Wash Bay Solutions » Case Studies

Wash Bay Solutions offers an NPDES Permit Holder a Solution in a Box

admin — Wed, 28 Sep 2011 02:16:33 +0000

Case Study on a re-manufacturer of heavy duty electric motors

A West Virginia re-manufacturer of heavy-duty electric motors for both the industrial and the coal industries was having major issues complying with the latest EPA rules. In the mid 1980’s, they were granted a NPDES permit to discharge the treated wash water to a local tributary.

Over the years, the requirements for the permit grew tighter and tighter. By 2010, the permit requirements were becoming quite onerous. Some of the issues included:

Tighter limits of the original testing parameters and the addition of new requirements to test for metals
The ever increasing the cost of compliance (They were spending $1100/mo on water analyses)
The prospect they may not be granted a permit renewal.

They feared that they could be told to shut down the wash bay operations if they did not meet permit requirements. Shutting down the wash bay would cause many production issues and was just not a viable option. So they contacted Wash Bay Solutions for help.

We first reviewed their permit requirements, as well as reviewed their wash bay needs and facilities. One of their particular issues was a lack of extra plant space to house any additional treatment equipment. After a review of their wastewater analyses and understanding their production washing requirements, we recommended our closed loop water reclaim system that would eliminate the need for the NPDES permit. Additionally, we offered our Transportable Equipment Room (TER) that could be set outside adjacent to their plant. The TER was designed for tough winter weather conditions to protect the equipment from cold weather and freezing issues.

Once given the go ahead, the entire system was built a transportable equipment room and tested in our factory. The on-site installation was simple. Our customer ran utilities to the TER and within two days, their system was up and running. Their wash bay was never down and their production was never altered. Best off all, they no longer needed their NPDES permit and they were able to cut the pipe delivering water to the tributary.

Scratch one NPDES permit, the cost of compliance, and best of all, the fear of noncompliance. Not bad for a solution in a Box.

Transportable Equipment Room (TER)

Locomotive Wash Upgrade

admin — Mon, 30 May 2011 02:37:21 +0000

Originally, the first stage of the locomotive wash system consisted of three different wash arches. Circa 1970, this wash system included a wetting system to wet the locomotive, a second arch to apply soap and finally, an acid wash to serve as a surface brightener. The second original stage was a rinse arch system that included a 10,000 gallon storage tank, a 100 HP rinse pump, a rinse arch with galvanized nozzles and a 1970‘s vintage process controller.

Problem: The whole system was out-dated, expensive to run and maintain, and no longer performing efficiently. Many of the parts were hard to locate and expensive, while environmental issues long ago decommissioned the acid arch. The wetting portions of the wash performed very poorly. And the dated pumps were simply worn out. Finally, 1960’s vintage control panels were outdated and hard to maintain.

Solution: Engineers used as much of the existing components as possible and integrated new equipment, piping, and wiring. The overhaul process consisted of the following tasks:

A comprehensive study was conducted of existing wiring in order to integrate the new control panels into the system
New stainless steel control panels were installed with new conduit and heavier wire to supply the proper amperage needed for the new pumps.
New high efficiency pumps were installed with new Schedule 80 PVC piping tied into the existing PVC pipe.
The existing nozzles were removed and replaced with re-engineered nozzles.

Due to budge and time constrains, this entire project, from initial engineering investigation to design to construction to start-up, was completed in just 90 days.

During that time, the maintenance personnel were able to continue working. The client reports that the locomotives washing is much more thorough and efficient.

Municipal Waste Management Truck Wash Facilities

admin — Wed, 22 Apr 2009 01:07:48 +0000

Wash Bay updates for automated truck wash tunnel.

PROBLEM: A new municipal waste management truck wash facilities needed several large water recycling systems to handle the high volumes of water needed for their automated truck wash tunnels. The new facilities required up to 600-gpm of recycled water.

In addition, the systems needed to collect and isolate heavy solids loads, provide strong disinfection for odor and bacteria/BOD control, and filter the water adequately for reuse.

SOLUTION: Washbaysolutions provided 600-gpm engineered systems for each location to collect, treat, disinfect, and store clean recycled water for reuse. Large conical-bottom tanks assisted with the extensive solids removal required, along with screen and basket systems and in-line filters. A large ozone disinfection system was utilized to control the odors and organic contamination.

Automated solids transfer pumps, programmable controllers, and an automated fresh water makeup system enabled the equipment to treat and maintain sufficient clean recycled water for continuous truck wash operation.

DATE INSTALLED: April 2009

RESULTS:The initial two locations have operated successfully since 2003 without any major problems. As the facility maintenance personnel became familiar with the operation of the system and its capabilities to handle the large solids loads, the quality of the recycled water soared above their initial expectations.

