Calibration Evolution and Revolution

Transcription

1 Calibration Evolution and Revolution Case History: City of Cape Coral FL Drinking Water Production Plants Standards Certification Education & Training Publishing Conferences & Exhibits Speakers: Chris Caglioti-Chief Operator Cape Coral North RO Plant 2016 ISA Water / Wastewater and Automatic Controls Symposium August 2-4, 2016 Orlando, Florida, USA

2 Presenter Chris Caglioti-Chief Operator North RO Plant Class A Licensed water treatment operator 28 Years municipal experience ISA Member ISA CCST Level 1 Member FWPCOA Member SEDA Headshot photo 2

3 Presentation Outline-Let s Have Fun! Why Calibrate? What is it? Is it important? Traceability Our story What we measure A few examples Then and now Now what? 3

4 but seriously, why calibrate at a drinking water plant? Because we have to! FL DEP : administrative codes SFWMD: Water management districts EPA 334.0: On-line chlorine analyzers Local Department of Health: Audits! Performance Data: Cost benefit Normalized Flow: How s my system? 4

5 Why Calibrate? Without calibration we d all pay more for Fuel at the pump Food at the store Manufactured goods Production chemicals SO, What is Calibration? 5

6 Calibration is: A comparison of 2 measurement devices or systems between a known and an unknown. 6

7 Is accuracy important? YES! 7

8 Traceability (the known) The value of a standard whereby it can be related to stated references, usually National or international standards, through an unbroken chain of comparisons all having stated uncertainties. 8

9 Standards and Buffers Point of reference 9

10 Actual NIST chemist preparing buffers 10

11 A little about us, after all, it is a case study. 11

12 City of Cape Coral Water Production History Oldest continuing operating RO plant in the world-1977 Brackish water RO-80% recovery. Upper Floridan Aquifer-approx ppm TDS South RO 18 MGD-North RO 12 MGD Membrane Feed Pressure average 150 psig Deep Injection Wells Raw Water Blend for mineral balance post treatment Finished Water Quality 8.75 ph, 400 ppm TDS, 110 ppm total hardness Over 1000 process control instruments 12

13 What We Measure Conductivity Analytical ph, Turbidity, Cl2 residuals.. Flow-DP-Pressure Level-Ultrasonic-Radar-DP 13

14 Let s Look At Pressure Standard Pressure Transmitter Coplanar Manifold Mount HART Smart Material/Process Compatibility Rangeablity Local Display Loop Powered 4-20 Milliamp Output 14

15 Typical Pressure Transmitter Loop Field Process Device Process Input Communication Bus Physical Connections Interference-Noise Scaling-Ranging Dampening SCADA input 15

16 Calibration Methods You are not the first 16

17 Back When I Started 17

18 You ve got it easy today! Process Documenting Calibration System Multi-Function Unit 18

19 What does it all do? Loop Power Communication-HART, Fieldbus, ProfiBus Range, Dampening, Trim, Calibrate Data Storage PC Interface-IR-Bluetooth-Cloud Documentation Now let s take a look at Flow.. 19

20 A Look At Flo You saw that coming right? 20

21 But seriously Old School Not So Accurate 21

22 Flow: Calibrate or Verify? What s the process? Available Methods In-situ or on the bench? Flow rig? Proprietary? Custody transfer? Production cost? 22

23 OK, how do we do it? Calibration Process 23

24 Now What? I ve got data! Audit trail-what Accountability-who History Trend-when Preventative-I hope it doesn t break Predictive-It might break Reactive-It s broke Asset Managementlet s buy another one 24

25 Verification Certificate Verified the Functionality Satisfied the Regulations Traceable Audit Trail Asset Management Historical Data 25

26 Am I compliant? FLDEP Operations and Maintenance of Public Water Systems in accordance with the manufacturers recommendations or in accordance with a written program established by the supplier of water That would be YOU! 26

27 Here s The Plan-Summary (yes we re almost done) Say What You Do-Write it down in detail Do What You Say-follow documented procedures Record What You Did-record before, results after Check The Results-tolerances, deviations, limits Act On The Difference-adjust, repair, re-range, replace Strive for Accuracy Require Accountability 27

28 Questions? 28

29 Thank You! 29