Special Applications Series:

Water and Wastewater

Treatment
 Water: Essential To Life,
Invaluable To Measure.
In a world more focused than ever on safe, sustainable stewardship of our water resources, it is critical to
continue to improve the ways in which we measure and treat potable water and wastewater. Increased public
awareness drives the need for safe, accurate and reliable level and flow instrumentation, in the harshest
environments, under the most extreme conditions. At the same time, the regulatory climate requires plants
to implement next-generation process improvement – moving from energy efficiency to energy independence
and realizing cost-savings in doing so. To effectively manage the technological demands, make your preferred
partner Magnetrol®, for extensive level and flow control solutions that will help you achieve your goals.

2
Level & Flow Control Applications for
Water & Wastewater Treatment
Water and Wastewater Treatment Efficiency Opportunities 4–5

Liquid Level Applications 6–7

Air, Gas and Liquid Flow Applications 8

Application Case Studies 9

Level & Flow Control Technologies 10–11

3
 Level & Flow Efficiency
Throughout wastewater and water treatment operations, numerous opportunities exist to measure and
improve process conditions. The use of effective level and flow instrumentation can enhance your facility’s
efficiency, safety and environmental impact.

Wastewater Treatment

Collection Systems Influent Pumping Primary Clarification

Coagulants Oxidants Phosphorus Precipitation

2 2 2 4
Headworks Primary Clarifier

3 1 2 3
Grit Removal

11
To Landfill To Methane Processing
5 4

1 Supernatant Return to Process 2

6
Lift Stations

Water Treatment

Pumping Aggregation Clarification

Coagulants pH Adjustment

3 2

1 2 Flocculation Basin
2 4
Settling Tank

Liquid Level Applications

1 Lift Station Pump Control pg. 6 5 Sludge Level pg. 6

2 Chemical Feed Tanks pg. 6 6 Digester Level pg. 6

3 Splitter Box Level pg. 6 7 Water Storage Tanks pg. 7

4 Clarifier Level pg. 6 8 Filter Tank Level pg. 7

4
Opportunities Liquid Level

Air, Gas or Liquid Flow

Water Flow

Sludge Flow

Chemical Treatments

Biological Process Secondary Clarification Disinfection

Corrosion Inhibitors pH Adjustment Disinfection

2 2
Aeration Basin

2 2 4
2
Secondary Claifier

4 3
Mixed Liquor Neutralizer
Contact Basin

2
Activated Sludge 5
2 1

To Sludge Distribution

Filtration Storage Distribution

Polymers Disinfectant Neutralizer Fluoridation
Lime Silo 12
2 Dry Product 2
1
8 9 10
2 2 7 2 1 2
Open or Enclosed Storage

1
To Sludge Distribution

Air, Gas, Liquid Flow Applications

9 Lime Slurry Level pg. 7 1 Open Channel Flow pg. 8

10 Carbon Slurry Level pg. 7 2 Closed Pipe Water/Sludge Flow pg. 8

11 Screening System pg. 7 3 Pump Protection pg. 8

12 Lime Silo Dry Product pg. 7 4 Blower Air Flow pg. 8

5 Digester Gas Flow pg. 8

Please Note: The instruments recommended in this guide are based on field experience with similar
applications and are included as a general guide to level and flow control selection. Because all
applications differ, customers should determine suitablility for their own purposes.
5
 Liquid Level Applications
1. Lift Station Pump Control
Proper level control in wet wells alleviates pump
surging and frequent cycling, and minimizes the
downstream drop of influent flumes. 1 7
• Pulsar® or Model R82 Pulse Burst Radar Transmitters
• Eclipse® Model 706 Guided Wave Radar Transmitter
1 7
• Model T10 Tethered Float Switch 1 7

