Removing the Risk of Corrosion in HVAC Systems with Water Quality Monitoring

Continuous monitoring of water quality within HVAC systems plays a vital role in ensuring the long-term health and longevity of building networks, avoiding costly repairs, replacement or downtime. 

Fluctuations in Pressure, pH and Conductivity could indicate a leak or burst, or alternatively can suggest an issue with the chemistry of the water, where the additives added to kill bugs and germs have become compromised.  Monitoring safe levels of Dissolved Oxygen also helps to maintain system health and prevents corrosion.

Even small changes in these water quality parameters can, over time, lead to the deterioration of the HVAC system which, if left unidentified, will require large scale repair or replacement.  Proactively identifying changes at an early stage helps to remove the risk of corrosion, while also potentially avoiding health issues such as outbreaks of legionella.

ATi’s unique HVAC MetriNet is the only monitoring instrument that can detect these subtle changes ahead of time, therefore preventing long-term and costly damage. Flexibility is key with this class-leading system, with its modular nature allowing unique monitoring solutions tailored for individual site requirements.  At the heart of ATi’s MetriNet solutions are the industry-leading digital M-Node sensors that are connected to the water supply using a purpose designed ‘click-connect’ flow cell arrangement. 

Through the provision of live, continuous data, ATi’s HVAC MetriNet provides a constant health-check and is key to protecting the lifespan of the HVAC system and the future of the building. Utilising the MetriNet alongside Badger Meter’s inline electromagnetic and ultrasonic technology, along with non-invasive fixed and portable clamp-on ultrasonic flow and energy meters, helps to create energy efficient HVAC solutions in mechanical building services, new build, retrofit HVAC plant and district heating-cooling networks.

Discover more about some of ATi’s HVAC MetriNet installations and how the ultra-low powered, smart digital sensor technology offers sustainable solutions, delivering proactive management to safeguard water quality and system optimisation in a variety of different applications.

Hot Water Systems

This two-parameter MetriNet solution was installed on a hot water system to measure Conductivity and Dissolved Oxygen on a hot water loop, where a temperature reading was also provided without the need for an additional sensor. Installing a cooling block to cool the water sample prior to it reaching sensors ensured that the temperature was within the correct measurement range. This installation utilises the Q52 MetriNet Controller with a 3G modem to store and send the data to a cloud-based platform or server of choice.

Cold Water Systems

Installed to monitor water quality on a cold-water loop, no cooling block was required as the water sample fell within the required range for the sensors.  This three-parameter system measures pH, Conductivity and Dissolved Oxygen, with a temperature reading provided as part of the solution. Utilising the Q52 MetriNet Controller and 3G modem, data is tracked and recorded to monitor the health of the HVAC system within the building.

Cool Water Systems

Installed to monitor the water quality on a cooling tower, this particular installation sees the use of the Q51 portable controller / M-Node calibrator that stores all of the data gathered, which can then be downloaded to a laptop via a cable.

A Q46 Monitor has also been added for the measurement and control of Dissolved Ozone, as Ozone is added as a biocide to act as a disinfectant in the water to prevent legionella. The Q46 is used to monitor the levels of Ozone to ensure that they remain at pre-set levels – any drop in the biocide could cause significant risk to public health.  It is also possible to measure Dissolved Ozone using the MetriNet by adding an additional M-Node sensor, however, in this instance the customer already had the Q46 installed so this was not required.

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Ultrasonic, smart sensor, sludge blanket monitoring

The composition and concentration of sludge varies throughout the treatment pathway, therefore understanding the settling characteristics is vital to optimise control of both the plant and wastewater process.  ATi’s Senior Service Engineer, Mark Holmes, discusses how the measurement of sludge levels with contactless, ultrasonic monitoring technology enables operators to study the sedimentation characteristics of suspended solids, understand sensitivities due to disturbances and manage sludge levels, whilst allowing sufficient buffering for incoming hydraulic load variations.

