Solving Flow Monitoring Challenges for Reliable Operation and EPA Compliance

The facility faced a recurring operational issue with their equalization (EQ) bypass tank monitoring system. The mechanical float device installed on the bypass tank would occasionally hang up on internal tank structures, preventing consistent activation of the flow meter required for both regulatory monitoring and plant operation.

This type of intermittent failure creates multiple problems for wastewater treatment facilities:

• Compliance Risk: EPA NPDES permits require continuous and accurate monitoring of discharge flows. Gaps in flow measurement can result in permit violations and potential enforcement actions.
• Operational Uncertainty: Without reliable flow data, operators cannot make informed decisions about treatment processes or verify system performance.
• Maintenance Burden: Mechanical float systems require regular inspection and intervention, increasing labor costs and creating safety concerns when accessing tank internals.

Control Associates' technical team developed and implemented a replacement system utilizing a Dwyer OMEGA capacitive level switch. This solution offered several critical advantages over the previous mechanical float system:

• No Moving Parts: Capacitive level switches operate without mechanical components, eliminating the physical interference issues that plagued the original float system.
• Robust Performance: The technology is specifically designed to provide dependable flow meter performance in challenging wastewater environments where debris, foam, and turbulence can compromise mechanical devices.
• Reliable Activation: By eliminating mechanical interference, the system ensures consistent flow meter activation whenever the bypass tank reaches the monitored level.

Following integration, calibration, and verification of the upgraded monitoring system, the facility now experiences:

• Consistent Operation: The flow meter activates reliably every time, providing uninterrupted monitoring data.
• Reduced Maintenance: The elimination of moving parts has significantly decreased the need for intervention and adjustment.
• Greater Compliance Confidence: Continuous, reliable flow measurement ensures the facility maintains full compliance with EPA NPDES permit requirements.
• Enhanced Operational Control: Plant operators can now trust the flow data for making process decisions.

Flow monitoring represents one of the most fundamental requirements in wastewater treatment operations. EPA regulations mandate accurate measurement and reporting of discharge volumes to protect water quality. When monitoring systems fail—even intermittently—facilities face:

• Potential regulatory violations and associated penalties
• Inability to demonstrate compliance during inspections
• Compromised process control
• Increased operational stress and uncertainty

This project exemplifies Control Associates' practical approach to environmental compliance and process automation:

• Understanding Real-World Conditions: Recognizing that wastewater treatment environments present unique challenges that require purpose-built solutions.
• Leveraging Proven Technology: Selecting appropriate instrumentation based on reliability and proven performance rather than lowest cost.
• Complete Implementation: Providing full integration, calibration, and verification to ensure systems perform as designed.
• Long-Term Support: Offering ongoing technical support to maintain system reliability throughout its lifecycle.

With over 57 years of experience serving municipalities, manufacturers, and utilities across Ohio and Western Pennsylvania, Control Associates understands the technical and regulatory requirements that wastewater treatment facilities face. Our team specializes in:

• EPA compliance monitoring and reporting systems
• Flow measurement and calibration
• NPDES permit support
• Process control automation
• SCADA integration
• Remote telemetry systems

Whether you're facing flow monitoring challenges, seeking to upgrade aging instrumentation, or need support maintaining EPA compliance, Control Associates brings the technical expertise and practical solutions that keep critical operations running reliably.

Contact us today to discuss how we can help ensure your facility maintains continuous compliance while improving operational efficiency.