plants, good engineering
practices require minimizing pump starts because starting a motor heats
it much more than running it and accordingly shortens the pump motor's
service life; frequent pump start-ups are also very wasteful of electricity.
Because of all these considerations, a storage time-constant of 30 minutes
at "average" pumping rate is recommended for most on-off liquid-level control
systems. (Storage time-constant for a wet-well is defined as the time
required to pump out the well's working volume with the particular pumping
strategy used).
A common criterion for designing wet-wells and pumping stations is to
minimize wet-well costs. By using variable-capacity pumping systems,
pumping rates can be maintained equal to influent rates, and wet-well
volumes can be kept small. A storage time-constant of 10 minutes at maximum
pumping rate is recommended as a practical rule of thumb to ensure that the
wet-well neither overflows nor runs dry. Except for rather small systems,
multiple phased-operation pumps are used; the control system for such an
installation can become complex and requires separate study.
Flow, or hydraulic-loading, equalization requires a combination of large
capacity wet-wells and variable-speed pumping systems to minimize
undesirable flow surges. Proportional control with unity gain would provide
maximum pump speed at maximum level and, conversely, minimum pump speed at
minimum level. Other gains might be more suitable, but the choice would
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depend on the wet-well time-constant and the anticipated influent flow
variability. To be effective for flow equalization purposes, the wet-well
would require a time-constant of several hours, but this would require an
expensive structure and cause difficult problems in preventing settling
and septicity. Non-linear control, to provide slow changes in output rate
when the level is reasonable and yet change the rate sharply as the level
approaches an extreme, would also be useful. (Analog controllers of this
type are commercially available.)
Field Experiences
All level-control systems encountered in the survey used on-off pumps, multi-
step or variable-speed pumps with proportional control. Of the 33 cases
reported, 3 were unsatisfactory and 3 were marginally acceptable, for an
acceptance of 82%. Level control is not a major problem with commercially
available equipment because precise level control is usually not required;
oscillatory or conditionally stable control is adequate in most cases. For
these reasons, presently available liquid-level control systems are suitable
for almost all wastewater-treatment activities.
Flow Control
Principles and Applications
Liquid flow is a fast-responding process which has a small capacitance.
Usually the sensor, transmitter, and controller account for the largest
lags; process lag is often negligible. Accordingly, controllers that
feature low proportional gain with fast reset action are most frequently
used for liquid flow because this control mode avoids false actions based
on noise, yet its fast reset feature causes it to act promptly to correct
any persistent error.
Field Experiences
Most automatic flow-control loops, which this survey encountered in wastewater-
treatment plants, regulated rates of return sludge and compressed air flow.
For this purpose, these installations used proportional-plus-reset closed-
loop analog controllers. Although liquid flow optimization of large
streams is rare in wastewater-treatment facilities, one plant practiced
influent flowrate equalization. They regulated the influent flowrate by
means of variable-speed pumps, rather than control valves, to minimize
energy losses and pumping costs. All 20 of the observed, automatic,
flowrate-control systems performed satisfactorily for 100% acceptance.
Presently available commercial flow-control systems are adequate for
regulating flowrate in wastewater-treatment facilities.
TREATMENT PROCESS CONTROL
Chlorination Control
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Principles and Applications
Disinfection, one of the most important unit processes practiced in most
water and wastewater-treatment plants, kills most microorganisms present:
in sewage by contacting the wastewater with an effective bLocide.
Chlorine is used in the majority of these facilities. For safety,
convenience, and economy, pure chlorine is received as a pressurized
liquid which is then applied, in the form of a relatively concentrated
aqueous "carrier" stream, in ratio to the main process flow as shown in
Figure 8.
Almost all chlorinators have been designed to reduce the incoming chlorine-
gas pressure to below atmospheric. The flow of water through the ejector
draws the chlorine out of the chlorinator; thus, in case of a broken or
leaky line, chlorine is not released to the atmosphere. The high-pressure
chlorine system is quite conservatively designed, and it is treated with
care so that chlorine leaks rarely occur.
Successful disinfection with chlorine depends on good mixing, adequate
chlorine concentrations and sufficient contact time; a contact chamber
ensures complete reaction before the effluent is discharged from the
facility. This contact chamber usually holds the wastewater for at
least 30 minutes at maximum flowrate .
CHLORINE VAPOR UNDER PRESSURE
SAFETY VENT
VAPORIZER
~L J
CHLORINATOR
(LIQUID CHLORINE)
CHLORINE GAS UNDER VACUUM
EJECTOR
TREATMENT
PROCESSES
— —i AUXILIARY PUMP OR
(} CONTINUOUS,
CONSTANT-FLOW PUMP
-CLEAN WATER SOURCE
SAMPLE POINT
FOR CONTROL
Figure 8. Flow-proportional chlorination control
58
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The following methods of automatic chlorination control are practiced in
wastewater treatment:
Open-loop flow-proportional control
Compound control: flow-proportional control of Cl~ addition, with
residual chlorine feedback to the chlorinator to trim dosage
Post-contact (i.e., downstream) residual chlorine control, plus
compound control (cascade configuration); this control strategy is
also called double compound control.
Open-loop flow-proportional control is simple and fast; unfortunately, it is
also not flexible enough, especially for widely varying chlorine demands.
Nevertheless, flow-proportional control is adequate for many plants. Better
control, however, is obtained by trimming the chlorinator's set point with
residual chlorine feedback; this automatically re-adjusts the ratio of
chlorine flow to main process flow, as shown in Figure 9.^' If the waste-
water has a high chlorine demand, the residual chlorine concentration drops
and the feedback controller increases the ratio of chlorine added to the
wastewater; for lower chlorine-demand wastewater, the residual chlorine
feedback controller automatically lowers the ratio of chlorine added. This
compound control loop provides somewhat slower, but more accurate, control;
the survey team observed many successful compound chlorine control loops.
A common chlorinator design that is inexpensive and requires no auxiliary
air supply utilizes the vacuum developed by the ejector to control chlorine
gas flow in ratio to the main process flow. A flow transmitter, similar
to a conventional pneumatic transmitter, leaks air into the vacuum signal
line to maintain a vacuum-control signal proportional to the flow differ-
ential in the main line. This vacuum, applied to a special regulator,
maintains chlorine pressure-drop proportional to main-flow pressure-drop.
The residual signal, on the other hand, drives a servo that re-adjusts a
linear valve (usually a Vee-notch valve) in the chlorine vapor line. Mass
flow of chlorine is, therefore, proportional to the product of hydraulic
flow through the plant and residual chlorine concentration.
Good residual chlorine control, however, poses some difficult problems
because most standards and codes require that a prescribed residual chlorine
be maintained after at least 30 minutes contact time. On the other hand,
residual chlorine feedback control systems which have potential 30-minute
lags are prone to instabilities. For the feedback control system to perform
adequately, the overall response time of the loop should be within a three-
to 10-minute range; this means that residual chlorine must be determined a
short time after mixing. The difficulty now is to relate the control
residual to the residual at the end of the proper contact period. This is
best handled by a second residual chlorine analyzer that records the
residual after sufficient contact. To assure an adequate residual, it may
59
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be necessary to use a second, or post-contact, residual chlorine analyzer
to readjust the chlorine application rate at the head of the contact
chamber as shown in Figure 10; note that the second analyzer's output
signal controls the set point of the first analyzer (cascade control).
Field Experiences
Since the chlorination process is dominated by large reaction-time lags,
the aqueous chlorine concentrate must be well mixed into the main flow,
the main process flow signal must be properly represented at the point of
chlorination, and the measurement lag should not vary appreciably with
rate of plant throughput; if these conditions are met, residual chlorine
feedback control will be optimum. Residual chlorine control was found to
be successful at 10 sites, unsatisfactory at 1 and fair at 2, for an
acceptance rate of 77%.
Presently available, automatic, residual-chlorine control devices are
well proven for assuring proper chlorination of wastewaters, especially
after secondary treatment. Occasionally, chlorination control of raw
sewage, stormwater and combined sewage may fail because of the residual
analyzer plugging with debris. Residual chlorine control systems are
usually cost-effective since they pay for themselves in chlorine savings
and assure compliance with discharge standards.
Dechlorination Control
Although most wastewater facilities effectively disinfect their effluents,
in some cases the effluent must also be essentially free of active chlorine
to protect shellfish beds, bathing beaches, etc. To accomplish this,
active chlorine is usually reacted with aqueous sulfur dioxide (i.e.,
H SO.,), whereby sulf ite is oxidized to sulfate and hypochlorite is reduced
to chloride, as shown by equation 1:
(1) H0SO_ 4- HOC1->H0SO. + HC1
/ j 24
The sulfur dioxide gas feeder is practically identical in construction
and function to the common chlorinator.
A continuous, automatic, residual chlorine analyzer is essential in all but
the smallest plants if residual chlorine is to be kept very low (perhaps less
than 1 ppm), while simultaneously avoiding excess sulfite. The extent of
instrumentation will vary with the seriousness of the problem, but alarms
and signal limiters from the analyzer to the feeder are recommended to
avoid chemical over-dosages.
A residual chlorine analyzer is usually necessary to control the sulfur
dioxide feeder. The arrangement and precautions are the same as given for
chlorination, but one signal is reversed so that as residual chlorine in-
creases the sulfur dioxide feed is increased, and vice-verse. Automatic
dechlorination was included under residual control in the survey results.
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Dissolved Oxygen Control
Principles and Applications
To achieve high BOD removals with any of the activated sludge process
modifications, proper dissolved oxygen (DO) levels must be maintained in
the aeration basins. Adequate DO should be available to satisfy the
metabolic needs of the aerobic microorganisms. If the DO decreases below a
critical level, the aerobic bacteria lose their activity, and effluent
quality deteriorates. Excessive DO concentration, however, can hinder
secondary solids settling. Moreover, the aeration equipment consumes
wasteful amounts of energy when the DO level is too high. Oxygen demands
fluctuate over a wide range because of changes in flowrate, organic
concentration, ease of degradation, and activate biomass concentration.
The degree of nitrification also affects oxygen demand.
Most of the surveyed plants practiced manual DO control where the
operator attempted to regulate the oxygen transferred in proportion to the
oxygen demand. To save manpower and assure adequate oxygenation, most
operators provided more oxygen than necessary. With the current energy
shortage, automatic DO control has become very important since it can reduce
aeration power consumption by as much as forty percent. •*-
Automatic DO control paces oxygenation rate (input energy to the aeration
equipment) to oxygen demand. Two DO-control strategies were observed during
the user survey of automation practices in wastewater-treatment facilities:
flow ratio (or flow proportional) control and DO feedback control.
Flow ratio control regulates the rate of oxygen transferred to the mixed
liquor in direct proportion to the influent flowrate. This strategy, which
is simple, inexpensive and fast-responding, is predicated on a constant
oxygen demand per unit volume of sewage. Flow ratio control of the aeration
equipment, however, does not work well in most plants because the oxygen
demand per unit volume of sewage changes dramatically throughout the day.
For example, stormwater infiltration or industrial dumps cause large
variations in plant-influent oxygen demand. Only one plant out of the fifty
visited facilities practiced flow proportional DO control, and they dis-
continued it since a satisfactory DO level could not be maintained in the
aeration basins.
DO feedback control systems use actual DO data from the aeration basins to
regulate the rate of oxygen transferred. A DO probe senses the DO concen-
tration and sends a signal, by means of a transmitter, to a controller which
computes the deviation from the desired value (i.e., an error signal).
The controller, acting on the error signal, usually outputs a signal for
control action proportional to both the instantaneous error and the integral
of past errors (PI control). Other useful control modes include proportional
only, two-position, and combination flow ratio-DO feedback trim.
Final control elements such as motor-speed relays or valve positioners,
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execute the control strategy by producing corrective changes in the
manipulated variable which, in turn, alter the oxygen transfer rate.
Table 7 contains the manipulated variables and final control elements
for commonly available, oxygen transfer equipment; the corresponding
feedback control systems are shown in Figure 11.
Table 7. OXYGEN TRANSFER EQUIPMENT
Aeration Device Manipulated Variable Final Control Element
Air Diffusers Air Flowrate Valve, or variable-
speed motor, or blower
vane pitch
Submerged Aerator Air Flowrate Same
(Turbine/Orifice)
Surface Aerator Immersion Depth, or Motor Adjustable weir, or
Speed motor speed
For example, consider the diffused aeration tank equipped with variable-
speed blower. When the DO probe reports a low oxygen level the controller
generates an error signal that calls for increasing the blower's speed;
this then tends to raise the aeration basin's DO concentration.
Since the DO feedback control system acts on DO probe readings, it is
important that these DO data represent the "true" DO concentration of the
aeration basin. Consequently proper DO-probe location is essential for good
control. If the DO probe is located either remotely from, or in an
unrepresentative region of, the aeration basin, the control system may
exhibit erratic or unstable performance. Since the entire contents of a
completely mixed aeration basin are virtually uniform, DO probe placement
is not critical for this type of aeration.
For single- or multiple-pass plug-flow aeration basins with large length-to-
width ratios, the probe-mounting arrangement should have enough flexibility
to permit easy probe-locatioa changes since a significant DO gradient
exists along the tank length. For mechanically aerated plug-flow basins, DO
probes should be placed in each aerator's zone-of-influence; alternatively,
suitable single-probe locations may be found by trial and error.
Field Experiences
Four of the five treatment plants that utilized automatic DO feedback con-
trol were satisfied with the performance of such control - an 80% acceptance
These four plants could effectively hold their DO concentrations within 10%
of the desired operating level (i.e., anywhere within 1.0 to 5.0 mg DO/1 in
spite of widely varying oxygen demands. Plant managers commented that
aeration power savings ranged from 10 to 40% for automatic DO regulation.
Moreover, the BOD removal generally increased about 10% when DO control was
applied. One plant practiced a slightly more sophisticated DO control by
basing their equipment adjustments on the product of raw sewage flowrate
and aeration-tank DO level; but no significant increase in control
performance, cost savings, or BOD removal was observed.
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Most users cited excessive DO-probe maintenance, requirements as a major
disadvantage of presently available, automatic, DO-control systems.
Transmitters, recorders, indicators, controllers, and final control elements
functioned without any problems. Consequently, with proper installation
and periodic maintenance, satisfactory automatic DO control is within the
capabilities of commercially available equipment. Field observations
recorded decreases in power consumption, prevention of septic conditions,
and increased BOD removals as benefits of applying DO control to aeration
tanks.
Sludge Pump-Down Control
Principles and Applications
The two control objectives for pumping down a clarifier's sludge blanket
are (1) preventing the sludge blanket from spilling over the weir along with
clarified effluent, and (2) transporting a dense sludge to downstream
stabilization processes. Inherently, these two control objectives conflict
because control that leads to good thickening also tends to produce a high
sludge blanket which causes the effluent to pick up significant amounts of
solids. On the other hand, if the sludge blanket is too shallow, the solids
will contain excessive water. Ideally, keeping the sludge blanket within
an optimum range of heights will satisfy both requirements, but the non-
ideal nature of wastewater liquid-solid separations makes this approach
difficult. Instead of basing sludge-blanket level control on any set of
fixed rules, good judgment based on actual experience should guide the
control-strategy selection. It seems reasonable that more emphasis should
be placed on sludge-density control methods for primary clarifiers; whereas,
secondary clarifiers should use appropriate types of sludge-blanket level
control.
As might be expected, two possible control strategies (shown as a composite
in Figure 12) are practiced in wastewater-treatment facilities: With the
first strategy, a timer initiates sludge pump-down, during which time the
sludge density is continuously monitored; pumping is terminated when (1)
the density of sludge leaving the clarifier falls below some preset value or
(2) a predetermined pumping time has elapsed. Sludge pumping control by
density measurements is well established, but suffers from excessive sensor
maintenance (see Sludge Density Measurement).
With the second strategy, a photoelectric (or ultrasonic) level detector
monitors the liquid-solid interface height (sludge blanket level). When
the sludge blanket rises above a preset limit (i.e., above the photoelectirc
or ultrasonic sensor), sludge pump-down starts; pumping then continues until
terminated, usually by a fixed-interval timer. Other shut-off methods,
such as low blanket level or low density,, are possible but they were not
observed during this survey. Only one plant reported using sludge-level
probes in conjunction with automatic sludge-pumping control.
Field Experiences
Sludge-pumping control worked well in 72% of the 22 facilities which
practiced it. Poor sensor reliability (both sludge level and density)
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were mentioned as the principal drawbacks of automatic sludge-pumping
control. In spite of this sensor problem, commercially-available sludge-
pumping control systems are somewhat beneficial, but they need considerable
improvement to substantially improve sludge pump-down operations. Also a
combined (or combination) control strategy based on sludge blanket level and
sludge density should be further investigated.
Scum Removal Control
A highly instrumented, scum-pumping system was encountered at one plant (see
Figure 13). Unfortunately the system was ineffective because of poor
hydraulic design of the skimming operation. A more careful study of the
process would have prevented this misapplication of otherwise-good
instrumentation.
r*-| SLUDGE LEVEL
LJ PROBE
OVERFLOW
Figure 12. Sludge pumping control strategies
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INSTRUMENTS ON
MAIN PANEL
INSTRUMENTS ON
PANEL AT SETTLER
(SYMBOLS AND
LETTERS ARE FROM
ISAST'DS5.1)
Figure 13. Instrumented scum-pumping system
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In operation, the scum trough is rotated by the operator at either the
settler or main panel. Panel-mounted instruments also indicate degree of
tilt, level in scum pit, and speed of an automatically controlled, variable-
speed pump. The only part of this system that is truly automatic involves
control of scum level in the scum pit via a signal from LT and LC which,
in turn, adjusts the speed of the scum pump (e.g., via a linear variable
differential transformer, in combination with either a thyristor power
supply or a magnetic drive for the pump motor).
Chemical Addition Control
Principles and Applications
Chemical addition, in ratio to wastewater flowrate, is a well-established
automatic control procedure for adding coagulant aids, precipitating
agents, and nutrients. Typically, either a variable-speed pump or dry
feeder, driven at a rate proportional to the process stream's flowrate,
delivers chemicals by a feed-forward control configuration illustrated
in Figure 14-A. Automatic analyzers, good enough for reliable feed-
back control or feedback trim (Figure 14-B), are not available for most
parameters. Since dosage accuracy is not critical and the large process
capacitance adds a smoothing effect, the simple, inexpensive flow-ratio
controller is adequate for most plants. Occasional manual tests are made
to check that the ratio is correct and that the equipment is working
properly.
Although final control elements for most chemical feeders are usually
adequate, the newer equipment uses closed-loop control around the feeder to
assure linearity and dependability. A detailed discussion of feeders and
their working properties is given by Babcock (19).
Field Experiences
In the plants visited, variable-speed pumps and dry feeders delivered aqueous
ferric chloride, pickle liquor, alum, phosphoric acid, lime, and polymers in
ratio to the main process stream. Eighty-seven percent of the fifteen instal-
lations that practiced chemical addition by means of flow-ratio control
were satisfied with their control system's performance. The survey results
show that presently available, flow-ratio equipment for automatic chemical
addition is suitable for continuous duty in wastewater-treatment plants.
Digester Temperature Control
Since anaerobic sludge digesters have high thermal capacitances, simple
on-off temperature control is adequate to prevent temperature upsets.
Digester temperature controllers, which are similar to a home heating system,
measure the temperature of the digester contents and turn a hot water
circulation system on or off, depending upon the desired temperature. Most
commercially available temperature controllers can readily satisfy digester
service requirements.
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pH Control
When the pH fluctuates over a range of 4 or more units, pH control becomes
difficult because the pH measurement is logarithmic and each unit corres-
ponds to an order-of-magnitude change in hydrogen ion activity (concen-
tration) . Since buffering capacities change as a function of pH itself, the
loop gains change non-linearly with the pH. Consequently, controller
tuning is very difficult.
Merely measuring a wastewater's pH is often difficult (see pH Measurement
discussion), and simple automatic control is often not feasible. One
surveyed plant, which used lime as the pH adjusting agent, had an unworkable
pH control system. A dry feeder/slaker and long trnsport lines within the
control loop introduced so much time lag that the control system became
unstable. Out of all the plants surveyed, automatic pH control was observed
at only three plants, but was acceptable at 2 of them for a 67% acceptance.
As in many industrial processes, presently available pH control systems can
provide satisfactory control for many wastewater-treatment applications;
however, it may be necessary to install one of the newer, relatively
sophisticated systems (e.g., adaptive non-linear control) for those
situations requiring very tight limits for rapidly varying pH values.
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SECTION VII
CENTRALIZED CONTROL
INTRODUCTION
The main purpose of central control is to provide an efficient communication
link among the process, process controllers, plant operators and supervisors.
For safe and efficient treatment of wastewater, the. instrumentation network
must transmit all essential technical data to a convenient location. Accord-
ingly, indicators, recorders, alarms, automatic controls, manual controls
(for remote actuators) and background process information are brought
to a central location to inform and facilitate manipulation by a relatively
small number of human operators. This is practical in most plants because
of simple and reliable intra-plant transmission systems, compact instruments,
and a well-developed technique in applying automatic controls to processes.
This central point, usually built as a control room, uses vertical display
panels and consoles. One or more operators oversee the function of the col-
lective processes from this control room, while maintenance men and assistant
operators service the equipment. Data display, recording, remote process
adjustment and alarm display are the basic: functions of a well operated,
centralized, control system.
DISPLAY
Most of the available operating information, regarding process status
at a wastewater-treatment plant, is displayed on panels for two purposes:
To illustrate present and past information about the plant
To permit the operator to control the plant efficiently based on
this information
Historically, the graphic panel was once claimed to be the best arrangement
for mounting instruments because the display devices are organized into a
logical sequence that closely follows process layout. Many graphic panels
also include provisions for making adjustments to important automatic con-
trollers. However, the large increase in the number of centralized display
devices used in present-day wastewater-treatment plants makes the graphic
panel too complex, too expensive to build or modify, and too large to be
scanned from a single point.
