life12 env/es/000265 deliverable db1.3: user manual of

life12 env/es/000265 deliverable db1.3: user manual of
LIFE12 ENV/ES/000265
Deliverable D.B.1.3
LIFE Project Number
LIFE12 ENV/ES/000265
DELIVERABLE D.B.1.3: USER MANUAL OF BOTH PROTOTYPES.
ADNATUR: Demonstration of natural coagulant use advantages in
physical & chemical treatments in industry and urban waste water.
LIFE12 ENV/ES/000265
Deliverable D.B.1.3
CONTENTS
1.
2.
INTRODUCTION ............................................................................................................ 3
INDUSTRIAL WASTEWATER PROTOTYPE. ................................................................... 4
2.1. MAIN COMPONENTS OF THE PROTOTYPE............................................................... 4
2.2. START / STOP PROCEDURES. .................................................................................. 12
2.3. MAINTENANCE INSTRUCTIONS. ............................................................................. 13
2.4. POINTS TO CHECK IF MALFUNCTION. PROBLEMS AND SOLUTIONS. ................... 24
3. URBAN WASTEWATER PROTOTYPE. ......................................................................... 26
3.1. MAIN COMPONENTS OF THE PROTOTYPE............................................................. 26
3.2. START / STOP PROCEDURES. .................................................................................. 35
3.3. MAINTENANCE INSTRUCTIONS. ............................................................................. 36
3.4. POINTS TO CHECK IF MALFUNCTION. PROBLEMS AND SOLUTIONS. ................... 53
4. CONCLUSIONS ............................................................................................................ 60
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1. INTRODUCTION
The present report summarizes the most important properties of all the components of both
prototypes. Every item has been fully detailed including brief description, user instructions and
important warnings. Thus, start up and stoppage procedures have been completely explained.
The maintenance process is crucial in order to maximize the efficiency of the plants. For that
reason, an exhaustive point regarding maintenance issue has been also included. Finally, a
complete explanation of points to check in case of malfunction and what measures have to be
taken in order to solve the problems has been reported in current ADNATUR deliverable.
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Deliverable D.B.1.3
2. INDUSTRIAL WASTEWATER PROTOTYPE.
2.1. MAIN COMPONENTS OF THE PROTOTYPE.
2.1.1. Control box.
The aim of the control box is to monitor and control each constituent of the prototype and to
access in every moment to the current situation of the facility as well as the alarm and data log.
The setting of the pump frequency is important because it depends on it the water pressure
through the system and, accordingly, the inlet flow.
These kinds of controllers are modular systems that can be adapted optimally to the required
automation task. Thus, it is possible to be customized, using different modules. In case that later
the requirements of the system would change the controller is easily expandable by adding
further modules.
With the tactile screen the different states of the displays can be seen, as well as all variables of
the plant.
 Engines Stop / Start.
 Pumps Stop / Start.
 Flow reading.
 pH reading in the decantation tank.
 Hours of equipment operation, etc...
Graphical programming is structured into different screens with different security levels.
Different color graphics give a clear look of the current state of the plant stop and start of the
engines, and making graphic levels for those variables that require it.
2.1.2. Inlet wastewater pump.
The injection of inlet wastewater to the pilot plant is carried out with a pump with the following
technical specifications:
Height
Width
Depth
Est. Ship Weight
PVDF 5 kg (10 lbs) Air Inlet
Inlet
Outlet
Suction Lift
Displacement per Stroke
Max. Flow Rate
Max. Size Solids
277 mm (10.9")
234 mm (9.2")
201 mm (7.9")
Polypropylene 4 kg (8 lbs)
6 mm (1/4")
13 mm (1/2")
13 mm (1/2")
4.5 m Dry (14.7') 9.3 m Wet (30.6')
0.10 l (0.027 gal.)*
57.0 lpm (15.0 gpm)
1.6 mm (1/16")
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*Displacement per stroke was calculated at 4.8 bar (70 psig) air inlet pressure against a 2 bar (30
psig) head pressure.
Figure 1. Inlet wastewater pump for industrial prototype.
The air distribution system incorporates three moving parts: the air valve spool, the pilot spool,
and the main shaft/diaphragm assembly. The heart of the system is the air valve spool and air
valve. This valve design incorporates an unbalanced spool. The smaller end of the spool is
pressurized continuously, while the large end is alternately pressurized then exhausted to move
the spool. The spool directs pressurized air to one air chamber while exhausting the other. The air
causes the main shaft/diaphragm assembly to shift to one side — discharging liquid on that side
and pulling liquid in on the other side. When the shaft reaches the end of its stroke, the inner
piston actuates the pilot spool, which pressurizes and exhausts the large end of the air valve
spool. The repositioning of the air valve spool routes the air to the other air chamber.
2.1.3. Inlet water tank.
Water tank is cylindrical shaped, white coloured and made of polyethylene. At the top, have a
screw cap, also made of polyethylene but black coloured. Its capacity is 500 litres.
The water flows into the tank through a tube connected at the top, and then flows out of the
tank through a tube which is set at the bottom side. Inlet water tank includes a stirrer at low
speed with reducer crown. The axis of Stainless Steel Aisi-316, is coupled with key inside the
hollow agitator shaft. This kind of stirrers are designed for homogenization and flocculation
processes with flange for application to open or semi-open containers. The stirrer has the follow
specifications:
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Deliverable D.B.1.3
Type:
RV-12 S-35-05
Speed:
49 rpm
Relation:
1:30
Propeller:
600 mm
Material:
Aisi-316
Engine:
1/3 HP
Weight:
14,00 Kg
Figure 2. Stirrer for inlet water tank, including specifications.
2.1.4 Multi-parametric Sensor.
The current detector is a multiple digital controller system. It reads and controls up to 5 channels
that can be programmed to control pH, ORP (oxidation reduction potential), turbidity,
temperature, conductivity. It features 6 set point outputs, 6 proportional pump outputs, 6 mA
outputs, 1 cleaning probe output and 5 level tank inputs. I contains three way set point outputs
program mode: on/off - PID - PWM. The detector can be connected to a PC for remote controlling
/ programming using a standard USB port, RS485 connection, GSM or GPRS modem, ETHERNET.
The working ranges of the device are:

pH: from 0 to 14 pH.

ORP: from 0 to 1000 mv.

Turbidity: from 0 to 30 NTU.

Temperature: from 0 to 200 °C.

Conductivity: from 0 to 300.0 mS.
All the information is provided through a widescreen LCD display (240x64) provided with a
control wheel, in order to program the instrument. The detector is housed into a plastic box, and
its measures are: L325 x H235 x D125 (including wheel and connectors).
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Deliverable D.B.1.3
Figure 3. Multi-parametric Sensor.
2.1.5. Coagulation Tank.
The coagulation tank is rectangular shaped, made of stainless steel. Its capacity is 150 litres. A
stirrer at low speed with reducer crown is included. The axis of Stainless Steel Aisi-316, is coupled
with key inside the hollow agitator shaft. This kind of stirrers are designed for homogenization
and flocculation processes with flange for application to open or semi-open containers. In order
to have a proper mixer between the ADNATUR technology and inlet water, a mixer is used with
the following specifications.
Type:
RV-12 S-35-05
Speed:
49 rpm
Relation:
1:30
Propeller:
600 mm
Material:
Aisi-316
Engine:
1/3 HP
Weight:
14,00 Kg
Figure 4. Stirrer for coagulation tank, including specifications.
2.1.6. ADNATUR dosing system.
ADNATUR dosing system is probably the most important component of the prototype. It is
necessary in order to maximize the coagulant efficiency of the ADNATUR natural based products.
It contains a dosing pump and a static mixer system. This way, the product is reaching the
coagulation tank previously dissolved in water. However, dissolution procedure is made in situ so
the reaction time is low and then the stability of the product is unaltered. Proposed dosing pump
includes the following specifications:
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Power supply:
Number of pump injections:
Maximum flow (7 Bar):
Injections/Minute aspiration Height:
Room temperature:
Additive temperature:
Contamination level:
Sound level:
Delivery and storage temperature:
Protection grade:
Deliverable D.B.1.3
230 VAC (180-270 VAC)
115 VAC (90-135 VAC)
24 VAC (20-32 VAC)
12 VDC (10-16 VDC)
0 ÷ 180
6 litres/hour
1,5 metros
0 ÷ 45°C (32 ÷ 113°F)
0 ÷ 50°C (32 ÷ 122°F)
2
74 dbA
-10 ÷ +50°C (14 ÷ 122°F)
IP65
Figure 5. ADNATUR dosing system, including the dosing pump (left) and the static mixer (right).
2.1.7. Flocculant mixer.
The flocculant mixer is cylindrical shaped, white coloured and made of polyethylene. At the top,
have a screw cap, also made of polyethylene but black coloured. Its capacity is 200 litres. In order
to have a proper mixer between the wastewater, previously mixed with the coagulant, and the
flocculant, solid flocculant needs to be pre-dissolved in water. Accordingly, the product is
manually added in a deposit with water and exhaustively stirred. Finally, the solid content of the
flocculant, polyacrylamide based, needs to be between 0,1 and 0,2 per cent in water. Flocculant
tank includes a deposit and a stirrer in polypropylene and PVDF for acids without support with
flange for application on the tank. Sealing at the top is achieved against a fixed ceramic blind Vring and propeller through an O-ring. The stirrer has the following specifications:
Type:
Speed:
Voltage:
Engine:
Axis:
Coated axis:
E-600-4
940 rpm
230 single-phase; 230/400
1/6 HP
600 mm
P.P. or PVDF
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Propeller:
Weight:
Deliverable D.B.1.3
P.P. or PVDF
5 Kg
Figure 6. Flocculant mixer, including the stirrer (left) and the mixer deposit (right).
2.1.8. Flocculation tank.
The flocculation tank is rectangular shaped, made of stainless steel. Its capacity is 300 litres. In
order to have a proper mixer between the wastewater, previously mixed with the coagulant, and
the flocculant, previously dissolved in water, a specific deposit with a stirrer is required.
The stirrer is at low speed with reducer crown. The axis of Stainless Steel Aisi-316, is coupled with
key inside the hollow agitator shaft. This kind of stirrers are designed for homogenization and
flocculation processes with flange for application to open or semi-open containers. The stirrer
has the following specifications:
Type:
RV-12 S-35-05
Speed:
49 rpm
Relation:
1:30
Propeller:
600 mm
Material:
Aisi-316
Engine:
1/3 HP
Weight:
14,00 Kg
Figure 7. Stirrer for flocculation tank, including specifications.
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2.1.9. Decantation tank.
Once the chemicals are dosed and conveniently blended with the wastewater, the floc is formed
but still need some time to decant. For that reason a specific system called decantation tank is
still required. Its main specifications are described bellow.
Lamellar settler made of stainless steel AISI-304:
 Length:
1.600 mm.
 Width:
800 mm.
 Height:
1.100 mm.
Finishes:
 Stainless steel AISI-304.
Thickness:
 Body thickness: 2,5 mm.
 Cone thickness: 2,5 mm.
 Chamber separation: 2,5 mm
Accessories:
 1 Flange DN 50 (AISI-304).
 1 Flange DN 50 sludge outlet (AISI-304).
 2 Flange DN 50 reactors cleaning (AISI-304)
Structure:
 4 Pillar HEB-100.
 6 Beam HEB-80.
Stirrers:
 PVC Lamellas.
 Manual throttle valve DN 50.
 Automatic throttle valve DN 50.
Figure 8. Lamellar decanter of industrial wastewater prototype.
2.1.10. Sludge extraction.
When the floc is correctly decanted, the sludge needs to be extracted and sent to the dewatering
system. In this case, a sludge extraction pump with the following properties is required:
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Deliverable D.B.1.3
Height
277 mm (10.9")
Width
234 mm (9.2")
Depth
201 mm (7.9")
Est. Ship Weight
Polypropylene 4 kg (8 lbs)
PVDF 5 kg (10 lbs) Air Inlet
6 mm (1/4")
Inlet
13 mm (1/2")
Outlet
13 mm (1/2")
Suction Lift
4.5 m Dry (14.7') 9.3 m Wet (30.6')
Displacement per Stroke
0.10 l (0.027 gal.)*
Max. Flow Rate
57.0 lpm (15.0 gpm)
Max. Size Solids
1.6 mm (1/16")
*Displacement per stroke was calculated at 4.8 bar (70 psig) air inlet pressure against a 2 bar (30
psig) head pressure.
Figure 9. Sludge extraction pump for industrial wastewater prototype.
The air distribution system incorporates three moving parts: the air valve spool, the pilot spool,
and the main shaft/diaphragm assembly. The heart of the system is the air valve spool and air
valve. This valve design incorporates an unbalanced spool. The smaller end of the spool is
pressurized continuously, while the large end is alternately pressurized then exhausted to move
the spool. The spool directs pressurized air to one air chamber while exhausting the other. The air
causes the main shaft/diaphragm assembly to shift to one side — discharging liquid on that side
and pulling liquid in on the other side. When the shaft reaches the end of its stroke, the inner
piston actuates the pilot spool, which pressurizes and exhausts the large end of the air valve
spool. The repositioning of the air valve spool routes the air to the other air chamber.
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2.2. START / STOP PROCEDURES.
After filling the chemical tanks, the start-up of the plant can be carried out. The start-up of the
plant, in automatic mode, will be carried out placing all contactors containing three positions
(MAN-0-AUTO) to AUTO. In the first start-up, or when a stop light is made, it will also have to use
the reset button.
The pilot plant can be manually stopped, by pressing start-up switch to 0. In order to make an
immediate stop, just press the emergency stop button (red), so that the plant will stop and be
ready for its next start.
2.2.1. Electrical pumping panel description.

