Wastewater Industry SolutionsComplete and Reliable Liquid Analysis
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TRUSTED AROUND THE WORLD: THE MOST ADVANCED LIQUID ANALYSIS SOLUTIONS
WE START WITH ONE IDEA IN MIND: MAKE IT CLEAN
Homes, industry, schools and businesses all generate sani-
tary wastewater, or sewage. Wastewater is +99% water
and about 0.3% dissolved and suspended solid material.
Visualize an online analytical solution for wastewater
treatment that reduces labor with rugged instruments
and sensors that provide data for increased regulation
compliance and reduced maintenance costs.
Analyze your wastewater streams to meet local and
national laws that safeguard water quality.
Optimize your multi-stage wastewater process to speed up
the natural processes of water purification.
Depend on the liquid analysis professionals at Emerson
Process Management. We’re ready to put our 60-plus years
of experience to work for you by delivering the best in
knowledge and systems, and by doing it quickly, thoroughly
and cost-effectively, utilizing world-class Rosemount
Analytical sensors and instrumentation.
Typically, wastewater treatment includesfour basic treatment stages: primary,secondary, sludge and final treatment. Inthe primary treatment stage, larger solidsare removed from wastewater byscreening and settling. Secondarytreatment is a large biological process forfurther removal of the remaining suspend-ed and dissolved solids. Sludge isgenerated during the first two stages and
is treated to convert it into a stable organicsolid. In the final treatment, wastewater isdisinfected to kill any remaining harmfulmicroorganisms prior to being released.
The various stages of wastewatertreatment include physical, chemical andbiological treatment processes. The chiefliquid analytical measurements are:
> pH
> ORP> suspended solids> dissolved oxygen (DO)> chlorination > dechlorination
For these applications and more, counton Emerson. Our full line ofRosemount Analytical products forwastewater offer proven solutions.When you bring your problem toEmerson, consider it solved.
WASTEWATER TREATMENT: A MULTISTAGE PROCESS
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PlantIntake (influent)
PreliminaryTreatmentStage
EqualizationBasin
PrimaryClarifier
AerationBasin
SecondaryClarifier
NitrificationBasin
FinalFiltration
Waste ActivatedSludge (WAS)
Return ActivatedSludge (RAS)
Gravity SludgeThickener
SludgeDewatering
Centrate
Aerobic/AnaerobicSludge Digester
SludgeDisposal
Plant EffluentDisinfection
PrimaryTreatment
Secondary Treatment
FinalTreatment
FOR MORE INFORMATION ON INDUSTRIES AND APPLICATIONS, SEE US ON THE WEB AT WWW.RAIHOME.COM
Wastewater is generated by homes, businesses,and industries and is treated in two major steps,primary and secondary treatment, with disposalof solids during both steps. Analyticalmeasurements such as pH, ORP, and suspendedsolids are performed during the primarytreatment stage in order to monitor the removalof solids from the wastewater.
Secondary treatment relies upon biologicalprocesses to further purify the wastewater,and maintaining proper dissolved oxygen (DO)levels is critical to this process. The RDOoptical dissolved oxygen sensor is the perfectchoice for maintaining the proper amount ofoxygen required by microorganisms duringbiological processes.
Final treatment consists of chlorination anddechlorination and uses the Model 499ACLchlorine sensor. The final effluent is monitoredfor compliance and reporting purposes, and caninclude pH and chlorine measurements.
Wastewater Treatment
pH Measurement • Effluent pH monitoring
Chlorine Measurement • Monitoring chlorine in finaltreatment
Dissolved Oxygen Measurement• Monitoring and controlling oxygenin activated sludge process
Conductivity Measurement• Monitoring conductivity at influentand outfall
Model 3500pH Sensor
Model 1056Analyzer
Solutions
Mechanical or Physical Separation of Solids
The main activity of treatment occurring in the
Primary Treatment stage consists of
mechanical or physical separation of the solids
from the liquid. At the plant inlet, wastewater
can be loaded with biological activity
producing nuisance odors and hazardous
gases. To prevent odors and gases from
escaping from open tanks and basins into the
atmosphere, domed covers are often used to
contain these air contaminants. In turn, these
contaminants are removed via ducting
connected to an odor scrubber using a
combination of caustic and disinfectant
chemicals. The addition of these chemicals are
controlled using pH and ORP measurements.
