Latest Case Studies & White Papers

“Low-speed machines like our sewage sludge dryer are difficult to monitor with vibration measurement technology. With SONOTEC's ultrasonic technology, it was possible to detect roller bearing damage and assess its condition," says Tobby Brümmer, Head of Machinery Maintenance at PD Energy GmbH

Ultrasound is the technology for the first step in damage detection and has the advantage over other methods in that it can be used at all bearing speeds. Even with extremely low-speed bearings, damage can be detected at the earliest possible stage.

Focus on sewage sludge incineration

As a 100% subsidiary of PD energy GmbH, KSR sewage sludge recycling Bitterfeld-Wolfen GmbH operates a mono sewage sludge incineration plant in the Bitterfeld-Wolfen chemical park. The plant is designed for a rated thermal output of 19.9 MWth. Running more than 8,000 hours a year, the incinerator consumes up to 260,000 tons of dewatered sewage sludge from municipal sewage treatment plants. The thermal utilization of sewage sludge in mono-incineration plants will be an important disposal path in the future. With the construction of the plant, KSR sewage sludge recycling Bitterfeld-Wolfen GmbH is making a contribution to the phosphorus recovery that will be required in Germany starting in 2029. The finite resource is filtered out via various systems and fed back into the material cycle.

Slow-speed disc dryer

The core process in the treatment of sewage sludge is drying. Two disc dryers are used at the site for this purpose. The redundancy of the systems is important so that one dryer can always process sewage sludge. However, the system capacity is designed in such a way that both dryers are always running, if possible, in order to be able to achieve the appropriate utilization. Downtimes must be kept as short as possible, and if they are necessary, they should only affect one dryer at a time. "The availability of both disc dryers is extremely important to us," says Tobby Brümmer, Head of Machinery Maintenance at PD Energy GmbH. In the disc dryer, the material is slowly transported from one end to the other, reducing the residual moisture. Disks heated with steam form a large contact surface where indirect drying takes place. Scrapers ensure an even process and transport of the material. The rotor turns very slowly with only 7.5 revolutions per minute.

Roller bearing damage detected and evaluated

During the commissioning phase, noises were detected on a roller bearing on one of the two dryers, whereupon a vibration measurement was initiated. “The results of the vibration measurement were not useful for us. They showed no indication of damage to the examined roller bearing,” says Tobby Brümmer. After a short research it was clear that ultrasonic measurement technology could help. "We then contacted SONOTEC GmbH and asked for a measurement using ultrasonic technology," adds Tobby Brümmer.

During the on-site measurement, the damage could be narrowed down to the corresponding roller bearing. The measurement effect was clear and in comparison to the second dryer, a statement about the severity of the damage could be made on-site.

The subsequent evaluation by the application engineer from SONOTEC provided further insights. Tt could be confirmed that the damage to the roller bearing had to be severe and very advanced. Furthermore, the data analysis revealed that the outer ring must have been severely damaged and, in particular, that one race of the double-row bearing was more severely affected. “Such details are extremely important for us to be able to identify the causes as precisely as possible. This is the only way to take appropriate preventive measures to prevent the problem from reoccurring,” says Tobby Brümmer.

Solution for slow-movers: condition monitoring with ultrasound

The advantages of ultrasonic testing technology from SONOTEC are very apparent in this application. The broadband data evaluation enables an optimal adjustment to the conditions on site. In this way, characteristic values ​​can be calculated in the range from 20 kHz to 128 kHz. Frequency ranges with background noise can be suppressed with the adjustable filter function. The high sensitivity of the sensors enables early detection of roller bearing damage, making ultrasonic monitoring a very effective solution, especially for slow-running roller bearings. “We are excited about the statements that can be made with the help of the ultrasound data. Ultrasonic roller bearing monitoring will be an integral part of our maintenance measures for our slow-moving machines in the future,” explains Tobby Brümmer.