2. Chemical Feed Tanks

21 87
Stringent level monitoring ensures consistent, 1 7
ongoing chemical treatment. 2 8
• Model R82 Pulse Burst Radar Transmitter 2 8
• ECLIPSE Model 706 Guided Wave Radar Transmitter
• Echotel® Model 355 Ultrasonic Non-Contact Transmitter
• Vector™ Magnetic Level Indicator
2 8
2 8
9
3. Splitter Box Level 9
Level control in splitter boxes helps maintain balanced 3
routing of influent wastewater. 9
3
• Model R82 Pulse Burst Radar Transmitter
• ECLIPSE Model 706 Guided Wave Radar Transmitter
3
• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter 9
9
3 10
4
3 10
4. Clarifier Level
Continuous level management of the clarifier level 4 10
maximizes efficient treatment flow in sedimentation areas. 4
• Model R82 Pulse Burst Radar Transmitter
• ECLIPSE Model 706 Guided Wave Radar Transmitter 5 10
• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter
4 10
11
5
4
5 11
5. Sludge Level 11
Sludge level is monitored to control against
discharge or dilution. 5
• Model R82 Pulse Burst Radar Transmitter 5
• ECLIPSE Model 706 Guided Wave Radar Transmitter 6 11
11
12
• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter
6
12
6
12
6. Digester Level
Foaming requires advanced level control technologies 6
for measurement accuracy. 6 12
12
• PULSAR or Model R82 Pulse Burst Radar Transmitters
• ECLIPSE Model 706 Guided Wave Radar Transmitter

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7. Water Storage Tanks
Level controls in open atmosphere reservoirs must
frequently withstand punishing weather conditions.
1
• Model R82 Pulse Burst Radar Transmitter 7
• ECLIPSE Model 706 Guided Wave Radar Transmitter
1
• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter 7

1 7
8. Filter Tank Level
2
1 a terminal headloss
Pre-determined tank level indicates 78
value has been reached, triggering
2 filter backwash to
remove suspended solids. 11 8
77
• PULSAR or Model R82 Pulse Burst Radar Transmitters
• ECHOTEL Model 355 Ultrasonic 2Non-Contact Transmitter 8
• Model B10 Displacer Switch
2 8
9
9. Lime Slurry Level 22 8
89
3
Lime slurry tanks are often characterized by agitation
3 that inhibits or
and corrosion, requiring level sensing
is insensitive to media buildup. 9
• PULSAR or Model R82 Pulse Burst Radar Transmitters
• ECLIPSE Model 706 Guided Wave 3 Radar 9
• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter
3
10
4 99
10
10. Carbon Slurry Level
34
3
Fly-away dust, difficult-to-wet carbon properties and carbon 10
buildup call for non-contact level4technologies or contact
level sensing utilizing a single rod5probe. 10
• PULSAR Model R95 Pulse Burst 4 5 Level Transmitter
Radar 11
• ECLIPSE Model 706 Guided Wave Radar 10
10
11
44
• Thermatel® Model TD1/TD2 Flow/Level/Interface Switches
• Model B10 Displacer Switch 5
11
5
11. Screening System 6 11
Screening systems are usually at 5
5
the headworks and 12
are used to filter large particles. 6 11
11
12
• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter
6
• Model R82 Pulse Burst Radar Transmitter
12
6
12
12. Lime Silo Dry Product
66 for storage.
Lime silo dry product level monitoring
12
• ECLIPSE Model 706 Guided Wave Radar Transmitter 12

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 Air, Gas & Liquid Flow Applications
1. Open Channel Flow
Flow control devices must perform reliably despite
turbulence, solids content, corrosive chemicals or 1
1
varying flow velocities and depths.
1
• Model R82 Pulse Burst Radar Transmitter
• ECLIPSE Model 706 Guided Wave Radar Transmitter
• ECHOTEL Model 355 Ultrasonic Non-Contact Transmitter
1

2. Closed Pipe Water or Sludge Flow

Accurate and reliable water and sludge flow measurement
is essential throughout water and wastewater facilities. 2
2
• Polaris™ Electromagnetic Flow Meter 2

3. Pump Protection
Low-flow sensitivity, wide temperature operation and high 3
3
turndown are required of flow instruments, to prevent 3
seal damage.
• Thermatel® Model TD1/TD2 Flow/Level/Interface Switches 3
• Model F10 Vane Actuated Flow Switch
• Model F50 Disc Actuated Flow Switches

4. Blower Air Flow

Maintaining efficient air flows (both low and high) is
4
4
critical in enabling the microorganisms in the aeration 4
basin to break down waste materials and can also
reduce blower costs. 4
• THERMATEL TA2 Flow Meter
• THERMATEL Model TD1/TD2 Flow/Level/Interface Switches
• Model F10 Vane Actuated Flow Switch