For semi-graphic panels, the instruments (usually miniaturized versions of
the old "large case" instruments that were roughly 1-1/2 feet wide and 2
feet high) are mounted in groups in a rectangular array that is related in
some way to the process. A representative semi-graphic panel is shown in
Figure 15. (Previously used, non-graphic panels simply mounted the
72
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* t «t
Figure 15. Example of Semi-Graphic Instrument Panels
73
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instruments with no graphic reference, so that the operator had to identify
each instrument by nameplate, position, or a distinctive record. Mistakes
were easily made and comprehension of the process was difficult, especially
for complex plants.) Semi-graphic methods frequently use standardized sym-
bols for process equipment with corresponding symbols marking the display de-
vices; color-keyed block diagrams and display instruments also aid in
identification. The most recent development in centralized control sub-
stitutes a time shared computer for most of the individual display devices;
this extends automation as a replacement for human attention to an ever-
increasing degree. This latter trend is proceeding slowly, however, because
such installations are expensive and are usually most suitable (economically)
for large facilities.
OBSERVING AND RECORDING PLANT OPERATIONS
Whether or not computer control is incorporated, safety and the need for
reliable operation of the facility under all conditions dictates the use of
basic sensing and control methods to ensure continuing operation. (Flow,
wet-well level, and disinfection are usually the most important variables).
Consolidated analog recorders are the most, reliable (and usually the most
effective) means of informing the operator of plant status and trends.
The practice, still existing in old plants, of using banks of large one- or
two-pen recorders for a recorder density of about 0.2 recorder per square
foot of panel space, has been revised to the use of miniaturized instruments
for an effectiveness of about 0.8 recorder per square foot. Future designs
are unlikely to improve on this figure, but the multiplicity of miniature
strip charts with one or two variables is being replaced by larger charts
with multi-variable capability and by direct, computerized, data reduction.
Analog records will continue to be important for many plant operations, and
the use of a relatively few, large, multi-variable charts is superior to
the present practice of small strip charts because of labor and material
savings, improved data retrieval, and the ability to determine the rela-
tive timing of events. (The application of multi-variable recorders,
however, requires a judicious selection of variables, and usually requires
some degree of signal conditioning and manipulation.)
Computerized data-reduction and data-logging operations will inevitably be
incorporated into an increasing number of the larger wastewater-treatment
facilities, particularly the new installations now being designed or con-
structed. In view of the fact that perhaps 20% of the logged data will be
from automatically controlled systems, 20% more from automatic measuring
devices, and 60% from measurements obtained manually, it is evident that
automated data reductions must be compatible with many kinds of signal inputs.
REMOTE PROCESS ADJUSTMENT
The success of centralized control in wastewater-treatment facilities
depends on both automatic control and on the laboratory. Wastewater-
treatment systems are, at present, only partially capable of automation;
this is due almost solely to difficulties in making reliable, automatic,
remote measurements of certain, critically important, wastewater parameters
without simultaneously incurring prohibitually expensive maintenance
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problems. In practice many types of routine samples are collected from
various areas of the facility, brought back to the laboratory and, in due
course, analyzed. The operators review the laboratory data and make
appropriate adjustments to process parameters and equipment from the central
control room. Because of rapid advances in laboratory procedures over the
last decade, most analyses have been automated to such a large extent that,
in many cases, the analyst need only introduce the sample and evaluate the
instrumental results. This laboratory automation is often confused with on-
line automation: in the first case, the analyst has been provided with new
devices, but analyses cannot be made without his intervention, and control
actions must be made manually. In the latter case, human aid is required
only to install, and then periodically calibrate and maintain, the automatic
measuring and control system.
The time-consuming conventional procedure consisting of sample collection,
sample analysis, data recording, and process adjustment based on the
resultant data has been considerably shortened in some plants visited
during the survey. In these plants, sampling systems have been arranged so
that a representative sample of influent, effluent, activated sludge, or the
like, is piped directly into the laboratory. This is an expensive practice
and one which introduces some safety problems, but it is a major improvement
in overall control of the treatment process. (See Sampling.)
ALARM SYSTEMS
No human being can reasonably be expected to dedicate his entire attention
to graphic displays or indicating instruments for eight consecutive hours;
a typical waste-treatment plant operator must direct much of his attention
to other chores as well. For these reasons, alarm/annunciator systems are
needed to alert the operator to dangerous situations by means of flashing
lights and audible signals. Process alarms are well-developed forms of
persistent surveillance systems common to the process industries; they are
a natural result of automated production because they permit a large amount
of remote equipment to be safely supervised by only a few men. Most alarm
systems use simple on-off light systems. Some new plants with 100 or more
alarms use specialized sequenced signals, for which the order (or sequence)
of alarming yields very specific information. A typical alarm system uses
bells or horns, plus flashing lights, in a well-structured annunciator
configuration to draw the operator's attention to any preselected abnormal
condition for which he is directed to take action. The audible alarm
continues until the operator pushes an "acknowledge" button. The specific
condition then remains prominently displayed until corrected. Each alarm
variable has its own light and legend.
Commonly observed alarm functions in wastewater-treatment facilities include:
Escaping chlorine gas
Explosive atmosphere
Pump or pump-drive failure (e.g., low oil pressure or high bearing
temperature
75
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Malfunctioning flow regulator or tide gate
Jammed comminutor
Overloaded clarifier drive-motor
Jammed or broken sludge-scraper flights
Loss of aeration air (either air flow or air pressure)
Loss of chlorination (e.g., chloriaator malfunction, loss of
ejector pressure, interruption of flow signal to chlorinator)
Abnormal influent pH
Loss of instrument air
Abnormal wet-well level
Each of the above conditions is detected, and corrective action is taken;
the list is different for each plant.
Alarm systems consist of specially designed annunciators that are simple,
highly reliable, and easily tested and repaired. Several varieties of
procedural arrangement are available and have been codified . Alarm-
system wiring is usually well-defined, well-segregated, and fail-safe.
The alarm-condition detectors are on-off devices (switches or latching re-
lays), carefully selected early in the design of the facility to warn of
hazards to personnel, to facility, or to the treatment function, in that
order. Two of the major sensing devices for protection in wastewater plants
are chlorine gas detectors and explosive gas detectors. Each instrument
is equipped with a switch that actuates an alarm when a preset level is
reached. Alarm systems are reliable and useful only when properly inte-
grated into a general plant-protection policy. For example, an alarm system
connected to a hazardous gas detector thac is not properly tested and
maintained is worse than no detector at all since its protection may be
wrongly assumed when the detector itself has become inoperative. On the
other hand, putting an alarm contact on a measuring device that frequently
goes off-scale (even when no hazardous condition exists) quickly exasperates
the operator, and he is apt to disarm or ignore the entire system, to his
own and the plant's peril. This latter situation has caused many, avoidable,
industrial explosions in recent years.
Computer systems can add new levels of sophistication to facility warning
systems, but conventional systems should not be replaced until the more-
modern systems have proven their reliability.
SURVEY RESULTS
All but the smallest (e.g., less than 1 mgd) wastewater-treatment plants
had central control rooms. The older facilities reflected the concepts
of their times; whereas, the newer plants utilized the latest in central
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control layout, design and displays. Since industrialized central-control
technology and equipment is directly applicable to wastewater-treatment
facilities, wastewater activities can benefit from presently available,
central control devices. Because of the lack of some measuring devices,
central control may be less useful than it is in other industries. Central
control is, however, one of the areas of instrumentation and automation
that can be definitely justified on the basis of operating and labor cost
savings.
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SECTION VIII
COMPUTER CONTROL
COMPUTER APPLICATIONS
Computers are automatic devices capable of performing calculations and
logic operations at very high speeds. A list of tasks addressable to modern
computers seems almost endless, but as applied in wastewater-treatrnent
plants, computers are used primarily for three operations:
Data logging
Direct digital control (DDC)
Digital supervisory set point control (DSSC)
To realize the economic potential of computerization, project and plant
managers must properly match computer specifications to the application's
needs. In order to clarify the role of selection of computer systems in
wastewater-treatment projects, a brief discussion of computer function and
appropriate hardware follows.
AVAILABLE COMPUTERS
With the explosive growth and revolution in the computer hardware industry,
descriptive material is practically outdated before it is printed.
Computers, however, will probably continue to be classified as either
micro, mini, or large scale (occasionally termed "maxi"). These three
classifications are strictly arbitrary, however, and are frequently very mis-
leading to someone who does not closely follow the rapid advances in this
field. Core size, flexibility and cost are the principal bases for classi-
fication. As currently defined, microcomputers (increasingly referred to as
"microprocessors" by the control engineering profession) characteristically
possess 1 to 2K (K = 1,000 words) core sizes, and they cost approximately
$1,200 to $2,000, exclusive of software expenses. Auxiliary equipment, other
than analog-to-digital (A/D) converters, are not ordinarily used with micro-
computers. For limited applications, both the low cost and remarkably small
size of the microcomputer are encouraging the widespread adoption of
"distributed control", wherein several dedicated microcomputers are dis-
tributed over a wide area (where they are used for "local" control of
several unit operations), but yet they are all supervised by a larger,
centrally located computer.
Minicomputers are customarily used as dedicated machines that are
programmed in assembly language, but more sophisticated languages such
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as Fortran are also available. Although reprogramming can be difficult,
a knowledgeable programmer can make on-line changes. Minicomputers usually
are equipped with teletype and A/D converters; more-elaborate systems use
off-line storage devices, cathode ray tube (CRT) displays, paper tape,
and other input/output devices. Core sizes can range from 16K to 32K,
although 16K seems adequate for most installations. Typical micro-
computers systems cost $22,000 to $60,000 without software.
Large-scale systems provide maximum flexibility since all program changes
are implemented by means of a user-oriented language such as Fortran.
Smaller computers often employ less-user-oriented languages, although this
situation is rapidly changing. Additionally, large systems are furnished
with core storage in excess of 100K. Representative configurations utilize
teletypes, input/output devices, CRT displays, and external memory such as
disks or drums. Large-scale systems sell for upwards of $100,000.
DATA LOGGERS
Data loggers record, in an organized format and at regular intervals, the
important process variables and key equipment states. Except for special
cases, most data loggers employ inexpensive micro-type computers in con-
junction with A/D converters, teletype recording devices, and paper tape
punches. The accumulated data can be subsequently processed into a usable
operating report and/or lists of anticipated maintenance tasks. Data logging
systems sell for $5,000 to $50,000, depending upon the auxiliary equipment.
Simple data loggers may be advisable for plants in excess of 5 mgd when a
large amount of process and operating equipment data are available. Access
to an off-line large-scale computer for data reduction makes data logging
even more attractive.
DIRECT DIGITAL CONTROL (DDC)
Digital controllers, frequently referred to as direct digital controllers,
receive information about the process from on-line instruments at regular
intervals. From this data, a programmed control strategy (algorithm)
determines a control action which is sent directly to the final control
element for execution. Direct digital control usually involves a mini-
computer since large-scale systems usually cost too much and since micro-
computers lack sufficient flexibility. Digital control, unlike data logging,
places the computer in an active role in the facility operation; conse-
quently, back-up provisions must be available for plant operation during
computer downtime periods. Since back-up provisions may include manual,
analog, or a second digital computer, total computerization costs are
difficult to estimate, but computer main frames with auxiliary devices sold
for about $100,000 in 1973. If the basic programs have already been
developed, software costs about 20 to 25% of the hardware costs; otherwise,
software cost often exceeds hardware cost since new program development
(like all development projects requiring large expenditures for highly
qualified personnel) usually is expensive. Computer control is most easily
justified for large (i.e., greater than 50-mgd) plants where process
improvements and cost reductions of 3 to 5% offset computerization expenses.
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DIGITAL SUPERVISORY SET POINT CONTROL (DSSC)
Digital supervisory control computers monitor all available process
variables, key equipment status, and all other relevant data such as rainfall,
ambient temperature and receiving water quality. The basic objectives of
supervisory computer control involves analyzing all available data, and
determining the best operating strategy for achieving the facility's goals.
Supervisory control thus involves the total plant. This broader scope of
treatment-plant control frequently includes cost-saving sub-system optimi-
zation strategies. Sometimes, a portion of the computer's control strategy
is automatically implemented by instructions to analog loops or by direct
digital control (or by both). Other methods of supervisory computer control
generate instructions for the operator so that he can evaluate the wisdom
of the recommended strategy prior to any action. Computerized supervisory
controllers can also track running time of all major equipment, and publish
periodic maintenance schedules. Off-line computations, inventory control,
manpower requirements and statistical trend analyses can also be success-
fully addressed by supervisory computers. These devices, moreover, can be
programmed to generate monthly reports. Because of the inherent flexibility
and multiplicity of functions, automatic supervisory control requires a large-
scale computer system which costs about $230,000 (1973) for hardware.
Systems analysis, process investigation, software generation and training
expenses add another 30 to 50% of hardware costs.
Because of the high cost, supervisory computers can best be justified for
very large plants or sewer districts (i.e., greater than 100 mgd) where
process improvements, labor savings, and reduced operating costs (all
directly assignable to the supervisory computer) offset the computer costs.
On the other hand, if a large number of stations must be modulated, such as
in stormwater-overflow regulation, or if it is difficult for the operating
personnel to assimilate all the pertinent data and make operating
calculations, then it is also possible to justify a supervisory computer.
SURVEY FINDINGS
The survey team encountered ten computers in the fifty wastewater-treatment
plants. Four facilities used small computers for automatic data acquisition.
Over ninety percent of the users of automatic data loggers considered their
data-gathering devices acceptable.
Only two digital process-control computers were identified and both of them
performed satisfactorily. Unfortunately, no process-improvement or cost-
saving data were available.
Four large-scale computer systems were observed in the surveyed plants; two
of them were used as off-line computation devices, and the other two as
automatic supervisory controllers for stormwater-overflow regulation. All
of the large-scale computer systems performed satisfactorily.
Although computer control of wastewater-treatment facilities has received
considerable attention in the literature , most dry-weather treatment
80
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plants that had a computer used it as a simple data logger. No dry-weather
treatment facility, with a computer controlling a large part of the
treatment processes, was in operation during 1973. For storm- and combined-
sewage overflow control, process and supervisory control computers clearly
demonstrated their benefits by significantly reducing manpower and the
percentage of overflow events. Computers are successful for stormwater
control because sewer hydraulics and dynamics, although quite complex, are
well known and readily described by mathematical models. Additionally,
suitable physical-type sensors (e.g., liquid level detectors, position
indicators, and flow meters) are presently available to guide computer-
control efforts.
For example, a typical overflow-regulator station, as shown in Figure 16,
transmits combined-sewage level signals from the trunks and interceptor, as
well as from the outfall that is receiving water-level signals, to a central
computer. In the computer, level and rainfall data are put into programmed
hydraulic and hydrologic models, and a set point command is issued by the
computer to raise or lower the regulator and tide gates in such a manner as
to use the maximum storage capacities of the trunks and interceptors
without causing flooding conditions. The regulator- and tide-gate set
point commands are telemetered to the regulator station from where
position-feedback controllers raise or lower the regulator gates and tide
gates. One supervisory stormwater-control system visited during the survey
reduced overflow events by 52%.
Lack of adequate process models and suitable analytical sensors has greatly
impeded field demonstrations of the desirability of dry-weather computer
process control. Digital process and supervisory control computers have
proven their reliability and suitability elsewhere, but without appropriate
analytical devices, computers cannot improve wastewater-treatment efficiency
and reliability. Several computerized dry-weather treatment plants are
currently being started up, but meaningful performance data were still not
available as of the date this survey was cleared for publication.
81
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IV
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SECTION IX
MANPOWER REQUIREMENTS FOR
INSTRUMENT MAINTENANCE & CALIBRATION
To be successful, the instruments and automatic control devices employed in
any process must be suitably maintained and calibrated. Too often, plant
operators and administrators are not adequately informed of the man-hours and
levels of skill necessary to maintain their instruments properly.
Characteristically, operating personnel soon become disenchanted with
instrument performance, and subsequently the instruments are discarded or
abandoned. Although instruments can be abandoned for several reasons,
fairly high rates for some devices (such as sludge density meters) seem to
be due directly to the severity of maintenance problems. Because of the
fouling nature of wastewaters (grease coatings, biological growths, and
slime), the measuring devices which directly contact wastewater or sludge
require a large amount of maintenance. A recent study 9 of industrial
maintenance showed that sensors, analyzers, monitors and other on-line
measuring devices require an order of magnitude more maintenance than trans-
mitters, indicators, recorders, and final control elements, even for "non-
fouling" service encironments. For these reasons, this section will discuss
the maintenance skills, maintenance frequencies, mean-time-between-failure,
and life expectancies associated with sensors and measuring devices observed
during the plant survey.
SKILL LEVELS
Satisfactory instrument performance depends on the availability of adequately
trained instrument technicians. Clearly, the level of skill necessary to
inspect and clean a bubbler tube is different from the training needed to
service a chlorine gas detector. Because no distinguishing classifications
for instrument-maintenance skills exist, the survey engineers who are familiar
with wastewater treatment and instrumentation proposed the following
arbitrary listing of levels:
Level 1 - A plant operator without any training in instrumentation
Level 2 - A skilled mechanic, or electrician, whose ability is
limited to electro-mechanical repairs
Level 3 - An apprentice instrument technician who is capable of
executing routine maintenance for conventional analog instruments
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Level 4 - The equivalent of an industrial instrument technician
who is proficient in instrument calibration, tuning, and repairs
Level 5 - In most cases a high school graduate, with highly
specialized advanced training, who is qualified to maintain
complex instruments, automatic devices, and digital computers (or
to program digital computers).
The required level of skill for each plant was based on installed instrument
complexity, not on process or plant complexity. For example, a primary
treatment plant may use a high degree of continuous analyses and computer
control. Accordingly, this facility would require highly trained instrument
specialists for proper maintenance. On the other hand, a secondary plant.
may only use simple instruments which can be readily maintained by a low-
level instrument technician. In any plant, the instrument maintenance group
will contain a mixture of skill levels; but for this survey's purposes, the
highest level of skill necessary to supervise the group's activities is
listed. The survey team evaluated the maintenance requirements in detail
for each type of measuring device encountered; Table 8 summarizes this
evaluation.
Table 8.
SKILL-LEVEL DISTRIBUTION
Skill Level:
Percent of Plants that
require this level:
Percent of Plants that
actually have this
level available:
8
10
15
46
44
41
33
0
From the distribution of skill levels shown above, none of the surveyed
facilities could perform adequate instrument maintenance with only a level-1
instrument group, but 8% of the plants have maintenance personnel who are
unfamiliar with the basic principles of conventional process-measuring
instruments and analog controllers. Available maintenance skills agreed
more closely with the facilities' true needs for skill levels 2, 3 and 4.
Only 3% of the plants required a level-5 instrument group. Most of those
facilities had supervisory computer control and used outside contract
maintenance for their specialized maintenance needs.
Eighty-seven percent of the plants needed experienced level-3 and level-4
instrument technicians, and about 77% of the facilities indeed employed level-
3 and level-4 technicians. Accordingly, a large percentage of wastewater-
treatment facilities have adequately trained instrument-maintenance staffs.
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Instruments fail because of external and inherent causes. Causes of
external failures include environmental factors (such as corrosion and
signal interference), hostile process conditions (probe fouling), and inter-
actions with other utilities (line-noise effects and dirty instrument air).
Initial failures, wear-out failures, and random failures account for the so-
called inherent causes. Proper instrument design and appropriate instrument
maintenance minimize failures due to external factors, while preinstallation
testing and scheduled replacement can prevent most initial and wear-out
failures; however, random failures occur unpredictably. For this reason,
resident or short-notice contract-maintenance manpower should be available.
The instrument-maintenance staff, in addition to correcting failures, must
calibrate the instruments to keep their performance within specified limits.
In short, the instrument-maintenance group's mission encompasses repair tasks
(breakdown "maintenance"), preventive maintenance, and calibration chores.
Most wastewater-treatment facilities keep inadequate instrument-maintenance
records. Rather than anticipating maintenance requirements by accumulating
statistics and costs for instrument repairs and calibration services, they
have relied on intuitive judgments. Consequently, only a few facilities
could supply statistically supportable, maintenance-requirement data.
Using the information gathered during the interviews, and instrument
conditions observed in the plant inspections, the survey team prepared
Table 1 (Page 7) which describes the median maintenance requirements for
the important measuring devices. Reliability information (mean-time-between-
failures), life-expectancy data, and cost estimates are also listed.
A comparable survey of industrial instruments gives typical maintenance
requirements for non-fouling services; these are also listed in Table 1
for comparison purposes. In general, the wastewater and industrial
maintenance requirements agree, except where fouling is a major problem.
Industry appears more sensitive to the dangers from explosive gases
since it spends four times as much for servicing explosive gas detectors as
the wastewater-treatment industry spends.
To enjoy the benefits of instrumentation, plant management must be prepared
to supply enough skilled manpower for proper maintenance and calibration.
During the instrument planning stages, maintenance requirements must be
appraised since instrument failure frequency, as measured by mean-time-
between-fallures (MTBF), ranges from one month to ten years depending upon
the device and service. If an instrument is essential for plant operation
and it has a low MTBF, serious consideration should be given to using back-up
instruments. Failures of the less critical instruments may temporarily
impair treatment efficiency or increase operational manpower burdens;
nevertheless, the plant would continue to operate and back-up instruments
would not be required.
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SECTION X
REFERENCES
1. "Environmental Quality," Fourth Annual Report of the Council on
Environmental Quality (September 1973).