PRIMARY TREATMENT
Influent Treatment
In many wastewater plants, theinfluent pH and conductivity aremeasured. These measurementsare used for monitoring purposes,and will alert the plant operator of a possible upset condition. A sudden change in influent conductivity, for example, may indicate an unusual dischargeupstream from an industrial plant.
The toroidal conductivity sensorModel 228 is recommended, as it isnot sensitive to flow rate ordirection of flow, and is suitable forcoating applications such as thosefound at the plant influent.
The ideal pH range of the influent isbetween 6 and 9. A pH outside this
range is harmful to the microorgan-isms used to break down the waste-water, and a pH below 6.5 willdamage concrete.
The Oxidation and ReductionPotential (ORP) measurement will also give the plant operator an insight into the plant influent.Specifically, an increase in thestrength of the biological loading atthe plant influent will be indicatedby a sharp decrease in the ORPreadings. ORP is also gaining popu-larity as a trouble-shooting tool.
Preliminary Treatment
Large pieces of debris and othersolids are removed by large screens,preventing upstream equipmentdamage and clogged pipes. Thesematerials are a diverse assortmentof paper, plastic, toys, vegetablematter, jewelry and sometimeseven money. After screening, thesewage is passed through gritchambers for removal of heavyinorganic particles, and smallersolids such as stones, sand, coffeegrounds, eggshells and cinder. Thistreatment stage is especially impor-tant in a combined plant wheresewage and storm water arecombined and washed into thesewer system.
For monitoring influent, the ToroidalConductivity Sensor Model 228 is ideal forcoating applications and is not sensitive toflow rate or direction.
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explosion proof and intrinsically safeenvironments (NEMA 7B).
Various polymers and chemicals,such as ferric chloride and ferrouschloride, can be added at the gritchamber to assist flocculation, sedimentation and precipitate phos-phorus. The pH may also beadjusted to help the chemicals and polymers do a better job.
Primary Treatment
Organic and inorganic material,grease, oil and other suspended
solids are still present after screeningand grit removal. These smallmaterials and particles are removedin sedimentation tanks, primary clar-ifiers, settling tanks, or settlingbasins by allowing the material tosink to the bottom. With the help ofchemicals like ferric chloride andorganic polymers, waste particlesbond together in large enough massto settle out. Lime may be added forpH control to aid flocculation.
Since lime will gradually coat the pHsensor surface, a sensor withTUpH® ReferenceTechnology such asModel 396P includes alarge reference junctionfor minimal maintenancerequirements.
At this point, approximately 60 to80% of the total suspended solids inthe water have been removed. Thesebiosolids are commonly pumpedfrom the sedimentation tanks intothe sludge treatment stage, andmay be used for fertilizer or landfill,or may be incinerated.
A combined sewer system designcarries both sanitary wastewater andstorm water in the same pipe to thetreatment plant. During periods ofheavy rainfall or snow melt, thewastewater volume may exceed theplant capacity and excess untreatedwastewater is discharged to nearbystreams, rivers, and lakes. Thisdischarge disturbs the biological sys-tems, may contaminate our drinkingwater sources, and creates threats topublic health by coming in contactwith untreated wastewater. TheUnited States EPA estimates thereare thousands of these incidentseach year. Regulation, guidelines andmeasures have been established toprevent these conditions fromoccurring.
Odor problems develop in the sewer system due to decompo-sition, and odors are controlled bychlorine addition at the pumpingstations at fairly high chlorine doses(10 mg/L) and are gradually reduced to determine the minimum amount required.
Decomposition at the plant influent can also produce odors andgases such as hydrogen sulfide,which are hazardous, explosive, andcan cause corrosion and structuraldamage to plant equipment. Pre-chlorination with chlorine orhydrogen peroxide may be used in the preliminary treatment stage,but is not related to disinfection. It is used to temporarily prevent further wastewater decomposition,reduce odors, and protect plant equipment and personnel.
