Instrument Controller Provides Online Monitoring and Control for Effluent Treatment at Tenmat

Tenmat, a leading UK manufacturer of fire protection materials, called on Pi via TC Engineering Services to provide a reliable, online monitoring and control solution for their effluent treatment process at their Irlam (UK) site.

The challenge included two key requirements, an accurate pH adjustment/correction and effective flow proportional flocculant/polymer control. Given the harsh operating environment, Tenmat also required a system that could minimise manual intervention while maintaining the highest standards of process stability and compliance.

To meet these needs, Pi supplied two pH sensors, fitted with automatic cleaning hardware for direct insertion into the serpentine DAF inlet line. One sensor was configured to control alkali dosing, maintaining the pH within strict limits, whilst the second sensor provided continuous monitoring, ensuring accurate tracking of system performance. Thanks to Pi’s AutoClean functionality, the sensors remain effective even in foul conditions. This significantly reduces the maintenance burden on site operators, who no longer need to manually clean the probes to maintain measurement accuracy.

The CRIUS®4.0 instrument controller receives a flow signal directly from the plant’s effluent line flow meter, and using advanced flow proportional control, the CRIUS®4.0 adjusts the dosing of flocculant to match process flow rates in real time. This not only ensures compliance but also helps optimise chemical usage, thereby reducing costs.

All system data including pH values, flow, and control signals activity are logged by the CRIUS®4.0  on an integral micro-SD card. This provides a full audit trail and visibility of process conditions. Additionally, the system is fully online, giving Tenmat engineers the ability to remotely monitor trends, adjust control parameters, and receive support directly from Pi’s in-house engineers. This remote access capability ensures rapid troubleshooting, minimises downtime, and provides peace of mind that the effluent treatment process is always under control.

By combining robust self-cleaning pH sensors with the versatile CRIUS®4.0 controller, Pi delivered a reliable and low-maintenance effluent treatment solution for Tenmat. With intelligent control, real-time data logging, and remote support, Tenmat has increased confidence in that their effluent treatment process is being managed efficiently and cost-effectively.

Click here to watch a short video on Pi’s sensor cleaning options. Contact us here if you think your system could benefit from Pi’s pHSense.