2. Anderson, J., "Sewer and Plant Automation," Water Research, 6^, 611-615
(1972). ~
3. Molvar, A.E. and Roesler, J., "Selected Abstracts for Instrumentation
and Automation of Wastewater Treatment Facilities," Natl. Tech. Infor.
Ser., Accessn. No. PB-225 520/6 AS (1973).
4. Smith, R., "Wastewater Treatment Plant Control," Twelfth Joint Automatic
Control Conference of the American Automatic Control Council,
Washington University, St. Louis (August 1971).
5. "Process Design Manual for Upgrading Existing Wastewater Treatment
Plants" Environmental Protection Agency, Office of Technology
Transfer (October 1971).
6. "Cost Effectiveness and Clean Water, Volume II," Environmental
Protection Agency, Water Quality Office (March 1971).
7. Kollar, K. L. and Youngwirth, W. G., "A Growing Market for Water and
Wastewater Treatment," Water and Sewage Works, 1T7_, 9, 319 (September 1970)
8. Liptak, B. G., "Cost of Process Instruments," Chemical Engineering, 77,
19, 60-76 (September 1970).
9. Upfold, A. T., "Manhour Ratings Standardized for Instrument Maintenance,"
Instrumentation Technology, 18, 2, 46 (February 1971).
10. Spink, L. K. , "Principles and Practice of Flow Meter Engineering,"
Foxboro Co., Foxboro, Mass. (1972).
11. Liptak, B. G., "Instrument Engineers Handbook," Chilton Book Co.,
Radnor, Pa. (1969).
12. Ryder, R. A., "Dissolved Oxygen Control in Activated Sludge." Proc 24th
Ind. Waste Conf., Purdue Univ., 238-253 (May 1969),
86
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13. Daily, "Monitoring Toxic and Flammable Hazards," Instrumentation
Technology. 20_, 2, 23 (February 1973),
14. Metcalf and Eddy, "Wastewater Engineering," McGraw-Hill, New York (1972)
15. Shinskey, F. G., "Process Control Systems," McGraw-Hill, New York,
p, 147 (1967).
16. White, G, C., "Handbook of Chlorination," Van Nostrand-Reinhold Co.,
New York (1972).
17. Carroll, L. J., "Closed Loop Chlorination Control," Jour. San. Eng.
Div., Amer. Soc. Civil Engr., 9^, SA2, 51-57 (1966).
18. Shelly, P. E. and Kirkpatrick, G. A., "An Assessment of Automatic
Sewer Flow Samplers," Environmental Protection Technology Series,
EPA-R2-73-261 (June 1973).
19. Babcock, R. H., "Instrumentation and Control in Water Supply and Waste-
water Disposal," R. H. Donnelley Corp., New York (1968).
20. Instrument Society of America Standard RP18.1
21. Brouzes, P., "Automated Activated Sludge Plants with Respiratory
Metabolism Control," Advances in Water Pollution Research, Proceedings
Fourth International Conference on Water Pollution Research, London,
(1968).
22. Sewerage Commission, City of Milwaukee, "Wastewater Flow Measurements
Using Ultrasound," 11024 FVQ (Draft Report in the process of review).
23. Gushing Engineering, "Development of Electromagnetic Flowmeter for
Combined Sewers," Environmental Protection Agency, Contract No.
68-03-0341.
24. Hydrospace Challenger, Inc., "An Assessment of Automatic Sewer Flow
Samplers," Environmental Protection Technology Series, EPA-R2-73-261.
87
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APPENDIX A
DEFINITIONS AND INSTRUMENTATION SYMBOLS
DEFINITIONS
Accuracy
The conformity of an indicated value to an accepted standard or true
value . High accuracy is a desirable characteristic of a measuring
system, but repeatability is even more important when automatic control is
considered. "Accuracy is a static characteristic relating to the manner
in which a measurement is made and to the quality of the equipment,. Repro-
ducibility is the degree of closeness with which the same value of a
variable may be measured over a period of time. The periodic checking and
maintenance of a control system are generally for the purpose of obtaining
reproducibility rather than for determining the static error (i.e.,
accuracy) of indication" .
Analytical Sensor
A measuring device, or primary element, whose operation derives from
chemical, physical, or other analytical principles.
Cascade Control (Figure A-l)
A control action in which the output of the controller adjusts the set
point for another controller . For example, the flowrate through a
pump can be measured and controlled to satisfy the demand of a level con-
troller; see Figure A-l where the set point of FRC-1 is adjusted by the
output of LIC-1. Other examples of 2-loop cascade control are chlorination
rate varied in ratio to final effluent flowrate with the ratio adjusted
(or "trimmed") by residual chlorine measurement, and air flow varied in
ratio to effluent throughput rate, and the ratio adjusted (or "trimmed") by
a dissolved oxygen controller.
Central, or Centralized, Control
The centralized grouping of multiple readouts (display and recordings) and
control means to facilitate management of processes. Centralized control,
usually located in a specially designed control room, improves the
effectiveness and efficiency of human operators and thus simplifies control;
its success depends on well-performing sensors, transmitters, the centralized
readout and control units, and remote actuators.
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Closed-Loop
A signal path that includes a forward segment, a feedback segment and a sum-
ming point, thus forming a closed circuit A~3f jn the usual configuration,
the forward segment extends from the controller to the final control element
and thus to the process; the feedback segment extends from the process, by
way of the primary element (sensor), back to the controller, whereupon the
summing junction (in the controller) compares the feedback signal with the
setpoint to determine if automatic readjustment of the final control element
is needed and, if so, how much.
Computer
Practical process computers, which are electronic digital or analog
devices, automatically perform calculations and logic operations. A
digital computer is usually designed in a manner similar to a calculator
with memory, internal control (via the central processing unit or CPU),
arithmetic, logic, and input/output (I/O) facilities. Digital computers,
the most popular type of electronic data processing machine, are classified
as large-scale computers, minicomputers, or microcomputers according to
memory size, speed, flexibility and cost. A further classification can
be made based upon whether a computer is a general-purpose machine or a
dedicated machine.
Controller
A device which has an output that can be varied to maintain a controlled
variable in a specified manner. An automatic controller varies its output
automatically in response to a direct or indirect input of a measured pro-
cess variable. A manual controller is a manual-loading station, and its
output is not necessarily dependent on a measured process variable because
this output can be varied only by manual adjustment A-4. In practice,
controllers usually have pneumatic or electric outputs for directing final
control elements.
Data Center
The term "Data Center", as used in this report, refers to stormwater
collection' and handling systems - not to the automatic data-acquisition and
data—handling activities of wastewater-treatment plants. These latter
activities have already been clearly defLned and thoroughly described in
Section VIII, "Computer Control", of the main text.
Stormwater data centers are usually begun as passive, off-line, data-
collection systems for logging precipitation rates, sewer levels, sewer
flows, gate position, etc., as a function of time. Active on-line centers
can then be set up to control the disposition of stormwater for an extended
area. Other data centers also exist to collect outlying sewage flowrates
for billing purposes and the like.
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Down-Time
The time duration that a machine or device is inactive during normal oper-
ating hours, usually because it is incapable of adequately performing its
prescribed function. Down-time can be scheduled for normal maintenance,
however, as well as an unscheduled occurence due to failure. Freedom from
down-time often characterizes a device's reliability.
Down-Time Frequency
See mean time between failures, MTBF.
Electronic
A term relating to the behavior of electrons, as in solid-state or vacuum-
tube devices; this term now covers electric systems as well. Electronic
intra-plant signals between instruments are usually standardized as 1 to
5 volts dc, or as 4 to 20 (or 10 to 50) milliamperes dc, in each case repre-
senting 0 to 100% of measurement.
Feedback
A control strategy in which a measured process variable is compared to its
desired value (the setpoint) to produce an error signal that is utilized
by a controller in an effort to reduce the magnitude of the error. Because
feedback systems act on errors incurred, some tolerance for minor errors
(or noise) must be "built into" the feedback system to prevent undesirable
overcontrol which would otherwise be occuring almost constantly as a result
of normal, but minor, disturbances or pertubations in the system.
Feed-Forward
A control strategy in which advance information concerning conditions that
can disturb the process is converted into corrective control action that
is then applied to minimize deviations of the process before these
deviations become significant. Since feed-forward control schemes mathe-
matically mimic the process to anticipate the effects of disturbances, it is
theoretically possible to have almost perfect control; an accurate process
model, however, is rarely available. Instead feed-forward control can be
effectively combined with feed-back control to generate satisfactory correct-
ive control actions.
Final Control Element
The device that directly changes the value of the manipulated variable of a
control loop A~4. The final control element in wastewater treatment is
commonly a pump or control valve.
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Graphic Panel
A panelboard on which the instruments are arranged to conform with a
graphic or pictorial representation of the process. Graphic panels are
practical when good, miniature, panel instruments are available. A semi-
graphic panel uses a process pictorial in close conjunction with instru-
ments mounted in a regular array A-5_
Instrument
A device used directly or indirectly to measure or control a variable, or
both. The term includes control valves, relief valves, and electrical
devices such as annunciators and pushbuttons. The term does not apply
to parts (e.g., a receiver bellows or a resistor) that are internal
components of an instrument A-4_
Level of Skill
The survey engineers, who are familiar with wastewater treatment and instru-
mentation, proposed the following level of skills:
Level 1 - a plant operator without any training in instrumentation,
whose ability is limited to inspection and cleaning tasks.
Level 2 - a skilled mechanic, or electrician, who is limited to
electromechanical repairs.
Level 3 - an apprentice instrument technician, capable of executing
routine maintenance for conventional analog instruments.
Level 4 - the equivalent of an industrial instrument technician; an
individual who is proficient in instrument calibration, tuning, and
repairs.
Level 5 - in most cases a full technician, with highly specialized
advanced training, who is qualified to maintain complex instruments
or automatic devices such as digital computers.
MTBF (Mean Time Between Failures)
The statistically-derived time that can be expected between failures of a
device when used in the service for which the MTBF was derived. It is the
reciprocal of the unscheduled down-time frequency.
Noise
The unwanted component of a signal or variable which obscures the infor-
mational content . It is highly desirable to have a large signal-to-
noise ratio. Sometimes a suitable filter can reject noise and recover
information that would otherwise be unreliable.
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Open Loop
A" 3
A signal path without feedback . An example of open-loop control is
simple chlorination, where the chlorinator is paced by a flow signal.
Since the loop is open, the ratio of chlorine flowrate to the main process
flowrate must be periodically readjusted manually to maintain the desired
residual. A residual chlorine analyzer could be used to close the loop
(See, for example, Figure A-l).
Fixed program control and remote manual control are also examples of
open-loop control.
Primary Element
Sensing element, or sensor. The instrument-system element that quantita-
tively converts measured variable energy into a form suitable for measure-
ment A~l.
(Also see Transmitter)
Pneumatic
Reference to the use of compressed air for providing power for control (or
control-loop) devices, and for signal transmission. Commercial, pneumatic,
instrument signals are based on a 3- to 15-psi range, corresponding to 0 to
100% of measurement.
Process
Any operation or sequence of operations involving a change of energy,
composition, dimension, or other property that may be defined with respect
to a datum A-4_
Process Variable
Any variable property of a process A~^.
Ratio Control
A-l
A control action that maintains a predetermined ratio between variables
Simple ratio control is usually found in open loops. In flow-ratio control,
(often called chemical pacing in water treatment), the "slave" flow delivered
by chemical-feeder pumps is maintained in ratio to a "master" process-
throughput flow. Chlorination control via flow-ratio control is another
example of open-loop control. The addition of a continuous residual
chlorine analyzer, however, provides a feedback signal to make the system
closed-loop. The combination of flow-ratio control with residual chlorine
measurements may be regarded as a feed-forward feedback loop because it
anticipates (i.e., it feeds forward) changes in flowrate and also employs
chlorine-residual feedback information for high accuracy.
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Reliability
A measure of the ability of a system or device to function properly in its
assigned role for a predetermined period of time. See Down-time and MTBF.
Repeatability
The degree of agreement among repeated measurements under the same con-
ditions. In continuous operation and control, good repeatability is com-
parable to a "low-noise" signal and also indicates low drift. For process-
control purposes, repeatability is usually more important than accuracy.
Response Time
The time interval from the occurrence of a step change in sample concen-
tration at the instrument's sample inlet to attainment of a preselected
fraction, or percentage, of the ultimate recorded output; in this report,
response time is usually assumed to be 90% of the ultimate recorded output.
Sensor
(See Primary Element).
Storm-Flow (Wet-Weather) Treatment Facility
A structure dedicated to the treatment of stormwater and combined sewage
during storm events prior to discharge to receiving waters. These
facilities are only operational during storm events, and they frequently
utilize liquid-solid separation techniques and disinfection. Some authors
refer to these facilities as satellite, or auxiliary, excess-flow plants.
Transmitter
A device that senses a process variable through the medium of a primary
element, and that has an output whose steady-state value varies only as a
predetermined function of the process variable. The primary element may or
may not be integral with the transmitter.
INSTRUMENTATION SYMBOLS
The application of instruments and control devices to production facilities
has become a highly organized engineering discipline in several industries.
A body of symbols, abbreviations, and specifications is standardized by A_^
ISA Standards Committee No. SP 5.1 of the Instrument Society of America ,
and these are generally practiced. The engineering function of such symbols,
etc., has also become generally standardized. ISA symbols, as used in the
Survey, are shown in Figure A-2, while Instrument Abbreviations are shown in
Table A-l.
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INSTRUMENT SYMBOLS
or
M
WATER SURFACE
ANY PUMP
BLOWER
SCREEN
SLUICE GATE
CHECK (FLAP) VALVE
BUTTERFLY VALVE
ANY VALVE
DIAPH. ACTUATOR
SOLENOID ACT.
HANDWHEEL ACT.
ADJUST. OR VARIABLE
Q-
ELECTRIC MOTOR
HYDRAULIC DRIVE
AIR PURGE. UNIT
WEIR
FLUME
VENTURI OR FLOW TUBE
ORIFICE PLATE
POS. DISPL. METER
PITOT TUBE
FILLED CAPILLARY
TEMP. SENSOR
ELECTRIC LINE
PNEU. LINE (3-15 PSI)
INSTRUMENT IDENTIFICATION
LOCATION
BEHIND PANEL
ON PANEL
ON AUX. PANEL
LOOP NO.
ASSIGNED
BY ENGINEER
FUNCTION
SEE TABLE - 1
(NONE) - FIELD
= TWO INSTR'SIN ONE
Figure A - 2 ISA symbols
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Table A-l. INSTRUMENT ABBREVIATIONS
EXAMPLE IDENTIFICATION LETTERS FOR INSTRUMENT "BALLOONS" - -
A typical tag for a Flow Indicating Controller FIC-3A, can be deciphered
as follows:
second
letter.
F
first
letter
Measured or
Initial, Variable
A Analysis (1)
B Burner (flame)
C Conductivity (Electrical)
D Density or SP. GR.
E Voltage (EMF)
F Flowrate
H Hand (Manually Initiated)
I Current (Electrical)
J Power
K Time or Time Schedule
L Level
M Moisture or Humidity
N Special (3)
P Pressure (Vac.)
Q Quantity or Event
R Radioactivity
S Speed or Frequency
T Temperature
U Multivariable
V Viscosity
W Weight or Force
X Special (3)
Y Special (3)
Z Position
Differential
Ratio or
fraction (2)
Instrument
""^Function
Alarm
Special (3)
Control (controller)
Primary element
Scan
Special (3)
Totalize or
Safety
Special (3)
High
Indicate
Control Station
Low or Light (Pilot)
Middle or Intermediate
Special (3)
Point (test connection)
Integrate -
Record or Print (4)
Switch
Transmit
Multifunction
Valve, Damper or Louver
Well
Special (3)
Relay or Compute
Drive, Actuate, or Unclassi-
fied Final Control Element
(1) Type of analysis to be defined outside baloon as: pH, ORP, D.O.
(dissolved oxygen), R.C. (residual chlorine), TURB (turbidity), etc.
(2) As a modifying letter to designate (fraction) ratio; i.e. FFIC - Flow
Ratio Indicating Controller.
(3) As defined in Instrument List of each job.
(4) Or printer.
96
-------
BIBLIOGRAPHY
FOR
APPENDIX A
A-l. Scientific Apparatus Makers Association (SAMA), Standard No. PMC 20-2
(1970).
A-2. Eckman, D. P., "Principles of Industrial Process Control," John Wiley
& Sons, New York (1948).
A-3. American National Standards Institute, Standard No. C85.1 (1963).
A-4. Instrument Society of America, Standard No. ISA-5.1 (1973).
A-5. Considine, D.M., "Process Instruments and Controls Handbook", 2d ed.,
McGraw-Hill, New York (1974).
97
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• s
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-------
APPENDIX C
PLANT SURVEY DATA AND
INSTRUMENTATION SCHEMATIC DIAGRAMS
125
-------
GENERAL SURVEY QUESTIONNAIRE
OMB No 158-S72006
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Facility Ownership ind Address A-l
Responsible Supervisor
Flow Rate Design (Average and Maximum) 23-25 mgd (85 mgd by-passed)
Storm Water Collection and Treatment None (Sanitary sewage plus infiltration)
Type of Flint Description of r realm en I Process (Attach thematic diagram for
Primary
Performance Data (Individual Units and Overall)
•ring and Control systems )
YewBuut 1966
Ong,rulCoSt $5M
Mediations (Year and Description) Extensive process improvements by operating dept.
Modification Cost
instrumentation Minimal, much abandoned after plant start-up
Equipment Mag. Flow, sludge density
Finds Local
Installation and Stan up Costs Original Cost Total Cos
Instrumentation Modification
Desinptioi
Type
Process Control
Data Logging
S.orage
Softwue Description
CoiwuurCo.1
Parameter Frequency
Pa.imeler/Ftequency
Central Control None
Supervisory Control No
Alirm uid Safety Systems Local
In it. air from plant air compressor
Standby Diesels
MiintcMnce ind Calibration
Special Equipment By city, Off-site
Sptml Operaioi Tr.mmg None
Total In Flint Man Hours'> ear
Told Cost of Oulnde ServKe
Frequent (no mo I
b&limate of Over-all Benefit-, of Instrument Hun and AutomatKin
Typical wet-well level control and burner controls are indispensible.
126
A-l
-------
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-------
GENERAL SURVEY QUESTIONNAIRE
For in •pprovwJ
OMB No 158S72005
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Facility Ownership and Addre^ A-2
Responsible Supervisor
Ho* Ran. Design [Average and Maximum! 60 t't&d design, ^0 avg . , 120 mgd peak
imrm Water Colletuon and Treainient Onlv by way of regulators and Interceptors
I Performajut Ojia [individual i'mis and (KeriMt BOD 54% removal Note : Local lime plant also drains to plant, improves efficiency .
SS 76£ removal
V'earBmli 19n8
i
j Original ( jn $7i,l
Modifications (year and Dtwriplion) 1973 - Secondary
irisinimencition Honeywell, W & 1, F & P
j [quipmt.ni ! lov anu chlorination, sludge solids, etc.
Panels Lirge s^mi-^raphic display, central control console
Installation and Start up i i>,(i T^Ulp , ~ S-OOK Ufigm.il tost
ln«nnmen(.llion Mudifn i
t om pu le
Type
Prote-aContiol
Parameter'Frequency
Pa ram e tcr' Freq u e ncy
Software Dcs
Installation Cost
Tt-ndaJ < onlrot
Supervisory Ctintroi
Aiarrn ind Safely Sy,
Yes
f \ut ,T,»I(. hm-rgcu.y Program (eg. Power I aiJure; Standby generator handles entire plant.
Maintenance Jnd tal|hraln>n Inst . Shop .
ipeuai tquipmem Pneu. 1 oop checKer, manometer s , Down Time None
standard mv source, VOM, mag. meter checker
Spu ill Operalnr framing Frequeniy (no ;mo )
I Inst. man ;3 tech. school graduate w/ experience -
I foul In Pl.ni Man Haunt »c 2 j 00
Total cost of Out4ver all Benelir\ nt In strum en la turn and Automation
Reduced cost in the areas of chlorine addition, sludge pumping and manpover .
129
A-2
-------
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drained often, manually.
S9£
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Mech. balance servo is obsolete. Electrodes show high impedence,
scaling, are inaccessible.
s^A
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£ 1 J
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Records and controls. Checked by titration every other hour. Drifts
due to probe fouling. Reagent handling and corrosion are problems.
(W S T Titrator A790012)
S3A
ajdraEg
X5+
i
Demonstration unit proved that ORP could be used to indicate over and
under chlorine dosage, approximately, but inst. maint . (esp. cell
filling) excessive and awkward.
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LVDT type transmitter in conventional chiorldaLur to local
retransmitter .
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Otherwise, good. Uses source decay timer.
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*•• Local and centra)
130
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131
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132
-------
GENERAL SURVEY QUESTIONNAIRE
Form approved
OMB No 158-S720O5
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Facility Ownership and Address A-3
Responsible Supervisor
Flow Rate Design (Average and Maximum) 50 mgd (Ave. ) 170 mgd (Max.)
Storm Water Collection and Treatment Combined Sewer System
Type of Plant Description of Treatment Process (Attach schematic diagram for process monitoring and control systems )
Primary, with Chemical Precipitation (Seasonal - Lime and Ferric sulfate)
Performance Data (Individual Units and Overall I
55% S.S. 25% BOD Removal (using Polymers)
VearBuiit 1959
owl tot fill-3m (Bond Issue) ModlflcatlonCost
Modifications (Year and Description* 1963 Abandoned lime and ferric sulfate and substituted
polymer shortly after plant started.
