Process Solutions Corp. Industrial Instrumentation for Automation and Process Control near Houston TX

Instrumentation for Wastewater Applications

Roughly seventy-one percent of the Earth is covered in water, making it one of the most important resources we have to manage. From flow meters and leak detection, to level measurement and lightning protection, our affordable instrumentation can help decrease your operation costs. 

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Instrumentation for Wastewater Treatment

Reverse Osmosis Process Control

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Reverse osmosis systems are used to remove large particles from drinking water.
Signal Conditioning for RO Processes

Reverse osmosis is a water purification technology that removes larger particles from drinking water. Reverse Osmosis (RO) works by using a high pressure pump to increase the pressure on the salt side of a reverse osmosis membrane, forcing water through the membrane while almost all (approx. 95% to 99%) of the dissolved salts remain behind in the reject steam. The more concentrated the feed water, the more pressure will be required to overcome osmotic pressure.

ElectroMagnetic Flow Meter (Magmeters)

Electromagnetic flow meters measure the flow rate within the reverse osmosis system and provides critical process data to the PLC controller.

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CS10 Industrial Pressure Transducer

In a reverse osmosis system, temperature can be measured with two-wire transmitters that provide critical process data to the PLC controller.

Temperature Sensors?

In a reverse osmosis system can be measured with two-wire transmitters. The output signals from these transmitters can be connected to a local control panel and the main PLC for data logging and easy monitoring.

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Horner PLC

Output signals from the flow, pressure, and temperature transmitters can be connected to a local control panel and the main PLC for data logging and easy monitoring.

PR 3109 Isolated Converter / Splitter

The PR 3109 Isolated Converter and Splitter can power two-wire transmitters and provides high isolation between input and both outputs. This is a great replacement for older systems where one input is repeated using an extra analog output on the PLC.

Our solution results in increased signal accuracy with super fast response time and the spare PLC analog output channels are now available for other tasks.

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Multimedia Filter

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Multimedia filters reduce the level of suspended solids (turbidity) in incoming feed water.
Signal Isolation and Conversion for Multimedia Filter Applications

Multimedia filtration produces high quality, filtered water at much faster flow rates than traditional sand filtration. Pressure measurements in the multimedia filtration system are very important because of head loss.

As the water flows through the media, solids are trapped, increasing head pressure and decreasing flow. Eventually, the flow drops to a point where the filter must be cleaned.

CS14 Differential Pressure Transducer

A differential pressure (DP) transducer is used to measure when the backwash should be initiated.

The CS14 offers differential pressure measurement as low as 1 PSID, up to 300 PSID, in both uni-directional and bi-directional pressure ranges, and offers a wide temperature operating range. 

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PR 9116 Universal Converter

The 9116A Universal Converter will power, measure, and isolate the differential pressure transducer. The 9116A can also detect any error on the 4…20 mA input signal and set a relay contact output in addition to converting an active DP transmitter to a passive 4…20 mA output signal.

Clarified Water Storage Tank

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The clarified water storage tank is used to store water from the clarifier settling tank.
Signal Isolation and Conversion for Multimedia Filter Applications

In the clarified water storage tank, a high and low level alarm is needed to control the water level. The water level is measured with a two-wire radar transmitter level meter connected to a 4116 universal transmitter.

EchoTREK Series, Ultrasonic (radar) Level Transmitter for Liquids

High performance level transmitters for liquid level measurement in sumps or tanks, for tank contents measurement, or open channel flow measurement. Installed on the tank roof or above the liquid surface to be measured, these transmitters give analog output proportional to liquid level or transmit HART digital data. 

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PR 4116 Universal Transmitter

The 4116 Universal Transmitter doubles as a power supply for the level transmitter, while its two alarm relays are connected to a digital input card using on and off delay settings. The 4…20 mA signal from the sensor is converted to a 0…10 VDC signal for an analog input card on the PLC. Its high isolation and flexible AC or DC power supply makes the 4116 a great option.

Soft Water Tank

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These water tanks hold soft water generated by chemical softening processes.
Soft Water Tank Monitoring and Control Instrumentation

The soft water tank stores water that was previously softened by a chemical softening system and the WAC DC softening process. A level transmitter is used to measure the water contents in the tank. The transmitter is powered by an isolated converter, which also transmits data to the PLC.

