SOUTHERN FLOW, INC.

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SOUTHERN FLOW, INC.

• Instrumentation Control
• Presented to
• AWPCA

Larry Sears Sales Manager 6445 Industrial Way,
Suite A Alpharetta, Ga. 30004 404-713-8327 cell,
770-667-5169 770-667-5416 fax
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Instrumentation Controls Agenda

• 1)Evolution of Instrumentation Technology
• 2)Level Flow Instruments
• 3)Composite of 21st Century Scada Systems
• 4)Role Responsibility of Todays System
  Integrator
• 5)Follow Up Questions

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Instrumentation Control Evolution

• Water Wastewater I C Eras
• Mechanical(Floats, pulleys, weights)
• Analog(controller, graphic, recorder,
  annunciator)
• Digital(PLC/HMI networked systems)

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Flow Control Technology of Yesteryear
Direct Acting Rate of Flow Controller
Floats, Pulleys, Cables, Weights Pneumatics
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Era of Electronic Instrumentation

• Analog Recorders/
• Single Loop Control
• Alarm Annunciators
• Graphic Process Display

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Todays Control Systems

• Programmed PLC
• HMI 3D graphics, alarms,
• trending, reporting
• Fieldbus Communication

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Flow Level Instrumentation for Water
Wastewater Control Systems

• Open Channel or Wetwell Options
• Ultrasonic flow(flumes, weirs) level(tanks,
  wetwells)
• Radar
• Capacitance
• Submersible
• Bubbler
• Pressure
• Closed Pipe
• Primary Element(Venturi, Orifice) Differential
  Pressure
• Magnetic Flowmeters
• Ultrasonic Flowmeters-Clamp on Doppler Transit
  Time
• Mechanical-Turbine, Propeller, PD Meters

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Ultrasonic Principles of Operation
Measures time reflected sound wave returns to
Peizoelectric transducer
Piezoelectric Effect

• A transducer converts electrical energy into
  mechanical energy
• A transducer also converts mechanical energy into
  electrical energy
• A transducer is both a transmitterand receiver

Frequency (f ) Subsonic 0 to 20 Hz Audio 20 Hz
to 20 kHz (human hearing) Ultrasonic gt20 kHz
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Ultrasonic Level Flow

• Standard Key Features
• Non Contact With Liquid
• Easy to Install
• Relatively Inexpensive
• Auto false echo suppression
• Input / output options
• 4-20 mA I/O, relay I/O
• RS-232 / RS485 Modbus RTU,FieldbusCommunication
• Built-in control algorithms
• Low power, noise immune intrinsic safety
  transducer cable

• Limits
• Powders, heavy vapors, turbulence, foam, ambient
  noise, temperature affect application
• Not used for vacuum or high pressure applications

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Auto False Echo Suppression
True Echo
Without AFES
Tank Bracing
False Echo
0 ft
5 ft
10 ft
15 ft
20 ft
Beam Angle
TVT Curve
With AFES
Echo Profile
0 ft
5 ft
10 ft
15 ft
20 ft
TVT-time varying threshold
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Radar Level(RAdio Detection And Ranging)
FM(88-108 Mhz) MW(1-300Ghz) transmission at
speed of light

• 6.3 25GHz FMCW Pulse radar
• Non Contact
• Continuous level measurement
• Liquids/slurries some solids
• Range 2 from horn to 65 ft
• No influence from vapor, temperature, pressure VS
  Ultrasonic
• Extreme Process Conditions
• Up to 302F and up to 588psi
• Threaded or flanged connections
• .2" Accuracy to IEC 60770-1
• Hart Fieldbus Communication
• -- Hydrocarbons Can be Problem

Digester Silos
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Radar Process Technology
Pulsed Time of Flight
FMCW(frequency multiplier continuous
wave) Signal Processing
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Ultrasonic Radar Easy and Flexible
Installation
Easy aimer available
1.5 Horn-19?, 2-15?, 3-10?, 4-8?
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Ultrasonic or Radar?