Instrumentation
Equipment Penn, Foxboro, Bristol, Bailey
Panels FoxborO
Installation and Start up Costs Original Cost
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GENERAL SURVEY QUESTIONNAIRE
OMB No 158-S72005
STATE OF THE \RT
INSTRUMENTATION AND AUTOMATION
Facility Ownership and Addrc
Responsible Supervisor
How Rate Design (Averagt and Maximum.) 300 mgd -- maxi rum hydraulic cap
88 ragd - present average
„ ^lOQ, IPgtf - |esign average
Morro Wafer CoJJetlion and Treafineni-
The system contains about 80% combined sewers
Type of Plant Description (if Treatment Protest (Attain schenulu diagram for process monitoring anil C
Primary treatment plant with s Ludge digestion
Performance Data {Individual I'nits and Overall)
31% - overall BOD removal
59% - overall suspended solids removal
YearBu.li 1951 and 1969
OnpMlCotf $957,000
Modifica
1961 - Chlorination Facilities :.nsta31ed
1973 - Secondary Treatment Faci Li ;ies under construed on
1961 - $91,000
1973 - $16,190,000
nstrumeniatmn
Equipment Mostly electrical, some pneumatic
p No central control panel except for total flow and c lock in adirimstr at ion building.
Local control panels In screen house, sludge transfer building, sludge digestion building, chlorination
building.
Installation and Start upmost* Original 1951 cost? Original (osi I ballot!
_^ _ not available - Part of lump sum cost __ ___ _____
Description
Sludge Density Meters
for thickened sludge
Sludge Density Meters
for preheated sludge
Sludge Mass Recorder
for preheated sludge
Sewage and Sludge Metering
Cwrlw None
Type
Process Control
Data Logging
Yiar tquipmeni Panels I * S Tola!
1970 Installed slide gates and drilied holes to facilitate cleaning of
thickened sludge i rom meters
1970 Abandoned their use and operate without therr en preheated sludge
1970 Abandoned its use and operate without it
1969 $29,000
Softwue Description
Central Conlrol
Supervisory Control None
Alarm and Safety Systems Yes
Automata hmergemy Program
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158-S72005
Facility Ownership and Address A-5
Responsible Supervisor
Flow Rate Design (Average and Maximum)
Design Average - 125 ragd Max. Hydraulic Capacity - 350 mgd.
o w r- ., Present Average - 95 mgd
Storm Water CollecKon and Treatment
70% Combined 30% separate with high infiltration
Type of Plant Description of Treatment Process (Attach schema In diagram for process monitoring and control s> stems )
Primary treatment plant with sludge digestion.
35 - 40% BOD removal
65 - 70% Suspended solids removal
Year Built 1966
OngjrialCost $11.9 million
Mod.fi
Modifnation <
(Year and Description) Centrifuj'GS added - 1971
Vacuum f-.lters added - 1973
Flash mixers and post chlorination added -
$2.2 million for above modifications.
Equipment Pneumatic, electronic, mechanical
Panels, One central control panel; local control panels at clar Lf iers, digestors, effluent pumps, centrifuges,
process water pumps and chlorination. Foxboro Company $330,000
installation and Start up Costs Original COM Total t ost Minneapo 1 is Honeywel 1 $ 259,000
__ _Ta£lor _Inst£ume_nt_s $284,000
Description
Effluent Pump Control
Year bquipmenl Panels I & S
1969 Changed pneumatic Honeywell System to electronic Foxboro
(Part of general policy to convert pumping stations to
electronic in conjunction with CATAD System electronics
even though pneumatic systems were satisfactory).
Total
$1,000
Telemetry with Philco-Ford system
between computer in Metro office bui Id-
and
, Sigma II Computer located in
' MeEro office building as ,)CLweeI, tu,,,,,ui.ei 4-.. r«=i.iu Uilite uu
r^ part of CATAD System* «""—»• Xerox Data Systems .«<>-,> ing ^ prl^ter(wlth k board input
, , , , , , displayjat West Point Plant.
Process Control No direct process control. (Manual control with readout
on printer of alarms, operating data, and quality cata from
treatment plants, pumping stations and regulator stations).
Data logging of alarms, operating data and quality data of various locations.
Operating Data :
Date, time, where,
what levels, flows
Set points , etc .
Qua^ ity Data:
Date, time, whe
whal tempera turf
D.O , etc.
*Computer-Augmented Treatment
e and Disposal System.
Alarm Functions:
once every hour
storage Part of CATAD System, Frequency varies. Frequency varies.
SofiwueDesinpnor, Part of CATAD System
CompuierCost Part of CATAD SoftwareCost Part of CATAD muaiianon Cosi Part of CATAD*
West Point Terminal - $25,090 (1972) Cathode Tube Display Unit - $13,715 (1972)
Centra! Control
Supervisory Control No
Alarm and Safety Systems Yes
\jtomatic l mergency Program (eg .Power Failure) Automatic start for 3 emergency generators.
Digital Multimeter - Weston Model 1240, Density shims
Wallace & Tiernan Test Kit for Pneumatic Calibration WAA 650100;
Spend Equipment Foxboro. & Fischer and Porter Calibration Downfrne NO major instrument downtime causing plant
boxes ror magnetic meters; Wheatstone bridges;
S euaJO eratof TnrmflP0meterS ' Oscilloscope . Re n mo }
ffo1 special Training. 5n instrument specialists and 3,elec^rTc^l""
specialists maintain this plant and other plants and pump stations.
specialists maintain this plant and other pi
Total In-Plint Man Hours Year
1600 for instrument maintenance and repairs.
800 for instrument preventive maintenance and calibration.
Total Cost olOutade Serviic
Without use of instrumentation, the required number of plant personnel would increase and plant efficiency would
go down to a level where the plant would become inoperable.
142
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tried for 3 years to get them tu operate satisf ac tori! y. Tried
cleaning electrodes frequently . I ns tailed burn-out Ki ts on elect rodes
bu: burned out the probes . Replaced Teflon lining w] th porct lain.
Measure sludge by co\ er level .
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icbeivoir wa^ built for E).<', ano all electrodes. The probes still have
o be cleaned frequently.
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GENERAL SURVEY QUESTIONNAIRE
Form approved
OMB No 158-S72005
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Facility Ownership and Address A-6
Responsible Supervisor
How Rate Design (Average and Maximum) Design about 230 mgd average.
Storm Water Collection and Treatment No
100 mgd being handled with peaks about 170 mgd,
Perfoniiaiu, ^U ,!ndiv.du and Overall) 30% BOB Removal
60% SS Removal
Year Built. 1963
Gngmaitost $6.2 million
Mod.fintmn. /v^ar and D^r.prwn) 1 New Primary Digestor
MtxJiKaiurt i.<",i 51.5 million (estimated)
Equipment Control, recording and indication.
Pjnels Contrt-i
l.,Ulhl,... and Startup < o«, $25,000 eat.
slrumentation Modification Nnne
ngmai COM $300, OOOr,,uiC(»i 3325,000 to $400,000 est.
Parameler Fitquimj
Softwue Descnptio
CumpuferCou
Central Control
Supervisory Control No
Alarm and Safety SyMeros Yes - Pumps , f low, denSi tv , etc-
AutumaiK. I mt-rgL-niy Pr.jgram (L-JJ., Cower I aiiuff) Flow by gravity at plant.
Maintenance *nd ( iJihr*lwn
Speua) Equipment Typical testing equipment
Spcual OpL'rauir I ratninn Genera 1
Total In Plant Man Hour* Wa. 2600
To.a.tos.ofOu^acS^, «,000 est.
Reduces manpower .
Do»nTime Unknown
hrequenty (ni> 'mo ) Unknown
147
A-6
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158S7200S
Facility Ownership and Add re
Responsible Supervisor
Flow Rate Design (Average and Maximum) Avg , = 343 nigdj running 3 i3Q mgd
Max. = 978 mgd
Storm Water Collection and Treatment Treats Combined Wastewater
fypeof Plant Description of Treatment Process I Attain si.hem.itn. diagram lor proiev. num-Mring and uirtlrol sterns . Primary treatment - Screening and grit removal
at three remote headworks. Influent via deep rock tunnels. shaft level controlled by pumping based on telemetered
signals. Influent is pumped into settling tanks and chlor:nated. Sludge is anaerobically digested and discharged
into ocean outfall.
e Data ; Individual I mt<
BOr 29%, Sus- Sol. 46% (Removals)
Yt.rBi.iIt 1968
OnpMiroii $26,000,000
Modulations (Year and Description) Systematic (see below)
Modifk.liontoM ilO.OOO
instrumentation Telemeter, Electronic, Pneumatic
Foxboro & ITT ($1,000,000); F&P ($250,000)
i-quipm
Panels 25' central semi-graphic control panel., many Ji-cal panels.
5ns.allal.on »nd Star, up Com Ongmil t ,,»l f ,,Ul < ost $1,250, 000
Plant functions because of extensive duplication, planned
maintenance. (Pneumatic instrument troubles slight because
of quality Lnstrument air).
Instrumentation Modification
Descriptor,
Vacuurn Amplifier to
Solid State amplifiers
for mag meters
1970
Total
310,000
Compute,
Type No
Processtontfol
Data Logging
Storage
Software Descriptio
Computer Cost
Central Control Shaft levels at headworks maintained by pumping via telemeter system control
Supervisory Control No
Alarm and Safety Systems Level, temp ., engine failure, Cl^ faj lure, pump, etc .
AutomatK Lmergenty Program (eg .Power Failure) Generates own power from digester gas, purchased fuel.
Maintenance tnd t ahbrilion *
special Equipment Various gauges & electronic equipment r*..wn i .me
special Operator framing Foxboro & ITT at manufacturers' Fret-uentv (no m,> i ITT 1/tno.
facilities. F&p 1/mo_
TonllnnulMuHouilVcai 8000mh/yr
Total Cost o/Oul4deSer>
Intimate of Over all Benefit! of InMramentation and Automation
Influent pumping control essential for meeting hydraulic demands and preventing surges.
151
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154
-------
GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
OMB No 158 S72005
FtcUity Ownership tnd Address, A-D
Flow Rate Design (Average and Maximui
Stonn Water Collection and Treatment
420 ragd Average
No
720 mgd Maximum
Primary treatment; 100-MGD fixed rate to
activated sludge treatment
Y«rBu.J« 1950
Original Cost $45,000,000
dOveraio SS Removal 72.6% annually
BOD Removal 54.4% annually
Modifications (Year and Destf.ptioiD 1957 - 1960 - Added Headworks, primary settling, effluent
pumping plant, 7-Mile Sludge and 5-Mile Effluent ocean outfalls.
Modification Cost $33,000,000 1972-73 - Conversion of secondary digestion tanks and re-
build digested sludge screening facility.
simmenwiion Level, flow, residual chlorine, "digester gas flow, raw and digested, sludge flow, telemeter from out-
lying plants.
Equipment Analog control loops, process monitoring instruments, pneumatic - Honeywell, Taylor and Foxboro
PanHs Njne control, recording, alarm, and indication panels for: Headworks, Primary Settling, Secondary Treatment
Digestion (3), Eff. Pumping Plant, Power and Blower, and Shift Superintendent,
ins
n Modifies l
Description Vear Pquipment
Analog vO'itrol, process indicators, recorders, alarms
SlO,000/>ear for 22 years = $220,000
Computti
Type
Manufacturer
Planned completion July 1974
i'ODevices Remote Multiplexers (future)
installation Cost $1,100,000 including computers and software
\ium tint Safety System, Explosive gas alarm for gas compressor building, level alarms for digesters, sent to power and
blower building - man on duty 24 hours. Flow alarms sent to effluent pumping plant.
Manual transfer from plant-generated electrically to outside power utility.
me and Calibration Wheats tone bridge, osc. scope, tube tester, manometer
test gauges, dead weight tester.
istquir,mc,,i Lab. potentiometer, V.O.M. and V.T.V.M. Down Time )
) None due to instrument failure
tl Qpetator 1 raining Short COUTSeS at Honeywell and Foxboro Frequency (no /mo ) )
* Yeu 9240 (4 man-yrs)
rviic Virtually none - all done in-house
jMt_ alr ref rigcrator to remove mol3ture>
dry type compressor with teflon rings - air
also filtered through 5 micron filters.
Improved process control, monitoring, and reliability with minimum operator attendance are the main benefits
gained from instrumentation.
Present plant has about 240 personnel.
155
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Works well - Assures proper digester tank flow
distribution.
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Works wPll - Permits plant flow distribution to
3 primary settling tank batteraes - Eliminates
need for 3 (est) workmen - No major problems.
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to moisture.
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scum break up and internal heating and power.
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distribution for digester heating control.
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
[NSrR'JWENTATION AND AU TOMA1 ION
Form approved
OMB No 158S720O5
Faiility Owner^ip snj Address A-9
Responsible Supeivisor
Flow R*it Design < Average anU Maximum) 750 T,gd Avg . J 200 ^d Max.
Plant f Lows inciude intercepted storm water,
Morm Wdftr ( olletdoi. anJ Treaimem
!ype ot Pfjnl Devnpnon of Treatment
O
Primary sedimentation with polyrier and pickle liquor addition followed by chlorination.
Sludge disposal by vacuum r11trat ion and multiple hearth incineration.
individual i n.ujndoviuiij /,5 - 50? BOD reduction
60 - 701 Suspended solids
0 WodifiniiGiii(Vear ana Oes.nptiuj'i Major expansion program begun in 1968 to give greater
capacity, 2nd Treatment
" *" Modifnanoncoit jrXpanslur{ program construction costs,
_to _d.U_e j= y_05>1 _____ a _j __
Ii^chrit and Pnrter Velatro] t out rulb (local, electronic, analog; Local manual and local switchover to
.omputer contro I)
vMrii'us sites throughout plant foi local analog or manual control.
i,, Centralized, computer assisted, monitoring and control system with local analog back-up added
as pai't :>f expansion program.
>L-i, Iquipmeni panels I & S Total
197?-? 3 See oelow — $53C,000
F i P
(also Linde)
Yes
Type SC 17M (two)
On-]ine and Back-up
Pt(K
3 Videojet Printers
lufaciotcr Control Data Corp. i o Devices 2 Hazeltine 2000 CRT Terminals
4 G.E. Terminets
CRT ^ Oper. Cons.
•sstoimni Pj.ck.fe liquor and poLyinei feed, aeration tank flow & 2 Conrac Color i
level Control; final clarifier flow splitting, 1 CDC Card Bead'
chlorinated water flow splitting, process water pumping. 2 HP XY Plotter;
! P t F ' P- 'F
_.-r_^L^_|_^_^_^_
I'ala Loggyig
All otrier 11 ant. parameters
Lab Analyses
Process riOO Storing Paiamete
Out-uf-servi
12 Trend Records
I
I
oug«; j ^ ^-iTiil LLoc-woid disk drives
j.of£wutr De^r^ucn iin-ebt> MoniLormg & Control: Portran; Aurran; Data Reduction & Analysis
amputer O>M $400 ,000 boTlww f osl $129 , 000
t onit. i Graphic Panel and Computer-Assisted Operation Through CRT Oper. Console
afciv s»-ftm, Through Computer; Local On-^i Ire Alarms
Dual B.C. Power Supplies
I r.i'rgu, y t'r,,fcrani ' g I'ower I ailun-t Back-Up Power Sy-'jtemb, Dudl COntfOl Computers
ipi-u-l O
NO
al Shop Down Time None
hrequenty (nu mo) Norie
i»iii .npiari Man n-ur, V.M. None as such . Mechanicdl equipment primary. No remote control.
I oidi C osl ,*f OulsjJt Si-rvn t N/A
I stunjtir .if (ht Jil B' ndu-,i'l Insuumintalit.n jrli) Autonuliuii
Wastewat er trt?^ t merit process wi 11 be mom tored front central location thus helping to reduce manpower and increase
plant Lf f i-iei:- \ ,
161
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polymer sol'n with very good results.
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Works well in sensing sludge level in vacuum filter basin.
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Meters used only occasionally, since meter fails 4 to 6 hrs. after
cleaning electrodes.
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Old Simplex meters abandoned.
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Uses C/A thermocouples.
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tration rate.
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environment, dirty fluid.
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165
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AU TOMATION
Form approved
OMB No 158S7200S
Facility Ownership and Address B-l
Responsible Supervisor
How Rale Design (Average and Maximum) 1 mgd , max.; dry weather 0.7, infiltration (12-12-72) 1 mgd
Storm Water Collection and Treatment No
Type of Plan! Description of Treatment Protest (Attach schemata diagram for process monitoring and control systems )
Activated sludge w/aerobic digestion,
Performance DaU (Individual Units and Overall)
BOD Reduc. 95% Solids Reduc. 92%
Ve» Built 1947 (Trickle Filter) Modifications (Year and Description) 1969, Converted to act. sludge.
OnpnaltoM Mod.fkat.on Cost Approx. $1M
nstrumenuiion 3IF w/electric pulse-duration telemetering.
Equipment Flow meters, wet well level, chlorinators, D,0. probes.
Finds 1 Central indicating-totalizing panel
Installation and Start up Costs Original Cost Total ( ost
Instrumentation Modi fit a (ion No
Computer
Type NO
Process Con trot
Data Logging
Storage
Software Description
Computer Cost
Parameter/Frequency
ParaMeler/Frequeniy
Parameter /Frequency
Installation Co:
centralContiat Indication only. No control loops or automatic process control-
Supervisory Contioi
No
AJarm and Safely Systems 1 alarm (water seal pumps)
Automatic Emergency Program (e g , Power failure) None
limit nance and Calibration
Special Equipment None Down Tine None
Special Operator ruining None Frequen. y (no /mo )
Tow in-Plant Man Hours/Year All call-in (i.e., all M&C is conducted by outside personnel)
TOUI cost of Outside Service 20 hrs/mo @ S^/hr, or approx. $l,000/yr.
Estimate of Over-all Benefit;, of Instrumentation and Automata
Good operation with little manpower.
166
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158-S72005
Facility Ownership and Address B-2
Responsible Supervisor
Flow Rate Design (Average and Maximum) 6 mgd max.; running 2.2 (12-72)
Storm Water Collection and Treatment Combined sewage
Secondary, contact stabilization or extended aeration.
Performance Data (Individual Linus and Overall)
BOD removal 90-95% Settleable solids removal 75%
Vear Built 1972 Modifications (Year and Description)
Original Cost $5M
Modification Cost
utiumentation F & P electronic
Equipment
Panels Central Control with local panels
imwuttoi and start-up Costs
Or,g,nai Cos, S138K roltl Cosl S205K {including chlorinators)
Instrumentation Modification
Destriptioi
Computer None, although plant is designed to be computer compatible.
Type Manufacturer I C
Type
Process Control
Data Logging
Storage
Software DescnptK
Computer Cost
Parameter; Frequency
Paiameter/Frequency
Parameter/Frequency
Software Cos!
Cent™! Control Analog and remote manual
Supervisory Control Aeration rate and sludge return rate
AUim and Safety Systems Conventional
Automatic Emergency Program (e.g , Power Failure) No Standby generator, but tWO feeders (12KV)
Maintenance md Calibration
Special Equipment None
SpecialOpeMiwTraining, None (Instrument trainee left
position vacant)
Total In-Plant Man Hours/Yev
Total Cost of Outsdc Service
Estimate of Over all Benefits of Instrumentation and Automation
Dow. Time None
Frequency (no /mo )
170
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173
-------
GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMU No 158 S72006
Facility Ownership and Address B-3
Responsible Supervisor
Flow Raie Design (Average and Maximum) 6 mgd max. design, running 2-3 mgd
Stonn Water Collection andTreatmeni Mostly sanitary
Activated sludge (step aeration - 1.6 hr. aeration)
Performance Data (Individual Units and Overall)
BOD removal 94-98% Susp. solids removal - 97%
1961
Year Built
Original O
S2.5M
Modifications (Year and Description) 1970 Priitiary rebuilt as secondary
Modtfintionloit S5.5M
Instrumentation F & P Electronic
Equipment Density, samplers, flow, level, res, chlorine
Panels Central and local
Installation and Suit up Costs Original Cos( TulaHost §140,000 (e&t .) before installation
nstni m en UtKin Modification
£k scnp do
Computer
Type
Storage
SoftwueDestrrptM
Computer Cost
Parameter' Frequent y
Parameter Frequency
Parameter /Frequency
Parameter/Frequency
Software Cos
Stallation Cost
Central Control Pumping (effluent and sludges) and chlorinaiion rate. Local aeration control.
Supervisory Control
Alarm and Safety Systems Extensive
inIcmatic Emergency Program (e g , Power Failure) None
Maintenance and Calibration
Special Equipment Off-Site
Special Operator Framing None
Total IB-Plant Man Hours/Year 300 mh/yr.
Tola) COM of Out»de Service
Estimate of Over-all Benefits of Instrumentation and Automitioi
High performance, good labor savings.
Down T..ne None
Frequency (no/mo)
174
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reading with water. Long factory repair time.
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177
-------
GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
OMB No 158-S72006
Facility Ownership and Address g
Responsible Supervisor
Flow Rale Design (Average and M»
Storm Wafer Collection and Trealm
m) Ave. 4 mgd ; 6 ragd peak
None
Type of Plant Description of Treatment Process (Attach schematic diagram for process monitoring and control systems )
Conventional Activated Sludge Treatment followed by Oxidation Pones and Percolation Beds.
(set*-up for tertiary treatment not being used due to lack of Federal funding).
Performance Dau (Individual Units and Overall)
Average BOD Influent - 250 mg/!
BOD Effluent - 25 mg/L
Year Built 1967 ««>
Original Cost $2,224,944 Modification C
(Activated Sludge Process only)
conventional
plant only
(Year and Description)
None
or 90% BOD removal.
None
Instrumentation
Equipment Flow meter, turbidity meter, sludge density, alarms and general recorders.
