Ecolab Nalco Water STORM Settling Rate Monitor Instruction manual

Settling Rate Monitor
Installation, Operation & Maintenance Manual
By:
Nalco Water
Engineering & Project Development
February 2020
Nalco Reference No: ESTDS-STORM-IOM
Revision
Date
Comment
Prepared
Checked
Approved
K
20/02/2020
SC
DM
DM

STORM™ - SETTLING RATE MONITOR
INSTALLATION, OPERATION & MAINTENANCE MANUAL
ESTDS-STORM-IOM - REV K
Page i
CONTENTS
1 INTRODUCTION..............................................................................................................................1
1.1 Design Features.................................................................................................................1
2 SAFETY............................................................................................................................................2
3 SCOPE.............................................................................................................................................3
3.1 Equipment Specification ...................................................................................................3
4 INSTALLATION................................................................................................................................4
4.1 STORM Panel Location......................................................................................................4
4.2 Sample Hose Location.......................................................................................................4
4.3 Site Services ......................................................................................................................5
4.4 Electrical Terminations......................................................................................................5
4.5 Commissioning Checklist...................................................................................................7
5 PRINCIPLE OF OPERATION .............................................................................................................8
5.1 Description of Operation ..................................................................................................8
5.2 Settling Rate –Flocculant Dose Control............................................................................8
5.3 Supernatant Turbidity –Coagulant Dose Control.............................................................8
5.4 Sampling Sequence...........................................................................................................8
6 HMI OPERATION ............................................................................................................................9
6.1 Main (Home) Screen .........................................................................................................9
6.2 Flocculant Control Configuration Screen....................................................................... 11
6.3 Coagulant Control Configuration Screen ....................................................................... 12
6.4 Sampling Sequence Configuration Screen ..................................................................... 13
6.5 System Configuration Screen......................................................................................... 15
6.6 Manual Control Screen .................................................................................................. 17
6.7 Mode Select Screen ....................................................................................................... 18
6.8 Quick Start Settings for Floc control .............................................................................. 19
7 TROUBLESHOOTING.................................................................................................................... 20
8 MAINTENANCE............................................................................................................................ 21
8.1 Cleaning and Preventative Maintenance Intervals........................................................ 21
8.2 Turbidity Instrument Removal....................................................................................... 21
8.3 Settling Cylinder Removal and Re-installation............................................................... 22
8.4 Replacement parts......................................................................................................... 24
9 ELECTRICAL DRAWINGS .............................................................................................................. 25

STORM™ - SETTLING RATE MONITOR
INSTALLATION, OPERATION & MAINTENANCE MANUAL
ESTDS-STORM-IOM - REV K
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1INTRODUCTION
The Nalco STORM™ Settling Rate Monitor controls Flocculant and Coagulant dosing in Thickener
applications through measuring settling rate and final turbidity of samples drawn from the centre-well.
1.1 Design Features
The Nalco STORM™ Settling Rate Monitor has been designed and built in Australia to meet
International standards.
Item
Description
Control System
-Allen Bradley CompactLogix PLC control module.
-Colour touchscreen interface designed to give the operator
complete system control and operational information.
Quality
-Quality build components from major reputable
manufacturers; Allen Bradley, Endress & Hauser, G+F,
Burkert, Festo, Schneider.
Electrical
-Electrical wiring in accordance with AS/NZS 3000:2018
-Designed to allow a wide range of electrical supply options
from 90VAC to 550VAC, or 24VDC.
Services filtration
-Integrated supply services filtration as standard with air
filter/regulator and all water components designed to
accommodate variable levels of service water quality.
Cleaning
-STORM™ Settling Cylinder designed to allow simplified
turbidity probe removal for cleaning. Similarly, the complete
Settling Cylinder assembly can easily be removed for
cleaning and maintenance.
Backlight
-Bright LED backlighting installed behind the Settling Cylinder
to provide improved visibility of sample and visual detection
of sample interface.