1. Cost
2. Vapors or gases present
3. Pressure
4. Temperature at point of measurement
5. Dielectric constants
6. Mounting and power requirements
7. Number of measurement points
8. Physical characteristics of measured material
9. Process or storage vessel
10. Chemical compatibility

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Pressure Differential Pressure

• Traditional Technology
• High accuracy (0.071.0029TD) (incl.
  hysteresis repeatability)
• High long-term stability of 0.25 per 5 years
• Measuring spans of 0.4 H2O to 5800 psi
• Exotic Diaphragms and Fill Fluids for
  aggressive process materials
• Electronics and Capsule are Independent
• 4-20mA HART, FIELDBUS
• Hazardous Area ratings from FM, CSA CENELEC
• Intrinsically Safe, Explosion proof
• Flameproof

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Pressure Transmitter Cutaway
Electronics
Terminals
LCD
½NPT
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Pressure Transmitter Locations
PT 101
V 100
Reactor
FT 100
LT 102
Orifice Plate/Venturi
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Bubbler With Gauge Pressure Transmitter

• Advantages
• Low Cost
• Simple Design
• Easy to Install
• Disadvantages
• Susceptible to plugging
• Bubbler tubes corrode/break/freeze
• Not used in closed/pressure vessels
• Requires frequent maintenance
• Requires compressed air supply

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Submersible Level Transducers
Calculation of level P ? ? g ? Hmax P
hydrostatic pressure ? fluid density g
acceleration due to gravity Hmax measuring
range

• sewage can
• Degrade seals
• Move sensor
• Coat sensor

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Venturi Flow Tubes Bernoullis Principle

• Proven/Traditional
• Profile requires 10US5DS pipe diameters
• Accuracy determined by DP/Tube/Exponent
• Rangeablity 41
• Several components to clean and maintain
• 3-4 Headloss

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Magnetic Flowmeter Working Principal-Faradays
Law of Magnetic Induction
Voltage B(field) x V(velocity)xD(diameter)
Q V x A(area) Simply stated The faster water
flows through the magnetic field, the greater the
voltage
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Typical Magmeter Cutaway
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Flow Tube Parts 1. Measuring Tube 2. Liner
(Liquid Contact) 3. Electrode (Liquid
Contact) 4. Coil 5. Junction Box w/Lid 6.
Flange 7. Body
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1
7
3
2
4
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Magnetic Flowmeter Features

• Important features
• 0.25 or 0.5 NIST-traceable accuracy
• Headloss equivalent to pipe size
• Less sensitive to pipe profiling
• 1001 flow range
• Field Calibrator verifies field accuracy
• Flow tubes (NEMA 6P) submergence
• Battery operated units available
• Fieldbus communication

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Magmeter Installation Tips

• 5 Upstream X 2 Downstream Diameters
• With partially full pipes or pipes with free
  outlet, the flowmeter should be located in a
  U-tube
• The FLOW TUBE must always be full of liquid

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Clamp On Arrangement
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Transit-time Technique
tupgttdn(_at_ no flow) ?ttup-tdn
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Doppler Meter Configuration
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Clamp On Flowmeter Advantages Disadvantages
(Doppler Transit Time)

• Advantages
• Measure Pipes From ¼ 360
• No Pressure Drop or Energy Loss
• No Moving Parts to Wear or Foul
• Maintains Calibration
• No Process Shutdown for installation
• No Need to Cut Pipes
• Large Turn-Down Ratio.3to12 M/S
• Disadvantages
• Pipe Profile Sensitive 10US5DS
• Sensor Alignment Critical
• Sealant Requires Periodic Replacement
• Accuracy .5-2
• Expensive for Small Pipe Sizes

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Clamp On Leak Detection Configuration
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Maintenance Considerations

• Verify proper installation
• Use short wire runs where possible
• Use twisted pair, shielded wire for 4-20 ma
  signals
• Power signal wire in separate conduits
• Properly seal conduits to keep moisture and gas
  from entering instrument
• Hand tighten ultrasonic transducers to avoid
  excessive ringing
• Insure proper alignment for accuracy
• Install tubing close to sensor above/below Txr as
  required
• Eg Venturi-Water flow tubing below so bubble
  stays in pipe, steam, above so condensate drips
  back toward pipe
• Ground, ground, ground!
• Noise issues/instability arise from improper
  grounding of equipment/ enclosures. Follow
  Manufacturer, UL, NEC procedures!
• Use signal isolators where possible

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Maintenance Considerations contd

• Surge protection for AC signal circuitsGas
  discharge tube, MOV, Silicon avalanche diodes,
  Hybrid solution
• Protect both ends of loop
• Use Short ground leads to provide short path to
  ground
• Note Use of fiber optic cable reduces surge
  inductive characteristics of copper.
• Ambient temperature, moisture, gas
• Air Conditioning, heat exchangers should be
  considered for high ambient environments
• Conformal coat boards for H2S gas fungicide
  protection
• Some municipalities are installing instruments in
  2ndary enclosure for back up to avoid entry of
  gases

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Instrumentation Control Manufacturers
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Composite of 21st Century Scada System
Todays Technology Offer Many Choices?