Panels 4: testing, secondary, primary and blowers.
est.
Installation and Start up Cosis est. $20,000 Origin il Cost $100 , OOQoliJ Cost $120,000 est .
IIM
snUtion Modificj
Description Year
Micrometer totalizers converted 1972
from mechanical
Computer
Type
Process Control
Data Logging
Storage
Software De strip In
Computer Cost
Supervisory Control ^11 pumps and valves.
Alarm and Safety Systems Indus trial-type alarm system.
Automatic Emergency Program (eg. Power hailure) Generator f Or main pumps only .
Maintenance and ( alibration
Special Equipment Fox. Calibrator, Scope, Temp. probes Down Time
Megger multimeter
Special Operator Training tnqu;nty (no mo I
Foxboro, Taylor, Bristol, Honeywell
Total In Plant Man Hovf* Yea/
1 man.1700 hrs/yr.. available for instrument maintenance.
Total Cost of Uutade Servue
tstimate of Over all BeneHls of Inslrurnenlation and Automation
Permits operation of plant with 3 men; would require 6 to 8 -nen without use of instrumentation.
178
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183
-------
GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158-S72005
Ficility Ownership and Addre
Responsible Supervisor
Flow Rate Design (Average and Maximum)
5.0 mgd - Present Average; 5.0 mgd - Design Average; 25 mgd - max. hyd. capacity
Storm Water Collection and Treatment
The system is separated.
Type of Plant Description of Treatment Process (Attach stilt made diagram fur process monitoring and centre! systems )
Secondary treatment plant with activated sludge process and sludge dJ gestion.
Performance Data (Individual Units and Overall)
Overall BOD removal - 92%
Overall SS removal - 94%
Year Built 1965 Mod.fici
Original Cost $822,000
Modificat
Instrumentation
Equipment Mostly electrical
Panels One main central control panel, some local panels.
Installation and Start up Costs Original Cost
Controls for hydropneumatic tank & auxil $3,
Chlonnation equipment 6,
Flow metering equipment 8,
Gas control equipment & piping 3,
'-00
(1965)
(1965)
(1965)
(1965)
Instrumentation Modifkai.o
Computer
Type
Process ConireJ
Data Logging
Stotage
So ftware Desc np 110 n
Computer Cost
Parameter'Frequf
Supervisory Control None
Alarm and Safety Systems YeS
Automatic Emergency program (e g , Puwer f-ailuret Gravity flow through treatment plant continues during power failures . Portable
__ . ge.nerar.or actuated during power failures. „_.
Maintenance and C ifibritton
E^ectrica^ equipment maintained by
electricians.
Special Equi,
Special Operator Training None
Tol*l In Plant Man Hours Year 30+
Total Cost of Outside Service Minor
Down Time No plant down-time due to i nstrument down-time.
Frequency (ro mo) No down-time due to instrumentation
Lslimate of Over-all Benefitsof Instrumentation jnd Automation
More instrumentation at the plant would be desirable, such as measurement of primary am! waste sludge flow
and density. Automatic measurement of suspended solids would be helpful.
Most of the instrumentation is for record keeping and to assist in on-off operation of numps, ejectors,
compressor, etc.; would be difficult to operate without it.
184
-------
185
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jal readings of DO in aeration tanks are used
adjust the compressors. The procedure works
L, but is cumbersome— -requiring several
jstments per day, (See previous sheet)
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ial flow observations and manual adjustment of
re. A chart indicates valve position to give
red return rate. The valve has to be adjusted
4 times per shift and is time consuming.
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ial observations of sludge consistency are used
urn on pneumatic ejector. This procedure
•~s well, but requires several observations per
t and is time consuming.
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186
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187
-------
GENERAL SURVEY QUESTIONNAIRE
STATE OF THE A*T
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158-S72005
Facility Ownership and Address B-6
Responsible Supervisor
How Rate Design (Average and Maximum) 6'5 mgd average; 13,25 mgd Peak
Storm Water Collection and Treatment Combined storm-sanitary system with 5 regulator stations to divert excess flow to a river
without treatment.
TypeofPiant Descnptmn of Treatment Process (Attach schema!* d.agram for pro.es* mom.ormg and conlro! systems.) PartiaUy flow-equalized, 2-Stage hLgh-rate
Trickling Filter with PO, removal; Zimpro sludge treatment; vacuum filters for sludge dewacenng.
Performance Dita (Individual Units and Overall)
Yew Built 1963
Original Cost
InstrumeriUfion
Equipment
Panels Central Control
Installation and Start up Costs 2<4K
Modification Lost
s (Year and Description) 1971 - added PO, removal, retention basin, and Zimpro
sludge oxidation reactor.
Original Cost
Instrumenuiton Modification
Description
Mag flow meter, remote
station Telemetry,
PO, Analyzer
C.mpuln
Typ.
Process Con Uol
Data Logpng
Parameiei Frequency
Parameter i Frequent y
Paiametei/Frequency Parameter/Frequency
Software Descnption
Computer Cost
Installation Co-
entral Control
Superv.soryControl Pump stations, regulator over-flow stations, -ind essential in-plant wastewater and sludge pumps.
Alarm and Safety Systems
Automat Emergency Program (eg, Power Failure) 2 separate power feeds, & 'Stand-by generators.
Maintenance ind ( altbrafton
Special Equipment None
Special Operator Training None
Total In-Plant Man Hour'./Year 1, 000 man-hours /year
Total Cost of OutadeSemee Replacement parts
Estimate of Over-all Benefit;
fin;
The plant superintendent believes the remote control devices and the automatic control loops reduce the manpower
required to run this plant by about 50 percent. Previous experiences with analytical instruments, such as ortho-
phosphate, demonstrated that the maintenance requirements exceeded this plant's capabilities; they consider on-line
analytical sensors too unreliable for municipal treatment plants.
188
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Trickling filter recirculatzon control essential
for proper hydiaulic loading of these units.
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Because of frequent downtime and difficulty of
repair, automatic control of the vacuum filters was
abandoned. Part uf the problem was due to unavoid-
ably frequent start-up and shut-down of sludge-
dewatering operations .
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190
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191
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
B No 158 S72005
Facility Ownership and Addrev,
Responsible Supervisor
Flow Rate Design (Average and Maximum) ,
Average Design - 12 mgd Peak Design - 20 mgd U'tcess
Storm Water C0l.ec,,otedrfr§a1m^Ctt:Ual " l5 mgd Peak ACtUal ~ 2° m8d bVPassed)
None (separate system)
Secondary Treatment Plant with Actived Sludge Step Aeration- Effluent is groundwater—basin recharge.
The plant receives flow at a constant rate.
Performance Dila (Individual L'nils and Overall)
Suspended Solids - overall - 95,8% removal
BOD - overall - 96.1% removal
YewBuilt ^962
OnginalCost $1.7 million
Description* ]_963 - i if luent punps changed to variable—speed magnetic drives
1965 - primary sludge valves changed from butterfly to gate in
order to avoid p]ugging.
Instrumentation
Equipment Mostly electric, some pneumatic.
Panels Central control panel without subpanels
Installation and Start-up Costs — Original Cos
Instrumentation Modification
Description
Influert Pump Controls
Chlorine Tank Switchover
1964
1967
Bubble-tube level controls for speed control of oumps.
Automatic changeover system installed to switcrt from one chlorine storage
tank to another when chlorine runs out.
]a
Computer No
Type
Process Control: None
Data Logging: Plant operating data is phoned in to San Jose Creek daily. Monthly summary is prepared and sent
from main office to local plant . Time sharing console at San Jose plant is used for data transmission. Future
teletype is planned for surveyed plant .
Storage
Sofiwwe Desi-rtptio
Computer Cost
Installation COM
Central Control
Supervisory Control Waste sludge percentage, influent pump flow, primary sludge valve-opening schedule, and chlorin-
ation rate are set from central control panel.
Alarm and Safety SyMerns
Automatic Emergency Program (e g , Power Failure) Two tie lines, portable geierator.
Maintenance and Calibration
Spcc.a.E^p™, Ofiyi£gg°!ga ,Sf!lii|jJ*giteSttfr "an^eter,™ -m« No plan£ downtira* due to instrumentation; however,
some instrument downtime
Special Operator Training 2 hrs. per week for 4 men in the Frequent)- (no mo I -y
entire Los Angeles County Sanitation District *
Totalln-PUntManHou^/Year 6Q0 (4QO routine maintenance and 200 trouble shooting)
Total Cost of Outade Service None
Estimate of Over-all Benefits of Instrumentation and Automation
Improved plant efficiency.
Savings is required manpower (a total of 3 men run the entire plant; in case of emergency an operator can be
called in).
192
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The meters are satisfactory , There are some minor problems with
auxiliaries requiring some maintenance, particularly with switches.
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Sparling propeller meter to reduce plugging problems and because parts
are cheaper and easier to get.
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Plugging, pulsation, and foaming problems, as in the San Jose plant.
System abandoned
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flow. Residual chlorine analyzer is not in the
control loop .
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ludge blanket is made 8 times per day, requiring
5 minutes each time for operation of control
ralves. Turbidity meter was never in the control
oop.
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an be ased, since plant flow is constant.
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194
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195
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approval
OMB No 158-S72005
Facility Ownership and Address B-8
Responsible Supervisor
Flow Rate Design (Average and Maximum) 20 mgd Avg . ; 32 mgd Peak
Storm Water Collection and Treatment Some stormwater from Reno , plus Infiltration
TypeofPlant Description of Treatment Process (Attach thematic diagram for process monitoring and control systems) plug flow activated sludge With
post aeration; anaerobic sludge digestion with sludge drying beds (see attachments).
Performance Data (Individual Units and Overall)
Year Built
Original Co;
Modifications (Yen and Description)
Modification Cost
Honeywell pneumatic
Installation and Surl up C
Parshall Flumes ; level and flow measurement and control; D.O. monitoring and control; sludge density meas
s. and control.
trol room.
OngtnilCosi 155K Total Cost
with cl^rifier pump-down; Residual Cl_ meas. and control.
Panels 3Q-ft. graphic panel in central control room.
N/A
Description
Range change
l-quipment Panels
Return activated sludge controls
Computer None
Type
Process Control
Data Logging
Storage'
Software Descnptw
Computer Cost
Parameter'Frequency
Parameter/Frequent y Parameter/ Frequeni
Central Control
Supervisory Control Yes; most, important, unit operations and processes are automatically controlled from the central
control room.
Ai-m and Safety systems Annunciator panel alarms - (Minn-Honeywell); No Cl detector.
Automatic Emergency Program (e g.. Power Failure) No internal; but plant has two independent power sources.
Maintenance and Calibration Contract with Minn-Honeywell for control systems Win-plant analytical calibrations.
Special Equipment Lab D.O.
Speual Operator Training, In-plant programs
Total In-FlMt Han Hours Year 559 mhrs/yr
Total Cost of Outside Serv.ee $ 13 , 000
nTime Very short interruptions
Frequency (no >mo) Less than once a month
because of poo, _, , ,
ments would improve operations
196
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,th for Parshall Flumes (after gates) and direction changes.
brated with staff gauges.
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gn, and improper installation, render SD measurements useless,
atic operation; unacceptable performance; sludge density
truments abandoned.
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, sludge density equipment
ently, pump-down is timer
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approv«d
OMB No 158-S72005
Facility Ownership and Addre
Responsible Supervisor
Row Rale Design (Average and Maximum) 21 mgd 24 mgd (36 peak)
Storm water Collection and Tteatmtn i No. Sanitary with Industrial (paper mill waste) and heat, including 27,500 ppd solids
and infiltration.
1 ype of Plani Description of Treatment Process (Attach schema!it diagram for process monitoring and control sysierm )
Secondary (activated sludge). Paper mills have primary treatment, discharge cellulosic effluent.
Treatment plant adds ammonia and phosphoric acid to promote activated sludge.
Performance Dat
.nd Overall) BOD Removal 90%
SS Removal 90%
1936-1972
$10M
Modif.canons(YenmdDescription), 1972 - Secondary treatment added
ModificanonCost $7.5M
Instrumentation Fischer & Porter
Equipment Mag. meter, bubblers, D.O. , suspended solids, etc.
Panels Local
Installation and Start-up Costs Original Cost Tola.
(nsiru men tation Modification None
Desc
tquip
;nt
Compute,
Type
Process Control
Data Logpng
Software Description
Software Cost
Central Control No
Supervisory C onlrol Lo C 3 1 pane Is
Alarm and Safety System* Typical
\utom>n«. tme.genoy Program (e g , Power Failure) Two tie-lines.
Mimtenince and Calibration Mag . meter calibrators , ultrasonic power source , V-O-M
Special Fqu.pmenl Do^nr.me None
Spec laJ Operator Iram.ng None Frequency (no 'mo 1
ToiJ In Plant Man Hours'Year 80 mh
Total Cost of Outside Service Still on warranty
sinuate ot Over-all Benefits of Instrumentation and Automation
Reduction in manpower.
Good, consistent treatment efficiencies.
I
201
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204
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158S72005
Facility Ownership and Address B—10
Responsible Supervisor
Flow Rate Design (Average and Maximum) 24 mgd design, 10 mgd av. , 12 mgd peak
Storm Water Collection and Treatment No . Residential only .
Type of Plant Description of Treatment Process (Attach schematic diagram for process monitoring and control systems )
Secondary (mechanical aeration, flotation-type sludge thickening, sludge incinerators)
Yor Built 1972
Original Cost $10.8 Million
JU BOD - 88% Removal
SS - 887 Removal
Modifications (Year and Description)
Modification Cost
Ins
snUtion
Equipment
Panels
Installation and Start up Cos
Varied, mostly F & P
Flow, D.O. probes, level, etc.
Central for treatment, sludge disposal
Original Cost
Instrumentation Modification
Descrtpti'
rype
Data I oggmg
Software Description
entral Control
Supervisory C ontrol
Alarm and Safety Systems
\ulomatii hmergcrK.ypK.gram (eg. Power F
aintenance and ( all bra lion
Spttiil Equipment Very little
Speiial Operator Training On-Slte and future
Total in-PUnt Man Hours Year Not established
Toiai cost of Outside Sen-tie Still on warantee
Labor reduction
Effective treatment
Data production
Yes (treatment and sludge disposal)
Yes
Yes
Two tie lines only
Sone start-up problems
205
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non-indicating. Early failure rate on a previous production lot. 120
units in service .
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on sewage. Eight installed; all abandoned within first two months.
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unknown.
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form apprMMl
OMB No 158S72005
FatUity Ownership and Add re
Responsible Supervisor
How Rale Design (Average and Maximum) Average design - 24 mgd
stonr, water Collection andsi|«jrne£(.e systenij"less than 10% of area is combined? high infiltration
Type of Plant Descnpl
Maximum design - i.x ui6u
Average actual - 28 mgd Future (1973) Average design - 48 mg
of Treatment Process (Attach schematic diagram fur pcoicss monitoring and lontroi systems )
Secondary treatment plant with activated sludge process.
Contact stabilization in winter and conventional activated sludge process in summer.
No sludge digestion, sludge is processed at West Point STP.
Performance Data (Individual Units and Overall) Winter
Primary BOD Removal 34%
Primary Suspended Solids Removal 62%
1965
, Bud,
Modifications (Year and Descripti
1% Total BOD Removal
0% Total Susp. Solids Removal
Additional Aeration Blowers - 1967
Additional Chlorination Ejectors
Winter
90.5%
92%
Summer
"97.5%
9.0 Million
cos, Aeratlon _ $235,000
Chlorination - 15,00p
Pneumat ic , electronic, some mechanic-al,
Central graphic panel, pump control panel, primary control panel, secondary control panel, secondary
indicating panel, chemical control panel.
ind Start up Costs Original Cost
Foxboro instrumentation - $283,442
Fischer & Porter - 85,000
Description
DO CoriLrol System
Chlorine Control System
Influent and Effluent
Gate Controls
Pump Controls
Yew Equipment Pan
1967 Amplifiers & Probes changed
1967 Pneumatic to Electronic Control
1967 Pneumatic to Electric Control
1967 Level signal from Primary Tank
instead of pump
f15,000+
5,000+
Computer Sigma II Computer located in Metro
lype office building as part of Manufact
CATAD System*
Xerox Data Systems
~Telemetry with fhllco-Ford System be-—
tween computer in Metro office building
and printer with keyboard input at
surveyed plant.
UHIAJJ system"
DPr?rct°"c?nt?8ldife^o8IiieS!tfi0flHSiZlEiBSepnS:0.FB!pil§cIiuBiSnH^?r Wif.3lla5&»fol at present with readout on
printer or alairms, operating data, ana quality data from treatment plants, pumping stations and regulator stations.
Data Logging
Data logging of alarms^operating data^and quality data at various locations.
Alarm functions
Once every hour
Date, Time, Where, What
Also Repair status
shear pin failure
t of CATAD System
Paiametei
various parameters at surveyed STP,
17 Pumping Stations and 2 small treatment
' plants.
Computer Cos
entral Control
Supervisory ( o
i Part of CATAD Software Cost Part of CATAD
Operating Data Quality Data
wnat' £evilswhere' Date> time,vhere
flows, set points, what- Temp., D.fi
etc. 1 " * "
Frequency varies. Frequency varies
Example: StL depletion
^Computer Augmented Treatment and
Disposal System
:aIUt,onCost part of CATAD
s , process adjustments are made from central graphic panel data .
Alarm and safety Systems Yes , about 300 alarms are monitored at central graphic panel .
. t „ Emergency standby generator for lights, telemetry, instrumentation, blowers,
\utomatu Emergency Program (e g , Power Failure) & J J & 01 j •* ,,, e-.
sedimentation tanks. Also 80 hours of storage at normal flow are available in influent sewer
Current meters,.dead weight tester, voltmeters,
!nl scoe amSerom trie titrator f'ad cell " Downlime No downtime due to instrumentation failure.
tester, atmospheric detector-calibrator.
Special Opera
to train operators . Many ty .
.staff of V maintenance men. About 60% of their time is for surveyed STP instrumentation maintenance and cali-
r&tann-nanl Man Hoursnrear
ning Yes . 44-week session given at the plant E*requcnc>
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weeks, and recharged once per year. If they are not cleaned, false
readings result. In the initial installation, vibration caused
leakage. Extra "0" ring was put in and solved the problem.
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Cells, cleaned daily; complete cleaning weekly, fresh buffer solution
is prepared once per week. Chemical costs are $600 per year. Main-
tenance is also required on rotary Cuno filter, which plugs, and
3/8-inch sampling line, which plugs.
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Working satisfactorily; too small, initial Cipollettl Weir. Weir
capable of greater flow without excessive losses was required. Level
is measured by Foxboro bubbler tube and D/P cell.
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sufficient variation in head. Rectangular weirs are calibrated every
2 years. Level is measured by Foxboro bubbler tube and D/P cell.
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Air piping is susceptible co vibrations which can cause instrumen-
tation problems. Once the cause of problems was determined, it was
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The level transmitters were changed from Foxboro Model No. M45 with
0- 10 foot range to Foxboro Model No. 15A with 0- 20 inch range in
ordpr to provide a more sensitive control of sewage pumps .
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Tne position indicator was made by plant personnel by having a worm
gear off main shaft of limitorque operator operate 2 dashpots
into which 2 resistors were installed.
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to be working satisfactorily.
Operating exper
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was abandoned .
.idered critical.
visions to calibrate the instrumei
uent calibration, the instrument
of primary sludge flow is not con.
There are no prt
anticipated fre
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The sensor probe
was relocated tc
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month. Was intended to be used
jtotnatically when turbidity was toe
want to make the decision on clos
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calibrated ever)
primary gates ai
plant personnel
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ynaraatic Magnetic Clutches at a cost of $7,000.
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Chlorine demand highly variable; control of chlorine
in proportion to flow would waste chlorine. Too
high chlorine must he avoided in receiving waters.
The system works well.
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FIGURE B-ll(c): DETAIL B.
Turbitity limit signal
RAS
RECEIVING
RIVER
215
-------
GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158S72005
Facility Ownership and Address B-12
ReiponnMe Supervisor
Flow Rate Design (Average and Maximum) 35 rfigd Avg. dwf, ; 50 mgd Max. dwf . ; 70 MGD Max. wwf .
stormwitorCollectionand Treatment Separated System, Sanitary Only
Type of Flint Description of Treatment Process (Attach schematic diagram for proce
>nitonng and tonlrol sy ,lems )
Secondary CMAS, with sludge incineration
Performance DaU (Individual Units and Overall)
YMiBudt: 1972
Original Cost. $10.7 M
Modifications (Year and Description)
ModifK.at.on Cost
instrumentation Plant employs electronic instr. with the exception ol liquid-level bubblers.
Equipment. Status indicators; remote speed control; recorders; c .osed loop Cl control; SO,, control and
incinerator controls. Monitoring - Flow, DO, levels and sludge density, ^
Panel*. 30-ft. panel in control room; 20—ft. panel in incinerator room.
Installation and Start up Costs
Instru
n Modification
Description
Computer Control
EPA Demonstration Proj.
1972
Original Cost Total Cost
75K Instruments Only
Equipment
Computer
Panels
None
Computer EPA-Dernonstration Project
Type Mini-process Control
Disk, Teletype
Process Control ¥es; No DDC, but operator closes the loop; DO, RAS, Sludge Blanket, MLSS, FF-TOC,
FB-TOC, Resp. Rate Control
Datatoggmg Yes; Computer generates daily status report; monthly reports are also computer-prepared.
Para meter/ Frequency
Scans 6 sec.
to Disk-2 min.
DO control operate;
I? 1-min. data rate
2.5M (16 BIT Disk)
Software Description Data logging; report writing; process control-^iML/7 Language
Computer Cost 107K Software Cost 5QK (min) Installation Cos* 1 man-mo
Central Control BIF Control Room
Supervisory Control Yes; mostly pump speed control from central; incinerator has separate control room.