Inlet water tank pumps. Contactor which commands the start-up of submersible pump that
feeds the inlet water tank. The pump has three positions (MAN-0-AUTO). For operation in
automatic the position has to be AUTO.
2.2.2. Pilot plant electrical panel.

Alarm. The contactor which commands the reaction of the thermal of the plant has two
positions (0-1). In position 1, if a thermal cut-off occurs, the plat will stop, in position 0, the
thermal cut-off will only affect to the stopping of the corresponding motor.

General stoppage. Blue light signal indicating a stop of the plant.

Plant. The contactor which commands the start-up of the plant has three positions (MAN-0AUTO). In position 0, the plant is completely stopped; in manual position, the start up of the
plant will be carried out. In AUTO position, the automatic start up will be carried out.

ADNATUR dosing pump. The contactor which commands the start-up of the pump of
ADNATUR technology dosing has three positions (MAN-0-AUTO). For automatic operation
must be in the AUTO position.

Flocculant dosing pump. The contactor which commands the start-up of the dosing flocculant
pump has three positions (MAN-0-AUTO). For automatic operation must be in the AUTO
position.

Flocculant stirrer. The contractor which commands the start-up of the flocculant preparer
mixer has three positions (MAN-0-AUTO). For automatic operation must be in the AUTO
position.

Sludge discharge. The contactor which commands the start of the discharge of sludge by a
solenoid valve has three positions (MAN-0-AUTO). For automatic operation must be in the
AUTO position.
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Deliverable D.B.1.3
Reset plant. This device has the function of start-up the plant, it is used only when a stoppage
in the power supply occurs and in the initial operation of the plant.

Emergency stop button. It consists of an emergency stop device of the plant, according to
regulations.

Safety symbol according to ISO 3864-1984. Symbol of warning-risk, power danger not handle
any electrical power without prior authorization of the manufacturer.
2.3. MAINTENANCE INSTRUCTIONS.
2.3.1. General cleaning.
The plant cleaning depends on the estimated time of stoppage. In general terms, these two kinds
of cleaning can be carried out, but they always have to be done during the stoppage of the plant.

Deep cleaning of the decantation tank. It is recommended every three months. In order to
clean the plant, three quarters of capacity must be empty, enough to access the lamellar
filters and to clean the fouling.

Revision of piping and pumps of the pilot plant.

Cleaning of all the components of pilot plant, inlet water tank, coagulation tank and
flocculation tank.
2.3.2. Proper operation controls.
The proposed controls aim to optimize the operation of the pilot plant, prevent possible
breakdown and reduce the accidental risks. The next type of control must be done, in all cases
with the plant stopped. The main diary controls are described bellow:

Inlet water control: colour, smell, solids, pH.

Treated water control: colour, smell, pH.

Treatment: Coagulation and flocculation. In case that the treatment is not carried out
properly, the dose of chemicals will be change after test a sample.

Replacement of products: Product replacement should guarantee the correct dosage at any
time, thus, there will be no problems in the treatment during operation of the plant. In
addition, day of no attendance at the facility should be taken into account.

Flocculant preparation.

Checking:
-
Proper operation of inlet water pump.
-
Flow control valve.
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-
Proper operation of coagulant and flocculant pumps.
-
Regulate coagulant and flocculant pumps depending on the inlet water.
-
Sludge discharge control.
2.3.3. Pumps maintenance operations.
The aim of this section is, in the first place, to describe the pump in order to get to know its
operation mode. Then, details about its storage, manipulation, start up and stoppage procedures
are given.
The current pumps are horizontal end suction centrifugal with single impeller. Feet are casted
together with the pump casing which is open at the back to allow the rotating parts been
dismantled without disturbing the suction and delivery pipes of the system. The impeller is closed
type. The rotation direction is clockwise (to the right) viewed from coupling side. The sealing box
built into the casing cover is prepared to accept packing, with different types depending on the
liquid being pumped. The drive shaft is held by two rigid ball bearings, lubricated either by grease
or oil. Pump can be driven by a diesel engine or electric motor, set on a common bedplate and
joined by a semielastic coupling.
Storage.
The pumps should be stored in well-ventilated zones free of damp. For short storage periods the
machined parts should be protected with an oil or anti-corrosion product.
If the pump is to be left for longer periods in the store, precautions should be taken to prevent
the pump from corroding by using an anti-corrosion product, also proceeding to cover up the
suction and delivery flanges.
Turn the shaft by hand every 15 days to prevent any possible seizing up. Make sure that the
diesel engine or electric motor is not exposed to atmospheric agents which might not be
compatible with its degree of protection and might cause damage to it. Before storing a pump,
which has recently been installed, proceed to clean and then air-dry it (do not used hydrocarbidebased products).
Manipulation.
Pumps in bare shaft disposal must be handled using the delivery flange as lifting point, and to
position them use the suction flange and the bearing support if required. The electric motor
should be handled using the securing point(s) provided for this purpose consisting on a ring
located at the top of the casing.
To handle the motor pump set use a sling going under the bed so as to ensure stability during
lifting and displacement. Under no circumstances use the ring located over the motor or pump.
Start up and stoppage procedure indications.
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For the first start up, after making all the checks, this should be done with the drive valve closed,
to reduce the consumption of the pump as far as possible. When the running speed has been
reached, the valve should slowly be opened, observing at the same time the variation in
consumption, until this opens completely. In normal operation the consumption, measured in
amperes, should not be over what is stated on the motor plate.
To stop the pump, the delivery valve should be returned to the original position as before the
start up. When installation has an anti-water hammer device there is no need to close the
delivery valve for stopping the pump. Check that motor deceleration is normal and after it has
completely stopped close the auxiliary circuits.
When the equipment is to be idle for long periods, the pump and piping should be completely
drained, to prevent the risks of frost during the winter and any possible rusting of the mechanical
items that might be caused through trapped liquid.
2.3.4. Stirrers maintenance operations.
Precautions before commissioning.
Before starting the stirrer is essential to carry out the following checks. The motor voltage stated
on the nameplate must match the voltage available online. Check that the mechanical and
thermal motor protections are adequate for proper operation. The motor housing must always
be grounded. Remove the motor fan cover and turn the same hand to confirm that no blocking
points and the fan impeller rotates freely. During this check it must be made sure that the motor
or the machine is not connected to the network, to avoid any possible mishap.
After the test, proceed with the following checklist:

Replace the lid Fan verifying that the grid is unobstructed.

Confirm that the speed reducer (if any) have the appropriate level of lubricant.

Check the tightening of the screws holding the flange or plate agitator to structure is
correct and are not loose.

Check that the coupling screws connecting the head agitator shaft are properly
tightened.

In the case of the agitator shaft was attached to plates, prior to assembly, rigid coupling
must be removed any dirt from the faces that will be in contact.

Check the correct tightening of the screws that hold the propeller shaft.
Safety Recommendations. Protection against mechanical hazards.
The control system must be designed and installed to prevent the operation of the stirrer while
not in place and position, including:
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
Deliverable D.B.1.3
The control unit shall include a manually operated device that allows the unemployment
insurance.

