Special Applications Series:

Water and WastewaterTreatment

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Water: Essential To Life, Invaluable To Measure. In a world more focused than ever on safe, sustainable stewardship of our water resources, it is critical to continue to improve the ways in which we measure and treat potable water and wastewater. Increased public awareness drives the need for safe, accurate and reliable level and flow instrumentation, in the harshest environments, under the most extreme conditions. At the same time, the regulatory climate requires plants to implement next-generation process improvement – moving from energy efficiency to energy independence and realizing cost-savings in doing so. To effectively manage the technological demands, make your preferred partner Magnetrol®, for extensive level and flow control solutions that will help you achieve your goals.

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Level & Flow Control Applications for Water & Wastewater Treatment

Water and Wastewater Treatment Efficiency Opportunities 4–5

Liquid Level Applications 6–7

Air, Gas and Liquid Flow Applications 8

Application Case Studies 9

Level & Flow Control Technologies 10–11

Liquid Level

Air, Gas or Liquid Flow

Water Flow

Sludge Flow

Chemical Treatments

Liquid Level Applications Air, Gas, Liquid Flow Applications

Lift Station Pump Control pg. 6

Clarifier Level pg. 6

Sludge Level pg. 6

Lime Silo Dry Product pg. 7

Dry Sludge Pelets pg. 7Filter Tank Level pg. 7

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Open Channel Flow pg. 8

Closed Pipe Water/Sludge Flow pg. 8

Pump Protection pg. 8

Blower Air Flow pg. 8

Digester Gas Flow pg. 8

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Lime Slurry Level pg. 79

Chemical Feed Tanks pg. 6 Digester Level pg. 66 Carbon Slurry Level pg. 7102

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Splitter Box Level pg. 6 Water Storage Tanks pg. 7

Screening System pg. 7

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Pumping Aggregation Clarification StorageFiltration Distribution

Water Treatment

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Lime SiloDry Product

DisinfectantPolymerspH AdjustmentCoagulants

Settling Tank

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To Sludge DistributionDry Sludge Pellets

Open or Enclosed Storage

Neutralizer Fluoridation

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Wastewater Treatment

Collection Systems Influent Pumping Primary Clarification Secondary ClarificationBiological Process Disinfection

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Lift Stations

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Supernatant Return to Process

To Methane Processing

Coagulants Oxidants Phosphorus Precipitation Corrosion Inhibitors pH Adjustment Disinfection

Neutralizer

Secondary Claifier

Mixed LiquorContact Basin

Aeration Basin

Activated Sludge

Primary Clarifier

Flocculation Basin

Grit Removal

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Level & Flow Efficiency OpportunitiesThroughout wastewater and water treatment operations, numerous opportunities exist to measure and improve process conditions. The use of effective level and flow instrumentation can enhance your facility’s efficiency, safety and environmental impact.

Liquid Level

Air, Gas or Liquid Flow

Water Flow

Sludge Flow

Chemical Treatments

Liquid Level Applications Air, Gas, Liquid Flow Applications

Lift Station Pump Control pg. 6

Clarifier Level pg. 6

Sludge Level pg. 6

Lime Silo Dry Product pg. 7

Dry Sludge Pelets pg. 7Filter Tank Level pg. 7

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Open Channel Flow pg. 8

Closed Pipe Water/Sludge Flow pg. 8

Pump Protection pg. 8

Blower Air Flow pg. 8

Digester Gas Flow pg. 8

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Lime Slurry Level pg. 79

Chemical Feed Tanks pg. 6 Digester Level pg. 66 Carbon Slurry Level pg. 7102

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Splitter Box Level pg. 6 Water Storage Tanks pg. 7

Screening System pg. 7

7311

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Pumping Aggregation Clarification StorageFiltration Distribution

Water Treatment

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10987

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4 2222 2 2

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Lime SiloDry Product

DisinfectantPolymerspH AdjustmentCoagulants

Settling Tank

To Sludge Distribution

To Sludge DistributionDry Sludge Pellets

Open or Enclosed Storage

Neutralizer Fluoridation

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Wastewater Treatment

Collection Systems Influent Pumping Primary Clarification Secondary ClarificationBiological Process Disinfection

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2 2 2

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2222

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Headworks

Lift Stations

To Landfill

Supernatant Return to Process

To Methane Processing

Coagulants Oxidants Phosphorus Precipitation Corrosion Inhibitors pH Adjustment Disinfection

Neutralizer

Secondary Claifier

Mixed LiquorContact Basin

Aeration Basin

Activated Sludge

Primary Clarifier

Flocculation Basin

Grit Removal

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Level & Flow Efficiency Opportunities

Please Note: The instruments recommended in this guide are based on field experience with similar applications and are included as a general guide to level and flow control selection. Because all applications differ, customers should determine suitablility for their own purposes.