Measuring and managing the depth of sludge blanket is one of the most critical challenges in the production of good-quality effluent from wastewater treatment plants. Aside from lessening the environmental impact of human waste, modern plants have embraced advances in science and technology that allow significant, positive inputs, such as producing energy from biogases and in some cases generating revenue streams from processed biosolids, including nutrient-rich fertiliser for farming.   However, for these advanced systems to work effectively, one of the most important parameters plant operators must monitor is total solids, or sludge, as it moves through the plant.

Effective automation to improve process control

Primary sedimentation, biological stages, secondary treatment, effluent quality and subsequent sludge handling are all greatly affected by how well the settling has been achieved and, crucially, monitored.  By measuring sludge levels in both primary and secondary sedimentation tanks, operators can ensure sludge extraction pumps are used efficiently, while ensuring poorly settled sludge does not carry over into effluent paths.

While no two wastewater treatment plants are identical, the push to improve efficiency through automation and improved process control is a common theme.  Relying solely on manual sampling means that thorough analysis of plant characteristics and trends is limited to the frequency of sampling, with the addition of labour costs. In a plant with continuous, automatic measurement of critical process variables, there is a wealth of data that creates a robustness of system control, capable of rapidly identifying disturbances or operational problems.

24/7 contactless sludge blanket level measurement

For measuring the depth of sludge blanket, the contactless method is considered the most desirable, as it doesn’t depend on direct measurement by human operation.  ATi’s EchoSmart leading sludge blanket level monitor is trusted by water utilities across the globe, due to its superior sludge level detection for a wide range of water and wastewater applications, and monitors blanket levels 24/7, 365 days of the year.  This underwater interface level analyser technology is built on a digital platform and allows the analyser to be located in the sensor. The result is greater flexibility in equipment configuration options, enhanced communication capabilities and reduced installation costs

EchoSmart Sludge Blanket Monitor

The EchoSmart sensor generates an ultrasonic sound wave that propagates through a liquid medium and is reflected back from material that is present in the vessel, which are typically settled solids, suspended solids, or the tank bottom. The sound wave travels at known velocities, providing the ability to convert elapsed time into Range and Level measurements, offering continuous, real-time measurement.  The underwater acoustic measurement principle allows the sensor to track well settled blankets, as well as being configured to track dispersed solids, such as ‘fluff’ or ‘rag-layer’. 

Smart sensor technology

However, the EchoSmart sensor does more than just produce a raw signal.  It is also equipped with an advanced programmable microprocessor and dynamic memory, with the sensors employing interface-detection algorithms developed exclusively by ATi.  The smart sensor technology allows for field networks of sensors, enabling the control and monitoring of up to 16 smart sensors from one controller, which lowers the ‘per-tank’ cost. These field networks can also be created wirelessly, eliminating costly conduit and cabling runs.

Three sensor models provide flexible options for different applications: the standard sensor with multi-flex assembly for when surface skimmers are present; the self-cleaning sensor for applications without surface skimmers; and uniquely, a sensor with turbidity that offers further insight into water clarity, which is useful for less dense blankets.

The EchoSmart sensors also provide all signal control, enhancement and interpretation, and determine the final process measurement, whilst communicating with the EchoSmart Controller via digital communication.  This offers greater flexibility in equipment configuration options, enhanced communication capabilities and reduced installation costs. 

Bespoke engineered solutions

In addition, ATi utilises its engineering expertise to provide bespoke engineered solutions to suit individual site requirements.  This includes various bracketry solutions designed to ensure the EchoSmart equipment does not impede the settlement tank bridge walkway, in line with water utility guidelines, along with robust enclosures to house the controller.  This allows for smart, accurate, networked systems that meet regulatory compliance, are simple to install and operate.

The EchoSmart is installed on final settlement tank bridges and communication can be achieved through hard-wired connections or a more bespoke radio-link network, eliminating the need for costly installation.  For the radio-link network, a radio is placed on each tank, along with a base station that is wired directly to the site`s programmable logic controller (PLC) in the Instrumentation, Control and Automation section of the Motor Control Centre, providing a useful ‘mimic’ picture on the site’s SCADA.