5
5
5. Digester Gas Flow 5
Flow meters and switches that can handle low flows and
low pressures, as well as a combustible product, must be 5
selected for this application.
• THERMATEL TA2 Flow Meter
• THERMATEL Model TD1/TD2 Flow/Level/Interface Switches
• Model F10 Vane Actuated Flow Switch

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CUSTOMER CASE STUDY: Pulse Burst Radar
“Levels” Competition For Chemical Waste Tank
Process Control
A chemical plant in Upstate New York was experiencing random failures using competitive
ultrasonic level transmitters on chemical waste tanks. The units would work for awhile and then
lose their output. A number of these units had to be sent back to the factory for costly repairs.

To test the Magnetrol® Model R82 pulse burst radar device, a side-by-side comparison was
conducted to report outputs over a two-day period. The results, as demonstrated on the output
chart, were dramatic: the competitive ultrasonic unit’s output “wandered” widely across the
chart, while the Model R82 transmitter’s reading held rock solid, showing the moderate in- Magnetrol
R82
creases and decreases in the process level. The evidence convinced management and, within a
Competitor
few weeks, MAGNETROL received an order to replace all old transmitters with Model R82 units. Ultrasonic

CUSTOMER CASE STUDY: Thermal Dispersion

Technology Helps Utility Meet Federal Environmental
and Health Regulations
Instrumentation plays a pivotal role in meeting regulations set forth by the
Environmental Protection Agency, Department of Ecology and the Department of Health. When
Lakehaven Utility District in Washington needed flow meters on air and gas flow lines serving its
aeration basins and anaerobic digesters, the District turned to Magnetrol® Thermatel® Model TA2
thermal dispersion flow meter for its ease of use and ability to handle these difficult applications.

The THERMATEL Model TA2 thermal dispersion flow meters in the aeration lines
maintain a minimum flow rate to prevent the diffusers from getting plugged, while also being used in
conjunction with dissolved oxygen (DO) probes to provide enough flow to meet the oxygen demands
in the basin. On the digester gas lines, the units measure the amount of methane going to fuel the boiler
to generate hot water/steam for the plant, as well as the excess methane going to flare. Thermal flow
meters are well accepted in the municipal industry to provide reliable flow measurement at low
flows and low pressures.

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 Level & Flow Technologies
Pulse Burst Radar
Description
Pulse burst radar products feature non-contact radar technology, which detects the position of process liquids by
measuring the interval between the emission and return of high-frequency radio waves. The latest generation of loop-
powered, 24 VDC level transmitters includes the industrial-strength Pulsar® Model R95 and, a more economical choice,
the Model R82. Both units can handle difficult applications that in the past were left up to ultrasonic transmitters.

Benefits
Pulse burst radar technology measures effectively even when atmospheres above the liquid are saturated with vapor.
The advanced signal processing manages common disturbances such as false echoes caused by obstructions, multi-path
reflections from tank sidewalls or turbulence caused by agitators, aggressive chemicals or aerators.

Electromagnetic
Description
Polaris™ flow meters use the principle of electromagnetic induction to measure volumetric flow of conductive liquids
When a conductive liquid flows past the electrodes inside the sensor, a voltage is generated. This measured voltage
is proportional to the flow velocity.

Benefits
Throughout water and wastewater plants there is a need for water and sludge flow measurement. Knowing
what is flowing throughout the plant and its processes is essential to maintaining an efficient operation.
POLARIS flow meters have current, pulse and alarm outputs that are configurable through the display or a DTM.
Forward and reverse flow rates are measurable with the capability of empty pipe detection.

Thermal Dispersion
Description
Thermatel® flow meters and flow/level/interface switches utilize heat transfer to continuously measure flow or to
provide a switching action. A heated sensor is placed into the flow stream and as flow increases the sensor is cooled.
Similar heat transfer can take place when going from one fluid to another in level applications.

Benefits
This technology has a reputation for having a strong signal at low flow rates and low pressures with a wide operating
flow range (turndown). The sensor has no moving parts and is most often supplied as an insertion probe, simplifying
installation as well as future maintenance. An optional retractable probe assembly can be supplied for probe removal
under operation.

