SCIENCEGATE

Despite water treatment, over time, cooling towers will inevitably develop residual mineral buildup (calcium carbonate, magnesium, sodium) on the surfaces of their equipment, that periodically must be removed through the process of blow down. During which, water is drained from the tower, the equipment is cleaned, and freshly treated water is reintroduced into the tower. The removed water is either recirculated back into water treatment or used for another purpose. 

At this Midwest power plant, the blow down water is retained in an underground bulk storage tank, and reused for irrigating the acreage around the plant. Here, an EchoSpan ultrasonic level transmitter is mounted in the tank top. The non-contact sensor provides continuous level data to the PLC, which in turn, indicates the amount of reclaimed water available for irrigation.

Clarifiers are settling tanks used to remove solid particulates from wastewater. Such impurities fall into two categories, sludge which falls to the bottom of the tank, and scum which floats and collects on the surface of the liquid. The total clarification process requires multiple stages or tanks, with each stage achieving a greater degree of purification. The movement of wastewater from one clarifier to the next is gravity fed, and fine tuning the speed of movement is critical to the process. At this Midwest municipal treatment facility, an EchoSonic ultrasonic level transmitter is installed in each clarifier. The non-contact sensor provides continuous level data to the SCADA, which in turn, correlates level height with flow rate, to determine and control the speed of gravity flow through clarification. EchoSonic is reliable clarifier level measurement.

Cutting oil is a coolant and lubricant fluid designed specifically for metalworking, such as machining or stamping processes. Sprayed directly on the cutting tool, it lowers temperatures and reduces friction, maximizing the life of the tool, while preventing rust and corrosion. Cutting oil is delivered to the machine through a high volume pumping system that continuously sprays, reclaims, filters and recirculates oil to the tools and parts. At this Northwest machining company, EchoPod ultrasonic level transmitters are mounted over the oil filter baskets. The non-contact sensors provide continuous level measurement data to the PLC, which in turn, monitors the oil height to indicate when the filters need replacement. The sensor’s internal relay also provides an independent low level alarm. EchoPod is reliable cutting oil level measurement.

Americans spend about 11% of their annual income on food consumption, and food safety is of growing concern. In 2011, Congress passed the Food Safety Modernization Act, which fundamentally reforms US food safety laws, and overall shifts the FDA’s focus from responding to contamination, to preventing it at its manufacturing and supply chain sources. In so, food waste by-products are now considered toxins, that if not properly stored and disposed of, become breeding grounds for pathogenic micro-organisms. At this West Coast food processing plant, an EchoPod ultrasonic level transmitter is mounted over a food waste sump. The non-contact sensor provides continuous level measurement data to the PLC, which in turn, actuates the pump, transferring the waste into treatment. The sensor’s internal relays also provide independent high and low level alarms. EchoPod is reliable food waste level measurement.

Electronic manufacturers use acid in the etching of semiconductor wafers, PCB substrates and electronic parts. These wet processes generate substantial amounts of spent acid waste that must be collected, remediated and neutralized, before being released to the city sewer system. At this electronics manufacturer, acidic wastewater collects in PVC sumps. An EchoPod ultrasonic level transmitter is mounted in a stand-pipe in each sump. The stand-pipe separates the sensor from surface foam that may enter the sump and disrupt the acoustic signal. The non-contact sensor provides continuous level measurement data to the PLC, which in turn, actuates the pumps to periodically transfer the wastewater into treatment. The sensor’s internal relays also provide independent high and low level alarms. EchoPod is reliable electronic acid waste level measurement.

Rail transportation of chemicals represents about 12% of freight revenue for the Class I railroad companies, making chemical bulk storage efficiency and safety important factors to the industry. Ferric chloride, a moderately strong acid, is used in water and wastewater treatment applications, as well as metal etching in the copper and steel industries. A common mode of transportation between chemical manufacturer and distributor is by railcar. At this railway terminal, aqueous ferric chloride is stored in bulk tanks, before being loaded on to rail tanker cars for out of state deliveries. EchoSpan ultrasonic level transmitters are installed on each fiberglass bulk storage tank. The non-contact sensors provide continuous level data to the PLC, which in turn, provides inventory management data to the terminal operator, and onsite tank level indication to support the manual filling and emptying process. EchoSpan is reliable ferric chloride level measurement.

Automotive paint is created in a four-step process. First, powdered pigment is added to a mixer. Then, resin is added and mixed into the powder, creating a thick colored media with the consistency of honey. Next, the sap-like paint viscosity is cut into a spray able form so it can be evenly applied on the vehicle. Finally, mica flakes are added and blended to those paints requiring a metallic finish. At this OEM paint manufacturer, an intrinsically safe EchoTouch ultrasonic level transmitter is installed on a mixing tank. The non-contact sensor provides continuous level data to the PLC, which in turn, monitors the filling and mixing processes, and alerts the operators when each stage is completed. A hazardous sensor was required due to the presence of solvents. EchoTouch is reliable paint level measurement.

The global population of beluga whales stands at just under 100,000, and the Association of Zoos and Aquariums has classified their dwindling population as near threatened, and made their preservation and rehabilitation a top priority. This exhibit display tank holds 530,000 gallons of saltwater that’s supplied from two brine make up tanks behind the exhibit. The aquarium pH and salinity are monitored and adjusted through subtle changes in the make up tank composition. Here, an EchoPod ultrasonic level transmitter is mounted in a stand-pipe, located behind the scenes, at the back of the exhibit tank. The non-contact sensor provides continuous level measurement data to the PLC, which in turn, periodically refills the exhibit with fresh make up water. The sensor’s internal relays actuate independent high and low level alarms for the aquarium. EchoPod is reliable aquarium exhibit tank level measurement.

Ultrapure water is required in many industries such as the food, microelectronic, pharmaceutical, medical and energy markets to name a few. In these applications, contaminants negatively affect the quality of the product or the equipment used to produce it. Reverse osmosis (RO) is a water purification technology that uses a semipermeable membrane to remove larger particles from water. Potable city or feed water is pumped through the membrane system, and ultrapure water, which represents 80% or more of the original feed water, comes out the other side where it’s stored for use in a process.Here, an EchoSwitch ultrasonic level controller is installed on a RO storage tank. The non-contact sensor provides continuous level data to the PLC, which in turn, actuates the RO system to refill the tank when depleted. The sensor’s internal relays actuate independent high and low level alarms for the tank. EchoSwitch is reliable RO storage tank level measurement.

When we think about wastewater treatment systems, we generally picture large industrial manufacturers with substantial waste streams, flowing into a treatment facility. But lab neutralization systems can fit under a sink, in a cabinet or nearby closet. The typical system consists of mini-lift stations, two 10-gallon chemical feed tanks and a 30-gallon neutralization tank. Just as effective as their industrial counterparts, thousands of new lab neutralization systems are deployed each year in research and test facilities across the country. At this medical laboratory, two EchoPod ultrasonic level transmitters are installed in a mini-chemical feed acid and caustic storage tank. The non-contact sensor’s, provide continuous level data to the PLC, which in turn, actuates low level alarms, signaling the lab technicians to refill the tanks. When empty, the PLC will turn off the system to further protect the pumps. EchoPod is reliable chemical feed level measurement.