Automation and Process Control

Automation and Process Control
Conductivity instrument

Sludge blanket monitor

The Portable Optical Sludge Blanket Tracker from Cerlic Environmental Controls allows operators to accurately determine blanket and fluff depths. The device uses a stainless steel suspended solids sensor with a built-in pressure gauge for depth. It allows the operator to preset fluff and blanket suspended solids concentrations.

The unit displays the depth at which these concentrations are reached and can store this data. It can store up to 250 sample points with time and date. The unit is supplied with a 39-foot sensor cable and waterproof enclosure that floats. The same design is available as an automatic sludge blanket monitor for fixed or permanent installations. 404/256-3097;


Conductivity instrument

The Model 4083 EC meter from Amber Science is a multi-parameter instrument for measuring conductivity, resistivity, TDS, salinity and temperature of all types of water. It has a user-friendly interface, auto range, backlit display, and RS232 output for data logging and operates on a 9-volt battery or 115 VAC adaptor. The nonvolatile memory allows parameter setpoints to be saved when power is removed. Options include a remote audible alarm box that buzzes when measurements fall above or below the user set limits. Flow cells and dip cells are available. 541/345-6877;


Remote monitor

The NanoCourier Field Station from Automata is a tool for applications such as sending flow or soil moisture data. The unit is available with either spread spectrum communication to a base station or satellite telemetry with the convenience and flexibility of data display on the company’s website. Its low standby current makes it well suited to solar sites. 530/478-5882;


Multi-channel controller

Burkert Fluid Control Systems has developed the MultiCELL Type 8619 multi-channel controller for water treatment applications. In reverse osmosis systems, the controller can be used as a flow indicator, or to measure the ORP value or percentage retention value. It can also be used for control tasks such as regulation of pH and the dosing of chemicals and ratio control. The modular controller is adapted at the factory to the application and customer specifications.

The standard version includes the user interface, the main board and AC adapter, two analog and digital outputs, and two digital inputs. Six slots are available for connecting additional boards. The large, configurable graphic display with backlighting can display up to four readings at once. Further parameters and user-specific pages can be displayed by scrolling.

The digital and analog signal outputs enable transfer of process data and status signals. If more than two of these are needed, an output card with two additional digital and two additional analog outputs can be installed. All process values can be stored on SD cards with an optional data logger package for computer analysis using any standard software package. 800/325-1405;


Unidirectional switch

UDS1000 unidirectional speed switch with 907B sensor and rap from Electro-Sensors monitors high-service pump shafts to protect against reverse rotation. The unit is a failsafe reversal detection switch that constantly monitors a shaft to ensure that it is rotating in the correct direction. Relay contacts in the unit can be used to electrically lock out the starting circuit of the pump to prevent accidental startup during a condition of reverse rotation.

It continuously monitors incoming pulses from the sensor and magnetic wrap. A relay output is electrically interlocked directly to the motor starter circuit for the pump. If the slightest reverse rotation of the pump shaft is detected, it disables the pump starting circuit, preventing catastrophic damage caused by startup during reverse rotation. 800/328-6170;


Level transmitter

The Levelflex FMP55 multi-parameter level transmitter from Endress+Hauser measures the overall level of a liquid and the interface between two liquids. The multi-echo tracking algorithm that can track up to 20 tank echoes simultaneously as the tank level rises or lowers. The level sensor has a measuring range of up to 33 feet. The transmitter offers a 4-20 mA with HART output signal plus an optional second 4-20 mA output.

It carries a SIL 2 rating as certified by TÜV per IEC 61508 and has ATEX, IEC Ex, FM and CSA area classification approvals available. The transmitter is equipped with a HistoROM built into the main housing. All setup parameters are stored on the HistoROM and, in the event of an electronics changeout, all of the information will be uploaded directly into the new electronics module. 888/363-7377;


Gas detector

The G460 gas detector from GfG Instrumentation is a rugged, compact instrument for simultaneous detection of up to six gases. Installed sensor options include infrared (NDIR) for CO2 and PID for VOC measurements. The unit offers completely automatic calibration, one-button operation, top-mounted display and interchangeable battery packs for up to 25 hours of continuous operation.