The stirrer should be fixed stably working and so that parts phones are protected by the
container in which the work will develop.
Therefore, the control unit must include a protective device that prevents achieving moving part
of the agitator during their work. The agitator should not be possible to start while it may come
into contact with moving parts.
Protection against electrical hazards.
The user must connect the different electrical circuits and drives for completing the electrical
installation in accordance with EN60204-1, to operate the stirrer safe conditions.
Protection against chemicals.
Before installing the agitator, check that the selected model is appropriate to the possible
presence of chemicals in the work area of the agitator.
Moreover, if necessary, shall be provided in an exhaust system of toxic gases or dusts suspension
that may arise during agitation and related processes work.
Protection against risk of explosion.
Before installing the agitator, check that the selected model is appropriate to the classification of
the area where it will be installed stirrer. It is the user's responsibility adequacy of electrical
equipment to the characteristics of the area classified according to laws and regulations.
Transport and location.
For the maintenance of the agitator without packing a suitable suspension should be used to
weight model, taking into account its centre of gravity. Never submit to extreme efforts the
proximal shaft stirring element. The necessary space must be provided to make the installation
work and maintenance.
Connections.
When connecting the motor, you should check that the direction of rotation of the agitator
matches the indicated by arrow incorporating the agitator. Otherwise, you must change the
sequence of the phases.
2.3.5. Detector maintenance and calibration procedures.
In the following lines, how to control the detector is explained, including its menu points. Then,
the most important maintenance operation, which is calibration, is detailed for every
measurement.
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Located in the upper right side of the detector there is a wheel that must be used to control the
instrument. This wheel can be rotated in both directions to scroll over the menus and / or
pressed to confirm highlighted selection / value.
Note: Once changes are made press “OK” to save and exit from submenu. Press “ESC” to exit
without saving.
Figure 10. Detector set point screen.
Into main menu rotate the wheel to cycle-loop through all options.
Clockwise: Set point --> Calibration --> Option --> Manual -->Exit or Counter clockwise.
Figure 11. Detector set point channels screen.
Press the wheel to move on submenu for selected option. From main screen all instrument
functions can be reached by rotating the wheel and highlighting the selected option. Options
available are located in the low right corner of the screen.
Figure 12. Detector screen.
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The most important maintenance operation of the detector device is the calibration of its
measurements: pH, mV, NTU, temperature and conductivity.
Regarding the calibration process, from set up menu rotate wheel to highlight “Calibration” then
press wheel. Again rotate wheel until to reach desired calibration measure, as shown in the
figure:
Figure 13. Detector calibration screen.
a) pH calibration.
pH calibration procedure involves two calibration points and it requires two buffer solutions.
Default buffer solutions are pH=4.00 and pH=7.00. pH reading value can be also automatically
temperature compensated.
Figure 14. pH calibration screen.
In the following example, instrument will calibrate pH using default buffer solutions value. This
procedure assumes that the instrument is correctly configured and a working pH probe
connected. Otherwise unattended results may occur.
1st Point Calibration: Once into “Calibration pH” menu move wheel on “Calib 1st Pt” then press
wheel to enter into first point calibration submenu. Prepare 7.00 pH buffer solution and dip
probe’s sensor on it. Wait until reading value is stable and according to buffer solution value
move wheel until it is the same on display (“pH default” field). Default value is 7.00 pH. To end
procedure move cursor on “OK” and press wheel to proceed to next step.
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Note: Buffer solution value may change if environment temperature it’s different than 20°C. Read
solution’s label for more information. According to this occurrence “pH Default” must be
changed.
2nd Point Calibration: Move wheel on “Calib 2nd Pt” then press it to enter into second point
calibration submenu. Prepare 4.00 pH buffer solution and dip probe’s sensor on it. Wait until
reading value is stable and according to buffer solution value move wheel until it is the same on
display (“pH default” field). Default value is 4.00 pH. To end procedure move cursor on “OK and
press wheel to proceed to next step.
Note: Buffer solution value may change if environment temperature it’s different than 20°C. Read
solution’s label for more information. According to this occurrence “pH Default” must be
changed.
Comp Auto / Select Temp. Once into submenu, to enable automatic temperature compensation,
move wheel on “DISABLE”, press it and change option to “ENABLE”. This procedure will
automatically set temperature compensation. Otherwise, exit from this menu, move wheel on
“Select Temp” and according to the following table enter required temperature. This procedure
will manually set temperature compensation.
Figure 15. Typical electrode response as a function of temperature.
End procedure by moving cursor on “Exit” from “Calibration pH” main menu and press it. If an
error occurred during calibration procedure then the instrument will show an error message and
will ask to proceed to a new calibration, cancel current operation or restore default settings.
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b) mV calibration.
ORP calibration procedure involves one calibration point and it requires one buffer solution.
Default buffer solution is 650mV.
Figure 16. mV calibration screen.
This procedure assumes that instrument is correctly configured and a working ORP probe
connected. Otherwise unattended results may occur. Once into “Calibration mV” menu move
wheel on “Calibration” then press wheel to enter into calibration submenu.
Prepare 650 mV buffer solution and dip probe’s sensor on it. Wait until reading value is stable
and according to buffer solution value move wheel until it is the same on display (“mV default”
field). Default value is 650 mV. To end procedure move cursor on “OK” and press wheel to
proceed to next step.
Note: buffer solution value may change if environment temperature it’s different than 20°C. Read
solution’s label for more information. According to this occurrence “mV Default” must be
changed.
End procedure by moving cursor on “Exit” from “Calibration mV” main menu and press it. If an
error occurred during calibration procedure then the instrument will show an error message and
will ask to proceed to a new calibration, cancel current operation or restore default settings.
c) NTU calibration.
NTU calibration (turbidity) procedure involves probe “zero” calibration and 2nd point calibration.
It requires distilled water and a 30NTU buffer solution to inject into ETORB.
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Figure 17. NTU calibration screen.
This procedure assumes that instrument is correctly configured and a working NTU probe mod.
“ETORB” is connected. Otherwise unattended results may occur.
Once into “Calibration NTU” menu move wheel on “Range” to see probe’s scale. Then choose
“calib 1st Pt”. From ETORB inlet inject distilled water until it leaks from outlet. Move cursor on
“OK” and press wheel. Before to calibrate 2nd point be sure that all distilled water has been
purged from ETORB. Then repeat procedure for 2nd point calibration using a 30NTU buffer
solution instead of distilled water.
End procedure by moving cursor on “Exit” from “Calibration NTU” main menu and press it. If an
error occurred during calibration procedure then the instrument will show an error message and
will ask to proceed to a new calibration, cancel current operation or restore default settings.
d) Temperature calibration.
Temperature calibration needs an external thermometer to match probe’s reading value.
Figure 18. Temperature calibration screen.
This procedure assumes that instrument is correctly configured and a working temperature probe
connected. Otherwise unattended results may occur.
Once into “Calibration Temp” menu move wheel on “Calibration” then press wheel to enter
system temperature obtained from a thermometer. Press wheel to confirm then move cursor on
“OK” and press wheel to proceed “Calibration Temp” main menu. End procedure by moving
cursor on “Exit” from “Calibration Temp” main menu and press it.
If an error occurred during calibration procedure then the instrument will show an error message
and will ask to proceed to a new calibration, cancel current operation or restore default settings.
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e) Conductivity (μS) calibration.
Conductivity calibration involves several points. The procedure must be followed carefully in
order to get correct conductivity values. After a defective calibration, the efficiency of the
detection could be greatly decreased. The current steps are briefly described in the following
lines:
1) Working scale setup
Figure 19. Conductivity calibration screen 1.
Move cursor on “Range” then press wheel. According to prove reading capacity
select proper scale by rotating wheel. Once satisfied press wheel, move cursor on
“OK” and press wheel again.
2) Turn off the detector. Remove cover and locate CD module jumper settings. Set jumpers
as required. Put cover back to the detector.
3) Turn on the detector. Once into conductivity menu choose Calib 1st Pt. Calibration.
Conductivity calibration procedure involves a zero calibration (1st point calib) and a 2nd
calibration point that requires a buffer solution with value near working range. During
this procedure probe must be dry and clean and not installed in plant. Once into
“Calibration uS” menu move wheel on “Calib 1st Pt” then press wheel, move cursor on
“OK” and press wheel again.
Figure 20. Conductivity calibration screen 2.
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Move wheel on “Calib 2nd Pt” then press wheel to enter into second point calibration
submenu. Prepare buffer solution and dip probe’s sensor on it. Wait until reading value is
stable and according to buffer solution value move wheel until it is the same on display (“uS
default” field). End procedure moving cursor on “OK”.
Figure 21. Conductivity calibration screen 3.
This procedure assumes that instrument is correctly configured. Otherwise unattended results
may occur.
4) Move cursor on “Comp Auto” then press wheel. Rotate wheel to Enable or disable
automatic temperature compensation. Enabling this option will override “Select Temp”
setup then move cursor on “ESC” or “OK” and press wheel to confirm.
Figure 22. Conductivity calibration screen 4.
5) Move cursor on “Temp Coeff” then press wheel. This option set conductivity % variation
based on temperature. To disable it enter 0.0 % as value. Move cursor on “ESC” or “OK”
and press wheel to confirm.
Figure 23. Conductivity calibration screen 5.
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6) Move cursor on “Select Temp” then press wheel. If a temperature probe is not
connected, pool temperature must be set manually. Rotate wheel to set it and confirm
by pressing wheel. Move cursor on “ESC” or “OK” and press wheel to confirm.
Figure 24. Conductivity calibration screen 6.
Measurement temperature has a significant influence on conductivity readings; but appropriate
temperature compensation is a powerful tool to allow meaningful comparison of readings taken
at different temperatures. The analyst must ensure that the type of temperature compensation
utilized is appropriate for both the type of sample being analysed and the required test accuracy.
This is an essential factor for determining the suitability of a conductivity instrument for
measurement applications. A conductivity measurement taken with the sample at the reference
temperature will always be more accurate than a temperature compensated reading taken away
from the reference temperature. This point is essential for critical applications requiring high
accuracy of measurements.
2.4. POINTS TO CHECK IF MALFUNCTION. PROBLEMS AND SOLUTIONS.
Breakdown
No wastewater arrives to the plant
The wastewater flow is insufficient
The plant does not start up
Possible Cause
Verify the proper performance of feeding pump.
If in the control box the pilot is in red, reset
thermal protection.
Verify valve opening.
Check that the tank has enough water for proper
pumping.
Check position of the feed valve.
Systematically check the following points:
If there is level inlet water above the level
sensor.
If it is not pressed any safety shutdown.
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Breakdown
No coagulation and flocculation occurs
Deliverable D.B.1.3
Possible Cause
Verify that the water and coagulant and
flocculant mixing occur and are dosed correctly.
Verify that there are reagents in coagulant and
flocculant preparation tanks.
Flocculation occurs irregularly and the resulting Verify that reagent dosing is correct and, in that
liquid is very turbid and flocs escape through the case increase them.
top of the decanting tank
Flocculation occurs irregularly and the resulting Verify that reagent dosing is correct, and in that
liquid is slippery
case reduce it.
NOTE: Checking of circuits to prevent leakage of chemicals should be done every 24 hours with
the plant stoppage, using the appropriate personal protective devices. For any sign of leakage,
the replacement of the damaged material before the start of the plant should be carried out.
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3. URBAN WASTEWATER PROTOTYPE.
3.1. MAIN COMPONENTS OF THE PROTOTYPE.
3.1.1. Control box.
The aim of the control box is to monitor and control each constituent of the prototype and to
access in every moment to the current situation of the facility as well as the alarm and data log.
The setting of the pump frequency is important because it depends on it the water pressure
through the system and, accordingly, the inlet flow.
These kinds of controllers are modular systems that can be adapted optimally to the required
automation task. Thus, it is possible to be customized, using different modules. In case that later
the requirements of the system would change the controller is easily expandable by adding
further modules.
With the tactile screen the different states of the displays can be seen, as well as all variables of
the plant.
 Engines Stop / Start.
 Pumps Stop / Start.
 Flow reading.
 Ammonium-nitrate reading in the anoxic tank.
 Dissolved oxygen reading in the biological reactor.
 Hours of equipment operation, etc...
Graphical programming is structured into different screens with different security levels.
Different color graphics give a clear look of the current state of the plant stop and start of the
engines, and making graphic levels for those variables that require it.
3.1.2. Inlet wastewater pump
The injection of inlet wastewater to the pilot plant is carried out with a pump with the following
technical specifications:
Flow
Temperature
Model
Number of vanes
Solids pitch
Pressure port
Nominal tension
Power output
Power factor
2,5 m3/h
20 °C
MF 334 D
6
30 mm
1½"
400 V
0,556 kW
0,86
Trademark
Impeller
Impeller diameter
Frequency
Rated speed
Yield
Nominal current
Nominal torque
Protection grade
ABS
Vortex
98 mm
50,0 Hz
2560 l/min
66,8 %
1,4 A
2,07 Nm
<IP 68>
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3.1.3. Anoxic tank.
Anoxic treatment is the first step of the process. In this case, oxygen content is absent and, this
way, nitrogen and ammonium content is conveniently reduced. The structure of the tank is
similar than the biological reactor, rectangular shaped, made of fibreglass. Its capacity is 900
litres. The tank contains a specific stirrer in order to keep the water/sludge conveniently
homogenized. It is a stirrer at low speed with reducer crown. The axis of Stainless Steel Aisi-316,
is coupled with key inside the hollow agitator shaft. This kind of stirrers are designed for
homogenization and flocculation processes with flange for application to open or semi-open
containers. Technical specifications of the anoxic tank stirrer are described bellow:
Type:
RV-12 S-35-05
Speed:
49 rpm
Relation:
1:30
Propeller:
600 mm
Material:
Aisi-316
Engine:
1/3 HP
Weight:
14,00 Kg
Figure 25. Stirrer for anoxic tank, including specifications.
The water flows into the tank through a tube connected at the top, and then flows out of the
tank to the biological reactor though a tube at the top that connects both tanks. At the bottom
there is another tube for the active sludge recirculation. In order to ensure the correct
recirculation ratio a specific pump is defined. This way, activated sludge is returning from the
biological reactor in order to fit defined requirements. Selected pump presents the following
technical specifications:
Flow
Temperature
Model
Number of vanes
Solids pitch
Pressure port
Nominal tension
Power output
Power factor
2,5 m3/h
20 °C
MF 334 D
6
30 mm
1½"
400 V
0,556 kW
0,86
Trademark
Impeller
Impeller diameter
Frequency
Rated speed
Yield
Nominal current
Nominal torque
Protection grade
ABS
Vortex
98 mm
50,0 Hz
2560 l/min
66,8 %
1,4 A
2,07 Nm
<IP 68>
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Deliverable D.B.1.3
3.1.4. Ammonium-Nitrate probe.
Ammonium-Nitrate levels help us to determine the efficiency of the anaerobic process, for this
reason ammonium-nitrate probe is installed in anoxic tank with specifications explained in the
table below. The probes have been developed for use in municipal waste water applications.
The ISE feature ion-selective electrodes for continuous measurement of ammonium and/or
nitrate in the tank itself. They operate without reagents and require no further processing of the
sample. The ammonium/nitrate ions are measured using an ion-selective electrode. The only
wearing part is the sensor cartridge. The sensor cartridge consists of the ion-selective electrodes
for ammonium and potassium (compensation electrode for ammonium) or nitrate and chloride
(compensation electrode for nitrate), a pHD reference system and a temperature sensor for
comparing temperatures.
The functioning of the ion-selective electrodes is because they have a special membrane to which
only a specific type of ion can adhere. As a result, an ion-specific potential forms on the
membrane surface. To measure a potential difference, a reference system is required that will
not be affected by the sample to be measured.
The CARTRICALTM technology reduces cross-sensitivity by calibrating not only the individual
electrodes but also the measuring electrode against the compensation electrode and the
reference; this is carried out at the factory. The reference system is designed using pH-differential
technology and is therefore particularly stable in terms of drift and contamination.
The AN-ISE sc probe uses the ion-selective electrode technology to measure ammonium ions
(NH4+) and nitrate ions (NO3–) in a waste water sample.
Known interfering factors due to potassium (when measuring ammonium), chloride (when
measuring nitrate) and temperature are compensated by suitable built-in electrodes.
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Deliverable D.B.1.3
Figure 26. ISE probe and sensor cartridge.
General information
Measurement method
Measurement range
Precision
Reproducibility
Response time (90 %)
Measurement interval
pH range
Calibration methods
Power consumption
Power supply
AN-ISE sc
Potentiometric measurement using ion-selective electrodes (ISE)
Ammonium and potassium, nitrate and chloride, reference system
0 to 1000mg/L [NH4–N]
0 to 1000mg/L [K+]
0 to 1000mg/L [NO3–N]
0 to 1000mg/L [Cl–]
5 % of the measured value + 0.2 mg/L1
5 % of the measured value + 0.2 mg/L1
< 3 minutes (5 to 50 mg/L)
Continuous
pH 5 to pH 9
Sensor code for sensor cartridge, 1 and 2-point value correction or
matrix correction
1W
Via sc controller
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Data transfer
Ambient data
Typical environment
Storage temperature
Deliverable D.B.1.3
Via sc controller
Used in the biological phase of municipal waste water treatment
Sensor: –20 to 60 °C (–4 to 140°F)
Sensor cartridge: 5 to 40 °C (41 to 104°F)
Air: –20 to 45 °C (–4 to 1 13 °F)
+ 2 to 40 °C (35 to 104°F)
< 4 m/s
Can be immersed to a depth of 0.3 to 3.0 m (1 to 10 ft);
Maximum pressure: 0.3 bar (4.4 psi)
Operating temperature
Sample temperature
Maximum flow velocity
Maximum sensor
immersion depth/pressure
Maximum Compressed air
output during cleaning
3.1 bar (45 psi)
unit operation
General information about the probe
Probe dimensions
+ 2 to 40 °C (35 to 104°F)
Standard: 10m (33.8ft)
Extension cables are available as an option in the following lengths:
Length of probe cable
5, 10, 15, 20, 30, 50 m (16.4, 33.8, 49.2, 65.6, 98.4, 164ft).
Maximum overall length: 100 m [328 ft]
Probe weight
Approximately 2380g (83.95oz)
Only for immersed installations:
Probe: stainless steel (1.4571), ASA + PC, silicon, PVC and PU
Wetted materials
Sensor cartridge: PVC, POM, ABS, stainless steel (1.4571), NBR
Optional cleaning unit: TPE, PUR, stainless steel (1.4571)
Installation angle
45° +/– 15° vertically in flow direction
1
With standard solutions and ISE electrodes under laboratory conditions
3.1.5. Biological reactor.
Biological reactor is the second step of the process. In this case, oxygen content is present and,
this way, organic matter and phosphorus content are conveniently reduced. Biological reactor is
located in the same structure that anoxic tank. Thus, it is rectangular shaped, made of fibreglass,
and its capacity is 4000 litres.
The water flows into the reactor though a tube at the top which connect anoxic tank and
biological reactor, and then flows out of the reactor to the conical decanter through a tube
connected to the ADNATUR dosing system.
In order to have the proper amount of dissolved oxygen the biological reactor has an aeration
system. This system consists in a blower group time-controlled, which introduces air uniformly
though fine bubbles diffusers and low maintenance, in order to guarantee proper oxygen supply.
In this way it is possible to reduce energy costs by introducing only the necessary oxygen. An
irregular oxygen application can produce biological problems and, as a result, in the effluent. Fine
bubbles diffusers have the next advantages:
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
More efficiency in the transfer of oxygen.