• Processor-PLC, Fixed Board, or DCS?
• HMI/Graphic Programs-Tabular or Graphic?
• Communication Mediums-Fiber optic, Twisted
  Pair/Copper, Cat5, Coax
• Network Topologies-Fiber Optic Ring, Wireless,
  Star, Daisy Chain, Line, Bus
• Field Instruments Communication Interface

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Processor Technologies Implemented
PLC
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Programmable Hardware Manufacturers

• Allen Bradley
• Bristol Babcock
• Control Microsystems
• GE/Fanuc
• Modicon
• Siemens

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HMI Functions
Scripting Trending
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HMI-Effective Management Tool
Trending

• Equipment Monitoring
• Provides predictive preventative maintenance
  data
• Scheduled Maintenance to
• Protect system integrity
• Extend pump equipment life
• Save energy
• Monitor Process Performance
• Manage expansion due to population growth
• With the ability to store and trend flows
  throughout the network, increases in demand
  become apparent and can be identified for future
  planning and engineering
• Historical information helps to identify future
  needs

Graphics, Reporting, Alarms
Provides Scale Equipment Representation Visual of
operational status complies with regulatory
reporting requirements
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HMI Software Vendors

• Citect
• GE/Fanuc Proficy
• Intellution iFix
• National Instruments Lookout Labview
• Rockwell RSView
• Trihedral
• Wonderware Intouch

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Scada SOLUTIONS
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Scada Fiber Optic
Configuration
ET200S
SCALANCE W Client Module
Mobic
Mobic
Standard Switch
Configuration PC Imap, Step 7
S7-416F, CP443-1
Fiber Ethernet Ring
S7-317/PN F
Pre-Existing System
Standard Switch
Sinamics Drives
MP370 HMI
PCS7 OS
Generic Ethernet PLC
Generic Ethernet PLC
3rd Party SCADA PN OPC Server CP1616 Card
S7-317/PN
SIMotion
X200 IRT
S7-315/PN
TI505 Ethernet PLC
ET200Pro
ET200M
SINAMICS G120
ET200S
Sinamics Drives
PN/PB Proxy
Profibus
ET200M
Profibus
ET200S
ControlLogix
Hilscher PN/Dnet Proxy
Comtrol PN/Serial Proxy
PN / AS-I Proxy
Profibus
HMS PN / Modbus Proxy
DeviceNet
ET200S
RS232
AS-I
MCC
ET200M
Vision Sensor
Bar Code Scanner
Generic Modbus Device
RF180C RFID
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Filter Consoles
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Pump Control Panels
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
Smith Utility District, Tn
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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3D HMI Development
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HMI Development
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HMI Development
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Current Instrumentation Scada Trends

• PC/internet use has created ethernet explosion
• Fieldbus instrument connectivity increasing
• Radio communication has become industry buzz
  word (VHF licensed, 900 Mhz FHSS, 2.4 Ghz)
• Complexity, responsibility, rapidly emerging
  technologies have System Integrators replacing
  traditional EC role to furnish interface items,
  such as VFDs, Smart MCCs
• Emphasis on standardization/optimization of PLC,
  fieldbus, protocol, communication, HMI from
  package OEMs(UV, Dewatering, Membrane) to
  optimize centralize data

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Wastewater Treatment Plant Scada
Network
PG/PC
Industrial Ethernet 2
Industrial Ethernet 1
Main Control Bldg
Chemical Bldg
Influent PS
Main Control Bldg
Maint Bldg
Link Maint Bldg
Maint Bldg IM
Maintenance Bldg Fieldbus
RAS/WAS
Link RAS/ WAS
RAS/WAS
VFD
VFD
Motor Mgmt
VFD
VFD
Smart MCC
RAS/WAS Fieldbus
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Automation, Communication and Plant Optimization
Scada Solutions Scope
Master Control Center
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This is Why Fieldbus is Becoming Popular!
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Which One- Hardwire or Fieldbus?
Cabinet
Planning
Documentation
Terminal blocks
Installation
Terminal block
Terminal block
Safety barrier
Service
Commissioning
Distributor
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Role of System Integrator

• Knowledge of Processes in Water Wastewater
  System
• Act as Information Resource on Latest Technology
  for Clients
• Proficiency in PLC, HMI, Networking,
  Communication
• UL508 Panel Shop for Greater Safety Reduced
  Insurance Costs
• Adequate Programming Technical Staff to Meet
  Customer Needs
• Furnish and interface to broader equipment range
  such as VFDs, MCCs
• Provide system designed to meet consultant
  customer needs

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Questions?
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The Internet Linked to FIELDBUS
City Hall
Water plant
Digital Telephone Network
Industrial Ethernet
Router
Ethernetmodule
HMI Application
Ethernet
Router
Fieldbus
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Southern Flow Motorsports