Flexible, smart networked monitoring

EchoSmart can be used for a wide range of applications and industries, such as sludge thickeners in wastewater, primary or final settlement tanks, and also within the clean water treatment process, including clarifiers on water treatment works.  It is adaptable and can be programmed to suit various shapes and tank sizes. 

There are also options available for a variety of installation requirements, including a remote or local controller, a stand-alone system, or alternatively a network of up to 16 sensors added to one controller.  The system comes standard with analogue and digital outputs, as well as Modbus, but other digital communications can be attained if required. 

With automatic initialisation for easy start-up, adaptive algorithms in each sensor for uninterrupted operation, EchoSmart offers the ultimate in installation and networked flexibility, providing an advanced yet user friendly solution, offering cost effective, trouble-free and reliable sludge blanket measurement.

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Water quality management & control in service reservoirs

Careful management of service reservoirs is essential to safeguard drinking water quality, requiring accurate and reliable monitoring for a detailed understanding of supply configuration, asset condition, along with and the expertise of a multi-disciplined team. ATi discusses how the data provided from analytical sensor technology can provide vital insight into reservoir performance, allowing the optimisation of systems and the early identification of issues to prevent the deterioration in water quality, compliance breaches and regulatory sanction.

Service reservoirs are a fundamental component of water distribution networks, providing vital reserves of treated water to supply system shortfalls during peak demands.  Over recent years, the water industry has become far more knowledgeable about the need for optimisation of service reservoirs, recognising the significant role they play in delivering clean, safe water and regulatory compliance is now more important than ever.

The storage of water within service reservoirs can represent a risk to the quality of drinking water if not closely monitored, resulting in the reduction in chlorine concentrations due to long water age leading to bacterial growth, ebb and flow supplying mains may be present, poor mixing characteristics and the potential for ingress following structural failure when residence times are excessive. It is therefore essential to perform regular inspections and monitoring to ensure they operate in a manner that maintains necessary disinfection levels.

Historically, the quality of water within service reservoirs was monitored through the collection and analysis of grab-samples on a weekly basis. Such a monitoring regime, however, is unable to rapidly identify any sudden deterioration or variation in water quality. As a result, it is now widely acknowledged that weekly sampling is no longer adequate to appropriately manage water quality for the optimisation of asset operation.

Monitoring critical parameters at inlets & outlets

Continuous, smart sensor technology monitoring of critical water quality parameters, including chlorine residual, conductivity, turbidity and pH, plus BOD, COD, TOC & DOC organics, at even the most remote locations is now possible. Smart water quality monitoring solutions, such as ATi’s MetriNet for the critical water quality parameters and s::can’s spectro::lyser for organics, provide water companies with industry-leading, tried and trusted methods for providing data points from as little as one minute apart onto any chosen platform.

ATi’s MetriNet and s::can’s spectro::lyser

The installation of such proven, continuous monitoring solutions, both on the inlet and outlet of service reservoirs, is enabling water companies to meet compliance while understanding the operation, performance and management.

Regulatory Compliance

The installation of continuous monitoring instrumentation allows detailed understanding of the reasons for low chlorine levels eg is it due to the incoming supply at certain times of the day or residence within the reservoir? Such insight allows operational modifications to be made, including changes to supply routes or forced turnover of water within the reservoir in order to improve chlorine concentrations and protect against statutory sample breaches. Often, forced turnover is the natural response to low chlorine levels, however, if the issue is actually upstream then this could jeopardise resilience without addressing the root cause.

Microbiological Sample Failures

Ingress into service reservoirs following heavy rainfall is one of the most common reasons for microbiological sample failures and this can result in a loss of chlorine residual or changes in other parameters, such as conductivity. Where monitoring of water quality relies upon infrequent grab sampling, it could be sometime before issues are identified and, in many cases, after the water has reached the tap. Through proactive online monitoring, unexpected changes in water quality can be swiftly identified, and when aligned with information such as rainfall, allows for urgent investigation, intervention and mitigating action.