Analytical measurements in thishostile environment are ideallymade using the Model 5081 FamilyTransmitter, which is both corrosionresistant (NEMA 4X) and suitable for
The Transmitter Model 5081 is ideal for harshenvironments.
pH Sensor Model 396P requiresminimal maintenance.
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The Model RDOoptical dissolvedoxygen sensor
SECONDARY TREATMENT
Some plants use aeration tanks andsuspend microorganisms inwastewater. After leaving theprimary treatment stage, sewage ispumped into aeration tanks. Thesludge is loaded with micro-organisms and mixed with air orpure oxygen. As air is forced into theaeration basins, it increases theactivity of these microorganismsand helps keep the organic wastethoroughly mixed.
Dissolved oxygen (DO) is added tothe aeration basin to enhance theoxidation process by providingoxygen to aerobic microorganismsso they can successfully turn organicwastes into inorganic byproducts,specifically carbon dioxide, waterand sludge, which may containnitrates, phosphates, sulfates andhighly active bacteria. Statedsimply, there are two maincategories of microorganisms thatdigest waste—carbon eaters(carbonaceous) and ammoniaeaters (nitrogenous)—and both ofthese groups need oxygen to repro-duce and sustain life.
In order to metabolize food andreproduce, the microorganisms needat least 0.1 to 0.3 mg/L DO. Mostplants maintain about 2 mg/L of DOso the microorganisms containedinside the floc can also get oxygen. Ifthe DO is less than 2 mg/L, themicroorganisms in the center maydie since the ones on the outside of
the floc use up the DO first. If thishappens, the floc breaks up.
Maintaining an environment conducive to keeping thesemicroorganisms alive and most productive is a critical job for plantmanagers and operators. If the DOcontent is too low, the environmentis not stable for these micro-organisms and they will die due toanaerobic zones, the sludge will notbe properly treated and plants willbe forced to conduct an expensiveand time-consuming biomassreplacement process.
Because of this risk, many plantscompensate by adding excessiveamounts of DO to their process.However, when the DO levelsbecome too high, energy is wasted,expensive aeration equipmentundergoes unnecessary usage, andunwanted organisms (filamentousbiology) are promoted.
Power costs associated with theoperation of the aeration processgenerally run from 30 to 60 percentof the total electrical power used bya typical wastewater treatment facil-ity. Today, however, plant managers can equip their aerationbasins with on-line analysis systemsthat provide continuous DO measurement. Furthermore, anautomated aeration system can
Remove Remaining Organics
Secondary treatment removes up to 85% of
the remaining organic material through a bio-
logical process by cultivating and adding
sewage microorganisms to the wastewater.
This process is accomplished in a trickling
filter or an aeration tank. A trickling filter uses
a bed of stones or pieces of corrugated plastic
media. As sewage is passed through these
beds, micro-organisms such as bacteria and
protozoa gather on surfaces, multiply and
consume most of the organic matter.
With a complete range of measurementinputs that can be configured in anycombination, the Model 1056 is ideal formunicipal plants with dual measurementrequirements.
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maintain the correct amount of DO in the secondary treatmentstage. And according to the USEPA,plant energy costs may be reducedby as much as 50 percent.
DO introduced in the aerationbasins also provides the added ben-efit of mixing, thus bringing themicroorganisms, oxygen, andnutrient together. Mixing alsoremoves metabolic waste products.Too much mixing can break up thefloc or form unstable floc particles.If there is inadequate mixing, propersecondary treatment will not takeplace since there is a lack of contactbetween the bugs, their food andthe oxygen source. Finally, the mixing or aeration keeps this flocsuspended and prevents it from set-tling to the bottom.
In order to keep this waste treatmentprocess functioning properly, themeasurement of DO is a criticalonline measurement and can beaccomplished using the RDO fluores-cence quenching sensor and analyzer.
The aeration basins represent one ofthe toughest and most challengingenvironments for measurement sensors. The single celled bacteriaconsume proteins, carbohydrates,fats and many other compounds.During this process, their wasteproducts form a thick slime layeroutside their cell wall, making thecells stick together. This stickysubstance covering the outside ofthe cell allows the bacteria toagglomerate into a floc.
Bio-slimes produced by the microor-ganisms coat the sensors, requiringconstant cleaning and maintenanceon a weekly and sometimes dailybasis. With regular cleaning, theModel RDO sensor is less affected byfouling than membrane-coveredpolarographic sensors.