SONAPHONE: A modular approach with different apps and sensors

With the ultrasonic testing technology from SONOTEC, other applications in preventive maintenance can also be performed. The device makes it possible to locate and evaluate compressed air leaks, and steam traps can be tested and their condition evaluated. Both applications are moving more and more into the focus of many companies due to ever increasing energy costs. "We are also interested in the other possible applications of ultrasonic technology," says Tobby Brümmer.

With various apps and corresponding sensors, the ultrasonic testing device SONAPHONE can be easily adapted to the respective application. “This means that the investment in the testing equipment pays for itself very quickly. And the device is better utilized by using different departments. It is used between the regular routes on the disk dryers for other applications," says Tobby Brümmer.

Interview partner: PD energy GmbH, Tobby Brümmer, Head of maintenance for machine technology

Find more about SONOTEC here: https://www.sonotec.eu/en/

KSR sewage sludge recycling Bitterfeld-Wolfen GmbH (Source: PD Energy GmbH)

Data acquisition at the disc dryer (Source: SONOTEC GmbH)

Mapal has surpassed its fund target of £400,000 via Crowdcube, with 475 new investors choosing to inject over £467,000 into the business that has completed over 100 installations of its energy-saving, wastewater aeration solutions.

Due to the high demand, the deadline to invest was extended by 14 days as more and more parties expressed their interest in becoming part of the Mapal success story, which has seen projects delivered worldwide, including the UK, Australia, Israel, South Africa, and Chile - with critical acclaim.

Mapal’s Chairman/Director, Ilan Diamond, commented: “It is very encouraging to not only achieve our target, but beat it.  Investors can clearly see the major benefits and huge potential of our innovative systems that are 50-60% more efficient than traditional mechanical surface aeration.”

He added: “As well as providing general working capital, this new boost in funds will enable us to further develop our sales and marketing teams. We can also fund a pre-sale trial (rental) fleet and continue to develop our key research into ammonia removal in aerated lagoons.”

Diamond explained that while some aeration methods partly address higher than ever energy (and maintenance) costs of conventional surface treatment, they often require very specific conditions. This can prove price-prohibitive as a new-build, and requires the process to be shut down for upgrades, resulting in costly and potentially damaging downtime. In contrast, Mapal’s floating and retrievable fine-bubble aeration solutions, which do not need a levelled floor, can be installed and maintained while the plant is operating; without personnel having to enter the wastewater.

mapal-ge.com

this article can also be found in the issue below.

There has been considerable growth in the wind power industry over the past few years. However, further exponential growth of the industry is required in order to ensure that the net-zero by 2050 pathway (outlined in the Paris Agreement) is successfully reached.

Figure 1 - Maintaining the integrity of wind turbines with polymeric technology

In order to support this seismic growth, polymeric repair and protection technology has an important part to play. Designed to safeguard the integrity of wind turbine blade leading edges for the long term, this technology plays a critical role in supporting this burgeoning industry.

Wind Electricity Generation Needs to Grow Fourfold by 2030

According to the International Energy Association’s (IEA) Wind Electricity Tracking Report

(September 2022): “In 2021 wind electricity generation increased by a record 273 TWh (up 17%). This was 55% higher growth than that achieved in 2020 and was the highest among all renewable power technologies.”

While the industry has undoubtedly experienced impressive levels of growth in these years, according to the IEA, wind electricity generation needs to reach four times the record levels set in 2020 by 2030. The Report said: “Our pathway calls for scaling up solar and wind rapidly this decade, reaching annual additions of […] 390 GW of wind by 2030”.

Figure 2- Wind electricity generation needs to grow fourfold by 2030 (IEA. License: CC BY 4.0)

How is the Scale-Up of the Wind Industry Being Financed?

According to the IEA’s Report: “Policy support remains the principal driver of wind deployment in the majority of the world.” Indeed, over the past few years, several policies have been launched that are designed to drive forward the roll-out of renewables.

For example, in August 2022, the US brought in the Inflation Reduction Act (IRA) which includes $369 billion (US dollars) of investment, in the European Commission’s Green Deal Industrial Plan, $270 billion (US dollars) was pledged, and since the UK government’s Ten Point Plan was launched in November 2020, over £26 billion of government capital investment has been mobilised.