Uniform distribution of dissolved oxygen in every cross-section of the tank, avoiding
deposition of solids can cause odors.

Less volume of air to be supplied with the consequent energy savings.
3.1.6. Dissolved oxygen electrode.
In order to control bacteria requests and correctly grown, dissolved oxygen should be controlled,
for this reason dissolved oxygen detector with the following specifications is included in the
biological reactor.
Figure 27. LDO sensor.
Specification
Details
Wetted materials
Standard Probe, Standard Class 1-Div 2 Probe
 CPVC, sensor end and cable end

Polyurethane, over-molding on cable end and
cable jacket
 316 stainless steel body and screws
 Viton, O-ring
 Noryl, nut on the cable end
IP classification
Wetted materials (sensor cap)
Measurement range (dissolved oxygen)
IP68
Acrylic
0 to 20 ppm (0 to 20 mg/L)
0 to 200% saturation
Below 5 ppm: ± 0.1 ppm
Above 5 ppm: ± 0.2 ppm
0.1 ppm (mg/L)
T90<40 seconds
T90<60 seconds
0.01 ppm (mg/L): 0.1% saturation.
0 to 50 °C (32 to 122 °F)
± 0.2 °C (± 0.36 °F)
+
+
No interferences from the following: H 2S, pH, K , Na ,
2+
2+
+
3+
2+
2+
2+
2+
Mg , Ca , NH4 , Al , Pb , Cd , Zn , Cr (total), Fe ,
3+
2+
2+
2+
2+
3223Fe , Mn , Cu , Ni , Co , CN NO , SO4 , S , PO4 , Cl ,
Anion Active Tensides, Crude Oils, Cl2 < 4 ppm
Measurement accuracy (dissolved oxygen)
Repeatability (dissolved oxygen)
Response time (dissolved oxygen)
Resolution, sensor (dissolved oxygen)
Measurement range (temperature)
Measurement accuracy (temperature)
Interferences
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Storage temperature
Maximum temperature
Hazardous location classification (9020000C1D2 sensor only)
Certification (9020000-C1D2 sensor only)
Minimum flow rate
Calibration/verification
Probe immersion depth and pressure limits
Sensor cable
Probe weight
Probe dimensions
Power requirements
Warranty
Deliverable D.B.1.3
-20 to 70 °C (-4 to 158 °F)
0 to 50 °C (32 to 122 °F)
Class I, Division 2, Groups A-D, T4 / Class I, Zone 2
Group 2C, T4
Note: This product dos not fulfil the requirements of the
94/9/EC Directive (ATEX Directive).
ETL listed to ANSI/ISA, CSA and FM standards for use in
hazardous location.
Note: This product dos not fulfil the requirements of the
94/9/EC Directive (ATEX Directive).
Not required
Air calibration: One point, 100% water-saturated air
Sample calibration: Comparison with standard
instrument
Pressure Limits at 34 m (112 ft.), 345 kPa (50 psi)
maximum; accuracy may not be maintained at this
depth
10 m (30 ft) integral cable with quick disconnect plug
(all sensor types)
Up to 100 m possible with extension cables (non-Class
I, Division 2 sensor types only)
Up to 1000 m with junction box (non-Class I, Division 2
sensor types only)
2.0 kg (2 lb, 3 oz)
Standard probe (diameter x length): 49.56 x 255.27 mm
(1.95 x 10.05 in.)
12 VDC, 0.25 A, 3W
Probe: 3 years against manufacturing defects
Sensor cap: 2 years against manufacturing defects
3.1.7. ADNATUR dosing system.
ADNATUR dosing system is probably the most important component of the prototype. It is
necessary in order to maximize the coagulant efficiency of the ADNATUR natural based products.
It contains a dosing pump and a static mixer system. This way, the product is reaching the
coagulation tank previously dissolved in water. However, dissolution procedure is made in situ so
the reaction time is low and then the stability of the product is unaltered. Proposed dosing pump
includes the following specifications:
Power supply:
Number of pump injections:
Maximum flow (7 Bar):
Injections/Minute aspiration Height:
Room temperature:
Additive temperature:
Contamination level:
Sound level:
230 VAC (180-270 VAC)
115 VAC (90-135 VAC)
24 VAC (20-32 VAC)
12 VDC (10-16 VDC)
0 ÷ 180
6 litres/hour
1,5 metros
0 ÷ 45°C (32 ÷ 113°F)
0 ÷ 50°C (32 ÷ 122°F)
2
74 dbA
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Delivery and storage temperature:
Protection grade:
Deliverable D.B.1.3
-10 ÷ +50°C (14 ÷ 122°F)
IP65
Figure 28. ADNATUR dosing system, including the dosing pump (left) and the static mixer (right).
3.1.8. Conical decanter.
Once the chemicals are dosed and conveniently blended with the water coming from the
biological reactor, the floc is completely formed but still need some time to decant. For that
reason a specific system called conical decanter is still required. Its main specifications are
described bellow.
Conical settler made of fibreglass:

Length:
1.400 mm.