The optical dissolved oxygen sensoris simple to install and has an accura-cy reading of +/- 0.1ppm between0.0 and 8.0 ppm. The analyzeraccepts a single or dual input.Calibration is simple and can be cali-brated wither against a refereeinstrument or in water-saturated air.Air calibration is completelyautomatic. A manually enteredcorrection for salinity is alsoavailable. Maintenance is fast andeasy and consists primarily of replac-ing the sensing cap every year.
In addition to DO, a proper pH rangemust be maintained in the aerationbasin to support an active andhealthy biological system. The idealpH range is between 6.5 and 8.5, anda pH sensor Model 396P is recom-mended for this coating application.
Partially treated sewage from thesecondary treatment process flowsto a secondary clarifier, also called asettling tank, for removal of excessmicroorganisms. Some of thesludge collected at the bottom ofthis tank is wasted and is calledWaste Activated Sludge (WAS).Most of the sludge however isrecycled back to the aeration tank
to consume more incoming organicmaterial. The term Return ActivatedSludge (RAS) is used because thesludge being returned from the set-tling tank to the aeration tanks con-tains microorganisms that havebeen depleted of food for sometime, and are in an activated or hun-gry condition ready to biodegrademore waste.
This is a continuous flow process,and the measurement of suspendedsolids is critical to wastewater plantoperations. These measurementstell the operator exactly how muchsludge to return, and how much towaste. The results of a grab sampleanalysis in a laboratory usually take2 to 24 hours, and accurate real-time adjustments are impossiblesince the process conditions havealmost certainly changed due tothe time lag.
Process changes in the condition ofthe influent flow or solids can occurduring a rainstorm or an unplannedload change from an industrialdischarge.
Sensor andAnalyzer ModelRDO for dissolvedoxygenmonitoring
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The increased need to reuse waterfor industrial and domestic use andto protect the receiving water haverequired additional treatment stepsand advanced tertiary wastewatertreatment. Advanced waste treat-ment techniques include phosphorusand nitrogen removal, physical andchemical separation such asfiltration, carbon adsorption andreverse osmosis. As waste effluentsare purified to higher degrees bysuch treatment, the effluent watercan be used for industrial,agricultural, or recreationalpurposes, or even drinking watersupplies. It can also be pumpedback into the ground to prevent salt water intrusion.
Often, treatment consists of passingthe wastewater through a filtermedium. This method removesalmost all bacteria, reducesturbidity and color, and removesodors and most other solid particlesfrom the treated water. Often acombination of filter media is usedto provide a course to fine filtrationas water passes through the filter.
As filtration proceeds, the headlossthrough the filter increases until itreaches an unacceptable level oruntil solids breakthrough occurs andthe effluent becomes unacceptable.
Measurement of turbidity using the Clarity II On-Line Turbidimeteris an important indicator of filterbreakthrough. At this point, the filter is backwashed.
Advanced treatment of sewagemay also include a two step processof nitrification and denitrificationfor removal of nitrogen. The majori-ty of nitrogen is in the form ofammonia and can be toxic toaquatic life. It is not removed, butconverted by microorganisms feeding on ammonia to nitrite andnitrates. Regardless of the methodchosen, sufficient oxygen must beavailable for nitrification to occur.
Nitrification systems are alsosensitive to pH variations; theoptimum pH is approximately 7.8 to9.0. Continuous online measurementof pH and DO is critical fornitrification. DO levels must begreater than 2 mg/L to preventdenitrification. The Model RDO canprovide a reliable DO measurement.
Denitrification reduces nitrates to nitrogen gas in the absence of oxygen. This reaction is alsodependent on temperature, pH andoccurs in the absence of oxygen.
SLUDGE TREATMENT ADDITIONAL TREATMENT
Volume Reduction andDecomposition
During the wastewater treatmentprocess, sludge has been generatedalong the way from the settlingbasins or clarifiers, and secondarytreatment. This sludge contains highconcentrations of microorganisms,many of which are pathogenic, andwill decay and produce odors. Sludgehowever can be used for a soil condi-tioner, agricultural fertilizer, or forlandfill after it has been treated toremove the harmful contaminants.
