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September 5, 2018
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New Locomotive Wash Bay Pump

A national railroad freight company called and requested a complete overhaul of their 40-year old locomotive wash. This 1970’s era locomotive wash system consisted of three different wash arches – a wetting arch to wet the locomotive, a second arch for soap application and washing, and a third arch with an acid wash for surface brightening.

The wash system was overhauled with to improve the following metrics:

  • Improve the wetting stage process by increasing both water volume and pressure as well as the nozzle design to apply the wetting water on the locomotive; and
  • Improve the soap application process by redesigning the nozzles’ flow patterns and volumes, increasing total flow to the nozzles, and finally adding additional pressure the process.

We started the overhaul process by removing the old soap and rinse pumps as well as the associated wiring and conduit. All of the existing control panels and associated conduit and wiring were also removed. Some equipment was retired in place to reduce demolition, re-piping and re-wiring costs. We then installed the following new equipment:

Locomotive wash bay control panel
Locomotive wash bay stainless steel control panel

Control Panel – A new stainless steel control panel was mounted, which replaced the existing four electrical panels. New conduit and heavier wire was also installed to bring it up to existing codes. The dual electric eyes were re-wired back into the new panel. New liquid level floats were installed in the storage tanks to provide both fluid level control, as well, as provide new a pump shut down safety, in the event of a low water condition in the water storage tanks.

Wetting Pump – A new 15 hp, cast iron pump was installed to supply water to the wetting arch. New, larger PVC piping as well as new heavier electrical wire was installed through new conduit to supply the proper amperage for the new higher horsepower pump.

Soap Pump – A new 15 HP stainless steel pump was installed for the new wash soap arch. New heavier wire was pulled through new conduit to supply the proper amperage needed for the new pump. The new pump was plumbed into the existing PVC piping in the pump house.

Wash Tunnel Nozzles – The existing nozzles could no longer be utilized due to flow and pressure differences from the new pumps. The existing nozzles were removed and replaced with a set of brass nozzles. A total of 42 new nozzles were installed in all three arches.

Rinse System Pump – The existing 100 hp motor and pump were removed and a new 25 hp motor and pump was set in place, aligned, and bolted to the exiting pump base.

Rinse System Control System – A new PLC-based control system housed in a stainless steel panel was installed and integrated with the existing control wires. New wiring was installed from the original motor controller system to the new control panel.

Rinse System Nozzles – The original nozzles, which were sized for the flow from the one hundred horsepower pump, were removed and new brass nozzles were installed.

The entire overhaul took less than a week to install and brought the whole wash system into the 21st century! The client has been very happy with its performance.


June 26, 2018
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Robustly designed for range of industrial applications from oilfield pipe washing to large equipment washing, our (PWS – Series) portable parts washing stands can provide an economical alternative to a concrete wash pad.

FEATURES:

  • Designed to be surface-mounted
  • No excavation required
  • Placed directly on top of existing surface
  • Built to any size and configuration
  • Fiberglass composite system consisting of a 1/4” steel plate core completely encapsulated in fiberglass
  • 12” high walls, various lengths & widths available
  • Easy to relocate by forklift without disassembly
  • Drain port for fluid removal or connection to plumbing
  • Simply maintained
  • Projected useful life of 15-20 years

ADVANTAGES:

Minimal site preparation, no excavation, fast, clean installation, immediate use, non-porous design, superior chemical resistance and portability are only some of the many our parts washing stand’s advantages.

Each parts washing stand is manufactured from heavy-duty fiberglass laminations completely encapsulating a steel core. The steel core makes it the most rugged and durable wash water containment system available today. This core keeps the spill containment system strong and flexible no matter what. In addition, each system includes (4) 1-1/2″ threaded coupling with 2 bronze ball valves for fluid drainage.

two removable pedestal frames

SUPPORT PEDESTALS

Inside are two removable pedestal frames to support the grates and raise equipment above the surface. Each system also has a 2″ divider wall running across the middle of the system to compartmentalize wash water or spills.

portable parts washing covers and walls

OPTONAL COVERS AND WALLS

To contain the wash water, the system is available with an optional 10′ high canopy mounted to the system. Each end is left open for access.

Fiberglass or poly walls are also available. They come in 4’, 6’ or 8’ heights and can be placed on 3 sides for efficient washing.

Interactive 3D Visual of our Portable Parts Washing Stands

Please click the image below to interact with the drawing. It may take a few seconds to load.

Give us a call for more product information – 800-453-8639


March 15, 2018
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This video shows our MM-20/1000 Mighty Monitor Demucker System in operation in northern Canada. Trucks come in caked with grit, frozen mud and snow.

Using the hand-held wand, the operators can easily vary the flow from stream to cone to safely and effectively wash all parts of the vehicle.