Width:
1.400 mm.

Height:
1.900 mm.
Finishes:

Fibreglass.
Accessories:

Flocculation cylinder.

Pipes, valves and electrovalves.
Structure:

4 Pillar HEB-100.
Figure 29. Conical decanter of urban wastewater prototype, including main specifications.
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Deliverable D.B.1.3
3.1.9. Sludge extraction.
When the floc is correctly decanted, the sludge needs to be extracted and partially sent to the
dewatering system and back, to the biological reactor. In this case, a sludge extraction pump with
the following properties is required:
Type
Efficiency level (Reg. 640/2009)
No. of Poles
Rotation speed [min-1]
Insulation Class
Protection degree(CEI EN 60034-5)
[kW]
Power rating
[HP]
Frequency [Hz]
Voltage [V]
Casing material
Base material/motor support
Dimensions of cable entry
Maximum working pressure [MPa]
Impeller
Construction
Pipe Connection
Material
Shaft seal type
Bearing
Suction
Discharge
Casing
Impeller
Casing cover
Shaft seal
Casing cover
Shaft
Bracket
Applicable standard of test
Electric - TEFC
Three Phase
IE2 from 1.1 kW up to 3.0 kW
2
» 2800
F
IP 55
1.1 ÷ 3
1.5 ÷ 4
50
230/400 ±10%
Aluminium
Aluminium
PG11 - PG13.5
0,8
Open centrifugal type
Mechanical seal
Sealed ball bearing
G2
G2
AISI 304
AISI 304
AISI 304
Ceramic/Carbon/NBR Ceramic/
Tungsten Carbide/Tungsten Carbide/FPM (for DWOHW)
SiC/Tungsten Carbide/FPM (for DWOHSW)
Carbon/FPM (for DWOH) SiC/SiC/FPM (for DWOHS)
SiC/SiC/FPM (for DWOHS)
AISI 304
AISI 304 (Wet extension)
Aluminium
ISO 9906 – Annex A
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Deliverable D.B.1.3
Figure 30. Sludge extraction pump for urban wastewater prototype.
3.2. START / STOP PROCEDURES.
After filling the chemical tanks, the start-up of the plant can be carried out. The start-up of the
plant, in automatic mode, will be carried out placing all contactors containing three positions
(MAN-0-AUTO) to AUTO. In the first start-up, or when a stop light is made, it will also have to use
the reset button.
The pilot plant can be manually stopped, by pressing start-up switch to 0. In order to make an
immediate stop, just press the emergency stop button (red), so that the plant will stop and be
ready for its next start.
3.2.1. Electrical pumping panel description.

Inlet water tank pumps. Contactor which commands the start-up of submersible pump that
feeds the inlet water tank. The pump has three positions (MAN-0-AUTO). For operation in
automatic the position has to be AUTO.
3.2.2. Pilot plant electrical panel.

Alarm. The contactor which commands the reaction of the thermal of the plant has two
positions (0-1). In position 1, if a thermal cut-off occurs, the plat will stop, in position 0, the
thermal cut-off will only affect to the stopping of the corresponding motor.

General stoppage. Blue light signal indicating a stop of the plant.
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
Deliverable D.B.1.3
Plant. The contactor which commands the start-up of the plant has three positions (MAN-0AUTO). In position 0, the plant is completely stopped; in manual position, the start up of the
plant will be carried out. In AUTO position, the automatic start up will be carried out.

ADNATUR dosing pump. The contactor which commands the start-up of the pump of
ADNATUR technology dosing has three positions (MAN-0-AUTO). For automatic operation
must be in the AUTO position.

Flocculant dosing pump. The contactor which commands the start-up of the dosing flocculant
pump has three positions (MAN-0-AUTO). For automatic operation must be in the AUTO
position.

Flocculant stirrer. The contractor which commands the start-up of the flocculant preparer
mixer has three positions (MAN-0-AUTO). For automatic operation must be in the AUTO
position.

Sludge discharge. The contactor which commands the start of the discharge of sludge by a
solenoid valve has three positions (MAN-0-AUTO). For automatic operation must be in the
AUTO position.

Reset plant. This device has the function of start-up the plant, it is used only when a stoppage
in the power supply occurs and in the initial operation of the plant.

Emergency stop button. It consists of an emergency stop device of the plant, according to
regulations.

Safety symbol according to ISO 3864-1984. Symbol of warning-risk, power danger not handle
any electrical power without prior authorization of the manufacturer.
3.3. MAINTENANCE INSTRUCTIONS.
3.3.1. General cleaning.
The plant cleaning depends on the estimated time of stoppage. In general terms, these two kinds
of cleaning can be carried out, but they always have to be done during the stoppage of the plant.

Deep cleaning of the decantation tank. It is recommended every three months. In order to
clean the plant, three quarters of capacity must be empty, enough to access the lamellar
filters and to clean the fouling.

Revision of piping and pumps of the pilot plant.

Cleaning of all the components of pilot plant, inlet water tank, coagulation tank and
flocculation tank.
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3.3.2. Proper operation controls.
The proposed controls aim to optimize the operation of the pilot plant, prevent possible
breakdown and reduce the accidental risks. The next type of control must be done, in all cases
with the plant stopped. The main diary controls are described bellow:

Inlet water control: colour, smell, solids, pH.

Treated water control: colour, smell, pH.

Treatment: Coagulation and flocculation. In case that the treatment is not carried out
properly, the dose of chemicals will be change after test a sample.

Replacement of products: Product replacement should guarantee the correct dosage at any
time, thus, there will be no problems in the treatment during operation of the plant. In
addition, day of no attendance at the facility should be taken into account.

Flocculant preparation.

Checking:
-
Proper operation of inlet water pump.
-
Flow control valve.
-
Proper operation of coagulant and flocculant pumps.
-
Regulate coagulant and flocculant pumps depending on the inlet water.
-
Sludge discharge control.
3.3.3. Pumps maintenance operations.
The aim of this section is, in the first place, to describe the pump in order to get to know its
operation mode. Then, details about its storage, manipulation, start up and stoppage procedures
are given.
The current pumps are horizontal end suction centrifugal with single impeller. Feet are casted
together with the pump casing which is open at the back to allow the rotating parts been
dismantled without disturbing the suction and delivery pipes of the system. The impeller is closed
type. The rotation direction is clockwise (to the right) viewed from coupling side. The sealing box
built into the casing cover is prepared to accept packing, with different types depending on the
liquid being pumped. The drive shaft is held by two rigid ball bearings, lubricated either by grease
or oil. Pump can be driven by a diesel engine or electric motor, set on a common bedplate and
joined by a semielastic coupling.
Storage.
The pumps should be stored in well-ventilated zones free of damp. For short storage periods the
machined parts should be protected with an oil or anti-corrosion product.
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If the pump is to be left for longer periods in the store, precautions should be taken to prevent
the pump from corroding by using an anti-corrosion product, also proceeding to cover up the
suction and delivery flanges.
Turn the shaft by hand every 15 days to prevent any possible seizing up. Make sure that the
diesel engine or electric motor is not exposed to atmospheric agents which might not be
compatible with its degree of protection and might cause damage to it. Before storing a pump,
which has recently been installed, proceed to clean and then air-dry it (do not used hydrocarbidebased products).
Manipulation.
Pumps in bare shaft disposal must be handled using the delivery flange as lifting point, and to
position them use the suction flange and the bearing support if required. The electric motor
should be handled using the securing point(s) provided for this purpose consisting on a ring
located at the top of the casing.
To handle the motor pump set use a sling going under the bed so as to ensure stability during
lifting and displacement. Under no circumstances use the ring located over the motor or pump.
Start up and stoppage procedure indications.
For the first start up, after making all the checks, this should be done with the drive valve closed,
to reduce the consumption of the pump as far as possible. When the running speed has been
reached, the valve should slowly be opened, observing at the same time the variation in
consumption, until this opens completely. In normal operation the consumption, measured in
amperes, should not be over what is stated on the motor plate.
To stop the pump, the delivery valve should be returned to the original position as before the
start up. When installation has an anti-water hammer device there is no need to close the
delivery valve for stopping the pump. Check that motor deceleration is normal and after it has
completely stopped close the auxiliary circuits.
When the equipment is to be idle for long periods, the pump and piping should be completely
drained, to prevent the risks of frost during the winter and any possible rusting of the mechanical
items that might be caused through trapped liquid.
3.3.4. Stirrers maintenance operations.
Precautions before commissioning.
Before starting the stirrer is essential to carry out the following checks. The motor voltage stated
on the nameplate must match the voltage available online. Check that the mechanical and
thermal motor protections are adequate for proper operation. The motor housing must always
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be grounded. Remove the motor fan cover and turn the same hand to confirm that no blocking
points and the fan impeller rotates freely. During this check it must be made sure that the motor
or the machine is not connected to the network, to avoid any possible mishap.
After the test, proceed with the following checklist:

Replace the lid Fan verifying that the grid is unobstructed.

Confirm that the speed reducer (if any) have the appropriate level of lubricant.

Check the tightening of the screws holding the flange or plate agitator to structure is
correct and are not loose.

Check that the coupling screws connecting the head agitator shaft are properly
tightened.

In the case of the agitator shaft was attached to plates, prior to assembly, rigid coupling
must be removed any dirt from the faces that will be in contact.

Check the correct tightening of the screws that hold the propeller shaft.
Safety Recommendations. Protection against mechanical hazards.
The control system must be designed and installed to prevent the operation of the stirrer while
not in place and position, including:

The control unit shall include a manually operated device that allows the unemployment
insurance.