Marina Water Recycling Systems

admin — Mon, 13 Apr 2009 01:01:51 +0000

Water Recycling Units for new Florida Marina.

PROBLEM: A large new Florida marina needed to provide clean recycled water to 18 boat wash hose locations for hull cleaning. Since no city sewer was available, all water had to be captured and recycled.

The marina wanted the system to operate 24/7 with minimal maintenance and constant exposure to the heat, sun, humidity, and salt air.

SOLUTION: Washbaysolutions designed a 200-GPM closed-loop reclaim system to capture, treat, store, and deliver clean recycled water to the hose bibs.

The system incorporated a large ozone disinfection system, fully automated filter valves for filter backwashing, PLC control of all filter functions, and all non-ferrous components and hardware.

The system also incorporated a rain detection system to manage excess rainwater in the collection system, and a fresh water makeup system to compensate for evaporation losses.

DATE INSTALLED: April 2009

RESULTS:The customer is very happy since the system has operated continuously since start-up with no downtime. It continues to deliver extremely clean recycled water. Average maintenance time is minimal.

Construction Mining Equipment Transportable Wash Bay

admin — Fri, 20 Feb 2009 01:16:27 +0000

Location: Eastern Tennessee

PROBLEM: A rural large distributor of construction and mining equipment was cleaning their equipment on an uncovered wash pad. The combination of the equipment washing and rain water accumulation often caused the pad to overflow into a nearby canal, creating environmental concerns. The company was seeking a solution that would eliminate the overflow problem, completely recycle all their wash water, and require minimal new site construction. They also needed a system that would be easy to move since their corporate officials were looking at new facilities.

The customer needed two types of cleaning systems – high volume washdown for heavy solids removal and hot water pressure cleaning for grease and oil removal. The facility also needed a completely self-contained water recycling system since there was no sewer connection and rainwater detection and water level controls to eliminate the wash pad overflows.

SOLUTION: The site was an excellent candidate for the WWMI TWP System – a transportable equipment room containing all washing and recycling equipment needed to completely collect, store, treat, and redeliver the water for all cleaning requirements.

The 40-foot modular equipment room contained a 20 GPM, 300 psi Demucking System, a 4 GPM, 3000 psi electric hot water pressure washer, closed loop recycling system with 1500 gallons of processed water storage, and a Rain Detection System (RDS). The entire Transportable Wash Bay (TWB) System was shipped intact and pre-tested, enabling the client to rapidly put it into operation. The integrated RDS System provided for the capture of all contaminants in the water during a rain event, and allowed only clean storm water to divert to the adjacent canal.

DATE INSTALLED: February 2009

RESULTS: The client has utilized the system without any environmental or operation problems for over 1500 hours/year. They use the Demucking System 80-85% of the time to clean their equipment, minimizing the need for high pressure. The adjacent canal is now clear and pollution-free.

Truck Repair Facility

admin — Mon, 12 May 2008 00:47:19 +0000

Truck Repair Facility uses the Oil Water Separator to recycling the oily water when the trench was full.

Location: Morganton, NC

PROBLEM:
The facility had an old oil water separator system that was no longer working well. City environmental officials had visited the facility and mandated that the facility install a new system.

Since this facility was discharging to the city sewer system, city officials gave them a very short period of time to correct the situation.

SOLUTION:: Using their existing trench system, we designed an automatic pump transfer system that would transfer the oily water to the new oil water separator when the water in the trench got to a certain height.

Since time was an issue, we modified our production schedule to meet the city’s installation date demands. Funding was also an issue so we also worked with a leasing company to secure a simple, short-term equipment lease for the customer.

DATE INSTALLED: May 2008

RESULTS:Customer is very pleased with the system and city environmental officials are happy with the effluent from the oil water separator.

Regional Car Dealer and Repair Facility

admin — Mon, 10 Mar 2008 00:55:37 +0000

New wash bay piping for the car dealership

PROBLEM: As part of a Phase 1 audit for a purchase transaction, engineers discovered that old piping within a car dealership service bay was discharging wastewater to the local stream. The environmental audit company and the car dealership enlisted our help to design new wash bay piping and install a new sewer pretreatment system.

SOLUTION:: The car dealership had multiple wash bays and a large service area. We worked with the environmental engineers and plumbing contractor to design and install a new under-concrete piping system with our sewer pre-treatment system. The new piping system will collect oily wastewater from all of the wash bays and service areas and send it to the SPT Series system to be processed before discharge to the sewer.

DATE INSTALLED: March 2008

RESULTS:The purchase transaction was smoothly completed and the facility is operating well within environmental regulations.

Installation for a Sewer Pretreatment System at a Car Dealership.