Alarm and Safety Systems Major equipment status indicators and alarms; Cl. gas detection.
Automatic Emergency Program (e g , Power Failure)
Stand-by generators for pumping sewage during power failures and minimal lighting.
Maintenance and Calibration N . A .
Special Equipment Signal generator; 0-Scope; DVM;
Time pulse generator; power supply.
Special Operator Tramm* Ins trumen t Tech .
Total In-Plan! Man Hours/Year 0. 5 man/yr . , W/O computer
Total Cost of Outs.de Struct N.A.,W/O Computer
Down Tune
Frequency (
Estimate of Over-all Benefits of Instni
ation and Automatio
Better supervision of plant start-up.
Economies in power and chlorination.
Computer reduces manpower requirements for data logging and producing periodic reports.
Inv. Comments^ - Very little process control w/o EPA project most control involves equipment status, alarms
and remote speed adjustments.
216
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Influent wet-well level used to manually control pump speed In
such a manner as to keep wet-well level within acceptable range.
Also, effluent wet-well level used for manual by-pass control.
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Flow rates are used in flow-proportion chlorination; also, flows
are recorded and logged into the IBM-7.
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instructions for blower speed adjustment. Desired DO level 1.5 to
2.0 mg/1.
For good processing and economic reasons, after checkout ., DO control
wiJ 1 be completely automated .
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Air flow rates to individual aeration. Tanks a. jperator-
adjusted via electrically operated butterfly valves.
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DO control - extend blower life.
Flexible set pt.; power savings.
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Zero residual chlorine after
dechlorination.
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158-S72005
Facility Ownership and Address B-13
Responsible Supervisor
Flow Rate Design (Average and Maximum) Design max. 36 mgd , running at 22 ragd
Storm Water Collection and Treatment No ' sanitary and industrial waste.
Secondary, with trickle filters and activated sludge.
Performance Da la (Individual Units and Overall)
70% removal, BOD and settleable solids
Year Built 1958 Mediations (Year and Descnpiioni Continuing slight inst. improvement s
Original Cost $5M Modifnalion Cos!
wtnimenution Foxboro, Pneumatic, etc .
Equipment Flumes, raag- flow and orifices (for gas), flow-control valves, pH and gas analyzers, density meter,
Panels Central graphic (record, alarm, flow control) and auxiliary boards.
Installation and Start up (osls Original COM XTOcKElKtX (InSt. Equip. ) $25QK
n Modification (See above)
Description
Computer None
Type.
Process Control
Data Logging
Software Descuptx
Computer Co si
Central Control plow distribution
Supervisory Control
Note: Low maintenance needs attributed to
cleatij^_dry_,_ oij.-free instrument air.
Alarm and Safety Systems Conventional, industrial type
Automatic Emergency Program (eg , Power failure) None, plant is entirely seIf-contained, generates its own power .
Maintenance and Calibration
Special Equipment None
Special Operator Training None
To,aJ In-Plant Man Hou,s/Year 4QO (Est>) + 1QO hrs . call-in
Total Cost of Outside Service A „..
Down Time None
Estimate of Over-all Benefit? of Inslnimentation and Automation
Use of instrumentation is basic to the operation of the plant. Plant operation would not be feasible under
manual control. Automatic data generation used for historical purposes.
226
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229
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form •fipr(M«d
OMB No 158 S72005
Facility Ownership and 4ddre
B-H
Responsible Supervisor
How Rate Design (Average and Maximum) 30 mgd, 36 mgd (Expanding to 50)
Siorm Water Collection aiH ,ieaimeni No (Sanitary and infiltration only). >0 mg influent storage.
Secondary, activated sludge (diffused air), secondary sludge flotation, sludge filtration, incineration (hearth)
Performance Data (Individual I nils and Overall) 90% SS Removal
90% BOD Removal
Year Buili
OngrnaJ Cost
1959
S6M
Modifications (V ear and De scrip tic
1964 (24 mgd - 36) 1971 1971
Storage, pumps, power Incinerator
$6.4M S1.5M
nsmimentatron Basically Foxboro
Equipment ^ag flow, air flow, remote valve operators, filter and incinerator systems.
Rands L.OC&1
Installation and Start up Costs Original < ost I otal« ost
None
Computer
Type
Process Control
D»t. Logging
Parameter Frequent y
Parameter'Frequency
Softwu« DescrtptH
Central Control By areas
Supervisory Control Yes
Alum »nd Safely Systems Conventional industrial
Automat it Emergency Program (e,g . Power Failure) Two tie line
MaintenancemdCifibmion By two licensed electricians.
Spetiat Equipment
Minor
SPec.al Operator Tra.n.ng None, BXCCpt that both plant Inst. r.>eqUen:y(n0/m
maintenance men are licensed electricians.
Totil In-Plant Man Hours/Yes
Total Cost of Oulade Service
400 mh
$100
Estimate of Over-all Benefits of Instrumentation and Autt
Major reduction in manpower.
Improved performance.
230
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power applied Lo probes not successful.
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233
-------
GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AL TOMATION
Form approved
OMB No 158S72005
Facility Ownership and Address B-15
Responsible Supervisor
Flow Rate Design (Average and Maximum) Average Design - 37.5 mgd, Peak Hydraulic Capacity - 120 mg
Average Actual - 31.0 mgd
StotmWm, Collection ndTnunent None (separate aystem)
Type of Hint Description of Trealmenl Process (Allaih sthemadL diagram for process monitoring and control *y stems I
Secondary, with activated sludge, step aeration in 4-pass system.
Performance Data (Individual I n
Yew Built 1971
Original Cost $9M
d Overall) Suspended solids - Overall Removal:
BOD - Overall Removal- 88%
%, Primary Removal:
Modif nations (War and DtscnpiLoni 1973 - Facilities for addition of polymers in aeration tanks .
Mod.ficanontosl $25,000
Instrumentation
Equipment Costly electric, some pneumatic.
Pands Central control panel and sub -panels at ch lor mat ion s :ation, air compressor staticn, return sludge pumping
station and influent sewage pumping station.
Installation and Siart up Costs Original Cosl loulfost $350,000 - Robertshaw Control Co .
Description Vtar
Method of control of return 1971
activated sludge flow.
rquipment Panels \& S Total
Changed control from sludge turbidity to sludge blanket level.
Teletype Corp.
CSC-1108 computer
teletyper
Process Control
Data Logging None at plant
^ j*ar3meltr Frft)ueni> I Paiamelei t-iequeniy
Plant operating data are gathered, pr'Iptre^EnceTct.
icggcd and transmitted once per dav to ana sent frpm mair'
main office. Plant flow. COD primary, lattice to the plant
COD secondary, waste activated sludge tlncl. many useful
flow, suspended solids, MPN and other 'parameters such as1
data^?<"*8e residence time, air rat e
Memory bank in central computer per pound of COD.
Software Description
Some programs are in process of being written.
Computer Cost .Software ( Os( Ins
§65.00 per mo. for time sharing console rental.
$100 per month total including insta Llation and
telephone costs for time sharing console.
ent/aJ ( ontiol
Supervisory Control Return activated sludge flow, chlorination rate by ad]usting set point, primary sludge valves, air
compressors, waste activated sludge valve, and other process as are controlled from main c ontrol panel.
Alarm and Safety Systems Yes .
Automata Emergenty Program (eg , p»wei i aiiuret Standby generator for total plant load except for p roc ess air compressors ;
battery backup for control systems.
Maintenance and Calibration
Speti*i Equipment Scope, test gauges, water manometer, [)o«niime
precision milliamp detector, magnetic flow meter calibrator.
Spenal Operator Training Two hours per week for four men in the Frequeity*
entire sanitation district.
Total In Plant Man Hours Vear J ( 5QQ
No plant downtime because there are spare units.
Infrequent downtime to chlorinators and influert
pump controls.
' "10 ' 0.17
Total Cost of Outade Servit
None
Estimate of Overall Benefits of instrumentation and Automation Data logging and gathering, although manual, gives information to operate
the plant better. Without instrumentation and automatic contrcl, the same number of people would operate the plant
less efficiently. Instrumentation and automation does not save manpower, but increases efficiency. Automatic control
of air for activated sludge is very useful.
234
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The instrument is satisfactory provided the probes are cleaned
once every 2 weeks; readings are tested 3 times per week with
portable equipment; calibration is required.
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238
-------
GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
OMB No 158-S72005
Facility Ownership and Add re
Responsible Supervis
The flow is highly seasonal, reaching design flow rate
during the canning season.
Flow Raw Des.gr, (Avenge and Mnimurn) Average flow rate - 23 mgd
Design flow rate - 44 mgd
Storm Wafer Collection and Treat men I
Separate system with high infiltration. Minor account of combined sewage.
Secondary treatment plant with trickling filters.
Sludge thickening, digestion and trucking to land disposal.
Perform nice D»U (Individual Units and Overall}
Year Built: 1964
Original Cost 3.3 million
Overall removal - 87% suspended solids, 89% BOD
Modifications (Year and Description) 1975; doubling plant capacity and adding Unox system of
activated sludge treatment.
Modification Cost 13.0 million (Future)
Instrumentation
Equipment Electrical mostly, some pneumatic.
p»nds One main central control panel.
Installation *nd Start up Costs — Original Co<
Ins
n Modifia
Influent gate-closure
control.
tquipmeni
Standby engine
Process Control
Da (a Logging
Central Control
Supervisory Control
Alarm and Safely Syil
None
s Yes
Automata hmerginty Program ! Over all Belief I
$500 to $1,000 per year
When the systems are working well, they are very useful and the operators couldn't do without them.
The most useful and important devices are high-water alarm and power-failure alarm.
239
-------
1 *=
8
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ter the f irst few months of operation. Build-up of grease
is readings so that the accuracy is very poor. Too much
e to keep it clean. Poor accuracy results in erroneous
1 of sludge pumps. They have changed to a manual reading
dge blanket .
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The operator of a portable sonic device for a few
minutes each day is easier, simpler and less costly
in a small plant than maintenance and operation
costs on a sludge density meter. (Determining
sludge blanket level)
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
OMB No, 158-S72005
Facility Ownership and Address B-l 7
Responsible Supervisor
Flow Rat* Design (Average and Maximum) Av. 40, design 44 mgd, 80 mgd peak
Storm Water Collection and Treatment Most sewers combined
Type of Plant Description of Treatment Process (Attach schematic diagram for process monitoring and control systems)
Secondary (activated sludge), with sludge incineration and landfill. Phosphate removal (Ferric chloride
and polymer).
Performance Data (Individual Units and Overall)
BOD Removal - 76%
SS Removal - 73%
Y«rBuiif 1929
ongnwicosi $2 million
* (Year and Descr.pt.on) 1950's - Enlarged 1973 - Enlarged and revised
Modification cost $5 million
wtramenution F & P. Brooks, Bristol, Etc. Process instrumentation being revised.
Equipment Pneumatic analogs being replaced with electronic for computer capability.
Panels Local
Installation and Start up Costs Original tosi Tola! Cost
Instrumentation Modification
Descripti
Monitoring & Control
1973
Equipment
computer with
auxiliary
Computer [jO£ yet in service
T"e Miniature, on-line
Proce« Control Direct Digital
Data Logging
8K 12 bit words (core)
520 K bit words (disc)
Software Dew: rip in
Computer Coil
Perf. Tape instructions
] Memorex printer
4 y/35 Teletypes
3 CRT/input stations
Parameter Frequency
Parameter 'Frequency
Central Conliol Not yet
Supervisory Control Will be computer controlled
Alarm and Safety Sys.enu WU1 be Computer controlled
Automatic tmergency Program (eg, Power Failure) Two ties , automatic Switchover
Maintenance and Calibration Inst. Shop for InSt's. Computer accessories
Special Equipment Scope, Heath Standards, VOM, Pwr Spls., Fr«j,*nTm
Gen. & Counter, Manometer.
Spei..al Operator Training Frequence
Electronic Technician
Total In-Plant Man Hours Year £QQ
total Cost of ouisde Service None at present
ateut UveraJI Benefits of Inslrumcniaiion and Automaiion
Reduced manpower, especially for remote stations.
Uniform operation.
243
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
OMB No 158S72006
Facility Ownership and Address B-18
Responsible Supervisor
Flow Rate Design (Average and Maximum) 105 mgd Avg. dwf: 225 peak Wwf .
Storm Water Collection and "seatmeni Combined system - no special provisions for stormwater
Type of PUnl Description of Treatment Process (Attach schematic diagram for protess monitoring and ion trot panslon to 150 mgd Avg. dwf .
Modification Cost
lattninwfttetKMi Mostly Fischer & Porter pneumatic-type instruments; F&P magnetic flow meters; bubble-tube level
indicators, with Flowmatcher liquid rheostat motor-speed controls; Wallace A Tiernan closed loop chlorination;
density gauges; and temperature indicators and conl.rollers .
p»nets 20-Ft. panel in Blower Bldg.; 15-Ft. panel in sludge control building.
Installation and Start-up Costs Original Cost Total ~ost
Instrumentation Modification
Description Ye4I
Replace Sludge Density Meters 1973
D.O. Monitoring 1973
ORP Monitoring 1973
Computer Control 1973
Lab TOC 1973
equipment
K-Ray
Beckman 735
Beckman
F&P
Beckman 1215
Computer Not currently installed (see above)
Type Mini Computer MwwteMw Varian 620/L
Process Control DO, Digester loading
Activated Sludge Wasting
Dal* Logging
StOTM
Parameter/Frequency
Hourly plant
Data Acquisition
Parameter, Freqm
Daily Lab
Data Acquisition
Parameter/Frequency
; Printers
CRT
Teletype
Card Punch
Card Readers
Parameter/ Fr«quenc>
16K core and 123K Disk
software D«cnpcwn Data logging; three-mode control; alarms; CRT display programs
Computer Cost Software Cost Installation Cost
Central Control Although plant currently displays about 50% of its equipment status and process indication on two
panels, there is virtually no remote control capabilities.
supervisory Control ^0 (iess than 10% of adjustments can be made renotely) .
Alarm and Safety Systems Torque alarms on mech. equipment; Hi-temp alarms; chlorine gas detector and alarm.
Automatic Emergency Program(«g.,Power Faiiute) Facility generates its own power from digester gas, natural gas and oil.
HuHtentiKe and Calibration
Special Equipment Press' test stand and calibration; O-scope; Downlime problem equipment abandoned
transistor checkers, signal generators,
p. test stand, diff. press, test stand. Fiequeilcy(no/mo)
Trained instrument technician
A,000 man-hrs/yr
Tottl Cost of Ou (ade Service
Special Operitoi 1
Total In-Plant Man Hours/Yei
Estimate of Over all Benefits of Instrumentation and Automation
Sludge density meters abandoned because of poor accuracy and reliability - special AEC license for servicing; very
poor blower control; automatic data logging being used. Since no process control instruments, other than flow
monitoring and manual adjustment, this plant derives little or no benefits from I & A.
246
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GENERAL SURVEY QUESTIONNAIRE
Form •
OMB No 158S720O6
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Faculty Ownership ind Addre
le Supervisor
Row Rate Design (Average and Maximum) 130 3V. 123 mgd design 200 mgd max.
Storm Water Collection and Treatment No. Combined system. Plant bypass to lake over 200 mgd.
Type of Plant Description of Treatment Process (Attach schemaiu diagram for process monitoring and control systems.)
Secondary (activated sludge); sludge exported.
Performance Data dndrviduai units and Overall) BOD removal 90% and more, neglecting occasional bypass.
SS removal 90% and more.
Yewflu.lt 1931-38
Original Tost $9.5M
Modifications (Year and Description) 1973 expansion
Modification Cost SliM
instrumentation Bailey Meter Company originally
Equipment Mostly obsolete, but many mag. flow and sludge density meters
Panels Local
Instrument air compressors
(Oil and water-free)
Installation and Start-up Costs
Original Cost
ToiaJ Cost
iirumenfation Modification
Description
Flow meter
1972-73
Bailey to BIF
Differential meters
Total
$0.5M
Typ*
Process Control
Data Logging
Storage
Software Description
Computer Coti
Parameter/Frequency
Parameter 'Frequency
Parameter/Frequency Parameter/Frequency
Central Contioi Primary system only.
Supervisory Control
Alarm and Safety Syitenu Ye-S
Automatic Emergency Program (eg, Power Fa.li.re) None _ Gravity flow.
Maintenance and Calibrate
By meter group.
Special Equipment Mag. meter calibrator, loop tester, man- DOW, Time NO
ometers.
Special Operator Training , , , j i Freqjency (no /mo )
v ^ Inst. mechanics must be licensed elec-
tricians .
Total la-Plant Man Hours/Year _.
1000 mh
Total Cost of Oulade Serv
None
Estimate of Over-all Be
Minimal .
254
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
B No 158-S72005
Facility Ownership and Address B-20
ResponsiM e S uperv i sor
Row R«e Design (Average and Maximum) Av. 5Q mgd Peak Design 75 rag
Storm Water Collection and Treatment fjo
Type of Plant Description of Treatment Process (Attach schema lie diagram fur process monitoring and to
Primary Removal
SS 63%
VSS 65%
Performance Dm (Individual Units and Overall)
Yea,BuUt 1943
Original Cost —
BOD 35%
Irol systems)
Primary & Secondary Treatment
Sec. Removal
SS 66%
VSS W,
BOD 73%
Modification Cost
Total value, both plants
nd Description) Every year since 1957 to present
S'43.1 Million
Instrumentation
Equipment Mech., Pneumatic and electronic; mag meters, etc.
i-ands Centralized Control Panel and Building
Installation and Start-up Costs — OnginaJ Cost — T
(Orig. 1943 plant had little instrumentation)
since 1963, $600,000 (both plants)
Instrumentation Modification 1963
Description Year
Control Center; mag meters 1963
and most all instrumentation
tquipmen
See
Panels
Main Control
Tola!
5600,000
instrument panel and new
sheet
building; 40'
long panel
Type None
Process Control
Data Loggmg
Storage
Software DescrtplK
Computer Cost
Parameier/Frequt
Software Co-
Central Control Most plant functions indicated and recorded in manned control center.
Supervisory I ontrol Some Valves, GtC.
Alarm and Safety Systems Yes - levels and pressures
Automatic tmergency Program (eg., Power Failure); partial plant operation with generator, primarily for main pump.
Maintenance and Calibration
Special Equipment Manometers, V-O-M, digital
multimeters, oscilloscope
Special Operator Training General, plus 2 weeks F&P
Instrumentation Service School
Total I frPlant Man Hours/Year
Total Cost of Outside Service
1,000/yr.
Estimate of Over-all Benefits of Instrumentation and Automation
Central control of 2 plants (from Plant #1) highly effective. Instruments and control provide good
manpower usage.
258
B-20 No, 1
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 168-372006
Facility Ownership and Add re
Responsible Supervisor;
Flow Rate Design (Average and Maximum) Av . 100 mgd Peak 230 tngd
Storm Water Collection and Treatment No
Primal y
SS 57% Removal
„ , J Volatile SS 60% Removal
Performance Data (Individual Units and Overall) „„„ „ , . .
1968
HOD 242, (Low due to heavy industrial and oil field waste.)
Modifications (Year and Description)
Original Cost Modification Cost.
Total value ot both plants (1 & 2) $43.1 Million
Instrumentation
Equipment Mechanical, Pneumatic and electronic^ mag. meters, etc.
Panels, Scattered through plant - mam panel at Plant No. 1.
Installation and Start up Costs Origin*! C mi T ,11! Cost Sinct 1963 $600,000 both plants.
1963
Year Equipment
Instrumentation Modifkat
Description
Control Center; nag meters
and most all formal
instrumentation
1963
Panels
Main control panel
vt Plant No. 1
Total
$600.000
Computer
Type
Process Control
Data Logging
Storage.
Software Descrtptu
Computer Cost
Parameter Frequency
Parameter'Frequency
Central Control At Plant No. 1
Supervisory Control Some ', close valves , etc .
Alwm and s»fety Systems Yes, levels and pressures
Automatic Emergency Program (e.g , Power Failure) Partial plant operation kith generator, primary for main pum
Maintenance and Calibration
Special Equipment Manometers, digital multimeters,
Oscilloscope, etc.
Sp*nl Operator Traimng ^ + ^ ^^ p&p
Sch001
Total Con of Outside Serv
Estimate of Over-all Benefits of Instn
General operation permitting effective manpower use; however, it would also be good if some control were
available at Plant No, 2 instead of all at Plant No. 1.
264
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269
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approvMl
OMB No 158 S72006
Facility Ownership and Address B~21
Responsible Supervisor
Row Rate Des.gn (Average and Maximum) Design: 180 mgd (max.). Present average: 260 mgd
Storm Water Collection and Treatment Only from combined sewers
Type of Plant Description of Treatment Process (Attach sthematic diagram for piocess monitoring and control systems )
Secondary (Activated Sludge), with sludge disposal at sea.
Performance Dan (Individual Lnits and Overall)
Est, 80% solids, 80% BOD removal
Year Built 1936 Modifications (Year and Description) 1975: Complete new instrument & data-logging syst em.
OngmaiCosi $62 Million (1069 dolla*Hi)f|Ca"onCosl
instrumentation Extensive mechanical instrumentation for level, flowrate. Mostly abandoned.
No instrument-quality air available.
Equipment Venturis, mercury manometers, water columns, float and tape, selsyns, etc.
a^K Only for individual instruments
nstallation and Starl up Costs Unavailable Original Cost
Unavailable
n Modifier,
Descripti
Computer
Type
rV»cess Control
Data Logging
Storage
Softwve Description
Computer Cost
Parameter'Frequency
Parameter/Frequency
Central Control
Manual only (signal transmission for wet-well level). 11 Automatic recorders.