Safeguarding Expanding Fleets of Wind Turbines with Polymeric Technology

Given the critical role wind power plays in the transition to a net-zero future, as well as the significant amount of capital being invested into the renewables industry, the wind power sector is poised to experience considerable exponential growth in the upcoming decades. In order to support this growth, polymeric technology plays a significant role when it comes to maintaining the operational efficiency of the rapidly expanding fleets of wind turbines.

Polymeric systems such as the rebuild, blade filler material, Belzona 5711 and the cartridge-applied leading edge protection coating, Belzona 5721, are specially designed to repair damaged leading edges and protect them against rain erosion and impact damage for the long term.

In addition to the performance capabilities of these systems, maintenance engineers are investing in this technology due to the simple, in-situ application method and fast cure times the cold-curing systems facilitate. In turn, this helps to keep downtime to a minimum, and allows the turbine to be returned to service in the same day.

Belzona 5711 can be directly overcoated with Belzona 5721 in as little as 30 minutes at 20°C/68°F without the need for any additional surface preparation. At the same temperature, Belzona 5721 will be fully cured within five hours.

Below is a case study featuring the repair and protection of a wind turbine leading edge with Belzona 5711 and Belzona 5721.

Wind Turbine Blade Repaired and Protected

Belzona, a global designer and manufacturer of industrial protective coatings and repair composites, successfully addressed the wind turbine blade damage issue at Electricity Generating Authority of Thailand’s (EGAT) Khao Yai Thiang Windfarm in Thailand.

Figure 3 - Leading edge damaged by erosion

Leading Edge Erosion Damage

The windfarm features wind turbines with 40-metre-long (131.2 ft) blades. During routine inspections, evidence of damage measuring 300 cm x 14 cm x 2 mm (118 in x 5 in x 0.08 in) on the leading edge of one of the blades was discovered.
System Selection

Representatives from the 35-year-old Belzona Authorised Distributorship, Pan Mechanic Engineering, recommended the solvent-free, two-part repair paste, Belzona 5711, to reconstruct the damaged area on the blades, followed by the high-performance coating, Belzona 5721 , to overcoat the area.

Application Procedure

The application procedure involved surface preparation using an orbital sander, followed by the direct application of approximately 1.4 kg (3.1 lbs) of Belzona 5711 from a self-mixing cartridge onto the blade. The repair area was contoured using a piece of Belzona mixing board.

Figure 4 - Surface preparation using an orbital sander

Figure 5 - Self-mixing Belzona 5711 cartridge

After a two-hour curing period, a visual inspection was conducted to ensure the application's readiness for overcoating with approximately 3.5 kg (7.7 lbs) of Belzona 5721. Using a short-bristled brush, this system was then applied to the leading edge and left to cure. The blade was

back in service 24 hours later.

Figure 6 – Application of repair paste, Belzona 5711

Addressing the fast-rising cost of energy is rightly high on today’s agenda, so when four hefty 40HP rotors serving one’s aeration plant are also sitting at the top of your maintenance budget, finding a better means of mixing certainly concentrates the mind.

In Huntsville, Arkansas, the route to achieving optimum mixing of its oxidation ditches has been a marathon, not a sprint; but this meticulously operated wastewater treatment plant is now reaping the rewards of significantly reduced horsepower and reduced repair costs.

Managing oxygen levels at Huntsville has been a major, fluctuating challenge, especially with the wastewater taken in from a large-scale food manufacturer, nearby.

The 160HP (total) rotors had to run 24/7 in order to sufficiently mix and add oxygen to Huntsville’s WWTP aeration basin, but when the expanding food manufacturer upgraded its own treatment plant, the problematical rotors were creating far too much oxygen; contaminating the anaerobic and anoxic zones.

“We had to find a new, sub-surface means of mixing our oxidation ditch”, commented Bill Eoff, Wastewater Manager at Huntsville.