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 Guided Wave Radar
Description
Guided wave radar is based upon time domain reflectometry, which utilizes pulses of electromagnetic energy trans-
mitted down a wave guide (probe). When a pulse reaches a surface that has a higher dielectric constant than the
air in which it is traveling, a portion of the pulse is reflected. Pulse transit time is measured via high-speed timing
circuitry for accurate level measurement.

Benefits
The Eclipse® Model 706 transmitter has no moving parts, is immune to changing media properties and requires no level
movement for calibration. A four-button keypad and graphic LCD display allow for convenient viewing of configuration
parameters and echo curves. The transmitter offers remote mounting capabilities and contains nine common tank shapes
for volumetric output,and two standard flumes and four standard weirs for flow measurement.

Ultrasonic Mechanical Flow Switches

Description
Ultrasonic pulses are transmitted and received by
a piezoelectric crystal within a sealed transducer.
The electronics measure the time between the
transmission and reception. Since the speed of
sound is known, the time for the pulse to travel
to the material surface and back can be divided by
two to determine the distance to the surface. This
is used to derive reliable measurement of product
level, volume or open channel flow.
Benefits
®
Echotel Model 355 non-contact ultrasonic transmitters provide accurate
measurement independent of specific gravity, dielectric constant or viscosity,
across a wide range of applications. Volume applications are configured by
selecting from nine standard tank shapes stored in the transmitter. Open
channel flow is configured by either selecting from 35 flumes and weirs in
the transmitter, or by using the generic discharge flow equation that allows
for much higher accuracy than custom tables.
Description
In vane and disc/piston operated flow switches,
the surface area of the vane or disc in the flow line
determines the force of flow that will cause
actuation. When the force of the liquid or gas flow
overcomes the opposing forces, the vane or the disc
and piston assembly moves out of the path of flow.
This movement causes motion of the attraction sleeve
and actuation of the micro switch.
Benefits
Mechanical flow switches are renowned for their reliability, repeatability and
simplicity of function. They require no power and have been proven in a
variety of challenging applications for many decades.

Magnetic Level Indicator (MLI) Displacer Level Switches

Description
A float travels up and down in a chamber that is mounted to a
liquid-containing vessel. The float’s magnetic assembly interacts
with an externally mounted visual indicator. As the float follows
the liquid surface or liquid-liquid interface, the magnetic field
causes flags in the visual indicator to rotate, resulting in a clearly
defined representation of the liquid level in the vessel.
Benefits
MLIs are widely used to replace high-maintenance sight and gauge
glass indicators and are increasingly used in new applications. The
Vector™ MLI offers rugged, industrial-grade construction and a
continuous measuring range of up to 216 inches (549 cm). The
unit is compatible with electronic point switches and continuous
level transmitters for safe, reliable chemical feed tank control.
Description
The range spring is loaded with the weight of the displacer.
Liquid level change results in a change in the buoyancy
force equal to the mass of liquid displacer and causes the
range spring to change length. The change in spring length
moves the attraction sleeve, which is attached to the spring
via a rigid stem, into or out of the switch magnet, causing
the micro switch to actuate.
Benefits
Buoyancy technology is renowned for its reliability, repeatability and
simplicity of function. The dual-stage top-mounted displacer switch allows
for multiple narrow or wide differential actuation points with a single level
switch. Buoyancy switches have been proven in a variety of challenging
applications for many decades.

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Select the Water & Wastewater
Industry’s Preferred Partner for
Level and Flow Control Solutions.
When you partner with Magnetrol®, you
get more than world-class instrumentation.
We offer an extensive line of level and flow
technologies for single-source convenience,
deep applications engineering experience to
tackle the most challenging process control
problems, and an industry-leading service
network to keep your facility operating at
peak efficiency.

Contact your MAGNETROL representative today

for help in assessing your treatment facility’s
opportunities for efficiency improvement.
Accurate and reliable level, flow and volume
solutions from MAGNETROL.

CORPORATE HEADQUARTERS
705 Enterprise Street • Aurora, Illinois 60504-8149
Phone: 630-969-4000 • Fax: 630-969-9489
water.magnetrol.com • magnetrol.com • info@magnetrol.com
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registered trademarks of Magnetrol International, Incorporated.

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Bulletin: 41-190.1 • Effective: January 2014