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Liquid Level Applications1. Lift Station Pump ControlProper level control in wet wells alleviates pump surging and frequent cycling, and minimizes the downstream drop of influent flumes.• Pulsar® or Model R82 Pulse Burst Radar Transmitters • Eclipse® Model 706 Guided Wave Radar Transmitter• Model T10 Tethered Float Switch

2. Chemical Feed TanksStringent level monitoring ensures consistent, ongoing chemical treatment.• Model R82 Pulse Burst Radar Transmitter• ECLIPSE Model 706 Guided Wave Radar Transmitter• Echotel® Model 355 Ultrasonic Non-Contact Transmitter • Vector™ Magnetic Level Indicator

3. Splitter Box LevelLevel control in splitter boxes helps maintain balanced routing of influent wastewater.• Model R82 Pulse Burst Radar Transmitter• ECLIPSE Model 706 Guided Wave Radar Transmitter• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter

4. Clarifier LevelContinuous level management of the clarifier level maximizes efficient treatment flow in sedimentation areas.• Model R82 Pulse Burst Radar Transmitter• ECLIPSE Model 706 Guided Wave Radar Transmitter• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter

5. Sludge LevelSludge level is monitored to control against discharge or dilution.• Model R82 Pulse Burst Radar Transmitter• ECLIPSE Model 706 Guided Wave Radar Transmitter• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter

6. Digester LevelFoaming requires advanced level control technologies for measurement accuracy.• PULSAR or Model R82 Pulse Burst Radar Transmitters• ECLIPSE Model 706 Guided Wave Radar Transmitter

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7. Water Storage TanksLevel controls in open atmosphere reservoirs must frequently withstand punishing weather conditions. • Model R82 Pulse Burst Radar Transmitter• ECLIPSE Model 706 Guided Wave Radar Transmitter• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter

8. Filter Tank LevelPre-determined tank level indicates a terminal headloss value has been reached, triggering filter backwash to remove suspended solids.• PULSAR or Model R82 Pulse Burst Radar Transmitters• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter • Model B10 Displacer Switch

9. Lime Slurry LevelLime slurry tanks are often characterized by agitation and corrosion, requiring level sensing that inhibits or is insensitive to media buildup.• PULSAR or Model R82 Pulse Burst Radar Transmitters• ECLIPSE Model 706 Guided Wave Radar• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter

10. Carbon Slurry LevelFly-away dust, difficult-to-wet carbon properties and carbon buildup call for non-contact level technologies or contact level sensing utilizing a single rod probe.• PULSAR Model R95 Pulse Burst Radar Level Transmitter• ECLIPSE Model 706 Guided Wave Radar • Thermatel® Model TD1/TD2 Flow/Level/Interface Switches• Model B10 Displacer Switch

11. Screening SystemScreening systems are usually at the headworks and are used to filter large particles.• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter • Model R82 Pulse Burst Radar Transmitter

12. Lime Silo Dry ProductLime silo dry product level monitoring for storage.• Contour™ Acoustic Volume Mapping • ECLIPSE Model 706 Guided Wave Radar Transmitter

13. Dry Sludge PelletsDry sludge pellets before distribution• Contour™ Acoustic Volume Mapping

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Air, Gas & Liquid Flow Applications1. Open Channel FlowFlow control devices must perform reliably despite turbulence, solids content, corrosive chemicals or varying flow velocities and depths.• Model R82 Pulse Burst Radar Transmitter• ECLIPSE Model 706 Guided Wave Radar Transmitter• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter

3. Pump ProtectionLow-flow sensitivity, wide temperature operation and high turndown are required of flow instruments, to prevent seal damage.• Thermatel® Model TD1/TD2 Flow/Level/Interface Switches • Model F10 Vane Actuated Flow Switch• Model F50 Disc Actuated Flow Switches

5. Digester Gas FlowFlow meters and switches that can handle low flows and low pressures, as well as a combustible product, must be selected for this application.• THERMATEL TA2 Flow Meter • THERMATEL Model TD1/TD2 Flow/Level/Interface Switches• Model F10 Vane Actuated Flow Switch

2. Closed Pipe Water or Sludge Flow Accurate and reliable water and sludge flow measurement is essential throughout water and wastewater facilities.• Polaris™ Electromagnetic Flow Meter