The rechargeable NiMH battery pack can be equipped with “flash light” LEDs. The large, high-resolution top display can be flipped 180 degrees by pressing two buttons. Its watertight design incorporates an impact-proof, rubberized housing. The data logger records more than 1,800 gas concentrations and alarms. The data can be downloaded to a PC for viewing, storage and evaluation. A detachable, self-powered pump is available for sampling confined spaces before entry. It allows operation of the instrument in diffusion or sample-draw mode. 800/959-0329;


Calculation and editing tools

FACE (FlowWorks Advanced Calculation Engine) for real-time data analysis, and Graphical Editing QA/QC Tools are now part of the FlowWorks software platform. FlowWorks communicates with all SCADA and GIS platforms as well as USGS and NOAA data stations. It is hardware-neutral, receiving data from all manufacturers’ flow and level meters, instruments and enterprise data systems.

FlowWorks combines graphing, analysis, alarming and reporting with other engineering functions. FACE allows real-time modeling by enabling advanced math including algebra, statistics and logic equations. A Graphic Editor simplifies data manipulation by providing one common graphical interface across all data platforms. 206/859-6999;


Control consoles

Control consoles from Heritage Manufacturing are made of 304 or 316 stainless steel or a combination of stainless steel and painted mild steel. The consoles can be equipped to run all phases of water treatment plants, including pumps, injectors and filtration units. PLCs and HMIs are easily incorporated into any of the console designs and can be modified for specialized applications. 402/375-4770;


SCADA panels

The TCOM control panel from Orenco Controls is a modular, programmable remote telemetry control panel that can be used to regulate booster stations, reservoirs, and community wells. Features include color touchscreens with built-in programming and real-time data acquisition and control over an Internet, cell, or phone line connection.

The panels combine the functions of relays, timers, alternators, elapsed-time meters, and cycle counters, resulting in a compact panel design, and increased reliability. Standard TCOM panels have built-in communication protocols supported by widely used software already installed on, or easily added to, most computers. The panel’s TCOM Viewer software is free and works on Windows PC computers. It provides an easy-to-understand user interface along with remote access and control, plus the ability to retrieve, sort, and graph data. 800/348-9843;


Power measurement technology

EnergyVIEW software from IntelliSys Information Systems provides smart energy metering and power measurement technology to accurately measure, trend, store, analyze and report energy data. It is available with metering and sub-metering systems that link to SCADA or directly to a PC to collect crucial energy data.

The combination of hardware and software is designed to provide an end-to-end solution from measurement to utility billing audits. It improves the speed and quality of power measurement information so facility management professionals can make better management decisions, conserve energy and reduce costs. 800/347-9977;


Desalination technology

The Zero Discharge Desalination (ZDD) process from Kruger USA maximizes the volume of product water from a brackish source while minimizing impacts to the environment caused by concentrate disposal. The technology uses a combination of reverse osmosis (RO) or nanofiltration (NF) and a patented process called Electrodialysis Metathesis (EDM), a variant of electrodialysis (ED).

In the ZDD process, RO or NF brine is sent to the EDM for polishing. The EDM removes sparingly soluble salts such as calcium sulfate, calcium carbonate, barium sulfate, strontium sulfate and reactive silica. EDM diluate, or permeate, can be recycled to the RO feed, since these RO foulants have been removed from the waste stream. Previous pilot studies have demonstrated system water recovery of 95-99 percent on brackish groundwater with sparingly soluble calcium sulfate and moderate silica levels. 919/677-8310;


Gas detection transmitter

The OLCT 200 fixed transmitter from Oldham is used in monitoring for hazardous levels of gases. It is designed for use with multiple gas detection technologies including electrochemical sensors (H2S, NH3, O2, and others) and infrared sensors that detect combustible gases in more severe conditions where poisons like H2S could harm a catalytic cell.

