1. Instrumentation for Process Control Gregg Cunningham Consultant/Trainer Three Gez Consulting Email:greggacunn@comcast.net

6. Optimizing Process Performance

10. The analysis is only as good as the sample!

11. Recommended Sample Taps X Poor , may draw sediment X Poor , avoid ells, valves, T’s and other areas of turbulence Better Poor , may draw air Best X X X

21. On-Line Process Instruments

28. Cost of Ownership

30. Installation of On-line Instruments

36. Poor Sampling

37. Optimal Sampling

38. Increase flow but still Poor Sampling!

39. Crank it up to equal lower lag time? Big price to pay! 35,800 ml/min = 9.46 gal/min = 13,622 gal/day

40. Know Your Process

47. Specific Cost/Energy Savings Points

49. MIXER FLOCCULATOR CLARIFIER FILTERS CLEAR WELL Disinfectants Hardness Turbidity pH Turbidity pH pH Waste Water Backwash Turbidity Turbidity Particle Monitoring Chlorine and / or Permanganate and / or Manganese Aluminum pH Turbidity Disinfectants Hardness Alkalinity pH DRINKING WATER TREATMENT FLOW DIAGRAM Raw Water Effluent Turbidity Chlorine Alkalinity Particle Monitoring Distribution Solids Filter Effluent SCM Recycle Filter to Waste

50. Source Water

58. Source Water Monitoring Panel

59. Flocculation Aids

64. Streaming Current Monitor

65. Monitoring Filter Turbidity

71. Turbidity Measurement Particle Count Measurement Measurement of light scattered at an angle. For municipal water/wastewater applications light scattering measurements at 90º to the incident light path. Particle counting measurements can be light scattering or light blocking. Light scattering technology is appropriate for particle sizes <1µm. Light blocking technology is appropriate for particle sizes > 1µm. For municipal drinking water applications, light blocking > 1µm (typically >2µm) is appropriate. Not a specific measurement of anything, it is a qualitative measurement A quantitative measurement of particle size and particle number. Measurement is independent of volume Measurement is volume dependent Measurement is relatively independent of flow rate. Sample can be flowing or static Sample must be flowing and flowing at a constant rate. Unit of measurement is nephelometric turbidity units, NTU Unit of measurement is particle counting must state the number of particles, particle size or range of sizes and unit volume. For example 10 particles per ml > 5µm or 200 particles per ml 2-5µm. Peak wavelength response for lab, SS7 and 1720 series process is ~560nm, FT660 is 660 nm, for Accu4 ~ 850nm Wavelength is 790 nm Theoretical particle size sensitivity 10 -8 m (0.01µm) 2200 PCX sensitivity is > 2µm Turbidity Measurement Particle Count Measurement Size range from approximately 10 -8 m - 10 -3 m (large molecules to sand) For the 2200 PCX: 2-750 µm Color in water is a negative interference except for the Accu 4 Color does not interfere with particle count measurements Turbidity interferes. High turbidity is a negative interference. At high turbidity scattered light is blocked or absorbed by the large amount of turbidity and thus does not reach the detector. The turbidity will be false negative. This phenomenon is called ‘going blind.’ Turbidity interferes. High turbidity is a negative interference. Particle counters typically have a range of approximately 17,000 particles/ml > 2µm. The particle counter may be over range at turbidity between 1 and 10 NTU – typically approximately 5 NTU. The particle counts will be false negative. Light absorbing materials (i.e. activated carbon) are negative interferences. Light absorbing materials (i.e. carbon) block light well and thus are counted. They do not interfere Accuracy of measurement is influenced by particle size Accuracy of measurement is influenced by particle size Accuracy of measurement is influenced by particle shape Accuracy of measurement is influenced by particle shape Accuracy of measurement is influenced by a particle’s refractive index Accuracy of measurement is influenced by particle’s refractive index

72. Particle Sizes Practical Measurement Size in Meters 10 0 10 -10 10 -6 1 Meter- Boulders 1 Angstrom Ions Bacteria/Silt & Clay Viruses/Colloids Sand Multicell Organisms Visible Microscope Electron Microscope Turbidity Particle Counting 10 -3 10 -8

74. 1720C and PCX-10 Response to Fluoride and Carbon

96. AWWA Recommended Backwash Limit (10 - 15 NTU)

97. Large Filter with a 17,000 gpm BW Rate

109. Typical Data From BW Monitoring

112. After Installation of Stilling Chamber

113. Large Filters Filter Side A Filter Side B BW Trough/Launderer BW Trough/Launderer BW Trough/Launderer BW Trough/Launderer BW Trough/Launderer BW Trough/Launderer Flow Common Drain Gullet Mount Permanent Probe here to look into the stream Use second probe to move around the filter to assess uniformity of backwash

121. Surface Wash On 4,000 gpm 6,000 gpm Surface Wash Off Surface Wash On 3,900 gpm Surface Wash Off 6,000gpm 5,300 gpm 2,000 gpm

