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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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
             29%
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    NON-LABORATORY PROCESS INSTRUMENTS ONLY
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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                                                          17

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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

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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

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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.


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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
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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.
                                      46

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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.
                                      47

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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.
                                      48

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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
                                      51

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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
                                     52

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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
                                      54

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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
                                      55

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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
                                     56

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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
                                      57

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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.
                                      61

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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,
                                      63

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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)
                                     66

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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
                                    67

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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
                     68

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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.
                                      69

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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.
                                     71

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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


                                     74

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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
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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
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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.
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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),
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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.
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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.
                                     92

-------
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.
                                     93

-------
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.
                                      94

-------
                             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
                                95

-------
                    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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           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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130
                                             A-2

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-------
                                                  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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                                                    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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                                             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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                                              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
                                                                                                                                     A-9

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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

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                                                      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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                            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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                                                  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

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185

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adjust the compressors. The procedure works
L, but is cumbersome— -requiring several
jstments per day, (See previous sheet)
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                                                 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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abandoned. Part uf the problem was due to unavoid-
ably frequent start-up and shut-down of sludge-
dewatering operations .
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191

-------
                                               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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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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194
                                               B-7

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                            195

-------
                                                 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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atic operation; unacceptable performance; sludge density
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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

-------
                                                     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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-------
                                             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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ordpr to provide a more sensitive control of sewage pumps .
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into which 2 resistors were installed.

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want to make the decision on clos
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calibrated ever)
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plant personnel
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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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wiJ 1 be completely automated .
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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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f feeding only a very dense sli
D. W iw 43
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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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                                   233

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                                                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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                               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

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1 of sludge pumps. They have changed to a manual reading
dge blanket .
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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
                                                                                                                                        B-18

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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
                                                                                                                                                   B-X9

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                            257

-------
                                                   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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at present. System Design could use more flame
safety.
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                                              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
                                                                                                                                        B-20  No.  2

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                                      269

-------
                                                  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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                                                B-21

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                                    272
                                                                                               B-21

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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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                                                    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
                                                                                                                                                     8-23

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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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when sensor is kept clean.
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                                                   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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                                                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
                                                                                                                                        B-26

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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
                                                                                                                                                   01

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                                                 GENERAL SURVEY QUESTIONNAIRE

                                                        STATE OF THE ART
                                                 INSTRUMENTATION AND AUTOMATION
                                                                                                                    Form approved
                                                                                                               OMB No, 158-S72006
   Facility Ownership and Addre
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                                                   GENERAL SURVEY QUES1IONNAIRE
                                                                                                                            OMB No 1M 871000
                                                            STATE OF THE ART
                                                   INSTRUMENTATION AND AUTOMATION
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                                   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.
                                                             320

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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.
                                                             324

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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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System designers feel that pneumatic
instruments (from a few, highly reputable
manufacturers) are more reliable than
electronic inst's., where manufacturers are
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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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                                           F-2

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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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-------
                                                   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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-------
                                                   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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Performance good for pilot-plant service in which
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-------
351

-------
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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                                                     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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                                                   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
                                                                                                                                                    H-2

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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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-------
                                                    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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                                   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

-------