Ultrasonic Flowmeters in Waste Water Plants

Introduction
Waste Water Treatment Plants require a large variety of instrumentation in order to
monitor and control the processes in the different stages. For the purpose of flow
metering; do electromagnetic flowmeters and ultrasonic flowmeters offer the features and
performance which is demanded in these applications?
The small and compact ultrasonic clamp-on flowmeters are an attractive alternative to In-
line meters, which require a spool-piece. Clamp-on meters are easier to transport and
install, which not only makes logistics faster and easy but often enables cost savings as
well. Especially for big line sizes, the clamp-on meters are a more cost-effective solution
than spool-pieces. In the case of retrofitting, clamp-on meters are an unbeatable
alternative.
However, a few considerations are required to ensure the successful use of an ultrasonic
transit-time flowmeter in Waste Water applications. Therefore, it is important to understand
the applications, within a typical treatment plant, that are best suited for transit-time
ultrasonic flowmeters – and those that are best suited to electromagnetic flowmeters.
The objective of this article is to assist in deciding which type of instrument applies best, at
any given location.

Basic Principles
The principles for choosing between a Prosonic Flow ultrasonic transit-time flowmeter or a
Promag electromagnetic flowmeter, at any given location, are as follows:

1. Specify a Prosonic Flow clamp-on flowmeter if all of the following conditions

exist:
9 Air or gas is not added to or generated within the waste liquid - in the equipment
upstream of the meter.
9 Suspended solids content is not excessive. Solids contents of up to approx. 5% can be
handled by Prosonic Flow . The solids content may not be the only limiting factor in the
absorbing or scattering of sound waves; tiny gas bubbles, that cling to the solids
particles, can also be a source of the problem.
9 The meter is located as far as possible downstream of any pump to avoid the adverse
effects of pump cavitations. A straight run of at least 15 pipe diameters upstream and 3
pipe diameters downstream should be allowed between the flowmeter sensors and any
elbows, valves, tees or pumps.
9 The application calls for an absolute accuracy in the range of 1% to 2% (of reading) for
flow rates greater than 0.3 m/s.

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Ultrasonic Flowmeters in Waste Water Plants

2. Specify a Promag electromagnetic flowmeter for following conditions:

9 The solid content of 5% is exceeded and/or the process is generating gas bubbles.
These conditions typically apply across the sludge treatment stage, as well as in the
biological treatment stage. One important example, for a process, where such a
condition applies is Return Activated Sludge (RAS).
9 The application calls for an absolute accuracy in the range of <1%.

Wastewater Treatment Plant Overview

Summary Overview
The processes in a typical waste water treatment plant can be divided into two groups:
‰ Water Treatment
‰ Sludge Treatment
The water treatment may be considered the primary process of cleaning the waste water.
Ultrasonic transit-time meters are suitable for most of the flow measurement applications
in this section. Exceptions are: the location downstream of the aeration in the biological
treatment, and also the RAS and WAS lines. In the former, the sludge typically contains a
high content of gas, the latter contains a high solid content.
The processes within the section sludge treatment are generally the domain of
electromagnetic flowmeters because of generally high solids and sometimes gas content.

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Ultrasonic Flowmeters in Waste Water Plants

Process Description

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Raw Sewage — The rate of flow of raw sewage into the waste treatment plant is often
used as a basis for billing the source of the sewage - perhaps another municipality or a
large industrial facility. Since that the solids concentration is usually relatively low, transit-
time meters are usually specified. However, electromagnetic flowmeters might be used
because of the improved accuracy and traceability.

Interceptor Storage or Flow Equalisation — the interceptor storage tanks are typically
located on the raw sewage lines (into the plant and upstream of the bar screens). They
are utilised to minimise flow variations within the plant and thus help to achieve consistent
performance of the treatment processes. Since that the solids concentration is usually
relatively low, transit-time meters can be used.
Important Considerations:
Measuring in the overflow line (see graphic: to River) is normally a challenge for all
flowmeters because this line is often not filled completely.

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Ultrasonic Flowmeters in Waste Water Plants

Primary Clarifyer

Primary Clarification and Sludge Pumping — Primary clarifiers are tanks used to remove
or reduce suspended solids, and organic loading, from the wastewater, before it goes to
secondary treatment units. Electromagnetic flowmeters are suggested for the high solids
content of sludge flow to the thickeners (Primary Sludge, PS). Transit-time flowmeters are
usually recommended for the primary effluent (water treatment).

Return Activated Sludge (RAS) — A primary objective is to maintain the stability of the
activated sludge process. This is accomplished by recycling an active mass of micro-
organisms, in sufficient quantity, to break down most of the biodegradable organics
flowing as effluent from the primary clarifiers. The RAS is usually returned to a point just
upstream of the aeration tanks. Because of the high gas content, this a domain of
electromagnetic flowmeters.

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Effluent Line
The rate of flow of effluent from the waste treatment plant, into a nearby lake or river, is
usually monitored carefully; due to requirements for reporting to governmental authorities.
Since the effluent is virtually solids-free, transit-time flowmeters are usually recommended.
Important Considerations:
9 Note that effluent, cascading from the secondary clarifier or subjected to a final
aeration (in an open channel leading to the final closed effluent piping), may be full of
bubbles. In such cases, electromagnetic flowmeters are used.
9 In some cases the section of the pipe (which is located close to the upstream open
channel inlet) will not be filled completely with water. The only possible solution is to
move the instrument further downstream - to a section where the pipe will be
completely filled with water.

Sludge Treatment

The sludge treatment is generally a domain of electromagnetic flowmeters, because of

the generally high solid and sometimes gas contents.

Waste Activated Sludge (WAS) — The purpose of the secondary clarifiers is to

concentrate solids, a portion of which is recycled (RAS), and a portion of which is waste
(WAS). Due to the high solid content, electromagnetic flowmeters are recommended.

Sludge Thickening — The main objective is to concentrate the sludge as much as

possible, within the constraints of the process, to maintain as consistent an underflow
quantity, and composition, as can be achieved. Because solids and/or bubble contents
may be rather high, electromagnetic flowmeters should be specified. Transit-time meters
are usually unsuitable.

Digestion — This is the process of breaking down and partially liquifying waste solids by
the action of bacteria, so that the solids which remain are stable and can be disposed of
without posing a health hazard. In primary treatment, the process is anaerobic (i.e., in the
absence of air) and methane gas is generated. In secondary treatment, the process is
aerobic (i.e. in the presence of air) and air or oxygen is bubbled through the waste system.
In either case, the presence of gas bubbles point to the use of electromagnetic
flowmeters.

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Benefits of Ultrasonic transit time Flowmeters and Magmeters

Ultrasonic transit-time flowmeter Electromagnetic Flowmeter

Prosonic Flow Promag

9 Perfectly suited to bidirectional 9 Fluids with a minimum conductivity of > 5
measurement of pure or slightly µS/cm can be measured: water, waste
contaminated liquids with a gas content water, sludge, etc.
< 1 % or a solids content < 5 %. 9 Guaranteed accuracy of 0.5 %
9 Accuracy typically < 1...2% 9 Traceable (calibration)
9 Cost-effective alternative to magmeters 9 Cost effective for small line sizes
for large line sizes (>DN600) (<DN600)
9 Can afford a high solid and gas content

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