Truck Services Company Wash Bay – Oil Water Separator

admin — Tue, 15 May 2007 03:25:05 +0000

Oil Water Separator used for truck service company

Location: Sanford, NC

PROBLEM:
A major truck services company was constructing a new wash bay at their facility outside city sewer limits. They enlisted our help to design and install a closed loop system so they could recycle the wash water.

SOLUTION: : After visiting the site and talking with the service manager, we met with the local POWT officials who approved our Model VR/SPT-10 closed loop system for this location. We then met with the design engineers and construction managers to develop and efficient wash bay design for their busy wash operations.

The VR/SPT-10 closed loop recycling system is a complete self-contained system, capable of feeding up to 10 gpm to the pressure washer. It incorporates an extremely efficient patented filtration process utilizing fully automated solids filtration and activated carbon (GAC) polishing filtration. The VR series also comes standard with a corona discharge ozone generator to prevent odors. The clarifying oil water separator section will remove all settable solids and non-emulsified oil from the waste stream. All features of the system are designed and constructed to insure superior performance and minimal operating requirements while delivering a superior quality wash water.

DATE INSTALLED: May 2007

RESULTS: The client is extremely pleased with the equipment and the overall relationship. We also provide a monthly inspection of the system which helps the service personnel maintain the system more efficiently.

Forklift Dealer and Repair Facility

admin — Sun, 22 Apr 2007 00:39:39 +0000

Forklift Dealer has an SPT-10 Sewer Discharge System installed.

Location: Springdale, AR

PROBLEM:
During construction of a new wash bay facility, a forklift dealer/distributor enlisted our help to design a wash bay and install a sewer pretreatment system. While testing the SPT-10 Sewer Discharge System for the initial start-up, we discovered that the wash bay sump pit had a slow but potentially dangerous leak. This leak, if not corrected, would have lead to groundwater contamination with oily waste water and wash water from batteries. This deficiency had to be corrected prior to use of the wash bay.

SOLUTION: The fix needed to be permanent and 100% effective to protect the customer’s interests. If a leak contaminated the ground water and associated soils, clean-up could cost tens of thousands, if not hundreds of thousands of dollars.

Several solutions were developed including lining the sump with a water-proof grouting material, installing a stainless steel liner in the sump, and re-pouring the concrete. After analyzing all of the solutions, they decided that the water-proof grouting option would provide the best protection for the money.

DATE INSTALLED: April 2007

RESULTS: Since the problem was caught before washing operations commenced, no dirty, oily water leaked into the groundwater and no contamination occurred. The customer is very happy with the sewer discharge system which was designed to automatically pull water from the sump.

Heavy Equipment Wash Bay- Wash/Rinse Sewer Pre-Treat System

admin — Wed, 15 Dec 2004 03:19:07 +0000

Oil Water Separator used for the case study.

Location: Cary, NC

PROBLEM: This project was unique in that it was located in one of the strictest wastewater authorities in the state of North Carolina. During construction of a new wash bay facility, a major heavy equipment dealer/distributor enlisted our help to design and install a sewer pretreatment system.

OPERATING REQUIREMENTS: Required sewer pretreatment water recycling systems, 10-gpm flow rates with odor elimination; minimal system maintenance; fully automated filtration operation; large volume oil removal capability, heavy solids handling capacity, high-volume hot water pressure washing and 30-gpm demucking equipment.

SOLUTION: After visiting the site and talking with the service manager, we met with the local POWT officials who approved our Model VSD/SPT-10 sewer pre-treatment system for this location. This system is a complete self-contained system, capable of feeding up to 5 GPM to the pressure washer. It incorporates an extremely efficient patented filtration process utilizing fully automated solids filtration. The VSD series also comes standard with a corona discharge ozone generator to prevent odors. The clarifying oil/water separator section will remove all settable solids and non-emulsified oil from the waste stream.

Sewer Pre-Treatment System used for the case study.

Following installation, we completed the permit application for our customer and coordinated the filing with the city officials. Due to the complex permit requirements, we met with the local POWT officials several times during the construction period. As a requirement of the permit, the city required a $3,000 non-resettable, non-contact water meter. After numerous communications, we convinced the city that a $800 unit would work just as well – saving our customer $2,200 on a water meter!

DATE INSTALLED: December 2004

RESULTS: The client is extremely pleased with the equipment and the overall relationship. We now help coordinate the permit-required monthly water analysis for our customer – and they have been well within compliance limits every month. In fact, the City of Cary dramatically reduced our testing requirements after a couple years due to the consistently good analytical results indicating low Oil & Grease and Metals’ levels as well as low daily volume discharges.

PERIODIC MAINTENANCE REQUIRED: Averages 5 man-hours/month

ANNUAL PARTS AND FILTER COSTS: Approximately $1100