Category: Industrial Water, Waste Water & Fire Protection

Provided by CST Industries, Inc.

Watts Bar is like most rural utility districts. It serves 6,100 customers in parts of five counties in southeastern Tennessee, between Knoxville and Chattanooga. But one thing makes Watts Bar different from most utilities: its largest customer is a nuclear reactor.

The Watts Bar Nuclear Plant, part of the Tennessee Valley Authority (TVA), sits on 1,700 acres and produces 1,150 megawatts of electricity—enough to power 650,000 homes. When the second reactor opens this year it will double that output. The plant also uses a lot of water. So much water that Watts Bar utility maintains an unusually large storage capacity. Containing all that water is a big job, but Aquastore® tank from CST is up to the task. In fact, the utility has 17 Aquastores with a total capacity of more than 5 million gallons.

While the nuclear plant draws water directly from the Tennessee River for cooling, it relies on Watts Bar utility for every drop of water used on a daily basis by its 1,000+ employees. When a nuclear reactor is relying on you for its water, you can’t afford service interruptions, mechanical issues or contamination. That’s why Watts Bar Utility District has relied on Aquastore tanks since the first tank was installed in 1988.

Aquastore’s glass-fused-to steel technology is the water and liquid storage leader—outperforming concrete, steel bolted and elevated tanks. More than 100,000 have been installed in over 70 countries around the world. It’s resistant to extreme weather and leakage and retains its brilliant luster for decades, which means it doesn’t have to be repainted.

“Not having to paint means we potentially save millions of dollars over just a few years’ time,” says Wesley Barger, Assistant Manager at Watts Bar Utility District. “We just finished painting our one elevated steel tank for $330,000. Imagine if all our tanks required painting. That kind of expenditure just isn’t justifiable or sustainable.”

Barger continues: “Having to ask your board to approve over $4.5 million for tank painting would not go over well.”

Barger credits Southeastern Tank, the area’s exclusive Aquastore distributor, for making his life easier. He says he’s continually impressed by the service and attention he receives.

“Every once in a while something random happens and they’re Johnny on the spot,” Barger says. “For example, when a cable on a tank level snapped they were out here the next day to replace it.”

Even the bigger maintenance jobs don’t give Barger gray hairs: “We took two of the older tanks out of service to fix a bracket supporting an overflow pipe and to add cathodic protection and a sampling port. Southeastern did it all, including sweeping out the tanks, in a matter of days.”

Barger also appreciates the functional, elegant design of the Aquastore. Each panel is forged in CST’s DeKalb, IL manufacturing facility.

1. A panel of high strength low carbon steel is blasted and alkaline cleaned.
2. The panel’s edges are beveled and its surface sprayed with a stainless steel alloy.
3. Next, the panel is sprayed with a specially formulated slurry that gives it durability, consistency and impermeability. Unlike powder coatings or paint, the slurry is inorganic so it blocks corrosion.
4. The panel is then fired at temperatures above 1,500° F to fuse the porcelain coating and the steel.
5. Tests are conducted to verify integrity and durability, including high voltage testing to detect discontinuities.

Barger and his father, general manager Mickey Barger, have witnessed the Aquastore’s efficient construction many times over. The Aquastore is built using hydraulic jacking, which allows for top-down construction that’s safer and faster and takes up less space than traditional steel tank erection.

“Most of our customers own two or three tanks so Watts Bar is truly unique,” says Dustin Dowdy, Director of Sales at Southeastern Tank in Nashville. “With 17 tanks, their lifecycle cost savings can add up quickly, which satisfies their board and customers.

Dowdy and his staff prepared a lifecycle cost analysis on Watts Bar’s tanks by gauging how much money has been saved on maintenance.

“We assumed what it would cost to maintain welded tanks of similar capacity by calculating the cost per square foot over two 15-year cycles,” says Dowdy. ”It added up to millions of dollars in maintenance costs. That’s money that can be spent on new infrastructure.”

Whether it’s a second nuclear reactor coming online or new home construction, Watts Bar Utility District keeps the taps flowing in southeastern Tennessee and it starts with state-of-the-art storage technology from CST and Aquastore.