“And as we only have the one oxidation ditch”, he said, “this presented the extra challenge of finding mixers that could be installed without there being any interruption to our process”.

Bill and his Water Department Director, Sean Davis, had tried pulsing the rotors on timers, and had also been having to feed in chemicals at additional expense to balance out the process, so that the ratio of BOD to ammonia could be harmonized, but to no avail. So, they consulted with their local equipment representative, Instrument & Supply, who have been working with Huntsville for over 20 years.

“We believed that by far the best solution for the plant was to separate the aeration and mixing functions; and that included mixers made by Landia. This provided a subtle, but highly effective solution”, said Chris Enloe from Instrument & Supply.

“We were very confident of our recommendation; plus, the fact that no other mixer manufacturer could, or was prepared to install their mixers without draining down the tank, which was not an option at Huntsville”.

‘Sledgehammer!’

At first, to some, the installation of a mixer to a full and operating ditch might sound rudimentary, especially with what includes about twenty solid blows with a sledgehammer (!), but in keeping with Landia’s long-established designs, no-nonsense simplicity often proves best. Actually, there’s real precision in ensuring that the (pre-marked) guide spike is installed plumb; approximately half an inch into the base, with the mixer on the guide pipe set at nine inches above the base of what is typically an eight- or nine-feet deep ditch. Installation takes just two to two and half hours.

Chris Enloe added: “The team at the plant had to work without the benefit of grants or loans that come with a new design. Everything was funded piece by piece on cash reserves. This made the task all the more trying; for example, keeping the rotors until such times that a second blower could be purchased, in order to meet the state’s requirement for redundancy to be in place”.

‘Big win for the City’

Sean Davis, Huntsville’s Public Works Director, continued:

“The rotors were proving costly and time-consuming to maintain, especially the gearboxes, but although the changes we needed to make to meet our treatment needs took longer than we would have liked, it has already resulted in a 15% reduction in our energy costs alone. This is a big win for the city. In total, the 160HP of course used up a huge amount of resource. The blower is 100HP, but is only needed 25 per cent of the time – and the mixers at just nine HP each (36HP in total) are in comparison, extremely efficient and very effective indeed”.

Bill Eoff added: “Running 24/7, for over five years with no major issues, the Landia mixers have been a great investment. We pull them up every six months to change the oil and grease them – and that’s basically all the maintenance they need. We’re very happy with them. We know that there will inevitably we some wear and tear with shims and seals that over time need to be replaced, but overall, they are very easy to maintain. In five years, we’ve spent less than $3,000 on spares. This is a world of difference compared to the rotors, which no longer provide value.  As well as the help we’ve had from Instrument & Supply, Landia have been very supportive throughout, from start-up to supervising our first service – and much more with additional advice and training. They were and still are determined to help us succeed”.

‘Supports the greater Community’

Chris Enloe concluded: “Huntsville did not have the option to build a new plant, but with real determination they now have the tools to effectively operate the plant within permit – without breaking the bank. This supports the greater community by working together with its neighbors, including the food manufacturer, which is very important to the local economy. The result demonstrates just how good the Landia solution fits within the many constraints that are in Huntsville. Rightly so, the team at the wastewater treatment plant are very proud of their work”.

Introduction

Hydropower is a renewable energy source that has been harnessed for thousands of years. Today, it is one of the most important sources of electricity in the world, and its use is only expected to grow in the future. One of the key components of the hydropower industry is the use of epoxy coatings, which are used to protect the machinery and infrastructure used in hydropower operations. In this blog post, we will explore the role that epoxy coatings play in the hydropower industry and the benefits they provide.

Figure 1 Grand Coulee Dam in the United States

The Benefits of Epoxy Coatings in Hydropower Operations

Epoxy coatings are a popular choice for use in the hydropower industry because of the many benefits they provide. One of the primary benefits of epoxy coatings is their ability to protect machinery and infrastructure from corrosion. Corrosion is a major problem in hydropower operations because the equipment used is often exposed to water and other corrosive substances. Epoxy coatings provide a protective barrier that prevents corrosion from occurring, which helps to extend the life of the equipment and reduce maintenance costs.