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INSTALLATION, OPERATION & MAINTENANCE MANUAL
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2SAFETY
The Nalco STORM™ Settling Rate Monitor has been designed to run automatically with no operator
intervention except for periodic maintenance, inspection & cleaning. Personnel working on or around
the equipment need to be aware that the system will operate automatically without warning.
Prior to undertaking any maintenance activity on the equipment, a “Risk Assessment” should be
performed. Operators and maintenance personnel should be suitably qualified and trained prior to
undertaking any work on the equipment for the first time.
The power and control switchgear and terminations for the STORM™ unit are located in the left-hand
side panel. All power and control wiring is located behind the inner escutcheon door. Access to this
area must comply with all statutory and site electrical requirements.
The Settling Cylinder is located in the right-hand side panel. The sampling process is operated by
pneumatic instruments. Some lines may be pressurised (nom. 6 Bar). Air pressure must be relieved
from the system prior to disconnection of any lines or replacing pneumatic equipment.

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INSTALLATION, OPERATION & MAINTENANCE MANUAL
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3SCOPE
This manual details the operation and maintenance requirements of the Nalco STORM™ Settling Rate
Monitor.
3.1 Equipment Specification
Item
Description
Construction
-Painted stainless steel control cabinet
Electrical
-90‐264VAC or 180-500VAC, 50/60 Hz, or 24VDC (to be
selected at time of order)
-6A maximum
-IP66 control cabinet (NEMA 4X)
-Wiring to AS/NZS 3000
Water Supply
-20 L/min @ 3 bar
-0.5 L/min (consumed)
Air Supply
-10 L/min @ 6 bar
Dimensions
-900 x 600 x 380mm (W x H x D)
Mounting Dimensions
-950 x 500mm (W x H)
Weight
-Approx. 80 kg
Connections
-Water ‐ 10mm push fit
-Air ‐ 10mm push fit
-Sample ‐ 1” camlock (male)
Sample Line
-Unit supplied with 10 metres of 1” sample hose with
camlock fitting (female)
Outputs
-2 x 4‐20mA outputs for dosing pump control
-Optional Ethernet port for connection to site PLC/DCS

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INSTALLATION, OPERATION & MAINTENANCE MANUAL
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4INSTALLATION
4.1 STORM Panel Location
The STORM™ unit should normally be installed on the Thickener bridge, adjacent to the centre-
well. Common installation practice is to use the bridge handrails to mount the unit. The
STORM™ cabinet is provided with four (4) mounting brackets located at the rear of each corner
of the cabinet.
Figure 4-1 : Panel Mounting Details
4.2 Sample Hose Location
The sample point should be located :-
•In the thickener centre well.
•In such a position as to give a good cross-section of the thickener feed.

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INSTALLATION, OPERATION & MAINTENANCE MANUAL
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4.3 Site Services
The STORM™ unit requires the following site services;
Service
Specification
Details
Power
90-264VAC, 50/60Hz, 6 A (max.)
(or) 180-550VAC, 50/60Hz
(or) 24VDC
System power and control
Water
20 l/min @ 3 bar (peak),
0.5l/min (consumed)
Tube Cleaning –potable supply
recommended.
Air
10 l/min @ 6 bar
Vacuum generation, Cylinder purging.
4.4 Electrical Terminations
Power
The STORM™ can accept 90-264VAC single phase supply as standard.
Alternatively, 180-550VAC two phase, or 24VDC options can be supplied –to be specified at
order.
Input voltage range
Power Terminations
Standard
90-264VAC
L1 (Active)
N (Neutral)
Earth
Optional
180-550VAC
L1 (Phase A)
L2 (Phase B)
Earth
Optional
24VDC
24 (24VDC+)
0 (0VDC)-
Earth
Figure 4-2 : Power Terminations

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INSTALLATION, OPERATION & MAINTENANCE MANUAL
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Control & Status Signals
The STORM™ provides the following status and control signals for hard wired connection to
site control systems.
Description
Type
Terminal
Designation
General Fault
Volt Free
(VFC)
X3.01 Upper
Supply
X3.01 Lower
Return
Analogue Output #1 (Flocculant
Dosing Pump Speed)
*Ref Section 6.5.1
4-20mA
X3.02 Upper
+(32mA Fused)
X3.02 Lower
-
Analogue Output #2
(Coagulant Dosing Pump Speed)
*Ref Section 6.5.1
4-20mA
X3.03 Upper
+(32mA Fused)
X3.03 Lower
-
Additional status information can be made available upon request. Discuss with your
Nalco/Ecolab representative for further information.
Figure 4-3 : Control & Status Terminations