Supervisory Control
Alarm and Safety Syslems
Automatic Emergency Program (e g.. Power Failure)
Maintenance and Calibration
Specni Equipment $7K Calibration Console
Special Operator Triming None
Total In-Plam Man Hours/Yew JQQ (£st:.)
Total Cost of Outside Service
None
Estimate of Overall Benefits of Instrumentation and Automation
Instrumentation provides remote indication of wet-well and sludge-storage levels. Plant influent rate recorded.
Aeration air rate checked occasionally with existing Venturis and portable manometers. Conclusion: 80Z of original
instrumentation abandoned. Manual data logging in addition to the inst. jmentation being used is barely sufficient
to sustain plant operations. Benefits from instrumentation care minimal, due to lack of plant and operator
performance standards, inadequate initial installation and lack of funds for instrument improvement and/or maintenance
270
LAS, CE Maguire, 10/30/72 B-21
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273
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158S72006
Facility Ownership and Addre
Responsible Supervisor
Row Rate Design (Averse and Maximum)- 200 tngd design; 225 mgd peak
Siorm Water Collection and Treatment Only by way of regulators and interceptors.
Type of Plant Description of Treatment Process (Attach schematic diagram for process monitoring and control systems )
Secondary, with fine-screening instead of primary sedimentation. Phosphate removal. Sludge drying.
Performance Data (Individual Units and Overall)
95-98% BOD and SS removal.
v«,Buut 1925
Original Cost $85M
Modifications (Year and Description) 1932-enpanSlOn
Modification Cost $115M
1971-Phosphate removal
Instrumentation
Equipment Local f low controls, samplers, D.O. probes, chemical feeders .
Panels pew; scattered
Installation and Start up Costs Original Cost T< tal Cost
Instnjmenution Modification
D«!c,,pl,on
Added D.O. Probes
Computer
Type
Process Control
D»la Logging
Storage
Software Desctiptt.
Computer COM
Software Co:
Central Control Only slightly.
Supervisory Control No .
Alarm and Safety Systems Slight
AutorrutK Kmergen^y Program (eg. Power F«lure) None (Plant generates own power)
Sp^iiEq^pmen, N(me
SpetiaJ Operator Training None
Total In Plant Man Houis Year
Total Cost of Outside Service
2100
None
tstimate of Over all Benefits of Instrumentation and Automation
Manual solids determinations and flow ratioing maintain proper solids levels for fertilizer production.
Liquid and air-flow metering, D.O. monitoring, chlorine and additive pacing all reduce manpower needs and help
meet effluent quality standards.
274
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filter cake. System has been in operation many
years. Operator determines sludge solids with
centrifuge.
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No. 1SfrS72006
Facility Ownership »nd Addre
Responsible Supervisor
Design and Average
Flo* Rate Design (Average and Maximum) 218 mgd - 290 mgd Peak (Excess bypassed to river)
Storm Water Collection «r j Treatment Combined
Type of Flint Description of Treatment Process (Attach schematic diagram for pro
Secondary: high-rate activated sludge.
Performance Data (indmdual Units and Overall) JQJJ removal 74%
SS removal 83%
it ing and control systems.)
Year Built 1938
OnginalCosl
Modifications (Year ind Description) I960' S - Secondary
Plant $3.5 M Modification Cos
Interceptors $7.2 M
instrumentation F & P ,~~and "others ; ~ pneumatic and electronic
Equipment Fl°w» level, weight, pH, etc.
Panel* Centralized in pri., sec., and sludge disposal
Installation and Start up Cost) Original Cost
Instrumentation Modification No
Description Year Equipment
Computer None (for running plant)
Type- Maniilai iurer I/O Devices
Process Control Stormwater control system utilizes computer; is located at Metro plant.
Data Logging
Parameter Frequency
Parameter Frequent? Parameter/Frequenty Paramelei/Frequency
Software Destription
Computer Cost
Central Control
supeniaiiryControl ManV control centers.
Alirm »nd Safety Systems Industrial types.
Automatic Emergenty Program (e g , Power Failure)
Maintenance and Calibration
Special Equipment Extensive, pneumatic and electric
Special Opemtot Training Extensive
(Probes maintained by lab. tech.)
Total In-Plani Man Hours/Year
14,000
Total Cos, of O^deServK
Estimate of Over-all Benefits of Instrumentation and Automation
Manpower reductions. Sustained performance.
Dow i Time None
Frequency (no imo I
278
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GENERAL SURVEY QUESTIONNAIRE
Form a
OMB No 158-S72005
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Facility Ownership and Address B-24
ResponflMe Supervisor
Flow Rale Design (Average and Maximum) Primary Settling - 125 mgd Aeration -2-1/2 hr. detention
Final Settling - 175 mgd Max. Flow - 250 mgd, design maximum
Stoim Water Collection and Treatment
Combined System
Type of hint Description of Treatment Process (Attach \chematK diagram for process monitoring and control systems )
Secondary, activated sludge.
Performance Data (Individual Umls »ml Overall) 7Q-75% S.S. and 60-67% BOD removal
Orig, Imhoff - 1923
Original Cos
Modifications temperatures.
No auxiliary power; secondary treatment is bypassed during power failure.
Maintenance and Calibration ,
Q-Mj current , pressure, voltage, oscilloscope, millivoltmeter , wheat stone bridge, stand. gases ,
Special Equipment timers, electronic counters
Special Operator Training gee fonowing sheets
Total In-Plant Man Hours/Year 783
Total Cost of Outade Service
Frequenc> (no mot Once every 3 mos . , instrumentation is over-
hauled. Budget - $20,000/yr.
Estimate of Over-all Benefits of Instrumentation and Automation
W/0 instrumentation, plant could not operate effectively. Alarms prevent flooding and motor burnouts.
284
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287
-------
GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
OMB No 158 S72006
Facility Ownership tnd Addre
Responsible Supeiviscr
Row R.le Design (Avenge and M«x™am) 900 mgd, 900 Av., 1,080 peak
S.onr, Water Collect™ and Treatment Combined sewers
Type of Plant Description of Treatment Process (Attach schemitic diagram for pro
umjj and control systems)
Conventional secondary (Imhof f tank for primary sludge) . Various metHods for sludge disposal • considerable
development going on.
Performance Data ]IJn,ts and Overall) 90% BOD+ Suspended Solids removal.
YewBuilt (Imhoff tank) 1930 Mo4.fifat.ons (Year and D
Original Cost Modification Cost
1940 - Activated sludge, 1950 - Increased aeration
1961 - Zimpro, 1964 - Digesters
Equipment Flow recording and telemetering, sewer levels, sludge-level controls, Hach turbidimeters.
paneis 1 large, hydraulic, recording panel. Local manual controls.
Installation and Start up Costs
Instrumentation Modification
Original Cost Total Cost Relatively little.
Miscellaneous operational developments.
Description Year Equipment
None
Type
Process Control
Data Logging
Software Descnptu
Computer Cost
Central Control
One central flow-control board
Supervisory Control
No
Alum and Safety Systems j?ew
Automatic Emergency Program (e g., Power Failure)
and Calibration Experienced crew for process instruments.
Special Equipment Vpo Down Time
Spec* Operator T,.,,..,.* ,, weeks/man/year Fluency , no/mo >
Total fn-Plant Man Hours/Year
14,000 mh
Total Cost of Oulsde Service, Negligible
Estimate of Overall Benefits of Instrumentation and Automation
Instrumentation gives operational guidance.
Improved sludge separations.
Improvement over laboratory results (in accuracy and trend detection).
288
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290
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GENERAL SURVEY QUESTIONNAIRE
Form «pp«w*l
OMB No 158-572005
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Facriity Ownership md Address D
D
Responsible Supervisor
Flow Rate Design (Average and Maximu
Storm Water Collection and Treatment
6.0 mgd Average, 3,0 mgd Design, 18 peak
Separate collection facilities. Excess flows go to oxidation pond or to stream.
Type of Plant Description of Treatment Process (Alttch schematic diagram for process monitoring and control systems )
Primary settling, activated sludge treatment, final settling, sludge digestion, coagulation,
sedimentation, sand filtration, micro straining.
Performance Data (Individual Units and Overall)
SS & BOD Removal: Primary, Pri. & Sec., Pri.-Sec .-Ter.
30-35% 90% 98%
Ye.rBu.lt 1963 (2 mgd)
OngmaiCost $146,000
Modific
,s (Ye»
j Description) 1964, Activated sludge plant; 1969, tertiary treatment;
1970, aeration of ox.-ponds; 1972, 4 mgd expansion.
Modification Cost
$725,000, $1,126,000, $107,000, $2,778,000, resp.
instrumentation Mostly F & P (Fischer & Porter)
Equipment Flow and level sensors , D.O. probes, turbidity indicators, etc.
Panels 1 control panel in the pump and blower house.
Total Cost
1 control panel in the tertiary building.
Installation and Start up Costs Original Co;
Instru
N/A
Type
Process Control
Data Logging
Storage
Software Description
Computer Cost
Parameter Frequency
Software Cost
«nti»jcontrol Pump & Blower House control panel.
Supervisory Control One panel (control); one recording panel in tertiary building.
Alarm and Safety Systems Minor
Auto™^ bme.gency Program (eg. Power Failure) Seiected operation based on 1 of 2 lines. No standby; no spare tielines.
Spend Equ.pmeni
Special Operator Trai
Total Cost of Outside Sertic
New instruments, still under warranty.
e (off-site) °°x
Some Frei
ir Not yet established.
None (warranty)
Estimate of Over all Benefits of Instrumentation and Automation
Monitoring flow and treatment efficiency of medium-sized plant. Data will be used to helo forecast future
treatment requirements. Aids in gathering information pertaining to flow conditions, storm-weather flows, etc.
291
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Butterflies (M650) , #663. Good.
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GENERAL SURVEY QUESTIONNAIRE
OMB No 1S8-S720Q6
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Facility Ownerdilp Ind Address
C-l
Reaponable Supervisor
Flow RateDesign (Average and Maximum) 2 mgd (max.) Plant bypassed during rainy season.
Storm Water Collection and Treatment No • Sanitary, with infiltration.
Tertiary: Activated sludge with microstrainer.
Performance Dab (Individual Units and Overall)
98% removal, BOD and suspended solids.
Yew Built 1971
Modifications (Year and Description)
Modification Cost
Instrumentation
Equipment BIp Telemetry, W & T chlorine equip., Union Carbide D.O. probes, etc.
Pands Central graphic, with local indicating instruments.
Installation and Start-up Costs Original Cost Total Cost
Instrumentation Modification
Descnptii
Cotnputei
Type NO
Process Control
Data Loggtng
Storage
Software Description
Computer Cost
Parameter/Frequency
Parameter/Frequency
Parameter/Frequency
Software Cost
Installation Cos
Centra) Control jj0 _ Indication, recording and alarms on central panel, but no control.
Supervisory Control fJo .
Alarm and safety systems Conventional industrial type.
Automatic Emergency Program (e g Power Failure)
None
Maintenance and Calibration
Special Equipment None
SpeuaJ Operator Training None*
Total In-Plant Man Hours'Year Not yet established
TOM C«t of Outside Service Not yet establisned
Estimate of Over-all Benefits of Instrumentation and Automation
Instrumentation essential for performance and labor savings.
Down Time None due to inst. failure
Frequency (no ,'mo )
*Superintendent, however, is particularly conscientious
and experienced.
295
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STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No, 158-S72006
Facility Ownership and Addre
Responsible Supervise!
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excessive AP or by high turbidity, but plant
operates by manual backwash once per shift un
high A? or turbidity-alarm conditions exist.
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GENERAL SURVEY QUES1IONNAIRE
OMB No 1M 871000
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Facility Ownarthip ind Addrett
Raaponabla Supervii
0.36 mgd (Ava.) Retention Tanknjd.58 (Max.) Cyclator & Filter
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form ftDprovid
OMB Ho 158372006
Facility Ownership and Address
Responsible Supervise!
Flow Rate Design (Avenge and Maximum) 2 ragd Avg., containing 10-15,000 lb/d suspended solids
Siorm Water Collection and Treatment No
Type of Plant Description of Treatment Process (Attach schematic diagram TOT prtxess monitoring and Control systems )
Blending, neutralization, and activated sludge facility to handle nutritive, acidic, and hot wastes,
Performance Dati (Individual Units and Overall)
97% solids, 95% BOD removal. (Suspended solids in effluent helc below 40 ppm.)
Yeai Built 1958 Modifications (Year and Descnption) General, lO date
Original Cost $1. 7M Modification Cost Present evaluation, approximately $5M
Instrumentation j.
Pneumatic and electronic
Equipment Instruments to measure and control pH, temp., and TOC
Panels Centralized
Installation and Start up Costs Original Cost Total Os
Instrumentation Modification
Description Year Equipment Panels
Continuing in-house development of TOC sampling system, etc.
Computer
Type NO
Process Control
Data Logging
Storage
Software Descnptx
Computer Cost
Parameter 'Frequency
Paranielei/Frequency
Software Co!
Installation Cost
Central Control Yes
Supervisory Control
Aiam, >nd Safety Systems Conventional industrial
Automatic Emergency Program (e g , Power Failure)
Instrument air is clean, dry and oil-free.
M«pt«unce and Calibration All the facilities of a large, modern, first-class chemical plant.
Special Equipment Down Time
Special Operator Training Frvquein y (no 'mo )
Total In-Plint Man Hours/Year
Total Coil of Ou tsde Service
Estimate of Over-all Benefits of Instrumentation and Automation
Instrumentation helps assure that plant effluent meets EPA and other effluent standards.
312
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158S72005
Facility Ownership and Address p ,
Responsible Supervisor
Row Rate Design (Average and Maximum) Designed to treat 5-year-maximum s Corm flow of 233 mg
Siorm Water Collection and Treatment Treats combined stormwater overflows
Combined storrawater screening, pumping, settling, chlorination
Performance Data (Individual Lints and Overall)
Year Bull. May
OngmalCost 0
Modifications (Year and Description)
Modification COM
Instrumentation
Equipment Pneumatic and electronic
Panels 10-ft. graphic, plus 5-ft. recording and misc.
Installation and Siart up Costs (not broken Out) Ongmal tost $125 , OOOTGlil Cosi $125 ,000
Instrumentation Modification
DestnplK
Start-up adjustments only
Computer
Type None
Parameter'Frequency
Parameter Frequency Parameter/Frequency Parameter/Frequency
Computer Cost
Installation Co-t
Central Control Plant designed for automatic, unattended service. All essential controls on graphic panel located on
pump room floor.
Su pervijory C o n I rol
AlarmmdSafety Systems 13 systems: Low & high levels, burglar, station start-up, engine malfunctions, etc.
Automatic E tr Pro m (e Pow F ire) Standby generator for lights and chlorination (diesel-driven pumps); standby
cy ^ w "' system checked out 1 per inos.
lamtenutce and Calibration
Specm Equipment Calibrating rods for flow meters (i.e., Down Time Flow meter lines clogged; 25 hrs, out of service.
where flow is calculated from level data). Station operation not affected.
Special Operator Training Frequtncy (no /mo )
Hone Approx. 0.1/mo. (only flow meter)
Total In-PIam Man Hours/Year
50-100 (est.)
Total Cost of Outade Servic
Estimate of Over all Benefits of Instrumentation and Automation
Station has been designed for complete unattended operation, giving approx. four-fold saving In manpower.
316
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158S72005
FKIIily Ownenhip ind Address
E-2
Refponable Supervisor
Flow Rate Design (Aremge ind Mnimum) Design: 29 mgd, 29 mg storage (including interceptors)
StonnWMwColhcdonmdTnaunmt Yes _ Facilities' sole function
Type of Flint Description of Treatment Process (Attach schematic diagram for process monitoring and control sy^temi >
Stores and sterilizes overflow from storm and combined sewers. Any excess overflows to Jamaica Bay,
Hypochlorination. Grit removed; sludge exported.
Performance Dili (Individual Units and Overall)
Preliminary data (10-31-72) indicates good storage, sludge removal. Hypochlorination system being de-bugged.
Ye* Burii. 1972
OngmalCosl $17 Million
Modifications (Year and Description)
Modification Cost
mtnimenution Includes rainfall, flow, level, density, and residual chlorine measurements; dosage rate control an(j
flow computed from level and velocity.
Equipment Costly Fischer & Porter, pneumatic. See below.
Panels Main panel 6x6 ft., enclosed; 12 loops (mostly open). 29 Indie, or Record inst's. on 19-linear-foot
panel.
Installation and Stari up CosU Qnavai lab le Original Con $ 35K Tcfal C >sl
n Modification
Destnptioi
Computer
Type
Process Control
Data I ogging
Storage
Software Dcscnpti
Computer Cost
centrii Control Hypochlorination rate (Auto, or Manual). Extensive in-plant transmission. 7 automatic records.
Supervisory Control Alarms telemetered to remote supervisor.
Alarm and Safety Systems
Automatic Emergency Program (e g , Power failure)
Maintenance and Calibration Plant S tart-Up not yet complete
Special Equipment Residual Chlorine Titrator
Special Operator Franing None
Total In Plant Man Hours-Year 3QQ (Est.)
Total Cost of Ou lade Servite
and Automatic
Note: Plant not yet fully operational (cannot control
hypochlorination automatically); but plant only operate
i*nTine to handle stormwater overflows, is Idle- otherwise.
Estimate of Over all Benefito of Insln
System for open-loop chlorination control not yet de-bugged, (10-31-72)
Expected benefits from reducing manpower requirements have not yet been r
•ealized.
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No. 1S8-S72006
Facility Ownership and Address
E-3
Responsible Supervisor
Row Rate Design (Average »nd Maximum) 2** mgd i drains 240 acres
Storm Water Collection and Treatment Yes, plant treats overflow from combined system during wet weather.
TypeofFlant Descnption of Treatment Process (Attach schemata d.agram for process mon.tor.na and control systems.) Wet-weather Satellite plant: combined overflow
chlorinated and subjected to dissolved air flotation with the aid of alum, caustic and polyelectrolytes. Sludge
pumped to North Point MWT plant.
2 o
Performance Data (individual Units and Overall) TSS=90% @ 1 ,OOOgpd/FT ; 3 15% @ 5,OOOgpd/FT . This data was obtained from Eiig. Sci. but
Plant Engineer doubts the validity of this information. No operational data.
Year Built 1970
OngmaiCost $2.1X106
Modifications (Year and Descriptor.) Corrective measures
Modification Cosi 1Q72
Instrumentation
Equipment All-electric instruments and controls, mostly F & P; Flow-control loops; open-loop flow-proportioned
chemical addition.
*" s 10-ft. operator console.
Installation and Start-up Costs ,
N/A
Original Cost^ 7 5, 000 Total Cost
instrumentation Modificatii
Changes to correct faults in 1972
original design.
Bubble-type
level detectors
Automatic
samplers.
Telemetry
Total
30K
Compui
Typ.
None
Process Control
Dala Logging
Storage
Software DesciiptH
Compute! Cost
Pmrameler/Frequi
Parameter Frequenty
Panmeler/Frequenty
Centra) Control
In-plant (satellite plant only)
Superviaury Control
No
Alum and Safety Systems Equipment status - panel alarms
Automatn i-metgency Program (e g, Pi>*cr (-aiiurc) Stand-by generator for lights and hydraulic gates - no process power
Maintenance and Cal.bration
Special Equipment DoWn nme 100%,until needed; can be operated manually.
SpwiaJ Operator liammg InstTUUent tech. (by Contract) Krequ.my (no/mo t
Tola) In-Plant Man Hour,/Year
Total Coal of Outsde Serme
Esiimaieof Overall Benefits of Instrumentation and AutomaiMm Notwithstanding the designers' intention of unmanned operation, automatic
start-up and other control devices are not reliable enough for unattended operation of the Baker St. facility. In
fact, this facility never automatically responded to overflow events. As a last resort, 3 operators have been
assigned to a 24-hr., 3-shift watch during the rainy season (about 6 mo.); operators manually control this plant.
With the exception of plant meters, none of the instruments bave operated acceptably. Moreover, the plant was not
properly maintained. The plant supervisor doubts the soundness of dissolved air flotation for solving this
plant's operational problems.
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tested. In investigator's opinion^ chemical costs
are reduced about 40-50%.
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158S720O5
Facility Ownership and Address E--4
Responsible Supervisor
Flow Rale Design (Average and Maximum) Up to 28 mgd per installation (i) , to achieve 0.1 to 2.0 ppm Cl_ residual
Storm Waler Collection and Treatment Sole function - EPA demonstration,
Type of Hani Description of Treatment Process (Attach schematic diagram for process monitoting an
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GENERAL SURVEY QUESTIONNAIRE
Form approved
OMB No 1S8S72006
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Facility Ownership and Addre
Responsible Supervisor
Flow Rate Design (Average and Maximum) Not applicable
Storm Water Collection and Treatment Combined Sewerage Retention System.
Type of Plant Description of Treatment Process (Attach schematic diagram for process monitoring and control systems-}
Computer-directed system to utilize maximum storage within trunks and interceptors of combined sewerage.
The system includes regulator stations, pumping stations, river and sewer quality-monitoring stations, and rain gauge
Central digital computer with telemetry network to remote terminals.
Performance Data (Individual UniU and Overall)
Average reduction of overflow volume - 52%.
1971 - Installation
YearBuut Ig72 - Programming & debug&fe*g«"on'd.ric«t,onCost
EPA Demonstration Grant) Does not include cost of pump stations and regulator.
Instrumentation
Equipment Electronic (Telemetering over leased telephone lines); some pneumatic and mechanical.
Central control panel at Metro office.
pwieis Sub-panels at two STP's within the controlled area.