Another benefit of epoxy coatings in hydropower operations is their ability to provide a smooth surface for water to flow over. This is particularly important in turbines, where a smooth surface is essential for optimal operation. The use of epoxy coatings can help to reduce friction and improve the efficiency of the turbine, which can lead to increased power generation and lower operating costs.

Finally, epoxy coatings are also resistant to high temperatures and can withstand exposure to UV radiation. This makes them an ideal choice for use in the harsh environments found in hydropower operations, where machinery and infrastructure are often exposed to extreme temperatures and intense sunlight.

Hydropower Industry Case Study

Belzona had the opportunity to improve the condition of a 60-year-old Kaplan hydropower unit that was showing signs of wear and was due for a full mechanical overhaul.

Operators at the Hydropower Plant grit blasted and cleansed the unit with solvent. Belzona 1111 (Super Metal) was used to smooth over the wear and cavitation in a full skim coat. Once cured, the Belzona 1111 (Super Metal) was sanded down to the required profile, and frost blasted. Two full coats of Belzona 1341 (Super Metal Glide) were applied. The coating can provide increased efficiency on new and refurbished equipment while also providing full corrosion and erosion protection while immersed.

Surviving 60 years with minimal wear is impressive. However, by using Belzona 1341 (Super Metal Glide), the unit can continue to operate for many more years, providing reliable service and cost savings over the long term. The use of this product can improve the unit's resistance to wear and tear and can also provide an additional layer of protection against environmental factors such as moisture and chemicals.

Figure 2 Hydropower unit during surface preparation for Belzona 1111 (Super Metal) application

The Future of Epoxy Coatings in the Hydropower Industry

As the demand for renewable energy sources continues to grow, so too does the necessity for hydropower. This is expected to drive an increase in the use of epoxy coatings in the hydropower industry, as more and more equipment is needed to meet the growing demand for electricity. In addition, advances in epoxy coating technology are likely to make them even more effective at protecting machinery and infrastructure from corrosion and other forms of damage.

One area of particular interest is the development of epoxy coatings that are more environmentally friendly. As the world becomes increasingly concerned about the impact of industrial processes on the environment, there is a growing demand for coatings that are engineered with plant-derived ingredients. The Belzona Research and Development Team are currently in the process of formulating products made from bio-based materials that are produced from sustainable plant-based feedstocks, rather than the traditional fossil-fuel based ingredients.

Conclusion

Epoxy coatings play a critical role in the hydropower industry, providing protection against corrosion, improving efficiency, and withstanding the harsh environments found in hydropower operations. As the demand for renewable energy continues to grow, the use of epoxy coatings in the hydropower industry is expected to increase, and advances in technology are likely to make them even more effective. By working together, the hydropower industry and coating manufacturers can help to develop coatings that are both effective and environmentally conscious, ensuring a sustainable future for the industry and for the planet.

Lubrication is one of the most important success factors for time and cost-efficient maintenance. It is critical for low-friction and therefore energy-efficient machine operation and can contribute to greater sustainability in production. Incorrect lubrication is one of the most frequent causes of rolling bearing damage and machine failure. 

Schaeffler’s new white paper entitled “Can lubrication be easy and sustainable?” focuses on lubrication systems and lubricants, highlighting what is important when it comes to lubrication. The aim is to help you lubricate your machines more sustainably and cost-effectively, simplify your maintenance processes and prevent machine downtime.

The white paper will help you to discover how modern lubrication technology can pay off for your business; how lubrication systems can make your processes easier and more environmentally-friendly; and what you should consider when changing lubricants.It includes basic knowledge, expert tipsand guidance, as well asnumerous practical examples from a range of industrial sectors.

Automatic lubrication systems

In many companies, it is still common practice to lubricate machines manually with a grease gun. Not only is this time-consuming and sometimes involves working in hazardous areas, it also entails risks such as over-lubrication or lubricant starvation, as well as the use of inadequate types of lubricant. Automatic lubrication systems can eliminate these risks and offer additional significant benefits.