The stirrer should be fixed stably working and so that parts phones are protected by the
container in which the work will develop.
Therefore, the control unit must include a protective device that prevents achieving moving part
of the agitator during their work. The agitator should not be possible to start while it may come
into contact with moving parts.
Protection against electrical hazards.
The user must connect the different electrical circuits and drives for completing the electrical
installation in accordance with EN60204-1, to operate the stirrer safe conditions.
Protection against chemicals.
Before installing the agitator, check that the selected model is appropriate to the possible
presence of chemicals in the work area of the agitator.
Moreover, if necessary, shall be provided in an exhaust system of toxic gases or dusts suspension
that may arise during agitation and related processes work.
Protection against risk of explosion.
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Before installing the agitator, check that the selected model is appropriate to the classification of
the area where it will be installed stirrer. It is the user's responsibility adequacy of electrical
equipment to the characteristics of the area classified according to laws and regulations.
Transport and location.
For the maintenance of the agitator without packing a suitable suspension should be used to
weight model, taking into account its centre of gravity. Never submit to extreme efforts the
proximal shaft stirring element. The necessary space must be provided to make the installation
work and maintenance.
Connections.
When connecting the motor, you should check that the direction of rotation of the agitator
matches the indicated by arrow incorporating the agitator. Otherwise, you must change the
sequence of the phases.
3.3.5. Detector maintenance and calibration procedures.
3.3.5.1. Calibration and maintenance of Dissolved oxygen electrode for measurements.
CALIBRATION
The sensor is calibrated to specification at the factory. The manufacturer does not recommend
calibration unless periodically required by regulatory agencies. If calibration is required, let the
sensor come to equilibrium with the process before calibration. Do not calibrate the sensor at
setup. The next table shows options for calibration.
Option
AIR CAL
SAMPLE CAL
RESET DFLT CAL
Description
Recommended calibration method. This calibration modifies the
slope.
Calibration by comparison with a hand-held DO meter . This
calibration modifies the offset.
Resets the calibration gain (slope) and offset to the factory
default: default gain=1.0; default offset=0.0
Calibration with air.
User notes:
• Make sure that calibration bag has water inside.
• Make sure that the seal between the calibration bag and the sensor body is tight.
• Make sure that the sensor is dry when it is calibrated.
• Make sure the air pressure/elevation setting is accurate for the calibration location.
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• Allow enough time for the sensor temperature to stabilize to the temperature of the calibration
bag location. A large difference in temperature between the process and the calibration location
can take up to 15 minutes to stabilize.
1. Remove the sensor from the process. Use a wet cloth to clean the sensor.
2. Put the entire sensor in a calibration bag with 25-50 mL of water. Make sure that the sensor
cap is not in contact with the water inside the calibration bag and that no water drops are on the
sensor cap (Figure 37).
3. Use a rubber band, tie or hand to create a tight seal around the sensor body.
4. Let the instrument stabilize for 15 minutes before calibration. Keep the calibration bag out of
direct sunlight during stabilization.
5. Make sure that the current absolute air pressure or elevation is configured correctly.
Note: The manufacturer recommends the use of absolute or actual air pressure as a best practice.
6. Go to MENU>SENSOR SETUP>[Select Sensor]>CALIBRATE>AIR CAL.
7. Select the option for the output signal during calibration:
Option
Description
Active
The instrument sends the current measured output value during the
calibration procedure.
Hold
The sensor output value is held at the current measured value during the
calibration procedure.
Transfer
A preset value is sent during calibration. Refer to the controller user
manual to change the preset value.
8. The controller will show "Move the probe to bag". Allow the value to stabilize. Push ENTER to
accept the stable value. Alternately, let the calibration continue until the display shows
"Complete".
9. When the sensor is calibrated, put the sensor into the process. Push ENTER.
Figura 31. Air calibration procedure.
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If the value does not stabilize, the display will show "Unable to Calibrate" followed by an error
message. The next table shows the error message and resolution for calibration problems.
Message
Cal fail, gain
high
Cal fail, gain
low
Cal fail,
unstable
Description
The calculated gain value is too high.
The calculated gain value is too low.
The value did not stabilize in the maximum allowed
calibration time.
Resolution
Repeat the
calibration.
Repeat the
calibration.
Repeat the
calibration.
Sample CAL - calibration by comparison.
This calibration method uses an alternate sensor attached to a hand-held meter.
1. Put the alternate sensor into the process. Put the second sensor as close as possible to the first
sensor.
2. Wait for the DO value to stabilize.
3.
On
the
controller
for
the
first
sensor,
go
to
MENU>SENSOR
SETUP>[Select
Sensor]>CALIBRATE>SAMPLE CAL.
4. Select the option for the output signal during calibration:
Option
Description
Active
The instrument sends the current measured output value during the
calibration procedure.
Option
Description
Hold
The sensor output value is held at the current measured value during the
calibration procedure.
Transfer
A preset value is sent during calibration. Refer to the controller user
manual to change the preset value.
5. The controller will show:
• "Press ENTER when stabilized"
• The current dissolved oxygen measurement
• The current temperature measurement
6. When the measurement is stable, push ENTER. The display will show an entry screen.
Note: The measurement will usually stabilize in 2 to 3 minutes.
If the value does not stabilize, the display will show "Unable to Calibrate" followed by an error
message. The next table shows the error message and resolution for calibration problems.
Message
Description
Resolution
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Cal fail, offset
high
Cal fail, offset
low
Cal fail, unstable
Deliverable D.B.1.3
The calculated offset value is too high.
The calculated offset value is too low.
The value did not stabilize in the maximum allowed
calibration time.
Repeat the
calibration.
Repeat the
calibration.
Repeat the
calibration.
Exit the calibration procedure.
1. During calibration, push the BACK key. Three options are shown:
Option
Description
ABORT
Stop the calibration. A new calibration must start from the beginning.
BACK TO CAL
Return to the current calibration.
LEAVE
Exit the calibration temporarily. Access to other menus is allowed while
the calibration continues in the background. A calibration for a second
sensor (if present) can be started. To return to the calibration, push the
MENU key and select Sensor Setup, [Select Sensor].
2. Select one of the options. Confirm.
Reset calibration defaults.
Calibration settings can be reset to the factory defaults. Gain and offset values are set to 1.0 and
0.0, respectively.
1. Go to MENU>SENSOR SETUP>[Select Sensor]>CALIBRATE>RESET CAL DEFLT.
2. The display will show a confirmation message. Confirm to reset the sensor to the factory
default calibration curve.
MAINTENANCE
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Maintenance schedule.
The maintenance schedule shows minimum intervals for regular maintenance tasks. Perform
maintenance tasks more frequently for applications that cause electrode fouling.
Note: Do not disassemble the probe for maintenance or cleaning.
Maintenance task
Clean the sensor
Inspect the sensor for damage
Calibrate the sensor
Recommended minimum frequency
90 days
90 days
As recommended by regulatory agencies
Clean the sensor.
Clean the exterior of the sensor with a soft, wet cloth.
Note: If the sensor cap must be removed for cleaning, do not expose the interior of the cap to direct sunlight for
extended periods of time.
Set or change the clean interval.
Application conditions may need shorter or longer durations between manual sensor
cleanings. The default clean interval is 0 days. To change the interval, refer to the steps in
this procedure.
1. Go to MENU>SENSOR SETUP >[Select Sensor]>CONFIGURE>CLEAN INTRVL.
2. Change the shown value as needed. Confirm the change.
• To turn off the clean interval, set the value to '0'.
Change the sensor cap.
Replacement sensor caps and setup caps are shipped with installation instructions. Refer to the
included instructions to change the cap.
For best performance and accuracy, replace the sensor cap:
• Every two years
• When routine inspection shows significant erosion of the sensor cap
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3.3.5.2. Calibration and maintenance methods of the Ammonium-Nitrate ISE.
CALIBRATION
Matrix correction.
The four electrodes with the reference system of the compact sensor cartridge were calibrated
with one another at the factory using special standard solutions (CARTICALTM). However, the
membranes on the ion-selective electrodes are not 100% selective due to other substances that
may affect the measurement. Perform a matrix correction to compensate for other ions present
on the ISE electrodes.
Potassium has the largest interference effect on the ammonium membrane, while chloride has
the largest effect on the nitrate membrane. The AN-ISE sc probe compensates for this problem
with the aid of a built-in potassium/chloride electrode.
Sensor code calibration.
The sensor code is a calibration code and is delivered with the sensor cartridge certificate.
Instruments with automatic sensor code recognition (LXG440.99.x000x) read this automatically
and assume the Cartrical calibration.
Instruments without automatic sensor code recognition (LXG440.99.x001x) require the sensor
code to be entered during the initial setup and whenever a new sensor cartridge is activated. If
the sensor code certificate has been lost, carry out factory calibration (under the sensor code
menu) as a temporary solution.
After activating the code, the sensor is fully calibrated but not yet adapted to the specific matrix
of the relevant application on a waste water treatment plant. At least 12 hours must elapse
before a matrix correction is performed to allow the cartridge to adapt to the specific matrix.
Proceed as follows to change the sensor code: 1. Select S ENSOR MENU > AN-ISESC or AISESC or
NISE SC > CALIBRATE > FURTHER CORR. > SENSOR CODE > ENTER 2. Enter the sensor code. 3.
Press ENTER to confirm and activate the sensor code. The day meter for the cartridge is set to
zero.
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All old calibration data are now overwritten with the new calibration data from the sensor code.
The sensor code data is checked by the system. If an error is indicated, check the sensor code
and, if necessary, enter the sensor code again.
Matrix correction via LINK2SC.
The LINK2SC procedure offers a secure method of data exchange between process probes and
LINK2SC-compatible photometers using an SD memory card or via a local area network (LAN).
Two different options are available:
a. The pure laboratory control measurement
b. A matrix correction that involves the measurement data generated in the laboratory
being used to correct the probe
During a pure control measurement, the measurement data is transferred from the probe to the
photometer where it is then archived together with the photometric reference data that has
been recorded.
During a matrix correction, the reference data generated in the laboratory is transferred to the
probe to be used for the correction.
The matrix correction process requires operating steps to be completed on the sc controller and
on a LINK2SC-compatible photometer.
Refer to the LINK2SC user manual for a detailed description of the LINK2SC procedure.
Matrix correction – manual.
ISE probes offer different options for correcting the sensor value with laboratory values (as a
reference value).The laboratory value of the water sample is entered as nitrate nitrogen (NO3–N)
and/or as ammoniacal nitrogen (NH4–N). This laboratory value replaces the prior value measured