Sludge treatment has twoobjectives: the removal of part orall the water to reduce the volume,and the decomposition of theorganic solids into a stable organicsolid. One common sludgetreatment method is biologicaldigestion and can be either aerobicor anaerobic. Both of thesemethods require analyticalmeasurements including pH, DO,temperature and sludge blanketlevel. Aerobic digestion is similar tothe activated sludge process. Theanaerobic digestion processproduces a methane gas, which hasfuel value and can be burned toprovide heat or even run electricgenerators in the plant.
Sludge received from the plantclarifiers can be processed inGravity Thickeners prior to beingpumped into the digesters. Sludgeenters the thickener at 1.5% and isthickened to 8% to minimizepumping volume.
Volume Reduction andDecomposition
Since the early 1970's, an optionalstage that falls between secondaryand final treatment – known astertiary treatment – has come intouse in some areas. With a limitedamount of usable fresh water,combined with the contamination ofwater sources, there is sometimes aneed to reuse wastewater as a feedsource to drinking water plants. Thisreuse, commonly called "Toilet toTap", requires proper treatment andcontinuous monitoring and removalof various chemical components.
PERpH-X® pH sensor hasimproved durability andincreased reference electrodestability
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In many areas, local or nationalagencies regulate the amount ofchlorine allowed in the final planteffluent before being dischargedinto lakes, rivers, or the ocean. Thisrequires dechlorination, whichremoves the free and combinedchlorine residuals to reduce the toxi-city after chlorination and beforedischarge. Limits are between 0.01to 0.30 ppm of chlorine. Chlorine isclosely regulated because evensmall amounts are harmful to aquat-ic organisms. Typically, plants arerequired to monitor their wastestreams and report chlorine levels toa regulatory agency. Agencies canrequire either continuous or grab-sample testing.
Chlorine is added to the effluentfrom the final clarifier as it entersthe chlorine contact chamber.Excess chlorine is removed in adechlorination stage by addingsulfur dioxide, sodium bisulfite, sodi-um sulfite, or sodium metabisulfite.The chlorine concentration ismeasured in both the chlorinationand dechlorination stages using aModel TCL Total Chlorine System.
ORP sensors are also being used indisinfection, but the ORP readingdoes not indicate the chemicalconcentration, but instead indicatesthe oxidizing activity of water. Forchlorination, the ORP starting pointis highly variable, the control pointmay vary considerably, and changesin background wastewater composi-tion will affect the ORP readings. For
Model TCL, System for Total ChlorineMeasurement
ORP Sensor Model 396Pcan be used to establishthe ORP starting point.
Disinfection
In the final stage of wastewater treatment, disin-fectants are added to kill disease-causing organ-isms and microorganisms used in the treatmentprocess. Disinfection inactivates or destroyspathogenic organisms and prevents the spreadof waterborne diseases to down-stream usersand the environment. A common disinfectant ischlorine gas, but some municipalities use theirown chlorine solution such as sodiumhypochlorite.
FINAL TREATMENT
pH sensor Model 399 forgeneral purpose pHmeasurements.
chlorination the appropriatetreatment point is determined usinga laboratory method or portable colorimetric tests, and the corre-sponding ORP value is recorded. Fordechlorination, the setpoint valuedepends on the results of off-linechlorine tests made at ORP levelsaround the desired point.
At one particular wastewater facility,three Model 396P ORP sensors areused before the disinfection processto establish a back-ground ORPlevel, a level after chlorine is added,and the level after the sulfur dioxideis added.
Final effluent monitoring plays animportant role in wastewatertreatment plants and is required forcompliance monitoring, reporting toregulatory agencies, protection ofwetlands, and it provides anindication of overall plantperformance. Continuous onlinemeasurements of plant effluent caninclude pH, total suspended solids,ORP, and conductivity.