Summary

Service reservoirs are essential for the effective operation of water supply systems and for ensuring customer taps keep flowing. By their very nature, they pose a risk to drinking water quality, therefore effective monitoring is vital to optimise usage and to forewarn of any issues. Advances in smart sensor technology, battery-powered units and mobile communications means that accurate, reliable and continuous monitoring is helping water utilities to make informed decisions on management and optimisation, not only ensuring that supply demands are met, but crucially that safe water is being delivered.

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Delivering smart septicity monitoring for Yorkshire Water

As one of the UK’s most innovative and proactive water companies, Yorkshire Water has embarked on a ground-breaking project, utilising a first-of-its-kind, combined liquid and gas smart sensor technology solution to monitor, manage and control septicity.  ATi’s Senior Service Engineer, Mark Holmes, discusses how this latest technology is transforming wastewater and sewer network management, offering the ultimate smart septicity solution.

Septic sewage delivered into an activated sludge plant creates considerable process complications, with far-reaching consequences across the whole water distribution system and the environment.  With regulations now more stringent, managing and controlling septicity has become increasingly complex and is one of the most critical challenges in wastewater treatment, with high levels proving costly due to toxicity, corrosion and odour.

Until now, water professionals traditionally used a range of monitoring techniques, including weekly samples, analysing sediments, controlling flow and developing aerobic environments.  Controlling septicity also relied on maintaining the supply of oxygen to oxidise previously formed Sulfide; minimising Hydrogen Sulfide (H2S) gas emissions into the atmosphere, deodorising vented air and the use of protective coatings on pipes. 

However, as one of the only specialist manufacturers of both water and gas analytical sensors, ATi knew that negative Oxidation-Reduction Potential (ORP) readings in the region of -150mV and below, paired with high H2S gas values of 5ppm and above, were an indicator of septicity. By applying decades of expertise, ATi developed SeptiNet to provide a unified, smart solution for septicity monitoring and detection, utilising class-leading H2S gas and ORP water quality sensing.

As one of the UK’s most forward-thinking water companies, Yorkshire Water were keen to embrace these technological advances and became the first water utility to install the only pioneering, all-in-one septicity monitoring solution within a recently refurbished CSO as part of their drive for optimisation, resilience and safeguarding the environment. 

SeptiNet’s scalable, modular nature enables its operators to monitor wastewater quality, offering real-time, continuous data to their preferred platform via wireless or wired communications, delivering critical values to identify pollution issues.

Safeguarding Sewage

Wastewater becomes septic when organic matter decomposes and forms a foul smell, due to the absence of free oxygen. This common problem occurs within sewers when low flows and long retention times combine, resulting in bacteria multiplying in the anaerobic conditions that creates septicity. 

Consequent formation of H2S gas then causes a nuisance with its characteristic foul smell, leading to customer complaints.  This lethal gas also causes a hazard during entry into chambers and its reaction with moisture results in the formation of Sulphuric Acid, which has a costly, corrosive effect.

SeptiNet’s pioneering, preventative nature sees the ORP sensor submerged within the channel’s flow using ATi’s stainless steel, post-mount bracket system, offering flexibility when either positioning the sensor or when removing it for maintenance and cleaning.  The H2S gas sensor is then positioned above the channel and away from the sample water, with consideration taken as to where the H2S gas can be measured. Both sensors are directly hardwired into a GSM, which can be mounted either internally or externally to the CSO.

The unique nature of this combined data offers early indications of septicity, enabling access to data for both online and offline analysis and modelling.  This provides operators with an alert, allowing early decisions whether to dose chemical to counteract the septicity, or divert the flow. 

Early data from this project (see below) confirms the CSO is “healthy”, with ORP and H2S values within the accepted range.  However, if these levels deviate from the norm, it allows the water company to take preventative measures before septicity compromises the whole sewer network.