Benefits of CST’s Aquastore® glass-fused-to-steel tanks:

• No painting for life of tank
• Will not corrode or rust
• Lowest total life cycle cost compared to concrete & welded
• Turnkey services from approval drawings to tank testing
• Faster construction
• No need for cranes or other large equipment for construction
• Expandable
• Interior & exterior easily cleaned
• Tank can be easily relocated
• Available in diameters from 11 feet (3.3 m) to 204 feet (62.2 m) and capacity from 20,000 gallons (75 cu m) to over 6 million gallons (22,700 cu m)
• Specific tank designs, options and accessories to meet customer needs
• Industry best warranty
• White interior coating
• Multiple color options
• Authorized network of local Aquastore Dealers for convenient service and support

OptiDome® geodesic aluminium domes are the preferred cover solution for any storage application. Aluminum dome structures are superior to other cover designs of alternate materials due to: corrosion resistance, low lifetime maintenance cost, clear-span capability, fast and low cost construction and design flexibility.

Dustin Dowdy | Director of Sales
Southeastern Tank

Lisa Porter | WWTP Chief Operator
Lawrenceburg Utility Systems

After reading the title of this piece you may be thinking this is going to be a funny anecdote about wastewater—quite the contrary. This is a recent success story that involves a low-risk, very-high-reward decision and some clever problem- solving. It’s a tale about a water tank guy, a group of wastewater operators, and five minutes at a region meeting.

How a “Crazy” Idea Was Born

Several months ago I was at a Region 7 meeting, giving my standard presentation about water quality management. Towards the end, I briefly mentioned that Southeastern Tank also offers Medora GridBee AP air-powered lift station mixers that diffuse air, keeping the station clear and reducing odor.

The meeting ended and life went back to normal, but a few days later, my phone rang. On the other end of the line was Keith McCafferty of the Lawrenceburg Wastewater Treatment Plant. Keith had attended my presentation and he wanted to talk about those lift station mixers.

Steve and his team were having a bit of a problem. Their plant’s wet well grinder was under repair and a thick crust of debris had formed across the top of the well, impeding production. Since the grinder repair was taking some time, Keith had an unprecedented idea. What if, he thought, we tried one of the lift station mixers in the wet well?

At first, I didn’t think it would work since the wet well is 20’ x 25’ and an AP500 is designed for 6’ diameter lift stations. We had never tried one in a wet well of that size. Could the mixer really make an impact? And the size Keith wanted to use – the single horsepower AP500 – just wasn’t designed for a cubic volume so large.

Keith’s logic was that for less $3,000, it was worth a try. The air compressor is self-contained, it runs on 120-volt power and there are no electrical components in the wastewater. Fortunately for us, his boss, Lisa Porter, is also an outside-the-box thinker as well. The test would begin. A hole was punched in the debris and an AP500 was installed in the tank.

One week went by, and it seemed that the hole in the crust had gotten a bit bigger and more liquid was visible. Another week went by and the hole had grown even more. After three weeks, there was significant breakup of the crust in the wet well.

At the end of one month, there were still some deposits of debris around the edges, but the vast majority of the solid material had been broken up. The plant was running more efficiently, and the grinder had just been fixed. It was decided that we needed to use two AP500s to accomplish the task but the results were undeniable and it’s doubtful that a crust like that would be seen again.

One Good Idea Breeds Another

After seeing how well the AP500 performed in the wet well, Steve Summers, had a problem that bred another good idea. One of the blowers in a chlorine contact basin was broken. Replacing the blower would cost $4,000 and the blowers run on four phase power. Not only is an AP500 less expensive but it will cost less to operate. Steve approached Lisa about the idea and then called me. They wanted to try in the basin.

In order to control the amount of air, we installed a ball valve on the unit to allow Steve to control the air flow in the chamber. Keith ran 120 power to the area and another test began.