The unit is suited for gas monitoring in remote, hazardous or difficult-to-reach locations. It can be configured for two-wire and three-wire 4-20 mA analog output, Modbus RTU digital output and wireless communication. The device offers optional on-board programmable relays, a durable explosion-proof housing to resist corrosive agents, and a cold-climate heater for operation in harsh environments. A wireless gas detection system, the self-contained transmitter includes onboard battery power and wireless data transmission for most of the unit’s gas sensors. Its 900 MHz or 2.4 GHz wireless communication is directly compatible with all Oldham WX series alarm controllers and the MPSIV mobile monitoring system. 800/338-3287;


Process control software

LabLite process control software is designed for facilities that have repetitive processes and testing requirements. Based on user rights, operators see only what they need to do their tasks.

When operators enter a result, it is immediately compared to color-coded and named limits for fast recognition. If they make an entry error or enter over-limit results, a red flag alerts them to trouble. Using the included reporting tool, anyone can create professional reports and graphs. The program can also be set up to capture instrument and SCADA data and include that information in reports. 888/954-5483;


Modular sensor system

The modular IQ SensorNet 2020 XT system from YSI continuously measures water-quality parameters anywhere in a facility for process control. It accommodates up to 20 sensors in any combination. Any sensor can be changed at any time without rewiring. The IQ SensorNet terminal has an easy-to-read digital display. It can be kept at a fixed location or easily disconnected and added to a module for a simple mobile terminal solution. Benefits include better network visibility and management, early detection of network failures, improved permit compliance, savings on energy, pump/blower maintenance and labor.

The system can measure dissolved oxygen (optical or electrochemical), pH, ORP, conductivity, temperature, turbidity, TSS, ammonium, nitrate, potassium, COD, BOD, TOC, DOC, and spectral absorption coefficient. 800/897-4151;


Online water-quality monitoring

The LiquID Station from ZAPS Technologies uses multiple detection techniques built into a single platform. The station measures a range of parameters and indicators related to source water protection and detecting contamination events — such as agricultural runoff (fertilizers, pesticides, animal waste), sewage leaks, chemical leaks, and algae blooms — immediately as they occur.

The instrument also gives water system operators data related to key aspects of plant operation, such as optimizing coagulant dose, tracking chlorine residuals and protecting sensitive membranes from particulates. It works by monitoring many spectral frequencies, using both absorbance and fluorescence measurements, to understand the constituents of the complex water matrix.

Using this hyper-spectral approach, it measures a range of key water-quality parameters in continuous real time and with high sensitivity. These include nitrate with sensitivity below 50 ppb, total organic carbon (TOC) below 20 ppb, and many more. Since it uses only light, it requires no reagents, produces no chemical waste and operates with minimal operator interaction and maintenance. 541/207-1122; www.zaps


Data acquisition and alarming

IntelliLogger data acquisition and alarming instruments from Logic Beach can be used for pump station monitoring and alarming, remote and customer site flow totalization and reporting, energy auditing, and more. With the network-enabled capability, units can be connected to the Internet via LAN or cellular modem.

With Internet connectivity, they can send out status or alarm emails and text messages, send FTP-logged data back to central servers, and serve standard and user-designed custom Web pages to a browser. The unit accepts analog, digital and Modbus inputs and offers I/O expansion capabilities via bus-connected expansion modules. Isolated inputs, 18-bit resolution and field-configurable input types provide quick, accurate interface to most signal and sensor types. Industrial frame and weatherproof, packaged systems are available. 619/698-3300;


Pump controller

The MetroTech II controller from Metropolitan Industries features a color touchscreen operator interface for intuitive setup and operation of pump systems. The controller saves energy, reduces water hammer, and provides accurate setpoint control even under demanding conditions.

The controller maintains a constant discharge pressure by varying the speed of the water pressure booster pump. It also provides real-time troubleshooting. With a built-in Web page, the system can be monitored remotely by connecting to the onboard Ethernet port. The unit is available in standard configuration capable of controlling up to four pumps, as well as in customized configurations. 815/886-9200;


Online analyzer

The TOC-4200 online total organic carbon analyzer from Shimadzu Scientific Instruments uses the industry-standard 680 degree C combustion catalytic oxidation method to support analyses from 5 mgC/L to 20,000 mgC/L full-scale. With a high-sensitivity kit, the unit can measure samples with TOC concentrations from 0 to 1 mgC/L, such as underground water and public drinking water.