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4.5 Commissioning Checklist
Test
Action Description
Check
Electrical
Installation
Electrician to check electrical terminations and supply.
Mechanical
Installation
Check all fixings are tight and secure.
Check main incoming airline is firmly connected.
Check main incoming water line is firmly connected.
Check the sample hose is correctly installed.
Manual test
Navigate to the Manual Control screen
Select System Mode to Manual
Press Water Flush and confirm that clean water spray cleans the inside of
the settling cylinder.
Press Air Purge and confirm that air is purging the settling cylinder.
Press Vacuum Control. After a few seconds a sample should begin to be
drawn up into the settling cylinder
When the sample is roughly half way up the settling cylinder, release the
Vacuum Control button and press the Air Vent button. The half sample
should remain in the settling cylinder. If the sample continues to discharge
from the settling cylinder while the Air Vent button is pressed then please
check all air and water connections for leaks.
If the sample holds at a steady level, then release the Air Vent button and
allow the sample to discharge from the settling cylinder.
Sample test
(Manual)
Look through the settling cylinder clear wall and confirm you can see the
level probe stainless steel rods.
Press the Sample Test button. A sample will begin to be drawn up into the
settling cylinder. Continue to hold the Sample Test button. The vacuum
generator should automatically stop drawing the sample immediately when
the level of liquid in the settling cylinder touches the level probe set.
[If the level continues to rise above the level probe set then release the
Sample Test button immediately.]
If the sample is successfully held steady at the level probe set, then
continue to hold the Sample Test button for a few seconds.
Release the Sample Test button. The system will air purge and empty the
settling cylinder.
The level probe set may be cut to a shorter length, if a larger test sample is
preferred.
Backlight
Press the Backlight button. The LED backlight behind the settling cylinder
should illuminate. The LED backlight will stay illuminated for approximately
10 minutes, or until the button is pressed again.
Flocculant
Dosing
pump test
Navigate to the Mode Select screen
Set the Flocculant dosing pump manual speed setpoint to 20%
Select the Flocculant dosing pump mode to Manual
Confirm the operation of the Flocculant dosing pump.
Select the Flocculant dosing pump mode to Auto
Coagulant
Dosing
pump test
Navigate to the Mode Select screen
Set the Coagulant dosing pump manual speed setpoint to 20%
Select the Coagulant dosing pump mode to Manual
Confirm the operation of the Coagulant dosing pump.
Select the Coagulant dosing pump mode to Auto

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INSTALLATION, OPERATION & MAINTENANCE MANUAL
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5PRINCIPLE OF OPERATION
5.1 Description of Operation
The STORM™ Settling Rate Monitor is a stand‐alone Flocculant and Coagulant dosing control
system for use in Thickener applications. The device measures the settling time of Thickener
feed samples withdrawn from the Thickener centre-well.
A sample is drawn from the Thickener centre-well into the Settling Cylinder. When the Settling
Cylinder is full, the flocculated particles will start to settle, passing the optical sensor.
5.2 Settling Rate –Flocculant Dose Control
Turbidity monitoring is used to determine the settlement rate. The settling rate is used to
control Flocculant addition. When the flocculated material is draw into the Settling Cylinder it
will begin to settle, with an interface between the flocculated solids and the clear supernatant.
When this interface passes the optical sensor, the time is recorded. Should the sample settle
too quickly, the Flocculant dose rate will be reduced. If the sample settles too slowly, the
Flocculant dose rate will be increased.
5.3 Supernatant Turbidity –Coagulant Dose Control
The final supernatant turbidity can be used to control Coagulant addition. When all the
particles have settled, the supernatant turbidity is measured. This reading controls the
Coagulant dose rate. If the residual turbidity is too high, the Coagulant dose rate will be
increased. If the residual turbidity is low, the Coagulant dose rate will be decreased.
5.4 Sampling Sequence
Step
Description
Line purge
Air is blown into Settling Cylinder to purge sample tube
Vacuum
Air pressure is directed to a venturi vacuum generator to draw the
centre-well sample into the Settling Cylinder. Conductivity level sensors
in the Settling Cylinder stop the sample when the cylinder is full.
Settle Time
Settle timer begins counting when the cylinder is full. Settle time will be
recorded when the turbidity measurement instrument identifies the
solids/liquid interface.
Supernatant
Turbidity
After a further pre-set time, the supernatant (clear liquid) turbidity will
be recorded.
Vacuum Release
After the supernatant turbidity is recorded, the vacuum is released and
the sample is returned to the centre-well with the assistance of air
pressure line purging.
Cylinder Spray
Water is sprayed into the cylinder through a spray nozzle system to
clean the Settling Cylinder and the turbidity instrument.