Since the MM-20/1000 produces a powerful 20 gpm @ 1000 psi stream, this type of cleaning is much quicker than using a standard pressure washer.

MM-20/1000 Mighty Monitor Demucker System

  • 20 GPM @ 1000 psi, demucking station
  • High efficiency diaphragm pump
  • 15 hp TEFC motor
  • NEMA 4X control panel
  • Pressure gauge
  • 50’ x 3/4” High Pressure Hose
  • Long range adjustable stream to cone, wand/gun assembly
  • Stainless steel frame
  • Utilities required Power: 480V/3 PH/60 Hz 25 amp; 230V/3 PH/60 Hz 50 amp
  • Approximate dimensions: 18” W x 60” L x 24”H

Call for more information at 800-453-8639.


March 8, 2018
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New CF-CP Media (Cross-Flow/Corrugated Plate) Oil Water Separator Media
Image of our New CF-CP Media (Cross-Flow/Corrugated Plate)
Oil Water Separator Media

In many washing applications, solids are a main component of the washing process. Heavy solids such as rocks and muck are often washed off and fall onto the wash pad where they can be easily removed. Other, finer settleable and suspended solids, however, often become entrained in the oily wash wastewater. Separating these settleable or suspended solids from the oily wash water is critical so that they do not clog the separator media and interfere with the oil water separation process.

To insure our oil water separators work well in a high solids environment without clogging, we have introduced a new coalescing media with a corrugated, cross-flow design.

This new media design is both unique and simple. As the water enters the separator, the flow is directed evenly across the surface of the media plates. The solids are captured and fall to the trough area of the corrugated plates below and the oils rise and stick to the trough area of the plates above. This design maintains laminar flow throughout the media so the oil and solids do not remix. Since the plates are smooth, the solids slide down the corrugated plates to the hopper area where they can be easily removed. Separated oil flows upwards along the plates to the top of the separator where it can be removed.

  • Available in stainless steel, PVC, HPVC and polypropylene
  • Plate spacing of ½”, ¾” or 1 ¼” depending on application
  • Supplied in blocks for easy installation and removal

By coupling high efficiency separation with easy maintenance, this new media will ensure your oil water separator
operates at peak performance for years to come.

Give us a call at 800-453- 8639 for more information!

CF-CP Media (Cross-Flow/Corrugated Plate) Oil Water Separator Media
Introduced a new coalescing media with a corrugated, cross-flow design.
CF-CP Media (Cross-Flow/Corrugated Plate) Oil Water Separator Media
Site View of our new coalescing media with a corrugated, cross-flow design.

February 5, 2018
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Oil Water Separator Forklift Solution
SPT Clarifier Oil Water Separator used for the Forklift Application Solution

Issue: A major forklift manufacturer had an old oil water separator which had failed. The source of the water was a combination of coolants, wash waters, mop waters, as well as a pressure washer water. Over a four-quarter period, the company’s routine certified quarterly wastewater testing results showed fat, oils, and grease levels of 350 to 1270 mg/l discharging to the sewer, which was well in excess of the local limit of 100 mg/l.

Solution: The following year, the company purchased a Wash Bay Solutions SPT-10 to replace the existing separator. Over the next four quarters, the FOG in the wastewater averaged 14.75 mg/l. The actual test results were: 21, 27, 0, and 11mg/l.

Industrial Manufacturing Plant Fat and Grease (mg/I) vs. Time Oil Water Separator replaced with Wash Bay Solutions SPT System

Oil Water Separator Solution

Due to the unique design of the SPT unit, it has more opportunity to separate oil and grease than the typical oil water separator. While the SPT is not designed to break an emulsion, due it’s multiple compartments, it can trap and hold back some emulsions. Since it introduction, the SPT has been shipped to many different countries throughout the world. Additionally, many Fortune 500 companies have standardized the unit in their facilities, plants, and processes.


October 3, 2017
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Washing the wings of an aircraft.
The aircraft washing process is often a combination of foaming, washing and rinsing with either hot or cold water.

Since one of the company’s owners has been a pilot and flying enthusiast for the past 40 years, we also have extensive experience with aircraft maintenance and cleaning applications. In addition to supplying washing systems to military bases all over the world, we have also provided systems to many aircraft maintenance companies stateside.

Manual Wash – The aircraft washing process is often a combination of foaming, washing and rinsing with either hot or cold water. Depending on the aircraft type and location, we can design a system based specifically on your application.

For the initial foaming, we offer a state-of-the art portable foamer with a chemical concentrate tank which can easily be moved to the desired location near the aircraft. The operator can select either hot or cold water from the remote switch at the reel. An injection system in the foamer blends the chemical concentrate from the tank into the water stream to create an accurately diluted solution. Compressed air is then injected into the solution to create a thick, clinging foam which is then projected through the discharge hose and foam nozzle on to large surfaces at distances up to 40-45 feet.