A high-salt sample combustion tube kit increases the maintenance interval by 10 times when measuring seawater or other samples with a high-salt concentration. A variety of pretreatment units are available to match sample characteristics. The device offers an ECO mode to reduce waste by only using carrier gas and operating the sampling pump when needed. A carrier gas purification function is standard. A multi-functional sample injector allows for a multipoint calibration curve from a single high standard. 800/477-1227;


Controller systems

The new CDCN13 series of high-accuracy controller systems from Omega Engineering have NEMA 4X wall-mount enclosures. Features include conductivity/TDS control with choice of bleed programs, temperature monitoring, makeup and bleed water meter totalizers, a Langelier saturation index, six feed programs for four chemical additives, and a probe failure indication alarm. The device is fully programmable for complete chemical automation and can handle drinking water and wastewater treatment applications. 800/826-6342;


Chlorine sensors

The Chlorine Monitoring System from PureAire Monitoring Systems incorporates a sensor designed to provide accurate and stable readings over a wide humidity range, even 100 percent condensing relative humidity conditions. This allows the unit to be located near steam vents, in washdown areas, and in other hostile areas without compromising monitoring reliability.

The systems are available in a wide selection of models, measurement ranges, and performance features. The chlorine sensors are renewable. The units are designed for low-cost, 24 VDC operation and can be used as simple stand-alone monitoring systems or integrated into a facility-wide life safety system. 847/726-6000;


Valve actuators

IQ Pro electric, non-intrusive valve actuators from Rotork include a data-logging feature that monitors valve performance so users can forecast when valve maintenance might be required. The unit stores historical and current operating data, including valve torque profiles, number of operations, valve and actuator positions, and other vital performance and operational statistics.

Users can download the data by pointing a setting tool at the actuator. The information is downloaded wirelessly and stored in the setting tool in seconds. Then, users can upload the data to virtually any laptop PC or desktop computer. The devices integrate easily with most SCADA, PLC, and DCS networks. 585/247-2304;


Pumping control panels

The WS Series control panels from SEEwater are advanced simplex and duplex systems controlled by the company’s Smart Board, designed for water pump applications. The panels come standard with: NEMA 4X enclosure, upgraded pump protection, pump fault indicators and auxiliary contacts for accessing building management systems (SCADA). Custom options are available upon request. All panels manufactured by SEEwater and fully factory tested. They are ARRA Certified (made in the U.S.). 888/733-9283;


Event recorder

The 725B combined annunciator and event recorder from RTK Instruments uses CANbus communication technology and multi-redundant design to combine reliability, flexibility, usability and low cost of ownership. Features include modular construction available in shapes and sizes from one to 256 channels with a choice of three window sizes and six colors, interchangeable and ultrabright white LED illumination, and one-millisecond event recording functionality.

The unit has an optional universal supply for direct connection to 85-264 VAC or 88-360 VDC. Each system is supplied with six pushbuttons and dual audible alarms to cover almost all alarm applications as well as up to 32 output relays that can be configured as group relays, audible relays or diagnostic relays. 908/688-6709;


Remote connection security

The DNP3 protocol with AGA12-2 message encryption from Schneider Electric helps ensure that data is not tampered with over remote connections from the remote terminal unit (RTU) to the SCADA host. Encryption is used to essentially randomize data, so that third parties cannot view the data in a useful way.

Generally, RTUs that are monitoring-only stations do not require security unless the data monitored could be of value to competitors, or if the data contains billing or pricing information. AGA12 and full DNP3 level 4 support are offered in the company’s line of SCADAPack E Smart RTUs. The SCADAPack E may be used in a mixed DNP3 SCADA network of both encrypted and non-encrypted RTUs as required by the application. 888/778-2733;


SCADA software

Custom SCADA software for power control systems from Russelectric provides interactive monitoring, real-time and historical trending, comprehensive reporting, distributed networking and alarm management. The system enables operators to monitor and control a facility’s entire power system using full-color point-and-click interactive displays at the console. 781/749-6000;


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