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INSTALLATION, OPERATION & MAINTENANCE MANUAL
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6HMI OPERATION
The Nalco STORM™ settling rate monitor is equipped with a high-resolution colour touchscreen HMI
operator interface. The operator can view the status of the STORM™ and adjust operation parameters
via the HMI.
This screen has been selected to give optimal performance over a wide range of ambient light
conditions.
6.1 Main (Home) Screen
The Main screen is the default screen. The HMI will display this screen on power-up, and will
return to this screen after a period of inactivity.
Control Functions
The operator can select the mode of operation AUTO, OFF or MANUAL. The unit will normally
operate in AUTO mode.
In AUTO mode the STORM™ unit will automatically continuously cycle through the sampling
sequence.
In MANUAL mode the operator can individually operate any of the solenoid valves to test
functionality.
OFF mode will stop operation of the STORM™ unit.
The operator can toggle the sample tube LED backlight on and off and reset any fault condition.

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INSTALLATION, OPERATION & MAINTENANCE MANUAL
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Displayed Information
The operator can view the status of the Flocculant and Coagulant dosing pumps, the current
mode of operation (AUTO/MANUAL/OFF), and pump speed set-point (%). The Arrows to the
right of the pump icons indicate whether the pump speed is increasing, decreasing or steady.
The right-hand side of the screen displays a graphical indication of current state of the sample
sequence. This includes the current step number, description of the current step and bar graph
indication of step time remaining.
In the event of a fault condition, a red banner will appear at the bottom of the screen. This will
give the operator a description of the fault that has occurred.
The following status parameters are also indicated;
•‘SETTLING TIME SP’, target settling time (seconds)
•‘ACTUAL SETTLING TIME’recorded from the last sample (seconds)
•‘FINAL TURBIDITY SP’, target supernatant turbidity (mg/L)
•‘ACTUAL FINAL TURBIDTY’ of the supernatant in the last sample (mg/L)
•‘CURRENT TURBIDITY NTU’, actual real time measured turbidity (mg/L)
Navigation
There are three (3) navigation buttons at the bottom of the screen, allowing the operator to
open other screens;
•Configuration
•Manual control
•Historical trends

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INSTALLATION, OPERATION & MAINTENANCE MANUAL
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6.2 Flocculant Control Configuration Screen
The Flocculant control configuration screen is the first configuration screen and is accessed
from the Main screen.
Control Functions
The operator can adjust all tuning parameters of the Flocculant Pump control loop. The most
common parameters that require tuning are highlighted white. Parameters that are normally
not adjusted are ‘greyed out’.
If the ‘ACTUAL SETTLING TIME’(STs) is longer than the target ‘SETTLING TIME SP’(SP) then the
Flocculant Pump speed is increased. The increase is clipped to a maximum of .
  󰇛 󰇜 

If the ‘ACTUAL SETTLING TIME’ (STs) is shorter than the target ‘SETTLING TIME SP’ (SP) then the
Flocculant Pump speed is slowed. The decrease is clipped to a maximum of .
  󰇛 󰇜 

If the ‘ACTUAL SETTLING TIME’ is close to the ‘SETTLING TIME SP’ (within a deadband), then
the same pump speed will be maintained.
To improve the response time of the Flocculant Pump control loop (on system start-up), the
Flocculant Pump speed will begin from ‘Initial Speed (%)’.
The Flocculant Pump speed is limited to operate in the band between ‘MAX SPEED (%)’and
‘MIN SPEED (%)’.
Navigation
There are two (2) navigation buttons at the bottom of the screen, allowing the operator to
open other screens:-
•Main (Home) screen
•Coagulant Control Configuration