Acculevel Submersible Level Transmitter for Soft Water Tank

The Acculevel provides dual outputs, one analog (current or voltage), and one digital RS485. The RS485 connection allows users to retrieve both level and temperature data, interface with a PC, and rescale the analog output from 10% to 110% of the basic range.

Assembled in the USA, the Acculevel is NSF/ANSI 61 and 372 certified for use in drinking water applications and includes an internal circuit that provides a lifetime warranty against damage from voltage surge.

 

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PR 3104 Isolated Converter

The pressure transmitter is powered by a PR 3104 Isolated Converter and the signal is converted to 0…10 VDC, then retransmitted to the PLC with the added benefit of galvanic isolation and strong noise immunity.

WAC DC Softeners

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Water is softened by exchanging the calcium and magnesium in the water with sodium or potassium ions.
Water Softening Process Control

The WAC DC softeners accept raw water and soften it by removing the calcium and magnesium ions found in hard water and exchanging them with sodium (or potassium) ions.

This process is performed by passing the raw water through a bed of weak acid resin in the hydrogen form. Monitoring of the pH value in the post acid feed pump is very important in order to ensure an effective softening process. 

PR 5116B Programmable Transmitter

To monitor the pH post acid feed pump, a pH sensor is connected to a PR 5116B Programmable Transmitter. The pH signal is linearized by configuring a multipoint linearization in the device configuration software, PReset. The 0…10 VDC output from the PR 5116B is connected to the DCS or PLC.

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Filter Press Building

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The filter press uses a slurry pump to separate solids from water, following the pressure drive principle.
Water Softening Process Control

The filter press separates solids from the water by using the principle of pressure drive, provided by a slurry pump. The water is forced through the filters under pressure, enabling the filter to catch solids while the water passes through.

The filter press is a fixed volume and batch operation, which means that the process must be stopped to discharge the filter cake before the next batch can be started. As the filters are loading, system pressure increases due to the formation of thick sludge.

Horner PLC

A PLC is used to optimize the process and control the constant flow pumps through input from a pressure transducer and a flow meter. Ultimately, the PLC controls a VFD (Variable Frequency Drive) on the pump motor. 

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CS10 Pressure Transducer

Pressure transducers are used to measure and monitor the pressure within the filter press system. The pressure data is then sent to a PLC for process control.

ElectroMagnetic Flow Meter (Magmeters)

Electromagnetic flow meters measure the flow rate within the system and provides critical process data to the PLC controller.

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PR 5104A Repeater / Power Supply

Due to noise from the VFD, a robust, noise immune measurement system is needed. For filter press applications, one double channel 5104A repeater and power supply is used, providing power to the transmitters, high 3.75 kV isolation, and fast response time.

Sludge Holding Tank

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Sludge from the filter press is dewatered in the sludge holding tank to reduce volume of the stream.
Water Softening Process Control

Sludge is a byproduct of wastewater treatment. While treated water can be discharged to surrounding waters according to permit requirements, handling sludge is more complicated. Generally sludge is utilized as fertilizer on farmland, deposited at waste disposal sites, or sludge incinerated as fuel for energy generation systems.

In the sludge holding tank, sludge from the filter press is dewatered by gravity to minimize the volume of the sludge, thereby reducing the size and capacity requirements of subsequent treatment processes and equipment. Sludge pumping requires equipment that can keep viscous media moving without becoming clogged.

EchoTREK Series, Ultrasonic (radar) Level Transmitter for Liquids

An ultrasonic level transmitter is installed to perform continuous level measurement for uninterrupted monitoring of sludge volume.

Nivelco’s EchoTREK Series are high performance level transmitters for tank contents measurement or open channel flow measurement. Installed on the tank roof or above the liquid surface to be measured, these transmitters give analog output proportional to liquid level or transmit HART digital data. 

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PR 5715 Programmable LED Indicator

A simple on/off pump control function is accomplished by the PR 5715D Programmable LED Indicator, which has four relay outputs. The 4…20 mA signal from the PR 5715D is retransmitted to the control system.

Chemical Softening System

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Chemical softening systems increase water quality and improve subsequent bacterial treatment processes.
Water Softening Process Control

Wastewater is treated with chemicals in order to increase effluent quality and ensure optimal conditions for water treating bacteria. Due to the harsh nature of many of these chemicals, it is very important to dose them correctly. Dosing stations are most commonly used to control the flow of chemicals into the influent.