Sub-panels at pumping stations, regulators, and quality-monitoring stations.
installation »nd Start up Costs 2-man years to tune in OngmaiCost TotaiCosi $3.1 Million Philco-Ford Contract and interfacing.
^quipment. $700tjQO for programming.
Instrumentation Modificalioi
Description
Fire Monitoring System
Addition of one STP
Computer Console
1973
1973
Time sharing computer
console
Local sub-panel
Total
$20,000
$31,000
Computer Sigma II Computer
Type 16-bit word machine
Xerox Data Systems
Cathode Ray tubes. Digital inputs and
., D contact outputs. Peripheral equipment;
evice* carci punch^ card reader, paper tape
punch, pager tape reader, line printer, off-line c
punch, ofr-line card verifier, off-line tape prepa
lator stations. unit, plotter, operator s console. Remote treatmen
, , plant keyboard input, printed display, telemeterln
logging of alarms, operating data, Remote data collection and loa-to-digital converte
ta. 2 treatment plants and 35 remote multiplex units, Eelemetefif[gsufilts|g&tei (-ur"'eri-e
Process Control Speed control of pumps at pumping stations and
gates at regulator stations
Data Logging- Extensive data
and quality da
monitoring stations. pM;
.rd'
ation
Alarm functions; once every Elf rf!^?gl?lfld0nC
hour logged date, time, tfatej time, where,
where, what. Also repair (what. Levels, flow;
status. Scanned, 1-mln. get,points, gate
intervals. ro^«i nsf ? 9ra?e
»"«" installation engineer)
^Telemetering; Equipment $238,18.7 "...._ _. _.
Remote control of influent level adjusts set point signal for automatic speed control of pumps; remot
upemsory on control of overflow quality adjusts set point for automatic operation of regulator gates.
Alarm and Safety Systems YeS
Automatic Emergency Program leg Power Failure) System will restart automatically after power failure; no standby power, (may be
added later)
Maintenance and Calibrati
Special Equipment
TCU simulators, oscilloscope, digital voltmeter,
photoelectric digital rpm counter, r^ Tl_
electronic test,pressure gauges, etc.
Very little
per year.
^Resident Inspectors trained for maintenance by Metropolitan Engineers.
8,320 man-hours (2 men - full time from (Total operation and maintenance cost - $200,000 per
each of 2 Divisions)
Total Cost of Omsxie Servue $2,000 per year.
Total fit-Plant Man Hours'Ye;
year)
Estimate of Over all Benefits of Instrumentation and Automation
Reduction in pollution from overflows of combined sewerage system.
Eliminated manpower overtime by automatic speed control of pumps.
Quicker response to alarms in order to make repairs.
Uniform flow to sewage treatment plants, thus improving treatment, postponing expansion, and furnishing better
information and accumulated data for engineers.
333
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rol units gave good performance, but
3 scans in 45 seconds doubled (to 6
; some false alarms still occur .
RF noise is a problem in transm
occurred from noise bursts. Fi
partially successful . Frequency
system to augment auxiliary con
noise still a problem, Origina
in 45), but slowness is unwieldy
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resolution.
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personnel . Measures actuator ,
except for minor slope and poor
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capable of remote supervisory cc
backup.
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frequent cleaning. Algae and sc
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Typical pump system; works very well, There are 19
pumping stations within the system; all are
similar but differ in details,
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15 regulator stations within the system; all are
similar but differ in details.
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NOTE: Pneumatic instruments were converted to
electronic, starting in 1968, to be compatib
with CATAD system (especially telemetry)
and avoid excessive air consumption.
System designers feel that pneumatic
instruments (from a few, highly reputable
manufacturers) are more reliable than
electronic inst's., where manufacturers are
apt to be less qualified.
.
q
System not yet fully engaged, but it successfully
monitors, controls, collects data. Scheduled to be
fully On~llne,mid-'73, with final report in
Augustjl973.
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158-S72005
Facility Ownership and Address F~2
Responsible Supervisoi
Row Rate Design (Average and Maximum) Wastewater: 750 mgd DWF; up to 12 mgd in storms
Siorm Water Collection and Treatment No . Water and wastewater system monitoring
Central monitoring and control station for metropolitan sewage system monitors rainfalls, sewer levels, pumps,
overflows, and pump stations; controls pumps, sluice gates.
Performance Data (Individual Units and Overall)
General reduction in manpower and in overflows to the river
, n -,„ Modifications (Yew and Descript
Ye.rBuU«
Original Cos
S2.1M
Modification tosi
11 S1.5M
1972-1973^Replaced computer; extended system to control
more locations.
Level cells, rain gauges, proximity switches, electrodes, transmitters, scanners.
nstrumentarji
Equipment
r«ndi one, central (by Quindar)
Installation and Start up Costs
inUtion Modifies
I * S
Panels
Control Data SC-1700;
Hazeltine CRT, Disc Data Logging (2.4M word)
Modified computer Under construction
New emergency system will allow local stations to override remote control on communications failure.
Computer
Type PDP-8 (being replaced)
Process Control
Data Logging
Digital Equip. Corp. I o Devices Input - FSK telemetry and teletype
Output - Teletype, alarms, and analog
recorders
Parameter Frequency
Levels , every
5 minutes
Parameter Frequency
Rainfall, every
5 minutes
Parameter /Frequency
Status - on
occurrence
Parameter/Frequency
Functional scan -
continuous
Storage 4K in core, 32K on disc.
Software Description Scaling, alarms, logging
enirai control At downtown Water Board Building
Supervisory Control Remote control of pumps and sluice gates.
Alarm and Safety System* High-low and trend alarms, plus alarms from functional scanner.
Automatic Kmergemy Program (e g , Power Failure) None
Maintenance and Calibrahon Automatic checks for time and tOu6 .
Spec.aiEqu.pmeni Scanner tester, telemeter tester, etc. Down Time 25% (9-month CPU outage)
2 2-week courses (Quindar, Acco) Frequency im>
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installed.
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-------
GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
F arm approved
OMB No 158S72005
Ficility Ownership and Address F-3
Responsible Supervisor
Flow Rate Design (Average and Maximum)
Storm Wafer Colled ton and Treatment
Type of Plant Description of Treatment Process (Attach schematic diagram for process monitoring and control systems )
Rain gauge network and movable level transmitters are used to gather data on various parts of the city.
Performance Data (Individual Units and Overall)
Data collection only, for off-site reduction and refinement of $140 K run-off model.
Year Budt Modifications (Year and Description)
Original Cost, Modification ( ost
Instrumentation
Equipment Raingauges, level transmitters, telemetry system, and cata-gathering computer.
Panels No
Installation and Start-up Costs Original Cost Total Cost
Instrumentation Modification Minor
Description
Computer
Type,
Process Control
Data Logging'
GE-FAC-30
No.
Parameter/ Frequency
12 rain gauges Rainfall;
12 sewer levels Once every 45
seconds
Parametet/Frequi
Sewer Level
(fair weather):
1 per hour
Parameter/Frequency
Sewer Level
(stonrs):
6 per hour
°-5V, via variable tone (Quindar).
Punched tape output, plus optional
teletype.
Parameter/Frequ<
Rainfall trip point:
0.45"
Storage: 8 K
SoftwareDescriptwn Developed on-site for $100 K hydrograph model b> Watermation (Batelle)
Computer Cost Software Cost Installation Cost
Central Control NO
Supervisory Control No
Alarm *nd Safety Systems (Jo
Automatic Emergency Program (e g , Power Failure)
None
Maintenance and Calibration
Special Equipment Elect. & pneu. (for bubblers)
Special Operator Training NO
Tola) ln-Plant Man Hours/Year Est. $1, 000
ToUlCoMofOuHdeServ.ee ^St. $2,000
Down Time None
Frequency (no /mo )
Estimate of Over-all Benefits of Instrumentation and Automation
Provides accurate hydrographs, checks on storm-drain capacities, helps upgrade model of area.
340
F-3
-------
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341
-------
GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB Mo 158-S72006
Facility Ownership and Address
F-2
Responsible Supervisor
How Rale Design (Average and Maximum)
Swrm wa
Instrumentation
fcquipment Raingauges, level transmitters, regulators, and "Fabridams"
Panels No
Installation and Start up Costs Original Cosi Total Co ,t
n Modifica
Continuing improvement s .
Description Year tquipmenl Panels
DEC mag. tape preferred to disc as more trouble-free, more flexible,
Computer
Type PDP-9
Process Control
Digital Equip. Corp.
Paper tape reader and punch; numbers
33 and 35 teletypes; line printer;
magnetic disc and tape systems; analo;
recorders.
Rainfall;
1 per hr. (dry)
12 per hr. (rain)
Levels and dams:
1 per hr, (dry)
Control:
Manual
Fabridam
Pressures:
1 per 3 hrs. (
Storage 2AK words in core
2.5M words on discs
Fortran and assembly
Compute! Cost Software Cost
Installation Cost
Central Control
supervisory Comroi
Alarm and Safely Systems ^o
AuiomatK Lmergeniy Program (e g Power I ail
main treatment plant
Maintenance and Calibration
Special Equipment gouL^ne elect, and pneumatic.
Speual Operator Tiaming
DownTime g _ 5% (1 ^ _ ^ ^ ^^^
Ffequenc>(nomo( Q^
Total In-PI ant Man Hours, Yea
Torat Coil of Oulsde Service
6,000
Est. S3K
Reduced run-off to river ($1,75M investment equivalent to $200M plant).
Produced workable hydrograph model for area.
342
F-4
-------
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£ 3"
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158S72005
F»ciJity Ownership and Ad(
Responsible Supervisor
Flow Rate Design (Average and Maximum) 250 mgd av., 600 max.
Siorm Water Collection and Treatmeni No
System montors and totalizes sewage flow into the area.
Performance Data (Individual bnits and Overall)
3 to 5% overall accuracy achieved for" billing purposes.
Ye*i Built
Original Cot
1970
Modifications (V
Modification Co;
Instrumentation
Equipment Local flow transmitters, telemetry system, computer
Panets No
Installation and Start up Costs Original tosl Total Cost
Instrumentation Modification
Dewnphon
Computer
Type MH 316 (CSI-2000) Manufacturer Control Systems 1^0Devices Data Concentrators (Telemetry)
Industries Data storage disc
Process control No ASR 33 Teletype
DatsLogpng (15-second pulses received by computer as priority interrupts).
Parameter'Frequency Parameter frequency Parameter/Frequency Parameter /Frequency
Storage 16 K words in core
756 K words in each disc
Software Description
Assembly language, with diagnostic routines, off-line capabilities.
Computer Cost Software Cost Installation Cosl
S350K
Central Control
No
Supervisory Control
Alarm and Safety Systems
AutomalK Emergency Program (e g , Power Failure) None
Maintenance and Calibration
Special Equipment
Special Opera lor Training
DO*n rime 22 days in first year
frequent), (no rm. I Q _ 5
Total (oit of Ouiside Service Still on warrant!-
Automatically and accurately collects area sewage-flow data for billing outlying areas.
345
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 158-S72006
Facility Ownership and Address G-l
Reaponvbie Supervisor
Row Rite Design (Avenge ind Maximum) 45° SPm (Avg.)
Storm w«ter Collection and Treatment Treats Combined Storm Water from 11-acre site at a Pilot Test Plant.
Type of Flint Description of Treatment Process (Attach Khemaltc diagram for process monitoring and control sy> terns )
Pilot Plant for treating combined stormwater by microstraining and chlorination.
Performance Data
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Recorder: 1) differential pressure
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is in operation. j
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Speed control essential to effective operation.
Performance good for pilot-plant service in which
used.
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351
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Facility Ownership and Address _ _
t_r—£
Responsible Supervisor
Row Rate Design (Average and Maximum)
Storni Wiler Collection and Treatment
GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No 15S-S72006
1QQ ^ QQQ
Pilot Plant with complete physical chemical and completely mixed actived sludge capabilities.
Performance Data (Individual Units and Overall)
Yeai Built
Original Cost
Modrfications (Year and Description)
Modification Cost
instrumentation pH,D.0. , magnetic flow meters, NH3 & P04 analyzers, free residual chlorine, total residual chlorine.
Equipment Alarms, status indicators
Pand* Central control for physical chemical plant; no control panel for biological system.
Installation and Start up Costs- Original Cos! Tola! Coil
Instrumentation Modification
Descriptn
Computer Mini-Process computer
Type J.BM System/7
Process Control yes
Data Logging yes
Manufacture, IBM
Teletype and magnetic tape cassette
(development in progress)
None
Storage
Software Descnpl
Computer Cost
0(1 Chemical control algorithms
$100K to»»««con $?5K
Central Control
Yes; one panel for P.C. treatment (no panel for biological treatment).
Supervisory Cunlrol
Alarm and Safety Systems
Automatic femergency Program (e g , Power Failure) None
Maintenance and Calibration
Special Equipment Full pneumatic and analytical instr, shop rjown -,me
Special Operator Training Instrument Engineer and iechniciatfrequentj
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unsuitable for AWT-process monitoring and/or control.
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monitors wt . of lime added to primary
Satisfactory analog control; excellent
cers require much more maintenance ,
>out 700 mh/yr.
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control is essential for effective
chlorination. Most plant operators could
Lly control this process. Analog
break point chlorination yields marginal
,e ; DDC improved break point control.
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Farm approved
OMB No 158-S72006
Preliminary Survey *
Facility Ownership ind Address H-l
RefponaMe Supervisor
Flow Rate Design (Average and Maximum! 15 mga max. and avg .
Storm Watei Collection and Treatment principal function
Stormwater-treattnent demonstration plant.
Performance Data (Individual Units and Overall)
N/A
YearBuiII Under COnstr. during 1971(o
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361
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GENERAL SURVEY QUESTIONNAIRE
Form*
OMB No 1WS720Q6
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Preliminary Survey *
Facility Ownership and Address „ ~
Responsible Supervisor
Flow Ra.eDes.Bi, (Average .nd Maximum): 7'7 m«d max • and 3V8 •
Stonri Water Collect™ and Treilment Principal function
O'Brien & Gere, Syracuse
Type of Flint Description of Treatment Process (Attach schematic diagram for process monKormg and ton (tot systems I
Swirl chamber for stormwater treatment
Performance Dili (Individual Units and Overall)
N/A
Year Built Under COnSt. during 1973 Modifications (Vex and Deseripuon)
Expected completion 4/73
Original Coit Modification Cost
$65,600
•"•'Plant designed, construction in progress.
Instrumentation
Equipment Bristol, Drooks
Panels
Installation and Start up Costs
Output and recording equipment included
t $12,287ToiaiCost in cost estimate.
Instrumentation Modification
Description
N/A
Computer None directly involved. Process data is collected for later reduction in remote engineering office.
Type Manufacturer I/O Device*
Process Control Each measurement of flow produces a punched tape for future analysis. Digital readout.
Data Logging
Parameter/ Frequency Parameter Frequency Farameler/Frequency Parameter/Frequency
Storage
Software Description Tapes will be fed into office IBM 1130 located In O'Brien & Gere office.
Computer Cost Software Cost Installation ( ost
Central Control
Supervisory Control
Alarm and Safety Systems
Automatic Emergency Program (e g.. Power Future*
N/A
Maintenance and Calibration
Special Equipment
Special Operator Training
Total In-Plan I Man Hours/Year
Total Cott of OuMde Service
N/A
Down Time
Frequency (no/mo)
Estimate of Over-all Benefits of Instrumentation and Automation
Design data obtained by measuring overflow effluent and debris effluent.
Disinfection control has aided in meeting effluent health requirements.
362
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To be maintained by County personnel. Data
reads out on Digitera unit^and a punched tape is
generated.
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Typical open- loop treatment proportional to flow.
Proprietary design undisclosed.
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
B No. 158-572006
Preliminary Survey *
Facility Ownenhip and AddreM. H~3
Retponnblc Supemaor
Flow Rate Design (Average and Maximum): N/A
Storm Water Collection and Treatment Sole function
Type of Mini D«scnption of Treatment Process (Attach schema I* diagram tot procew monitoring and control systems.)
Performance Data (individual Units and Overall) Stormwater overflow treatment and control.
YemrBuiit Anticipated completion Modification* (Year and Description) *System designed, construction in progress.
1974 (late) N.B,: Not yet accepted by client. Do not release without
Est. cost $650>000 "-tawc-i OK from F. Drehwing-0'Brier, & Gere
Instrumentation
Equipment Badger Respirometer (BOD), Badger S.S. unit (not yet released for sale),
12 Badger Ultrasonic Flow Meters (12 represent about 80% of overflow)
Panels Possible use of technicians for C.O.D., etc.
Installation and Start-up Coils
Origin*! Cost
Instrumentation Modification
Description V«i
None
Computer Logger
Type ^ot sel
Pioceu Control
Data Logging
as yet
Parameter/ Frequency
Parameter' Frequency
Parameter/Frequency
Parameter/Frequency
Storage*
Software Dcscrrpti
Computer Cost
Principal use as Logger and Alarm
Soft*
[nilallationCoM
N/A
Central Control
Supervisory Control
Alum and Safety Systems
Automatic Emergency Program (eg , Power Failure),
Maintenance and Calibration
Special Equipment
speu»ioperatoriram.ng included in cost of purchase
Total In-Plant Man Hours/Year
Total Cost of Ou tsdr Service
ate of Over-all Benefits of Ins
and Aut
Instrumentation will be used to evaluate storm loading and determine the ability of the treatment plant to
accept the BOD & SS from Stormwater.
365
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366
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GENERAL SURVEY QUESTIONNAIRE
STATE OF THE ART
INSTRUMENTATION AND AUTOMATION
Form approved
OMB No, 158-572005
Preliminary Survey *
Facility Ownership and Add re
Responsible Supervisor
Flo* Rale Design (Average »nd Maximum) 100 mgd (1-yr. Storm) 240 hrs. operation
300 mgd (25-yr. storm) per year
Storm Water Collection and Treatment
Principle function
Storm water screening and sterilization,
Performance D«U (Individual Units and Overall)
Design (1-yr. storm): 99% coliform removal - 10% sus. solids removal
15% BOD removal
Year Built 1973
Original Cost $ 500K
Modifications (Year and Description)
Modification Cost
*The project Is being built! expected to
start mid-1973.
Instrumentation
Flow and sterilization
Equipment Flow, level, and analysis measurement; pump-de livery controls.
Panels One (centra])
Installation *nd Start-up Costs Original Cos! Total Cost
Instrumentation Modificat
Comput,
Type
None
Process Control
Dlta Logging
Storage
Software Descrtptu
Computer Cost
Parameter, Frequency
Parameter /Frequency
Parameter/Frequency
Parameter/Frequency
Central Control Yes
Supervisory Control fjo
Alarm uid S»f*ty SyMemi No
Automatic Emergency Propam (e.g., Power Failure)
Mimten»nc« tnd Calibratton
None
Special Equipment
Special Operator Training
Total In-Plant Man Hours/Year
Total Cost of Outside Service
entation and Automation
Estimate of Over-all Benefits of In:. .„ „..
Automatically controls sterilization and cleaning of overflow to Mystic River basin.
Provides pollution protection at reasonable labor costs.
367
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See other sheet .
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Closed-loop control, with inner loop controlling
pump speed proportional to channel flow and outer
(trim) loop controlling pump stroke inv, propor-
tional to res, chlorine.
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369
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370
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1 REPORT NO.
EPA-600/2-76-198
2.
!. RECIPIENT'S ACCESSIOONO.
4. TITLE AND SUBTITLE
Instrumentation and Automation Experiences in
Wastewater-Treatment Facilities
5. REPORT DATE
October 1976 (Issuing Date)
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Allen E. Molvar, Joseph F. Roesler, Robert H. Wise,
and Russell H. Babcock
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORG MMIZATION NAME AND ADDRESS
Raytheon Company
Box 360
Portsmouth, Rhode Island
10. PROGRAM ELEMENT NO. }gB043
ROAP 21ASC: Task 2
02871
11. CONTRACT/GRANT NO.
68-03-0144
12. SPONSORING AGENCY NAME AND ADDRESS
13. TYPE OF REPORT AND PERIOD COVERED
Municipal Environmental Research Laboratory
Office of Research £ Development
U.S. Environmental Protection Agency
Cincinnati, Ohio 45268
int-.firim-l 973-1974
14. SPONSORING AGENCY CODE
EPA-ORD
15. SUPPLEMENTARY NOTES
See also EPA-600/2-76-276, "Selected Applications of Instrumentation and Automation
in Wastewater-Treatment Facilities"
16. ABSTRACT
This report describes the results of a nationwide survey of instrumentation
and automation experiences in fifty wastewater-treatment plants. The data show
that the average wastewater-treatment plant spent about 3% of the construction
costs for installed instruments. This is about half the instrument utilization
rates of water supply and chemical process plants. Sensors measuring mechanical
or physical properties showed satisfactory performance records and were very
popular. Sensors measuring chemical parameters tended to be unreliable and were
subject to continued fouling from solids deposition, slime buildup and precipita-
tion. Automatic process control is only occasionally utilized in wastewater
treatment, but it performs well with sensors that have good performance records.
Approximately 20% of the visited facilities were used for data-logging computers,
and 90% of these facilities were satisfied with their systems. Process and super-
visory control computers are not well established in dry weather treatment plants,
but computers are being effectively utilized in stormwater control centers.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
*Automation, Automatic Control,
Automatic Control Equipment, Data
Processing, Digital Computers,
*Instruments, *Waste Treatment,Wastewater,
Process Control, Centralized Control
Activated Sludge,
Process Control Theory
13B
13 DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS {ThisReport)
Unclassified
21. NO. OF PAGES
379
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
371
-t? US GOVERNMENT PRINTING OFFICE 1976—757-056/5428
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