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INSTALLATION, OPERATION & MAINTENANCE MANUAL
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6.3 Coagulant Control Configuration Screen
The Coagulant control configuration screen is the second configuration screen and is accessed
from the Floc Control Config Screen.
Control Functions
The operator can adjust all tuning parameters of the Coagulant Pump control loop. The most
common parameters that require tuning are highlighted white. Parameters that are normally
not adjusted are ‘greyed out’.
If the ‘ACTUAL FINAL TURBIDITY’(Turbidity) is higher than the ‘FINAL TURBIDITY SP’ (SP) then
the Coagulant Pump speed is increased. The increase is clipped to a maximum of .
  󰇛  󰇜 

If the ‘ACTUAL FINAL TURBIDITY’ (Turbidity) is lower than the ‘FINAL TURBIDITY SP’ (SP) then
the Coagulant Pump speed is slowed. The decrease is clipped to a maximum of .
  󰇛  󰇜 

If the ‘ACTUAL FINAL TURBIDITY’ is close to the ‘FINAL TURBIDITY SP’ (within a deadband), then
the same pump speed will be maintained.
To improve the response time of the Coagulant Pump control loop (on system start-up), the
coagulant pump speed will begin from ‘INITIAL SPEED (%)’.
The Coagulant Pump speed is limited to operate in the band between ‘MAX SPEED (%)’and
‘MIN SPEED (%)’.
Navigation
There are two (2) navigation buttons at the bottom of the screen, allowing the operator to
open other screens;
•Main (Home) screen
•Sequence Configuration

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INSTALLATION, OPERATION & MAINTENANCE MANUAL
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6.4 Sampling Sequence Configuration Screen
The Sequence Configuration screen is the third configuration screen and is accessed from the
Coag Control Config Screen.
Control Functions
The operator is able to modify the sample sequence timing.
Step 10 ‘DILTUTION TIME (s)’is the duration of a short spray of water at the start of the
sample. This can be used to dilute the sample where turbidity is excessively high. [Default
time is 0 seconds].
Step 15 ‘FAIL TO FILL TIME (s)’is the time allowed for the sample to be drawn up into the
Settling Cylinder. If the time expires before the sample level reaches the level probe, then an
alarm message is displayed; and the sequence restarts. [Default time is 60 seconds].
Step 30 ‘MINIMUM SETTLING TIME’is used to prevent the sample returning a false early
settling time. A false reading can occur if the turbidity probe is slow to react to the new
sample’s turbidity. [Default time is 5 seconds].
Step 40 ‘MINIMUM WAIT FOR FINAL’ is the minimum time (after the sample settling time is
sensed) to wait before measuring final turbidity. [Default time is 10 seconds].
Step 60 ‘DUMP TIME (s)’is the time allowed for draining (under gravity), prior to flushing and
purge. [Default time is 2 seconds].
Step 70 ‘FLUSH TIME (s)’is the duration of the water flush at the end of the sample stage.
[Default time is 2 seconds].
Step 80 ‘PURGE TIME (s)’is the duration of the air purge which forces the sample out of the
Settling Cylinder and sample hose at the end of the sample sequence. [Default time is 2
seconds].
Step 90 ‘DELAY TIME (s)’can be used to reduce the number of sample cycles per hour, by
introducing a dormant period at the end of each sample. [Default time is 1 seconds].

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Navigation
There are two (2) navigation buttons at the bottom of the screen, allowing the operator to
open other screens;
•Main (Home) screen
•System Configuration