127. Sample Calculations of Savings

142. Disinfection Control

147. Ozone Residual Loss in Sample Line

152. Chlorination Curve Chlorine Added Chlorine Measured

154. Chlorination Curve Chlorine Added Chlorine Measured Chloramination I 5:1 Cl 2 :N Ratio

157. Chlorination Curve Chlorine Added Chlorine Measured Chloramination I Breakpoint 9:1 Cl 2 :N Ratio II 5:1 Cl 2 :N Ratio

159. Chlorination Curve Free Chlorination III Chlorine Added Chlorine Measured Chloramination I Breakpoint 9:1 Cl 2 :N Ratio II 5:1 Cl 2 :N Ratio

163. Chloramination Species Free Chlorination III Total Chlorine Free Ammonia Chlorine Added Chlorine Measured Chloramination I II

165. Chloramination Species Free Chlorination III Total Chlorine Free Ammonia Monochloramine Chlorine Added Chlorine Measured Chloramination I II

167. Chloramination Species Free Chlorination III Total Chlorine Free Ammonia Monochloramine Free Chlorine Chlorine Added Chlorine Measured Chloramination I II

169. Where Am I When Total Chlorine = 3mg/L? Free Chlorination III Chlorine Added Chlorine Measured Chloramination I II

170. I Am Here! Free Chlorination III NH 2 Cl = t-DPD f-NH 3 N > 0 NH 2 Cl < t-DPD f-NH 3 N = 0 t-DPD > 0 NH 2 Cl = 0 f-NH 3 N = 0 Chlorine Added Chlorine Measured Chloramination I II

173. Distribution

182. How the Algorithm Works Baseline Estimator Gain Matrix A Distance Measure Unit Vector Formation using Y(t) Vector Search X(t) Five Parameter Signal Vector Baseline Deviation Y(t) + - Resultant Vector Report Best Match Vector Libraries ( Agent, Plant ) A two-step process is used: Trigger when deviations indicate agent Classify agent in response to Trigger Is Threshold exceeded? No Yes Trigger Signal Threshold Level Trigger

183. Plant Event Defined Name: Pump Shut Off, Type: NORMAL

184. The plant uses caustic feed to control water pH and experienced an operational problem that resulted in the feed of excess caustic. That affected the pH and the conductivity of the water, causing the Event Monitor to alarm. The Event Monitor learned this Plant Event and can identify a recurrence of the event.

185. Road work near a distribution line dislodged biomass and other particulate matter from the lining of the pipe. There was a massive increase in turbidity, which not only showed up on the turbidimeter, but also showed up as an interference in the chlorine measurement ( optical ). As expected, the conductivity and pH also showed minor changes. The increase in biomass in the water was indicated by the TOC analyzer. This event illustrates the ability of the Event Monitor to detect and alarm on unanticipated events. This event also provides a signature for the materials adhering to the walls of the pipes in this location.

186. The Event Monitor is located in a building which experiences a daily variation in water pressure. The sample variation is associated with a turbidity increase that causes a Trigger. There is also a small pH decrease at that time, possible because of increased solubility of CO2 in the water, dropping the pH slightly. This pattern is recognized by the Event Monitor as a &quot;Normal&quot; event, rather than an alarm condition.

187. Effects of Variable Demand Daily events influencing turbidity, chlorine, pH and possibly conductivity are not completely understood but suspected to be caused by water demand fluctuations in the area. May indicate need for flushing and chlorine booster.

190. Possible Chlorine Feed Event On April 3, 2007 there was a turbidity and pH increase and a decrease in chlorine and conductivity. Operator believes that there might have been a problem with the chlorine feed at the plant. However, this cannot be confirmed. The plant was using free chlorine instead of chloramines at the time which rules out the ammonia feed problem.

192. Main Break #1 The break occurred on July 30 th , 2006. The line was a 36” water main located 1.0 miles from the WDMP. Conductivity, turbidity, and chlorine spiked. There appears to be two water flow interruptions to the WDMP the night before but it’s unclear if they are related to the break on the 30 th .

193. Main Break #2 The break occurred at night on September 20 th , 2006. The exact time of the break is currently unknown, although there appears to be a flow interruption to the WDMP the previous morning. The line involved was a 12” water main which is 0.4 miles from the WDMP.

194. Main Break Event #3 August 17 at 10:30 AM Pittsburgh, PA

195. Turbidity

196. Chlorine

197. Conductivity

198. Conductivity Main Break 48 Hours Before

200. A driver who was able to rescue a vehicle follows a man on foot out of a flooded parking garage, following a water main break

201. More than 20 million gallons of water poured out and into nearby parking garages and other low-lying areas Downtown.

202. Workers move a section of new pipe into position as the broken 36-inch water main can be seen in the background.

204. Questions?

206. Summary and Conclusions

209. Questions?