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ROSEMOUNT ANALYTICAL INSTRUMENTATION
Featur
es60
81 Series
1056
Series
1057
Series
56 Series
5081
Series
SoluCo
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Power
Lithium power
115 - 230 VAC or
115 - 230 VAC or
115 - 230 VAC
24 VDC
24 VDC
Requ
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24 VDC
or 24 VDC
Num
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pH and
pH/ORP/ISE, Conductivity,
pH/ORP/ISE,
pH/ORP, resistivity/conduc-
Select one: pH,
Select one: pH,
Mea
suremen
tscontacting
Resistivity, % Concentration,
Contacting
tivity/TDS, % concentration, ORP, Conductivity,
ORP, Conductivity,
conductivity
Dissolved Oxygen, Ozone,
Conductivity
ratio conductivity, total and
Resistivity, Dissolved
Resistivity, Dissolved
Flow,* Turbidity,* Chlorine
free chlorine, dissolved O2
Oxygen, Ozone,
Oxygen, Ozone,
(Total, Free, Monochloramine,
dissolved ozone, turbidity,
Chlorine, Gaseous
Chlorine
pH Independent Free Chlorine)
pulse flow, temperature
Oxygen
and raw 4-20m
A input
SMART
pH
Yes
Yes
Yes
Yes
No
No
HART
Yes
Yes
No
Yes
Yes
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Compa
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No
No
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Compa
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Wireless TH
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NA
Yes
No
Yes
Yes
Yes
Ada
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com
patible
Multi-ling
ual M
enus
Yes
Yes
Yes
Yes
No
Yes
Relays
NA
44
4NA
NA
PID Con
trol
No
Timer control only
Timer control only
Yes
Yes/Ff
Yes/Ff
Adv
ance
d Diagn
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Yes
Complete
Complete
Yes
Complete
Complete
Capa
bility
Area
Class 1, Div. 1
Class I, Div 2
Class I, Div 2
TBD
Class I, Div. 1 & Div. 2,Class I, Div. 1 & Div. 2
Classific
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(future option)
Explosion proof
Ava
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FM, CSA, CE, UL
CE, UL, CSA
TBD
CE, FM, CSA, ATEX
CE, FM, CSA, ATEX
11
Rosemount Analytical’s instru-ments are part of Emerson ProcessManagement’s PlantWeb® field-based architecture: a scalable wayto use open and interoperabledevices and systems to build
process solutions. The PlantWebarchitecture consists of intelligentfield devices, scalable platformsand standards, and integratedmodular software, all workingtogether to create, capture,
Emerson Process Management isthe proven supplier of RosemountAnalytical on-line electrochemicalsensors and instrumentation withover 60 years experience indrinking water treatment, wastetreatment and process control. Inrecognition of our dedication tocustomer service, productexcellence, and qualitywe have received the#1 ReadersChoice Awardfrom ControlMagazine for thesixteenth consecutive year.
With a fixed amount of fresh wateravailable for consumption and our
worldwide increased demand foraccess to safe water, continuousmonitoring and measuring of thewater treatment process and waterquality becomes one of the mostimportant elements to preventwater-related diseases caused by pathogens.
Producing a source of safe andreliable drinking water and theremoval of harmful microorganismsare the primary goals of every
drinking water treatment plant.Thousands were killed each year dueto cholera, typhoid fever, dysenteryand hepatitis before cities begantreating drinking water withchlorine. Today, chlorine, ozone and
use, and distributeinformation andprocess control data.
This architecture can reduce yourcapital and engineering costs,reduce operations andmaintenance costs, increaseprocess availability, reduce processvariability, and streamlineregulatory reporting.
To see what PlantWeb can do foryour operation, call or visit us atPlantWeb.com/RunSafe
UV are being used in primarydisinfection at the pre-treatmentstage and secondary disinfection inthe final stage to inhibit or preventregrowth of pathogens in the waterdistribution system.
Accurate on-line process instrumen-tation, such as pH, conductivity,chlorine, dissolved ozone, turbidity,and particle counters, plays a criticalrole in achieving the plant objectiveand meeting regulatory complianceat the local and federal level. Counton Emerson for the systems andsolutions you need in an ever-chang-ing, dynamic world. See us on theweb at RAIhome.com.
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Emerson's Rosemount Analytical Liquid Division provides technologies and services for the analysis of liquid processes. For a wide range of applications,Emerson provides more than 60 years of expertise in high-precision analytical sensors, instrumentation and services. For information, call 800.854.8257.
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