For washing and rinsing the aircraft, the operator can use pressure washer hose reel and gun assemblies normally located on both sides of the aircraft and select either hot or cold water. These pressure washing units typically provide approximately 8-10 gpm of water at 175-200 psi from each reel. They can be used separately or at the same time, and use either hot or cold water independently of the other. The flow rate and pressure can also be varied, based on your application.

The hose reel systems normally include remote control capabilities, and the system can be programmed to permit only foaming, washing or rinsing to occur at any one time so the maximum flow rate matches the water treatment system’s capacity.

Automated Wash – We also have engineered turn-key automated aircraft wash systems designed to efficiently wash a wide range of aircraft. The systems can be programmed with a number of potential aircraft wash profiles which can be selected by the pilot or ground personnel using either a PLC with PanelView screen or remote control. As the aircraft approaches the wash area, an infrared sensor system automatically starts the selected wash program.

The wash system typically consists of a low pressure undercarriage wash, a fully-automated side wash system for the fuselage and wings, automated actuator valves for flow direction and control, a heavy-duty supply pump system, and water storage tanks. All components are either stainless steel or non-ferrous for corrosion resistance. The systems can be configured to wash with either recycled water or fresh water, and often incorporate rainwater control capability as well.

Water Treatment – Wash Bay Solutions designs closed-loop reclaim systems to capture, treat, store, and deliver clean recycled water to the pressure washers. If sewer connections are available, sewer discharge systems treat the processed water before it is discharged to the sewer.

Total systems can incorporate ozone disinfection systems, fully automated valves for filter backwashing, PLC control of all filter functions, and all non-ferrous components and hardware.

The recycling system can include a fresh water bypass manifold system that enables an operator to manually switch the entire system over to fresh water if necessary or desired. The recycling system will also automatically replenish itself to maintain a minimum volume of water to make up for any losses to the system from evaporation or carry-off.

Consulting – We are also available to do consulting work with aircraft washing facilities to improve their washing, painting and wastewater processing procedures.


August 28, 2017

Case Study – University Test Tank

Problem: A technical university had a marine engine testing facility with multiple test tanks in interior and exterior rooms. The discharge from the engines was causing the water to get dirty so that the university was spending between $15-20,000 per quarter hauling water!

The interior rooms had sets of test tanks that could be manifolded together to be treated as one. The outside rooms did not lend themselves easily to manifolding the tanks together. They called us to develop a solution that would allow them to either treat and discharge the water to the sewer or recycle the water with no discharge.

Single Water Recycling System
Single Water Recycling System

Solution: After analyzing available options, we engineered and installed a single water recycling system adjacent to the building that was capable of receiving the water from all of the tanks at different times, removing the oils from the water, disinfecting the water, and returning the water to the respective tank system.

The tank manifold systems in the interior rooms are individually piped to the recycling system with a supply and return line. These attach to a dedicated automated valve system that is programmed to periodically select a specific tank system, draw out the water through the system and return it after treatment to that tank system. The PLC insures this sequence occur on a pre-determined schedule.

Piping drops were installed in the outside rooms so that a technician can manually place an oil skimmer assembly with an integrated suction/discharge hose assembly into any tank and send that water through the recycling system. A remote control panel allows the technician to start/stop the recycling system and to select a time period for the recycling to occur. Processed water passing through the recycle system is free of particles greater than 10 microns in size, substantially all emulsified oils, waxes and other volatile organic compounds.

The engineers at the university tell us that they are saving money and the system constantly “exceeds expectations”!


August 28, 2017
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VFD Controlled Pumping System
VFD Controlled Pumping System

The new FDA Food Safety Modernization Act (FSMA) rule on Sanitary Transportation of Human and Animal Food is now final under the FNA Docket Number: FDA-2013-N-0013.

The goal of this rule is to protect foods by keeping them safe from contamination during transportation.

The rule establishes requirements for shippers, loaders, carriers by motor or rail vehicle, and receivers in the United States involved in transporting human and animal food to use sanitary practices to ensure the safety of that food.

It also applies to shippers in other countries who ship food to the United States directly by motor, rail, ship or air, and arrange for the transfer of the intact container onto a motor or rail vehicle for transportation within the U.S., if that food will be consumed or distributed in the United States.

For more information, please see:
FSMA Final Rule on Sanitary Transportation of Human and Animal Food

Washing package for Sanitary Transportation

At Wash Bay Solutions, we have designed a pumping package for grocery and food shippers and distribution centers to comply with the new FSMA. We combined a high-pressure VFD-controlled pumping system with a high efficiency heating system to produce a sanitary washing package that will ensure compliance with the new rule.