Level Transmitter

Level measurements are performed by using a 2-wire pressure transmitter with diaphragm seal.

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Temperature Sensors?

Temperature measurements are performed using several temperature sensors.

PR 5337D 2-wire Transmitter with HART Protocol

The temperature sensors which are wired to PR 5337D 2-wire transmitters with HART protocol. These transmitters make it possible to measure the temperature sensors in hazardous areas.

PR 5337D 2-wire transmitter with HART protocol
PR 9106B HART transparent repeater
PR 9106B HART Transparent Repeater

Signals from both the pressure transmitter and the temperature transmitters are directed back to the safe area using the PR 9106B HART transparent repeater.

Water Recycle Tank

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Water recycling tanks store excess wastewater caused by rain and other sources.
Water Recycle Tank

Level measurements are necessary to avoid overflow of the water recycling tank, which is used to store excess wastewater during heavy rain.

Water Recycle Tank Level Measurement

Overflow protection is provided by two tank level switches, which relays on level measurements from the submersible level transmitter.

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PR 9202B Pulse Isolator

Both level switches are connected to the double channel PR 9202B pulse isolator. This solution eliminates potential ground loop issues because the field devices are not directly connected to a non-isolated input card.

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PR 9113B Temperature / mA Converter

The active mA signal from the level transmitter is connected to the PR 9113B temperature / mA converter. Output signals from the PR 9202B and PR 9113B are connected to the control system.

Forced Draft Degasification

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Forced draft degasification systems remove dissolved gases from wastewater streams.
Forced Draft Degasification

A forced draft degasification system is usually a tall column, which is filled with packing or trays that bring the liquid influent in contact with a gas phase for the purpose of removing dissolved gases from wastewater.

To protect the downstream pump, a level switch in the clear well is necessary in combination with a makeup valve on the ion exchange system. The level switch is connected to a pulse isolator, which is measured by the control system. An output from the control system activates a solenoid / alarm driver to control the makeup valve.

Water Recycle Tank Level Measurement

The water level within the tank is measured with a submersible level transmitter.

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Temperature Transmitters

Overflow protection is provided by two tank level switches, which relays on level measurements from the submersible level transmitter.

PR 9202B Pulse Isolator

Both level switches are connected to the double channel PR 9202B pulse isolator. This solution eliminates potential ground loop issues because the field devices are not directly connected to a non-isolated input card.

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PR 9113B Temperature / mA Converter

The active mA signal from the level transmitter is connected to the PR 9113B temperature / mA converter. Output signals from the PR 9202B and PR 9113B are connected to the control system.

Intrinsically Safe Instrumentation for Anaerobic Digester

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Measuring and Controlling Digester Processes

In the wastewater treatment process, sludge is separated from liquid in settling tanks, then pumped into a series of digesters. Anaerobic bacteria inside the digester decompose the sludge, releasing carbon dioxide and methane gas. Thus, the digester environment is potentially flammable.

The sludge is circulated through the tank and heated to approximately 95-130°F to speed up the digestion process. Pressure, temperature level, flow, and pH are measured to control the digester environment. Since methane gas is present inside the digester, intrinsically safe interfaces are used to safely make these measurements.

PR 9202B Pulse Isolator
  • Transmits signals to safe area from NAMUR sensors and mechanical switches in hazardous areas
  • Monitors error events and cable breakage via individual status relay and/or collective electronic signal via power rail
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PR 9106B HART Transparent Repeater
  • Supplies 2-wire SMART transmitters or used for 2-wire SMART current sources
  • HART & BRAIN protocols supported and transferred bi-directionally
  • Duplicates and migrates, outputs can be sent to two different DCS / PLC / HMI or monitoring system
  • Used as splitter:
    • Channel 1 for safety loop and channel 2 for any non-safety device
    • Channel 1 and 2 connect to same safety PLC and channel 2 is used as redundant diagnostic channel
  • Monitors error events and cable breakage on input via individual status relay and/or collective electronic signal via power rail
PR 9113B Temperature / mA Converter
  • Converts and scales temperature (Pt, Ni, and TC) and active current signals
  • Monitors internal communication and stored data
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PR 9113B Universal Converter
  • Converts and scales temperature, voltage, potentiometer, and linear resistance signals
  • Supplies power and isolates signal for 2-wire transmitters
  • Monitors error events and cable breakage via individual status relay and/or collective electronic signal via power rail