COSTARS Pennsylvania Purchasing Power

There is a new government program for Municipal Water & Wastewater Treatment Facilities in Pennsylvania.  The Pennsylvania COSTARS program has been set up to allow participating municipalities to purchase from suppliers without going to bid.  Once registered, water & wastewater treatment facilities can request quotations from COSTARS approved suppliers (like ES2), and purchase directly from them, referencing the COSTARS vendor number on their purchase order.  This puts the municipality in control, to save time and money and to work directly with their favorite supplier instead of the low bidder.  If you are a Pennsylvania Municipality and you are not registered, I recommend visiting the COSTARS website to register as a member (click here to get started).

Peter Hutwelker,  President ES2 Inc.

Wireless Process Control

There are so many ways to integrate systems using the latest wireless technology.  The use of WiFi and Bluetooth in our everyday lives has become so common that we sometimes take it for granted.  Next time you’re in the airport just imagine everyone using a PC or a tablet having a network wire connection; that would be some tripping hazard!  For industrial process control applications, wireless communication equipment is nearly always a consideration.  ES2 has designed and installed a number of wireless systems from basic single node transmission of a single contact closure or 4-20ma analog signal, to Ethernet/Modbus communications linking PLCs controlling multiple processes.  If you are updating your process control system we recommend considering a reliable wireless connection.

Peter Hutwelker, President ES2 Inc.

Blower Pad & Flare Integration & Control – Pennsylvania

Blower Pad and Flare IntegrationSupplied by ES2:

Control system design & Integration: P&ID control for (2) flares and the blower skid. The blowers and flares are influenced by landfill vacuum applied to the well field as well as pipe line pressure. During normal operation the blower skid feeds gas to a compressor plant at a set discharge pressure, which than provides gas to various industries in the area. When the well field vacuum drops below –70” WC the system automatically starts one of the flares. If the vacuum set point is not reached within a pre-determined time, a second flare will go online.

[Read more…]

Landfill Gas Blower Control System—Pennsylvania

ES2 Landfill Gas blower control system


A Pennsylvania Landfill required a control system for a new blower skid. The blowers pull a vacuum on a portion of the landfill and push the gas to a 4000 SCFM flare and a power generating facility for a total flow rate of 12,000 SCFM. A control system was required to provide a safe, stable, continuous landfill vacuum and gas flow.

[Read more…]

Water Filtration System Controls—Pennsylvania

Water Filtration SystemDescription:

A Pennsylvania water treatment facility utilizes a sand filtration system on spring water. The original control system, installed in 1996 incorporated a small PLC with mechanical relays and timers, panel lights and switches. The system was unreliable and did not offer full auto/manual control over the process.

[Read more…]

Sulfuric Acid Pump Replacement – Pennsylvania

Description:Sulfuric Acid Pump

A landfill leachate treatment facility with an SBR (sequencing batch reactor), requires acid to control pH in the two 25,000 gallon reactor tanks. 93% sulfuric acid is stored in a 1,000 gallon polyethylene tank with pump suction lines pulling from the top of the tank (not a flooded suction). The pump discharge lines extend approximately 100ft to the top of the 20ft high reactor tanks, where the chemical is fed into the process.

[Read more…]

Spring (bottled) Water Pumping System – Pennsylvania

Spring Water Pumping System

Process Description:

A PLC based spring water pumping control system maintains water level in a storage tank. Water is pumped from a sump fed by the spring and overflowing to the existing creek. An ultrasonic flow meter monitors creek water flow over a weir. A VFD controls the pumping rate to maintain flow to the storage tank while not the allowing creek flow to drop below the permitted rate. A truck load-out station is monitored for flow and all process variables are data-logged to a memory card located on the HMI. A great deal of attention was paid to surge protection as the spring located at a high elevation in remote location.

[Read more…]

Cooling Water Analysis & Control System – New Jersey

Cooling Water AnalysisProcess Description:

A canning process incorporates (2) cooling water loops: (1) closed process loop and (1) open cooling tower loop. A system was designed and installed to monitor both loops for: pH, ORP and Conductivity. Each process variable was then used to control (7) chemical metering pumps feed various cooling water chemicals. A time-based proportional control was incorporated to pulse the metering pumps (on & off) for a time, proportional to the deviation from set-point, saving cost on metering pumps and eliminated the need for analog PLC outputs.

[Read more…]

Landfill Gas Blower Control System – Pennsylvania

Process Description:Landfill Gas Blower

Landfill gas is drawn from the well field using (2) blowers on variable speed drives (VFDs). The blowers feed landfill gas to (1) 2000 CFM enclosed John Zink flare. Wellfield pressure (vacuum) is controlled with a PID control loop, modulating the designated VFD and blower speed based upon feedback from a wellfield pressure transmitter. Blower surge protection was included in the PLC logic and alarms are transmitted on a wireless transmitter to SCADA system. The PLC logs all process variable data to a memory card.

[Read more…]

Landfill Gas Handling Control System—New Jersey

Landfill Gas Handling Control SystemProcess Description:

Landfill gas is drawn from the well field using (3) blowers on variable speed drives (VFDs). The blowers feed landfill gas to (2) 2000 CFM enclosed John Zink flares and to a pipeline feeding a local power generating facility. Wellfield pressure (vacuum) and flow to the flares are controlled with a unique cascade PID control loop modulating the designated VFD and blower speed based upon feedback from a wellfield pressure transmitter and the flare flow meter.

[Read more…]