Prevention is better than the cure

Designed specifically for WWTW inlets, storm tanks, CSO inlets, outlets & overflows, pumping stations and manholes within the network, SeptiNet provides odour and corrosion management, reduces the formation of hazardous atmospheres and negative environmental impacts, safeguarding plants, whilst reducing overflow and pollution to rivers.

SeptiNet offers an end-to-end approach to managing wastewater assets and through innovative, smart technology, it is creating resilient, cost-effective and environmentally friendly wastewater systems, prolonging the life of assets and reducing pollution for a better, greener world. 

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Future-proofing water quality with Source to Tap solutions.

Discover how ATi’s trusted water quality expertise and solutions span every part of the water cycle from Source to Tap, empowering customers worldwide to safeguard water quality, meet regulatory compliance, build resilience, conserve water, reduce risk to human health and the environment, creating a future of intelligent, optimised, smart water networks.

The entire water industry has been entrusted with the responsibility of supplying vital water services to communities, safeguarding water at all points on its journey, and we are proud to lead the way in protecting the world’s most precious resource.  As custodians of this journey, ATi are trusted globally, delivering monitoring solutions for a vast array of different parameters; from the more fundamental parameters of chlorine, turbidity, pH, dissolved oxygen and conductivity, through to more bespoke measurements of nitrite, UV254, sulphites, peracetic acid, sludge blanket and filter backwash monitoring. 

ATi are one of the few companies able to provide an intelligent and sustainable Source to Tap journey, helping customers with water accessibility, environmental sustainability, resilience and return on investment (ROI), developing innovative solutions to improve water quality, extracting deeper insights on pipeline networks and enhancing operational efficiencies. 

Managing water quality from Source to Tap is the core responsibility of the water industry, with public health and regulatory compliance of paramount concern to proactively safeguard water quality for customer use.  Due to the strict standards set by the DWI, the quality of the UK’s drinking water is now among the best in the world, but the water industry has a responsibility to deliver this same standard of water to communities across the globe

Guardianship

ATi strongly believes that the entire water sector has been entrusted with the responsibility of supplying vital water and wastewater services to communities, safeguarding water at all points on its journey from Source to Tap.  In addition to delivering water that is consistently safe for drinking and of high quality, we also need to manage complex interactions between chemistry and energy consumption and continually develop innovative new solutions, with increased pressure from government regulators and stakeholders to manage these systems efficiently, effectively and in a transparent manner. 

Recent advances in digital technologies are now enabling better knowledge, system hygiene, more efficient monitoring, diagnostics and more targeted investments, along with intelligent system management.

Source to Tap Water Quality Solutions

ATi can provide an intelligent and sustainable Source to Tap journey, ensuring the guardianship and protection of water, thanks to our industry-leading range of Q-Series water quality monitors and Smart Water Quality solutions.  Our range of specialist, analytical instrumentation provides no-compromise water quality monitoring in service reservoirs, networks, valves, meter chambers and hydrants, along with waste water and gas monitoring, measuring right through to the end user.   

ATi’s Smart Water Quality range, including the KIWA and WRAS approved MetriNet solutions, creates real-time awareness of water quality throughout the cycle and suggests optimal control mechanisms to ensure the efficient delivery of high-quality water, reducing the risk of compliance violations and customer complaints.  By deploying a neural network of our digital, smart M-Node sensors at critical locations throughout the water distribution system, MetriNet offers water companies continuous, real-time assurances and evidence-based proof that the water is safe.  This approach is providing water companies with high-powered, smart tools to ensure the energy-efficient delivery of high-quality water to communities, in a more environmentally friendly way. 

Future-proofing Water Quality  

Universal access to clean, safe and wholesome drinking water is a basic human right and ATi, Badger Meter and s::can’s pioneering water technology and integrated solutions strive to provide real-time, actionable data for a more sustainable future. 