4. Blower Air FlowMaintaining efficient air flows (both low and high) is critical in enabling the microorganisms in the aeration basin to break down waste materials and can also reduce blower costs.• THERMATEL TA2 Flow Meter • THERMATEL Model TD1/TD2 Flow/Level/Interface Switches• Model F10 Vane Actuated Flow Switch

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Air, Gas & Liquid Flow ApplicationsCUSTOMER CASE STUDY: Pulse Burst Radar “Levels” Competition For Chemical Waste Tank Process ControlA chemical plant in Upstate New York was experiencing random failures using competitive ultrasonic level transmitters on chemical waste tanks. The units would work for awhile and then lose their output. A number of these units had to be sent back to the factory for costly repairs.

To test the Magnetrol® Model R82 pulse burst radar device, a side-by-side comparison was conducted to report outputs over a two-day period. The results, as demonstrated on the output chart, were dramatic: the competitive ultrasonic unit’s output “wandered” widely across the chart, while the Model R82 transmitter’s reading held rock solid, showing the moderate in-creases and decreases in the process level. The evidence convinced management and, within a few weeks, MAGNETROL received an order to replace all old transmitters with Model R82 units.

CUSTOMER CASE STUDY: Thermal Dispersion Technology Helps Utility Meet Federal Environmental and Health RegulationsInstrumentation plays a pivotal role in meeting regulations set forth by the Environmental Protection Agency, Department of Ecology and the Department of Health. When Lakehaven Utility District in Washington needed flow meters on air and gas flow lines serving its aeration basins and anaerobic digesters, the District turned to Magnetrol® Thermatel® Model TA2 thermal dispersion flow meter for its ease of use and ability to handle these difficult applications.

The THERMATEL Model TA2 thermal dispersion flow meters in the aeration lines maintain a minimum flow rate to prevent the diffusers from getting plugged, while also being used in conjunction with dissolved oxygen (DO) probes to provide enough flow to meet the oxygen demands in the basin. On the digester gas lines, the units measure the amount of methane going to fuel the boiler to generate hot water/steam for the plant, as well as the excess methane going to flare. Thermal flow meters are well accepted in the municipal industry to provide reliable flow measurement at low flows and low pressures.

Magnetrol R82

Competitor Ultrasonic

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Level & Flow Technologies

Thermal DispersionDescriptionThermatel® flow meters and flow/level/interface switches utilize heat transfer to continuously measure flow or to provide a switching action. A heated sensor is placed into the flow stream and as flow increases the sensor is cooled. Similar heat transfer can take place when going from one fluid to another in level applications.

BenefitsThis technology has a reputation for having a strong signal at low flow rates and low pressures with a wide operating flow range (turndown). The sensor has no moving parts and is most often supplied as an insertion probe, simplifying installation as well as future maintenance. An optional retractable probe assembly can be supplied for probe removal under operation.

Pulse Burst RadarDescriptionPulse burst radar products feature non-contact radar technology, which detects the position of process liquids by measuring the interval between the emission and return of high-frequency radio waves. The latest generation of loop-powered, 24 VDC level transmitters includes the industrial-strength Pulsar® Model R95 and, a more economical choice, the Model R82. Both units can handle difficult applications that in the past were left up to ultrasonic transmitters.

BenefitsPulse burst radar technology measures effectively even when atmospheres above the liquid are saturated with vapor. The advanced signal processing manages common disturbances such as false echoes caused by obstructions, multi-path reflections from tank sidewalls or turbulence caused by agitators, aggressive chemicals or aerators.

ElectromagneticDescriptionPolaris™ flow meters use the principle of electromagnetic induction to measure volumetric flow of conductive liquids When a conductive liquid flows past the electrodes inside the sensor, a voltage is generated. This measured voltage is proportional to the flow velocity.

BenefitsThroughout water and wastewater plants there is a need for water and sludge flow measurement. Knowing what is flowing throughout the plant and its processes is essential to maintaining an efficient operation. POLARIS flow meters have current, pulse and alarm outputs that are configurable through the display or a DTM. Forward and reverse flow rates are measurable with the capability of empty pipe detection.

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Mechanical Flow SwitchesDescriptionIn vane and disc/piston operated flow switches, the surface area of the vane or disc in the flow line determines the force of flow that will cause actuation. When the force of the liquid or gas flow overcomes the opposing forces, the vane or the disc and piston assembly moves out of the path of flow. This movement causes motion of the attraction sleeve and actuation of the micro switch.