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6.5 System Configuration Screen
The System Configuration screen is the fourth configuration screen and is accessed from the
Sequence Config Screen.
Control Functions
The System configuration screen is used to scale/range and tune the 4-20mA signal received
from the turbidity probe.
‘RAW_MIN’is minimum raw value received by the PLC from the turbidity probe. This
corresponds to 4mA.
‘ENG_MIN’is minimum turbidity (mg/L) scaled by the PLC. This corresponds to 4mA.
‘RAW_MAX’is maximum raw value received by the PLC from the turbidity probe. This
corresponds to 20mA.
‘ENG_MAX’is maximum turbidity (mg/L) scaled by the PLC. This corresponds to 20mA.
Using these 4 parameters (above) the PLC calculates the scaled turbidity value in mg/L.
‘SETTLED SETPOINT’(mg/L) is the turbidity reading at which point the sample is deemed to
have settled. When this setpoint is reached, the settling timer is stopped and the settling
time of that sample is recorded.
The operator can select if the Turbidity signal input channel is 4-20mA (default); or 0-10V
(only to be used with Nalco Eco Probe).
The operator can configure which signals are transmitted out from the STORM analogue
output channels. AO1 default is Floc Pump Speed, AO2 default is Coag Pump Speed. Both can
be reconfigured as either Settling Time or Final Turbidity
The operator can save parameter settings in 2 storage files by pressing the ‘SAVE SETTINGS
TO FILE’ buttons. The STORM™ can then load these saved settings by pressing the ‘RETURN
TO’ buttons.

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Displayed Information
The turbidity probe raw analogue input is displayed as ‘RAW_ IN’.
The scaled turbidity reading is displayed as ‘SCALED’ in mg/L.
Navigation
There are three (3) navigation buttons at the bottom of the screen, allowing the operator to
open other screens;
•Main (Home) screen
•Floc Configuration
•Admin screen

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6.6 Manual Control Screen
The Manual Control screen is accessed from the Main Screen. When the STORM™ sampling
system is selected in Manual mode, the operator can energise each solenoid valve individually.
Control Functions
The ‘VACUUM CONTROL VALVE’controls the vacuum generator. Energising this valve will
generate a vacuum and draw a sample up into the sample cylinder.
WARNING: Failure to de-energise this valve when the settling cylinder is full may permanently
damage the vacuum generator.
The ‘AIR PURGE VALVE’is used to discharge the sample from the settling cylinder.
The ‘WATER FLUSH VALVE’is used to spray clean water into the settling cylinder and clean the
turbidity probe sensor.
The ‘AIR VENT VALVE’allows air to enter the settling cylinder while the sample is being
discharged.
The ‘SAMPLE TEST’button is used to test the sampling function. The operator should press-
and-hold this button while a test sample is drawn up into the settling cylinder. When the
sample level reaches the level probe the sample suction should stop and the sample should be
held steady in the settling cylinder. When the operator releases the ‘SAMPLE TEST’button the
sample will be returned to the centre-well.
WARNING: Failure to properly connect the level probe may cause the Settling Cylinder to
overfill and permanently damage the vacuum generator.
Navigation
There are three (3) navigation buttons at the bottom of the screen, allowing the operator to
open other screens;
•Main (Home) screen
•Floc Configuration Setup
•Mode Select

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6.7 Mode Select Screen
The Mode Selection screen can be accessed from the Manual Control screen.
Control Functions
The operator can select the ‘STORM SYSTEM MODE’ to run in ‘AUTO’ or ‘MANUAL’, or turn
sampling ‘OFF’. In ‘AUTO’ mode the STORM™ unit will continually sample. In ‘MANUAL’ mode
the operator can energise valves individually for testing purposes.
The operator can select the Flocculant Pump ‘FLOC MODE’ to run in ‘AUTO’or ‘MANUAL’, or
turn Flocculant dosing ‘OFF’. In ‘AUTO’ mode, the Flocculant Pump is automatically controlled
by the STORM™ to maintain a fixed settling rate. In ‘MANUAL’ mode the operator can select
the Flocculant Pump speed set-point.
The operator can select the Coagulant Pump ‘COAG MODE’ in ‘AUTO’or ‘MANAUL’, or turn
Coagulant dosing ‘OFF’. In ‘AUTO’ mode, the Coagulant Pump is automatically controlled by
the STORM™ to maintain a fixed final (supernatant) turbidity. In ‘MANUAL’ mode the operator
can select the Coagulant Pump speed set-point.
Displayed Information
The STORM and dosing pumps mode selection is highlighted by the mode button changing
colour.
The ‘MANUAL’ mode speed setpoints for the Flocculant and Coagulant Pumps are displayed
in the white boxes below the respective mode.