Looking for the answers? The white paper answers four key questions surrounding modern lubrication:

Lubrication can be a curse or a blessing. Sometimes it’s just small details that make the difference between failure-prone production and smoothly running operations. The latter can often be achieved with fairly manageable investments, so take a look at the new white paper and see where your operations may benefit.

This article can also be found in the issue below.

Hoist & Winch Ltd has recently completed a challenging project for one of the UK’s biggest construction companies involved in large-scale new home development projects. Faced with a demanding and highly technical brief, Hoist & Winch rose to the task, providing a turnkey lifting system solution to ensure complete success for its client.

The requirement was to install a concrete ceiling mounted 7.5t swl (safe working load) lifting beam and manual chain hoist into the basement energy room of a large new tower block. This development is part of a large-scale prestigious regeneration project providing 5500 sustainable new homes in North London. 

At the design stage, following formal tender and contract award, Hoist & Winch set about identifying the optimal solution. Due to restricted access into the basement area, the company decided to utilise a two-piece lifting beam design with an overall length of 7m. To join the two lifting beam sections, Hoist & Winch designed a central splice joint of bolted construction with a reinforced bottom beam flange.

In order to spread the lifting loads over a greater area of the concrete ceiling slab it was decided to mount the lifting beam via four intermediate cross members, each having a four-bolt/anchor fix into the concrete ceiling at both ends. Featuring a robust bolted construction design it was possible to deliver the lifting beam to site in fully dismantled form for ease of transportation and access.

M24 resin anchors with an embedment of 255 mm into the 400 mm deep reinforced concrete slab fixed the intermediate cross members directly to the ceiling for maximum security. 

​​​​​​​​​​​​​Continued ……

For approval by engineers at the main contractor, Hoist & Winch submitted design drawings and calculations for the structural design of the lifting beam and loading of the resin-type ceiling anchors. 

With the design approved, Hoist & Winch could progress to manufacturing, followed by delivery to site. Using building column positions as datum points, the installation line of the lifting beam was marked out while working from scissor lifts and an aluminium scaffold tower located on the upper mezzanine floor. A surveyor’s laser line initially identified the correct lifting beam position, prior to overlaying with red chalk to ensure accuracy for the duration of the installation work.

Raising the two lifting beam sections into position required the installation of eight 1t swl hand chain blocks, with each one suspended from M16 swivel eye bolts supported from flush-mounted anchored resin inserts drilled into the concrete ceiling slab. 

Following sample pull load testing, Hoist & Winch raised each lifting beam section into position using four 1t swl hand chain blocks. To raise the lifting beams to the full height and clamp them hard against the concrete ceiling slab ready for drilling, the company used two special lifting rigs per beam section.

The first lifting beam section manoeuvred into position also included the 7.5t swl hand chain block, which was rolled on to the lifting beam at low level using a 1t swl hand chain block temporarily suspended from local steelwork. Once both lifting beams were in position, Hoist & Winch joined the two lifting beam sections using the aforementioned bolted splice plate.

Next, the company undertook ceiling slab drilling operations and resin anchor installation for all 32 ceiling anchorpoints after very carefully cleaning each hole with a special heavy-duty internal brush and suction pump. Following the specified resin curing time, Hoist & Winch could tighten each anchor bolt to the required torque levels.

​​​​​​​​​​​​​Continued ……

The final installation and test operation was LOLER (Lifting Operations and Lifting Equipment Regulations) inspection of the lifting beam and manual chain hoist unit. This activity included dynamic load testing of the entire runway beam length with a 7.5t skid-mounted test load followed by 125% static proof load test in accordance with BS 2853 2011. 

“Working as a subcontractor for the company supplying and installing the plant and services in the basement energy room, we delivered an entire turnkey lifting system solution,” states Andy Allen, Director of Hoist & Winch Ltd. “At completion we provided the client with an overall project records and documentation package, before clearing all site equipment and undertaking customer handover. This project is just one of many exemplifying the meticulous, competent and professional approach that Hoist & Winch customers can expect from our highly knowledgeable team.”