by the sensor.
Correction option
Application
MATRIX 1
A MATRIX 1 is the most commonly used correction option and performs a
1 point matrix correction for ammonium and/or nitrate. It is advisable to
perform a MATRIX1 as the first correction. The Matrix1 correction can be
performed both with and without correction of the compensation
electrodes (potassium or chloride); in most cases, it is sufficient to perform
it without correction. A correction featuring potassium and/or chloride is
only necessary if a high level of accuracy is required. With a MATRIX1, a
sample must be taken when the correction is triggered and analyzed in the
laboratory. The MATRIX1 is activated when the laboratory value is entered.
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VALUE CORR. 1
Value correction 1 (correction at one concentration point) corresponds to a
MATRIX1 correction with an alternative entry format. Comparison values
between the ISE probe and the laboratory can be collected over a period of
around a week with this correction. The correction can be performed at a
later stage.
VALUE CORR. 2
Value correction 2 (correction at 2 different concentration points) should
be performed if dynamic concentration fluctuations are present over at
least half a decade1 and a MATRIX1 or VALUE CORR. 1 does not achieve a
sufficiently accurate result. Comparison values between the ISE probe and
the laboratory can be collected over a period of around a week with this
correction. The correction can be performed at a later stage.
MATRIX 2
The MATRIX 2 correction corresponds to a VALUE CORR. 2, but uses an
alternative entry format and is recommended if there is a dynamic process
with a large nitrate/ammonium fluctuation greater than at least half a
decade1. With a MATRIX2, a sample must be taken for both points when
the correction is triggered and analyzed in the laboratory. The MATRIX2 is
activated when the laboratory value is entered.
HIST. CORR.
Return to one of the last matrix and value corrections performed if a
correction has not produced a successful result.
1
Examples of half a decade: The concentration of nitrogen nitrate shifts between 1 and 5 mg
NO3–N or between 5 and 25 mg/L NO3–N. (conc2 = (conc1 x 10)/2)
Performing the matrix correction.
Note: Take laboratory value measurements or reference values promptly or, alternatively, take these from the
stabilized sample. This will prevent changes in sample concentration, as time is a factor in comparative tests.
MATRIX 1 correction (1 point matrix correction)
Proceed as follows to perform MATRIX 1:
1. Select SENSOR MENU > AN-ISE SC > CALIBRATE > MATRIX CORR.
2. Select MATRIX 1 from the selection window and press ENTER.
3. Select the parameters you wish to correct and confirm by pressing ENTER.
Selection options for AN-ISE sc:
NH4 + NO3; NH4; NO3; NH4 + K; NO3 + Cl; NH4 + K NO3 + Cl
The sensor saves the current values of the selected parameters at this point.
4. Take a water sample immediately from the closest point possible to the
sensor. Filter the sample as quickly as possible and carry out a prompt
laboratory analysis of the selected parameters, as the measurement value can
change quickly.
When the laboratory value has been determined, proceed as follows:
5. Select SENSOR MENU > AN-ISE SC or AISE SC or NISE SC > CALIBRATE >
ENTER LABVALUE. 6. The laboratory values for the parameters can only be
entered if the MATRIX1 correction has been selected beforehand. Once the
laboratory values have been entered, select ENTRY COMPLETE to confirm.
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When the entered laboratory value is confirmed, the matrix correction is
activated.
7. Once the correction is activated, the result CORR-RESULT is shown.
Note: This process must always be carried out in full to make sure the matrix correction is
completed successfully. If a correction does not produce a successful result, calculations are made
with the previous correction.
Value correction 1
The one-point value correction VALUE CORR. 1 offers the option of
retrospectively performing a matrix correction at one point (MATRIX1).
1. Take several samples with different concentrations on various days,
preferably within one week. Analyze the samples in the laboratory. During the
time the samples are being taken, the sample temperature should be around a
maximum of 5 °C, as temperature changes are not taken into account in the
value correction.
2. Make a note of the two values measured in the samples and displayed for
the parameters to be corrected (ammonium and potassium values, or nitrate
and chloride values)
3. Also note the laboratory values measured for ammonium or nitrate.
These three values form the correction point.
4. From the values taken, select a correction point that lies in the middle of the
expected concentration range.
5. Go to the sensor menu and select CALIBRATE > MATRIXCORR > VALUE
CORR. 1 and confirm by pressing ENTER.
6. Select the parameter1 (NH4–N or NO3–N) that requires correction. Note: The
example opposite shows the NH4-N and K correction of the AN-ISE sc probe.
7. Enter the three values for the sought correction point and confirm with
ENTRY COMPLETE to activate the correction.
Correction result CORR-RESULT is shown.
Note: If a correction does not produce a successful result, calculations are made with the previous
correction. After successful completion of value correction, the corrected value is shown as the
display value for ammonium or nitrate the next time the menu is opened.
Value correction 2
The two-point value correction VALUE CORR. 2 makes it possible to perform a
subsequent 2-point correction (MATRIX2) to achieve higher accuracy for a
larger concentration range.
Note: Value correction 2 and MATRIX 2 are comparable from a calculation perspective.
1. Take several samples on various days with different concentrations,
preferably within a week, and perform an analysis of the samples in the
laboratory. During the time the samples are being taken, the sample
temperature should be around a maximum of 5 °C, as temperature changes are
not taken into account in the value correction.
Note: The MATRIX CORR. 2 concentrations should be within a range greater than half a
decade. The following formula can assist in the calculation of the half decade:
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Con2 
Conc1  10
2
2. Make a note of the two values measured with the sensor in the samples and
displayed for the parameters to be corrected (ammonium and potassium
values, or nitrate and chloride values).
3. Also note the laboratory value measured for ammonium or nitrate.
All three values form one of the two correction points.
4. Look for two correction points where the laboratory values are at least half a
decade apart and display typical operating conditions for the installation.
5. Go to the sensor menu and select CALIBRATE > MATRIX CORR > VALUE
CORR. 2 then confirm with ENTER.
6. Select the parameter1 (NH4–N or NO3–N) that requires correction.
7. Enter the three values for the first correction point and confirm with ENTRY
COMPLETE.
Note: The example opposite shows the NH4-N and K correction of the AN-ISE sc probe.
8. To activate the correction, enter the three values for the second correction
point and confirm with ENTRY COMPLETE.
Correction result CORR-RESULT is shown.
Note: If a correction does not produce a successful result, calculations are made with the previous
correction. After successful completion of value correction, the corrected value is shown as the
display value for ammonium or nitrate the next time the menu is opened.
MATRIX 2 correction (2 point matrix correction)
Proceed as follows to perform MATRIX 2:
1. Select SENSOR MENU > AN-ISE SC > CALIBRATE > FURTHER CORR..
2. Select MATRIX 2 from the selection window and press ENTER.
3. Select the parameters1 requiring a two-point matrix correction.
4. Select the point to be corrected.
5. SELECT MEAS CONC 1 or MEAS CONC 2
6. Take a water sample from the closest point possible to the sensor. Filter this
sample promptly and perform an immediate laboratory analysis of the selected
parameters. The measurement value can change very quickly:
When the laboratory value has been determined, proceed as follows:
7. Select SENSOR MENU > AN-ISE > CALIBRATE > FURTHER CORR. > MATRIX2
8. Select the parameters to be corrected with the laboratory value entry.
9. Enter the laboratory reference value and confirm.
The MATRIX2 CORR. is activated when the entry is confirmed for both points.
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MAINTENANCE
Schedule.
Maintenance task
2
Clean the probe
Replace the sensor cartridge3, 4
Check probe for damage
Compare the measured value with a reference laboratory analysis
and correct the values as required via a matrix correction3
30 days1
x
12 months
x
x
x
1
Recommended: Weekly during the first month of operation
The frequency of cleaning depends on the application. Some applications may require cleaning to take place more or
less frequently.
3
In typical operating conditions, a different interval may be required depending on the specific application and local
conditions.
4
Sensor cartridges are wearing parts and are not covered by the instrument warranty.
2
Note: Do not test the sensor with the usual NH4-N and/or NO3-N standard solutions, as the ion strength of normal
solutions is not high enough.
Clean the sensor.
1. Clean the sensor cartridge using the soft brush supplied.
2. Clean the probe body (not the sensor cartridge) with a sponge or brush.
3. Rinse the sensor with clean, lukewarm water.
Polish the chloride electrode.
Polish the chloride electrode if it looks heavily coated/contaminated. After polishing, a new
nitrate + chloride MATRIX1 correction should be performed after 12 hours.
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Figure 32. Chloride electrode.
Replace the sensor cartridge.
The sensor cartridge is replaced as described below.
1. Replace the cartridge using menu item
AN-ISE SC > DIAG/TEST > SERVICE > CHANGE CARTR.
2. Clean the probe and thoroughly dry the sensor cartridge and probe adapter.
3. Loosen the 4 socket head screws.
4. Pull the sensor cartridge out of the probe adapter and discard the old sensor cartridge as per
the applicable regulations.
5. Make sure that a new black gasket is installed every time the sensor cartridge is replaced.
Before the gasket is installed, clean the surface that faces the cartridge and the groove for the
gasket.
6. Insert the new sensor cartridge into the probe adapter. Observe the marker hole on the sensor
cartridge flange and the probe adapter.
7. Secure the sensor cartridge with the 4 socket head screws.
8. The sensor code (calibration data) is automatically read for instruments with automatic
recognition (LXG440.99.x000x). For instruments with non-automatic recognition
(LXG440.99.x001x), enter the new sensor code manually (refer to certificate).
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Figure 33. Replace the sensor cartridge.
Storage.
Take the probe out of the sample flow and clean thoroughly. Short term storage
Keep the membranes and reference system moist (do not use distilled or demineralized water).
This will help avoid long response times when the probe is placed back in the sample flow.
Otherwise, the correct operation of the probe is no longer guaranteed.
Long term storage.
Check the membranes and ensure they are still moist every 2-4 weeks, depending on
environmental conditions.
Note: A storage container is supplied to keep the sensor cartridge moist. Keep the sensor cartridge sealed in the storage
container during short and long term storage.
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Probe and sensor cartridge.
3.4. POINTS TO CHECK IF MALFUNCTION. PROBLEMS AND SOLUTIONS.
3.4.1. Pilot plant.
Breakdown
No wastewater arrives to the plant.
The wastewater flow is insufficient.
The plant does not start up.
Possible Cause
Verify the proper performance of feeding pump.
If in the control box the pilot is in red, reset
thermal protection.
Verify valve opening.
Check that the tank has enough water for proper
pumping.
Check position of the feed valve.
Systematically check the following points:
If there is level inlet water above the level
sensor.
No flocculation occurs.
Flocculation occurs irregularly and the resulting
liquid is very turbid and flocs escape through the
top of the decanting tank.
Flocculation occurs irregularly and the resulting
liquid is slippery.
If it is not pressed any safety shutdown.
Verify that the water and coagulant mixing
occurs and are dosed correctly.
Verify that there are reagents in tank.
Verify that reagents dosing is active and correct.