The VFD system offers substantial operational flexibility since the system will only utilize the power (speed of motor and pump) to match the output demands. For example: A 20 gpm system, set up for 5 users at 4 gpm each. If there is only one user on the system outputting 5 gpm, the motor/pump will only turn at 1/5” speed to meet that demand.

Sanitary Washing Packages
Sanitary Washing Packages

Our sanitary washing packages come complete with hose, guns and reels and can be custom-engineered to meet your requirements for flow rates, pressures and water temperatures. To learn more about our high pressure clean system products, please click here:

VFD Controlled Multi-gun High Pressure Cleaning Systems

Give us a call at 800-453-8639 for more information!


July 10, 2017
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Back in the day… oil water separators were basically concrete vaults or steel tanks that were sized based on their total holding capacity. This holding capacity was related to the retention time needed to separate the oil from the water. Most cities and counties would size the oil water separators based solely on the square footage of area draining into the separator. This method, which rightfully erred on the side of caution, often tended to require facility owners to purchase extremely large separators.

Today… our oil water separators are engineered with multiple compartments and equipped with extremely efficient coalescing media to separate the oil from the water mixture in a much smaller system! Our media is capable of removing essentially all free and dispersed non-emulsified oils to an effluent concentration of less than 5 ppm. We now size our separators based mostly on oil viscosity and flow rate so they can be much smaller than they were in the past.

If needed, we can provide information and analysis to the regulatory agencies, which indicates that, at the calculated overflow rate, the separator will be properly sized and provided with the required square feet of projected plate separation area to achieve the specified performance under laminar flow conditions. Calculations shall take into account the rate of flow, potential surge flow, influent concentrations, particle characteristics, fluid temperature, fluid specific gravities, and PH.

Above Ground Oil Water Separators

We offer a complete line of high efficiency, stainless steel above ground oil water separators that will remove nearly all free and dispersed non-emulsified oil and settleable solids from the waste stream.

Read More About Oil Water Separators

Sewer Pre-Treatment (SPT) System Oil Water Separator Clarifier System for High Solids Applications

Oil Water Separator Clarifier System

The SPT Series Integrated Pretreatment Systems integrate an oil water separator with a clarifier to remove both floating oils and settleable solids.

Read More About SPT Series Sewer Pretreatment Systems

Below Ground Oil Water Separator

Below Ground Oil Water Separator Design
Featuring one of our oil water separator designs to be placed under ground.
Our single wall or double wall below ground parallel corrugated plate oil/water…

Read More About Below Ground Oil Water Separators

List of Different Kinds of Oil Water Separators:


July 6, 2017
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Locomotive train washing bay systems
Locomotive train washing bay systems

Our arch locomotive wash systems are very robust with high efficiency pumping systems, stainless steel control panels, galvanized arch piping, and stainless steel nozzles.

It can be designed with multiple arch systems for wetting, washing, and rinsing. For our three-arch system, the train passes through an initial wetting arch with a dilute soap mixture at a very slow speed. The train then moves through the wash arch, which sprays wash water with soap around the full circumference of the locomotive as it passes. At the exit end, the locomotive passes through the rinse arch, which sprays rinse water around the full circumference of the locomotive.

Nozzles in the arches are sized to provide more intense cleaning on the undercarriage and front while minimizing intense water intrusion on more sensitive areas of the locomotive. Depending on the application, total wetting, wash and rinse duration can run between 2-10 minutes.

Locomotive High Efficiency Pumping System
Locomotive High Efficiency Pumping System

These locomotive wash systems can be designed for manual or automatic operation. For a manual system, an onsite operator turns on and off the pump stations for the arches as the locomotive passes.

For an automated system, industrial infrared photocell systems are installed at the entry and exit of the wash building or arches to monitor train movement. The automated control system initiates the wetting, wash and rinse processes and automatically cycles the pumps as needed.

Depending on the application, the locomotive wash equipment provided may include:

  • Skid-mounted high-efficiency pump stations with heavy-duty wash and rinse pumps
  • Water supply tanks with level switches for pump safety and fill control
  • Industrial photocell system for start/stop
  • Traffic light for engineer to view
  • Master control system to manage pumps, chemical metering pumps, photocells, and lights
  • 360-degree arch systems with frames
  • Stainless steel manifolds and stainless steel nozzles
  • Soap metering system to manage soap concentration in wash system
  • pH control systems to manage pH fluctuations due to acids and cleaners
Locomotive Washing Systems
Locomotive Washing Systems

Additional controllers are available that would enable the wash process to start only for those locomotives that desired to be washed, while permitting other trains to traverse the building without starting the wash cycle.

Following the washing, the wash water can be treated for discharge to the sewer or reclaimed for re-use.


North Carolina

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At WashBaySolutions.com, we have been specializing in high tech, custom-engineered solutions to complex washing and wastewater issues since 1991.
+ 1 800-453-8639

WashbaySolutions.com

info@washbaysolutions.com

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