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Process Control and Monitoring Options

Process Control and Monitoring Options. James M. Ebeling, Ph.D. Environmental Engineer Aquaculture Systems Technologies, LLC New Orleans, LA. Fundamental Design Strategies. The most sophisticated monitoring and alarm system is an attentive human operator!.

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Process Control and Monitoring Options

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  1. Process Control and Monitoring Options James M. Ebeling, Ph.D. Environmental Engineer Aquaculture Systems Technologies, LLC New Orleans, LA Recirculating Aquaculture Systems Short Course

  2. Fundamental Design Strategies The most sophisticated monitoring and alarm system is an attentive human operator! Routine Monitoring of Important Water Quality Parameters Recirculating Aquaculture Systems Short Course

  3. Fundamental Design Strategies If Anything can go wrong, IT WILL! • Imagine theWORST!! • Then Prepare for it! Recirculating Aquaculture Systems Short Course

  4. What Processes Do I Have In Place to Respond to Emergencies • Ready Phone List • Plumbers • Electricians • Staff • Fire/Emergency • Trained Staff • Logical Troubleshooting Procedures • Triage • Call for addition HELP! • Safety • System Designed to Fail Reliably Recirculating Aquaculture Systems Short Course

  5. Response Times • High (fast response time – minutes) • electrical power • water level in tank • dissolved oxygen –aeration system/ oxygen system • Medium (moderate response time – hours) • temperature • carbon dioxide • Low (normally slowly changing – days) • pH • alkalinity • ammonia-nitrogen • nitrite-nitrogen • nitrate-nitrogen Recirculating Aquaculture Systems Short Course

  6. Design Strategies • Basic System - critical parameters • Intermediate System • Computer Based System Three Levels of Monitoring and Control Recirculating Aquaculture Systems Short Course

  7. Basic System - Critical Parameters • Basic Parameters – Digital (On/Off) • Electric Power • Tank water level • Sump water level • Water flow through pumps • Air pressure Recirculating Aquaculture Systems Short Course

  8. Basic System - Sensors • Basic Parameters–(On/Off) • Electric Power • Tank water level • Sump water level • Water flow through pumps • Air pressure Recirculating Aquaculture Systems Short Course

  9. Electric Power System Designed to Fail Reliably Power goes out, these normally open solenoid values open and oxygen is sparged into the production tanks Recirculating Aquaculture Systems Short Course

  10. Basic System - Sensors • Basic Parameters–(On/Off) • Electric Power • Tankwater level • Sumpwater level • Water flow through pumps • Air pressure Recirculating Aquaculture Systems Short Course

  11. Water Level – Float Switches Recirculating Aquaculture Systems Short Course

  12. Water Level – Float Switches High Water Level Low Water Level Recirculating Aquaculture Systems Short Course

  13. Water Level – Float Switches Inexpensive Reservoir Alarm Sump Level Alarm Recirculating Aquaculture Systems Short Course

  14. Basic System - Sensors • Basic Parameters–(On/Off) • Electric Power • Tank water level • Sump water level • Water flow through pumps • Air pressure Recirculating Aquaculture Systems Short Course

  15. Water Flow – Flow Switches Recirculating Aquaculture Systems Short Course

  16. Water Flow – Flow Meters Turbine Flow Meters Paddlewheel Sensor Recirculating Aquaculture Systems Short Course

  17. Water Flow – Flow Meters Electromagnetic / Ultrasonic Flow Meters Recirculating Aquaculture Systems Short Course

  18. Basic System - Sensors • Basic Parameters–(On/Off) • Electric Power • Tank water level • Sump water level • Water flow through pumps • Air pressure Recirculating Aquaculture Systems Short Course

  19. Air Pressure – Pressure Switches Recirculating Aquaculture Systems Short Course

  20. Physical Plant Security Intrusion alarms, smoke, and fire alarms! Recirculating Aquaculture Systems Short Course

  21. Basic System – Phone Dialer • Monitors • Electricity • Temperature • Digital alert inputs - switch open/closed • High sound level • Battery condition • Alarm Response • Announces the alarm condition locally • Telephones four numbers with an alarm message Recirculating Aquaculture Systems Short Course