BenefitsMechanical flow switches are renowned for their reliability, repeatability and simplicity of function. They require no power and have been proven in a variety of challenging applications for many decades.

Magnetic Level Indicator (MLI)DescriptionA float travels up and down in a chamber that is mounted to a liquid-containing vessel. The float’s magnetic assembly interacts with an externally mounted visual indicator. As the float follows the liquid surface or liquid-liquid interface, the magnetic field causes flags in the visual indicator to rotate, resulting in a clearly defined representation of the liquid level in the vessel.

BenefitsMLIs are widely used to replace high-maintenance sight and gauge glass indicators and are increasingly used in new applications. The Vector™ MLI offers rugged, industrial-grade construction and a continuous measuring range of up to 216 inches (549 cm). The unit is compatible with electronic point switches and continuous level transmitters for safe, reliable chemical feed tank control.

Acoustic Volume Mapping DescriptionThree antennas on the Contour™ unit generate low frequency acoustic signals and receive echo signals from bulk solids and powders stored in a silo, bin or other container. This enables the unit to measure not only the time/distance of each echoed signal but also its direction. A built-in digital signal processor produces accurate level, volume and mass measurements, generating a digital 3D display of the position and form of the stored contents.

BenefitsCONTOUR acoustic volume mapping achieves precise volume measure-ment, enabling visualization of true consumption for improved inventory management and process control. Low-frequency acoustic technology measures challenging applications where buildup and surface irregularities occur and maintains signal strength even during dusty filling conditions.

UltrasonicDescriptionUltrasonic pulses are transmitted and received by a piezoelectric crystal within a sealed transducer. The electronics measure the time between the transmission and reception. Since the speed of sound is known, the time for the pulse to travel to the material surface and back can be divided by two to determine the distance to the surface. This is used to derive reliable measurement of product level, volume or open channel flow.

BenefitsEchotel® Model 355 non-contact ultrasonic transmitters provide accurate measurement independent of specific gravity, dielectric constant or viscosity, across a wide range of applications. Volume applications are configured by selecting from nine standard tank shapes stored in the transmitter. Open channel flow is configured by either selecting from 35 flumes and weirs in the transmitter, or by using the generic discharge flow equation that allows for much higher accuracy than custom tables.

Displacer Level SwitchesDescriptionThe range spring is loaded with the weight of the displacer. Liquid level change results in a change in the buoyancy force equal to the mass of liquid displacer and causes the range spring to change length. The change in spring length moves the attraction sleeve, which is attached to the spring via a rigid stem, into or out of the switch magnet, causing the micro switch to actuate.

BenefitsBuoyancy technology is renowned for its reliability, repeatability and simplicity of function. The dual-stage top-mounted displacer switch allows for multiple narrow or wide differential actuation points with a single level switch. Buoyancy switches have been proven in a variety of challenging applications for many decades.

Guided Wave RadarDescriptionGuided wave radar is based upon time domain reflectometry, which utilizes pulses of electromagnetic energy transmitted down a wave guide (probe). When a pulse reaches a surface that has a higher dielectric constant than the air in which it is traveling, a portion of the pulse is reflected. Pulse transit time is measured via high-speed timing circuitry for accurate level measurement.

BenefitsThe Eclipse® Model 706 transmitter has no moving parts, is immune to changing media properties and requires no level movement for calibration. A four-button keypad and graphic LCD display allow for convenient viewing of configuration parameters and echo curves. The transmitter offers remote mounting capabilities and contains nine common tank shapes for volumetric output,and two standard flumes and four standard weirs for flow measurement.

Select the Water & Wastewater Industry’s Preferred Partner for Level and Flow Control Solutions.

Contact your MAGNETROL representative today for help in assessing your treatment facility’s

opportunities for efficiency improvement.

Accurate and reliable level, flow and volume solutions from MAGNETROL.

CORPORATE HEADQUARTERS705 Enterprise Street • Aurora, Illinois 60504-8149

Phone: 630-969-4000 • Fax: 630-969-9489water.magnetrol.com • magnetrol.com • info@magnetrol.com

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Phone: 052 45.11.11 • Fax: 052 45.09.93

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Copyright ©2013 Magnetrol International, Incorporated. All rights reserved. Printed in the USA.

Bulletin: 41-190.0 • Effective: August 2013

When you partner with Magnetrol®, you get more than world-class instrumentation. We offer an extensive line of level and flow technologies for single-source convenience, deep applications engineering experience to tackle the most challenging process control problems, and an industry-leading service network to keep your facility operating at peak efficiency.