We are passionate about continuing the development of new and innovative solutions for the whole water cycle process, protecting the world’s most precious resource and providing access to safe and affordable drinking water for all. 

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How can utilities meet increased summer water demands?

Each year, the summer months go hand in hand with increased water demands and decreased supplies, with the UK’s water reserves already substantially strained. ATi discusses how efficiencies and innovation can optimise water supplies during these drier months.

Historically, water conservation was limited to water-use restrictions, however, increasing water efficiency through management, preparation and technology is now recognised as the future for sustainability and resilience.  Considering the UK’s aging assets, their limits on performance and the capacity for increase at set points is an essential exercise.  Thankfully, advances in digitalisation are providing better knowledge, efficient monitoring, diagnostics and intelligent system management. 

Increasing Reservoir Supplies

Reservoirs are a key source of water supplies, therefore considering which reservoirs can be temporarily brought back into supply is vital. How many have mothballed cells shut off on multi cell/tank sites? Can these be cleaned and brought back into operation? One additional cell at a small rural reservoir could negate the need for expensive tankering.

Adjusting reservoir capacity percentage levels could be advantageous eg. increasing the higher level by 10%, or even up to 95% full, can add additional storage. Allowing the reservoir to drop to a lower percentage will also increase the volume. Operational limits and requirements must obviously be considered, but tweaking levels, pumping and filling times can help eke out more water.

Recommissioning Boreholes

When recommissioning boreholes, there are issues ensuring water quality. Often quality monitoring on site is outdated, spares are no longer available and control equipment needs repair.  Utilising smart sensor technology offers the perfect solution to quickly bringing boreholes back online.  In a recent project involving ATi’s multi-parameter, portable monitoring and emergency start-up solution, SiteBox, conductivity, turbidity and pH were monitored in the raw water via the inlet.  These were cross-checked on a separate water stream in the middle of the process, with the addition of chlorine M-Node digital sensors, then again on the final water stream prior to discharge, using dual and triple validation.  This proactive technology enabled the utility to supply 25% more water. 

Pressure Optimisation

Leakage or unaccounted water can be reduced by pressure management, including Pressure Reducing Valves (PRV). Most utilities operate around 1 Bar or more above, at what is known as the critical point, but reducing this by 0.01 to 0.05 bar can reduce overall demand, be it real, leakage or unaccounted water use. Installing flow modulators onto PRVs can reduce pressure at off-peak times and increase it during peak demand times.

Pressure controlled pumps can also be adjusted to reduced pressure to have the same effects as PRVs. Modifications to existing pumps or renewals can improve control. Variable Speed Drives can accomplish this, either retro fitted or purchased with new pumps.  In addition, ATi’s NephNet portable turbidity monitor can be utilised to monitor for any subsequent turbidity issues caused by pressure fluctuations.

Reducing Leakage & Wastage

Leakage detection has been honed over the last few decades to a fine art. Technicians, utilising smart technology, are able to review data and target high-usage areas and DMAs to determine the leakiest locations. 

Water quality monitoring has proven to offer warning dimensions for leakage and high demand, eg. turbidity spikes can indicate increasing flow due to a developing leak. Or reservoir quality monitoring can indicate if ingress is an issue as where ingress occurs, the egress can also occur. A number of large UK smart network projects are currently combining data from acoustic, flow, pressure and ATi’s MetriNet to reduce leakage.  These machine-learning ‘AI brains’ tell engineers if pipes have sprung a leak, sending alerts before developing issues.

Other areas of water wastage include lack of reservoir inlet and outlet and poor trunk main metering, plus unreported wet patches at reservoirs or pumping stations can often go unreported due to operatives not always having the knowledge to confirm or report a leak. 

Conclusion

Although these insights may not answer summer problems in full, ultimately optimum drought preparation, resilience, management and water security will provide a more sustainable and efficient water system.  Protecting supplies and meeting increased demands through efficiencies and smart sensor technology will inevitably result in more cost-effective and environmentally friendly water management, prolonging the life of assets.

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