  22. The Basic System Recirculating Aquaculture Systems Short Course

  23. The Basic System • Basic Systems Disadvantage • Limited Expansion • Difficult to Disable Alarm Inputs • Difficult to Check Alarm and System Status Recirculating Aquaculture Systems Short Course

  24. Design Strategies • Basic System - Digital (On/Off) • Intermediate System – Analog Sensors • Computer Based System Recirculating Aquaculture Systems Short Course

  25. Intermediate System- Sensors Parameters - Analog (mV) • Dissolved Oxygen • high/low DO alarm relays • low DO control relays • data display • data transmission Recirculating Aquaculture Systems Short Course

  26. Intermediate System- Dissolved Oxygen Recirculating Aquaculture Systems Short Course

  27. Intermediate System- Sensors Parameters - Analog (mV) • Temperature • high/low temperature alarm relays • set point control relays • data display • data transmission Recirculating Aquaculture Systems Short Course

  28. Intermediate System- Sensors Parameters - Analog (mV) • pH • data display • data transmission Recirculating Aquaculture Systems Short Course

  29. Intermediate System- pH Controls Degassing of CO2 Control Dosing for pH Control Recirculating Aquaculture Systems Short Course

  30. Intermediate System- Sensors Parameters - Analog (mV) • Other Water Quality Parameters • Ammonia • Carbon Dioxide • Alkalinity • Others Recirculating Aquaculture Systems Short Course

  31. Intermediate System- Laboratory A water quality lab doesn’t have to be large, but it should be dedicated only to that task. Recirculating Aquaculture Systems Short Course

  32. Intermediate System Recirculating Aquaculture Systems Short Course

  33. Design Strategies • Basic System - Digital (On/Off) • Intermediate System – Analog Sensors • Computer Based System Recirculating Aquaculture Systems Short Course

  34. Computer Based System Design Strategies • Closed Loop Controller (PLC) Distributed Control System • Centralized Microcomputer Recirculating Aquaculture Systems Short Course

  35. Closed Loop Controller (PLC) Sensors, Valves, Actuators Recirculating Aquaculture Systems Short Course

  36. Distributed Control System Supervisory Computer Microcomputer Programmable Logic Controller Multiplexer Sensors, Valves, Actuators Sensors, Valves, Actuators Recirculating Aquaculture Systems Short Course

  37. Computer Based System Centralized Microcomputer Microcomputer Multiplexer Sensors, Valves, Actuators Recirculating Aquaculture Systems Short Course

  38. Computer Based System Centralized Microcomputer Microcomputer operates as the primary controller, monitoring, recording data, and controlling alarm functions Recirculating Aquaculture Systems Short Course

  39. System Design • choose sensors carefully, use the fewest possible, label everything and include expansion capability in all components. • aquaculture facilities are now included under the National Electric Code, it may not be of concern to you, but it is to your insurance agent. Recirculating Aquaculture Systems Short Course

  40. System Design • mount sensors and equipment where they are visible and easily accessible for service and calibration. • remember that water and electricity make for a fatal combination, so use low signal voltages (5 VDC, 12 VDC or 24 VDC or AC) to protect you and the fish. • clearly label the sensor's armed and unarmed modes preferably with LED's at each station to show sensor status. Recirculating Aquaculture Systems Short Course

  41. System Maintenance • Have a well prepared maintenance manual accessible to the staff. • Maintain a weekly/monthly/yearly maintenance scheduling plan and files of major service records and equipment manuals. • Maintain daily/weekly/monthly instrument check lists. Recirculating Aquaculture Systems Short Course

  42. System Maintenance • Perform regular (and some unannounced) system checks, including triggering of each sensor and checking operation of the automatic backup systems and phone dialer. • Provide staff training to handle routine alarms. • Ensure staff familiarization with the complete operating system, including water supply, aeration and emergency backup systems. Recirculating Aquaculture Systems Short Course

  43. Safety! • Electricity and water make a fatal combination! • National Electric Codes • Low voltage - 24 VAC or 12 or 24 VDC • Maintenance schedule & regular system checks • Staff training Recirculating Aquaculture Systems Short Course

  44. Questions? Recirculating Aquaculture Systems Short Course

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