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

Suck it up, pressurize it and send it to the treatment plant.

In theory, this should be a straightforward job for pumps at a lift station. However, as we all know, the curse of so-called ‘flushable’ products in our sewer systems is also proving that some so-called ‘non-clogging pumps’ are getting clogged.

If you don’t have a problematical lift station in your network, you’re either lucky or have the most environmentally responsible residents in the country. Or perhaps you’ve already solved the beast of a problem with a piece of equipment that has been around for over 70 years.

As more and more maintenance teams are having to contend with, the rise in non-biodegradable products almost inevitably results in problems for wastewater lift stations. This critical piece of infrastructure is further hindered by today’s low-flow household wastewater systems that honourably save water, but allow solids to build up.

Unclogging the supposedly non-clogging pump can be a thoroughly unpleasant job, especially for example, in Daphne, Alabama, where its main lift station at Windscape was besieged with ragging issues to the point of having a vac truck there at least once per week. All part of the job, maybe, but in conscientiously trying to run the process as best as one can, burning up hours of labour can be quite demoralizing; returning to that same problematical lift station again and again and again. The fact that some of those first to complain about back-up and odours might include people who have contributed to the problem is not lost on the engineers who are doing their best to make things right.

At Daphne Utilities, the top priority is always to provide a reliable wastewater collection and treatment system that supports the needs of its community, protects the environment and quality of life for all Eastern Shore residents, and meets or surpasses all federal and state requirements. The Daphne Water Reclamation Facility (WRF) can treat up to 4.17 million gallons of wastewater per day (MGD) but has the hydraulic capacity to process up to 9 MGD. The facility serves approximately 12,000 homes/businesses and treats an average of 3 million gallons of wastewater every day. 

Extensive pipe and collection system cleaning is in place, as well as a comprehensive pre-treatment/grease management program to combat fats, oils, and grease (FOG). This includes the requirement for grease interceptor devices at all food service establishments and for car wash establishments to have sand/oil interceptors.

‘Critical part of our network’

Despite all these pro-active measures, the recurring problem at Daphne’s Windscape lift station was getting some unwanted attention from some areas of the community. Goeff Wilkins, Water Reclamation Facility Manager at Daphne Utilities, said: “We have two 88HP pumps, but were still having ragging issues. Our power source was also unreliable, so our bypass pumps would soon become clogged. Windscape is our primary lift station, which with seven others feeding into it, handles about one million gallons per day; about 1500 gallons per minute, so it’s a very critical part of our network. I know some operators choose to use chemicals to address certain issues, but with wastewater being more aggressive, we wanted to find the best, long-term pumping solution”.

Always on the look-out for technologies that will help improve the Reclamation Facility and its sewage network, Daphne Utilities had established a link with leading process equipment provider, Cahaba Water Solutions Inc., (CWS) based in Birmingham. CWS suggested trialing an EradiGator from Landia, which is based on the very same Chopper Pump design that Landia invented back in 1950. Goeff Wilkins and his key engineers had also attended two national trade shows to weigh up the best options.

‘Continuing heavy presence of non-biodegradable products’

Tim Boyne, Owner/President of Cahaba Water Solutions, Inc, commented: “Daphne Utilities continues to be proactive in addressing and solving issues in their collection systems.  However, like all utilities, there is always a pump station where there will be a continuing heavy presence of non-biodegradable products.  We felt if we could demonstrate the performance of the Landia EradiGator under these tough conditions, we could greatly reduce their operation and maintence costs at the Windscape Station, as well as reduce the potential of overflows from clogged conditions”

Goeff Wilkins continued: “At the trial, we could see the chopping and mixing of the Landia EradiGator (only 20HP), which was priced very competitively. It immediately resolved the issues in the Windscape lift station, so we had no hesitation in investing in it”.