In that case, increase them.
Verify that reagent dosing is correct, and in that
case reduce it.
NOTE: Checking of circuits to prevent leakage of chemicals should be done every 24 hours with the plant stoppage,
using the appropriate personal protective devices. For any sign of leakage, the replacement of the damaged material
before the start of the plant should be carried out.
3.4.2. Troubleshooting of Ammonium-Nitrate ISE.
Error messages.
If the sensor is in an error state, the measurement value for this sensor will flash on the display
and the relay contacts and current outputs associated with this sensor will be stopped. The errors
are described in table below.
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Displayed errors
NH4 mV RANGE!
K+ mV RANGE!
NO3 mV RANGE!
Cl- mV RANGE!
REF1 mV
RANGE!
REF2 mV
RANGE!
TEMP RANGE!
Cause
Ammonium mV exceeds the measurement range
Potassium mV exceeds the measurement range
Nitrate mV value exceeds the measurement range
Chloride mV value exceed the measurement range
NO CARTRIDGE
No sensor cartridge connected
SENSOR CODE
Sensor code calibration failed
HUMIDITY
Humidity in the probe
NH4-N CONC
HIGH
NH4-N CONC
LOW
NO3-N CONC
HIGH
NO3-N CONC
LOW
K+ KONZ HOCH
K+ CONC LOW
CL CONC HIGH
CL CONC LOW
Deliverable D.B.1.3
REF1 reference value is out of measuring range
Resolution
Refer to
Troubleshooting
during operation
ORP electrode mV value is out of measuring range
Temperature value exceeds measurement range
Connect the
sensor cartridge
Refer to
Troubleshooting
during calibration
Inform service
engineer
Ammonium concentration value exceeds measuring range
Ammonium concentration value is below measuring range
Nitrate concentration value exceeds measurement range
Nitrate concentration value is below measurement range
Refer to
Troubleshooting
during operation
Potassium concentration value exceeds measuring range
Potassium concentration value is below measuring range
Chloride concentration value exceeds measuring range
Chloride concentration value below measurement range
Warnings.
In the event of a sensor warning, all menus, relays and outputs continue to function as normal
but a warning symbol lights up.
Warnings may be used to activate a relay; users can set warning levels to define the severity.
Warnings are defined in next table.
Displayed warning
Cause
RFID DATA
Cartridge faulty, read process failed
NH4 mV RANGE!
K+ mV RANGE!
NO3 mV RANGE!
Cl- mV RANGE!
REF1 mV RANGE!
REF2 mV RANGE!
TEMPERATURE
Ammonium mV value is closet o measuring range limit
Potassium mV value is closet o measuring range limit
Nitrate mV value is closet o measurement range limit
Chloride mV value is closet o measurement range limit
1st reference value is close to limit
2nd reference value is close to limit
Temperature is close to limit
Resolution
Replace
cartridge, check
probe with test
cartridge
Refer to
Troubleshooting
during operation
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CARTRIDGE OLD
Deliverable D.B.1.3
Sensor cartridge more than 1 year old
NH4-N CONC HIGH Ammonium concentration value exceeds measuring
range
NH4-N CONC LOW Ammonium concentration value is below measuring
range
NO3-N CONC
Nitrate concentration value exceeds measuring range
HIGH
NO3-N CONC LOW Nitrate concentration value is below measurement range
K+ KONZ HOCH
Potassium concentration value exceeds measuring range
K+ CONC LOW
Potassium concentration value is below measuring range
CL CONC HIGH
Chloride concentration value is below measurement
range
CL CONC LOW
Chloride concentration value is below measurement
range
AMMONIUM
OFFSET
Ammonium offset exceeds measurement range
SLOPE
Ammonium slope exceeds measurement range
POTASSIUM
OFFSET
Potassium offset exceeds measurement range
SLOPE
Potassium slope exceeds measurement range
NITRATE
OFFSET
Nitrate offset exceeds measurement range
SLOPE
Nitrate slope exceeds measurement range
CHLORIDE
OFFSET
Chloride offset exceeds measurement range
SLOPE
Chloride slope exceeds measurement range
Replace the
sensor cartridge
See
Troubleshooting
during operation
Refer to
Troubleshooting
during calibration
Troubleshooting during operation.
Symptom
Incorrect
measurement values
Possible cause
Corrective measures
Calibration too old; calibration was
not suitable for the particular Perform a suitable calibration.
application; large change in the waste
water matrix
Clean the sensor cartridge using
a brush and/or rinse the sensor
cartridge with clean water
(without cleaning agents), and
wipe the sensor cartridge
Severely contaminated membranes
carefully with a soft, clean cloth.
and/or reference electrode
Clean
all
components
(membranes/reference
electrode/temperature sensor)
Install the cleaning unit
Increase the cleaning interval
Sensor membrane damaged
Check
the
sensor
installation/replace the sensor
Reference element damaged
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Deliverable D.B.1.3
cartridge
Incorrect
measurement values
Unstable
measurement values
NO3 mV RANGE! (Nitrate mV value is
out of measurement range)
CL mV RANGE! (Chloride value is out
of measurement range)
Replace the sensor cartridge
REF1 RANGE! (measuring range
exceeded on 1st reference value)
REF2 RANGE! (measuring arrange
exceed on 2nd reference value)
Replace
the
sensor
TEMPERATURE (Temperature value is
cartridge/check the waste water
out of measurement range)
temperature
CARTRIDGE OLD (sensor cartridge
Replace the sensor cartridge
mote than 1 year old)
Dry the contact with a cloth or
paper. Check the black gasket for
Moisture at the contacts of the sensor
damage and make sure it is in
cartridge
the correct position. Screw the 4
socket head screws tight
Moisture inside the measurement
probe/faulty sensor electronics Check
the sensor electronics by using the
test cartridge.
If the test cartridge data is not
1 Select SENSOR MENU > DIAG/TEST >
within this range and/or if the
SERVICE > TEST CARTRIDGE > Test
test cartridge check is not
cartridge ready? Press ENTER
successful, contact the service
2 If all channels are confirmed with
department
OK, the sensor electronics are
operational: Test cartridge
OK
ENTER
Potassium concentrations too high
Switch off potassium/chloride
(e.g.: > 700mg/L in the case of small
compensation
(in
the
ammonium
concentrations)
or
configuration menu - then
chloride concentrations too high (e.g.:
potentially enter a fixed value
>1000mg/L in the case of small nitrate
for potassium/chloride)
concentrations)
Check the sensor installation.
Air bubbles, depth of immersion
Check
the
cleaning
unit
configuration.
Dry the contacts with a cloth or
paper. Check the black gasket for
Moisture at the contacts of the sensor damage and make sure it is in
cartridge
the correct position.
Screw the 4 socket head screws
tight
Sensor membrane damaged
Check
the
sensor
installation/replace the sensor
Reference element damaged
cartridge
Page 56 of 60
LIFE12 ENV/ES/000265
Deliverable D.B.1.3
Troubleshooting during calibration.
Symptom
SENSOR CODE
AMMONIUM
OFFSET
SLOPE
POTASSIUM
OFFSET
SLOPE
NITRATE
OFFSET
SLOPE
CHLORIDE
OFFSET
SLOPE
Possible cause
Sensor code entered incorrectly
Corrective measures
Using the certificate, check
whether the sensor code was
entered correctly.
Repeat the correction.
Error during the last ammonium
Use the previous correction.
correction, sensor cartridge too old,
Clean or replace the sensor
contaminated, faulty
cartridge.
Repeat the correction.
Error during the last potassium correction,
Use the previous correction.
sensor cartridge too old, contaminated,
Clean or replace the sensor
faulty
cartridge.
Repeat the correction.
Error during the last nitrate correction,
Use the previous correction.
sensor cartridge too old, contaminated,
Clean or replace the sensor
faulty
cartridge.
Repeat the correction.
Error during the last chloride correction,
Use the previous correction.
sensor cartridge too old, contaminated,
Clean or replace the sensor
faulty
cartridge.
3.4.3. Troubleshooting of Dissolved oxygen electrode.
Diagnostic and test menu.
The diagnostic and test menu shows current and historical information about the LDO sensor.
To access the diagnostic and test menu, go to MENU>SENSOR SETUP>[Select Sensor]>DIAG/TEST.
Option
SENSOR INFO
LOT CODE
SERIAL NUMBER
GAIN CORR
OFFSET CORR
PHASE DIAG
Description
SOFTWARE VERS—Shows the installed software version
BOOT VERSION—Shows the installed boot version
DRIVER VERS—Shows the installed software driver version
Shows the sensor cap manufacturing lot
Sensor serial number
Adjust the calibration gain value.
Range: 0.50 to 2.00
Adjust the calibration offset value (mg/L or ppm).
Range: –3.00 to +3.00
Shows the phase for total, red and blue wavelengths. Updates once per
second.
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LIFE12 ENV/ES/000265
AMPL DIAG
DAYS TO CLEAN
SENSOR LIFE
Deliverable D.B.1.3
Shows the amplitude for red and blue wavelengths. Updates once per
second.
Shows the number of days until the next scheduled manual cleaning.
Shows the number of days until the next scheduled sensor cap
replacement
Error list.
If an error occurs, the reading on the measurement screen flashes. Output behavior is
determined by controller settings. Refer to the controller manual for details.
To show the current sensor errors, go to MENU>DIAGNOSTICS>[Select Sensor]>ERROR LIST.
Error
Possible cause
RED AMPL LOW (Value is The sensor cap is not installed,
below 0.01) OR
or is not installed correctly.
BLUE AMPL LOW (Value is The light path is blocked in
below 0.01)
the sensor cap.
The sensor is not operating
correctly.
Resolution
Remove the sensor cap and
install it again.
Inspect the inside of the sensor
cap and lens.
Make sure that the LED is
flashing. Contact the
manufacturer.
Warning list.
When the warning icon flashes (sc100 and sc200) or when the screen turns yellow (sc1000), a
message is shown on the bottom of the measurement screen. On the sc1000, the screen turns
yellow
to
show
a
warning.
To
show
the
current
sensor
warnings,
go
to
MENU>DIAGNOSTICS>[Select Sensor]>WARNING LIST.
Warning
EE SETUP ERR
EE RSRVD ERR
Definition
Storage is corrupt. The values
have been set to the factory
default.
TEMP < 0 C
The process temperature is
below 0 °C (32 °F)
TEMP > 50 C
The process temperature is
above 50 °C (120 °F)
RED AMPL LOW
RED AMPL HIGH
BLUE AMPL LOW
BLUE AMPL HIGH
CAP CODE FAULT
Value falls below 0.03
Value is greater than 0.35
Value is below 0.03
Value is greaten than 0.35
The sensor cap code has
become corrupt. The code has
Resolution
Contact technical support.
Increase the process
temperature or stop use until
the process temperature is in
the sensor specification range.
Decrease the process
temperature or stop use until
the process temperature is in
the sensor specification range.
Refer to error list Table.
Call technical support.
Refer to error list Table.
Call technical support
Complete the sensor setup
cap procedure. If no setup cap
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LIFE12 ENV/ES/000265
Deliverable D.B.1.3
been reset automatically to
the default cap and lot codes.
is available for the sensor cap,
call technical support.
Event list.
The Event list keeps a log of changes to how data is recorded by the sensor. To show sensor
events, go to MENU>DIAGNOSTICS>[Select Sensor]>EVENT LIST.
Event
ALT/PRESSURE UNIT CHANGE
ALT/PRESSURE CHANGE
TEMP UNIT CHANGE
MEAS UNIT CHANGE
SALINITY CHANGE
SET DEFAULT
SENSOR SETUP CHANGE
CLEAN INTERVAL TIMER
CHANGE
SENSOR CAP LIFE TIMER
CHANGE
Description
Atmospheric pressure or altitude units have changed.
The value for altitude or atmospheric pressure has
changed.
The units for temperature have changed.
A new unit of measurement has changed.
The value for salinity has changed.
Sensor settings have been reset to the default values.
The sensor setup has changed.
The time between sensor cleaning has changed.
The time between sensor cap replacements has changed.
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LIFE12 ENV/ES/000265
Deliverable D.B.1.3
4. CONCLUSIONS
The present report summarizes the technical characterization of the components developed
prototypes, including the industrial wastewater plant and the urban wastewater plant. User
instructions are conveniently defined for both plants and, thus, every item has been briefly
described, including important warnings.
On the other hand, start up and stoppage procedures have been completely explained. The
maintenance process is also detailed because it is crucial to maximize the efficiency of the plants.
Finally, a complete explanation of points to check in case of malfunction and what measures have
to be taken in order to solve the problems has been reported in current ADNATUR deliverable.
Page 60 of 60
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