Set up on a timer to operate for 15 minutes per hour, the Landia pump now effectively protects the two existing 88HP pumps by its chopping and mixing action; the EradiGator designed with an external knife system that prevents unpumpable solids from entering the pump’s casing.

“It does a phenomenal job,” continued Goeff. “We can really see the difference at the headworks to our facility where there is now much less debris. We’ve saved huge amounts of time by not having to pull out the clogged duty pumps or send in the vac truck. Through SCADA and from daily inspections, we still check for any signs of matting and ragging, but the Landia EradiGator doesn’t need much maintenance. It works fantastic.

“Cahaba have been very helpful in finding us such a solid yet simple long-term solution to the issue we had with our main lift station. None of our team misses having to go there all the time”.

*

Landia has solved numerous lift station headaches, eliminating problematic scum layers.  In addition to the EradiGator, Landia also supplies the AeriGator, which is fitted with a venturi nozzle to inject air for applications where odour problems from hydrogen sulphide is an issue. Both solutions drastically reduce maintenance time because there is no longer any clogging.

How to ensure shared information on the status of the scaffold is instantly available to all employees from all parties involved in a challenging T5 project? Read the full story!

No question, the scale of the T5 project is impressive and challenging. 16 major projects and 147 sub-projects make it one of the most talked about developments in the industry. But it is not only the size of the project that has attracted so much attention. The innovative approaches to safety employed have hit the headlines too.

BAA, which owns six other major UK airports as well as Heathrow, has focused on creating a proactive safety culture across all operations. This culture is intently participative rather than prescriptive. In 2000, BAA launched its renowned “One in a Million” campaign to set a challenging target for the reduction of reportable injuries. As the name suggests, the campaign involves an ongoing benchmark target of only one reportable accident per million hours worked.

As an addition at T5, it has introduced its “Incident and Injury Free” (IIF) programme. The idea of IIF is to make everyone on site responsible for safety - not only their own, but their colleagues. safety too.

The ultimate objective is to create an incident free site. Achieving this culture requires a strong degree of partnership amongst suppliers working on the project.

BAA already uses a custom designed Towertag system for managing its mobile towers on all other Heathrow terminals and its other airports. However, due to the scale of the project and number of contractors involved, an even wider range of Scafftag systems is in operation on T5.

Scafftag used by all contractors

The Scafftag scaffold tagging system has been specified by the T5 project team to be used by all contractors operating the vast structures which are in place. This helps to ensure shared information on the status of the scaffold is instantly available to all employees from all parties. It means that individuals are empowered to make informed decisions about the safety of the structure. This reinforces the culture of everybody taking ownership for safety. 

Safetrak improves efficiency

The Safetrak system has also been adopted at T5 to move all scaffold inspection processes into a paperless, automated format. Inspection information is electronically transferred between the equipment tagging systems and handheld computers using RFID (Radio Frequency Identification) technology. The information is then synchronised and centralised by the Safetrak software.

Beyond scaffolding, the Microtag system has also been specified to all T5 contractors to help control HAVS (Hand Arm Vibration Syndrome). A Microtag® is attached to portable tools subject to HAVS in order to indicate the maximum daily usage time and provide clear, up to date details of inspections.

The Microtag system is waterproof and ensures maximum durability in outdoor industrial environments. 

Results that speak for themselves

BAA has invested major resources into safety on the T5 project. This has clearly paid off in noticeable results. T5’s safety record is four times better than the industry average. Over 70% of the workforce believe that T5 is the safest place they’ve ever worked. The statistics go on as Russell Hyam, Health, Safety and Environmental Manager for BAA, points out: Through IIF BAA has focused on shaping a positive force at T5 a safe working culture. The visibility of Scafftag’s systems plays a vital role in supporting this culture.

This probably goes some way to explaining why Scafftag systems have been adopted on some of the other major airports across the globe. These include Dubai International, George Bush Intercontinental (Houston, Texas), Toronto International, Melbourne International and Adelaide.

Find out more about Scafftag tagging systems >>

Scafftag – A Brady Business

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