After two days, Steve saw something he had never seen before. The chlorine contact basin was so clear that he could see the bottom of the chamber. The induction of diffused air that is provided by an AP500 had clarified the entire basin. Not only did the AP500 work and chlorine residuals maintain, but during regular operations, the hope is that even less chlorine will be needed due the reduction of algae in the basin. All this using less power.

After this experience, Keith and Steve started telling the Lawrenceburg collections department about their success. Shortly thereafter, we installed an AP500 in the Sundance lift station. Located next to Wal-Mart and several restaurants, the station is notorious for grease capping after only a few days after cleaning. This obviously leads to odor issues and loss of control when grease affects the float switches. After two weeks of operation, the lift station remained completely clear without any evidence of grease.

AP Series Mixers Are Making An Impact

Lawrenceburg is currently in the process of evaluating larger units, AP8000s, for use in their aeration basins. These units will be suspended in the basins, above the silt layer which allows air flow to be maintained unlike traditional diffuser grids that can short circuit only after a year or two of operation due to sludge build up. Also by using 120 volt, 20 amp power, the AP8000s could significantly reduce the power usage as Keith estimates that the current blower system consumes almost 50% of plant’s kilowatt usage per month.

Given the success that Lawrenceburg has seen, we think they are similar solutions for other facilities using this simple, scalable air diffuser. GridBee AP diffusers range in size from a 12-inch chimney with a single-horsepower compressor all the way up to a six-foot chimney and whatever diffuser array is needed. Whatever the challenge, there is a properly sized diffusor to address the issue.

This isn’t just a story about how a piece of equipment helped Lawrenceburg Wastewater Treatment Plant. It’s about how its team of operators captured on an idea they picked up at a region meeting and put it to use. I’m pretty good at running my mouth and have all the AP500s you could ever want but without the knowledge and ingenuity of Lisa, Keith and Steve, its all just talk.

What could a low voltage, air-powered mixer do for you?

Pictured: GridBee AP Mixer Series.

Most companies want to keep their wastewater tanks out of sight and out of mind, but compliance with local rules and EPA regulations is essential. Here are some quick tips for keeping your wastewater on the right side of the law and off your to-do list.

Tip #1 – Stay One Step Ahead Of Enforcement Agencies

Inspections from your local authority are no one’s idea of a good time, but there is no way to avoid them. These inspections occur annually and, in some cases, even more often. If an inspector finds something they don’t like, it can lead to costly unplanned downtime and an expensive laundry list of repairs and maintenance.

It is far more cost-effective to stay one step ahead of compliance regulators by conducting objective third-party tank inspections. When you know what’s going on with your wastewater tank, you can schedule rehab, maintenance or replacements on your timeline, rather than your local authority’s timeline.

Tip #2 – Don’t Let Wastewater Treatment Impede Business Growth

Every business wants to grow, but wastewater regulations can actually have an impact on how quickly and profitably you can expand product lines. Even though the EPA sets federal guidelines, it’s important to understand that the regulations you must follow are put in place by your local authority—so get to know them!

Need proof? You may be familiar with the explosion in popularity of Greek yogurt in recent years. One major US yogurt producer quickly discovered that expanding into a line of Greek yogurt wasn’t nearly as simple as adding machinery inside the plant, and it all had to do with waste.

The wastewater from Greek yogurt has a much different chemical composition than waste from regular yogurt, which results in a stronger waste stream. The company was forced to invest in new treatment methods and tanks just to handle that new output.

Something seemingly as simple as a new product line can have a major impact on your ability to stay compliant within your current discharge permits.

Every time you consider a product expansion that impacts your wastewater, consult with an expert to ensure accurate estimates so you can plan appropriately for any necessary changes to the way you treat your water.

Tip #3 – Consider The Long View

To avoid having to think about your tank while also remaining compliant with local, state and federal regulations, it’s just good business to invest in a tank that will keep you on the right side of regulators for the longest amount of time possible. A durable tank with a long life and a tank that doesn’t require much in the way of maintenance is the best choice for anyone that doesn’t want to have to think about waste.

Glass tanks are about as set-it-and-forget-it as you can get when it comes to wastewater.

The upfront investment is more significant than for an epoxy tank however, you save money over the life of the tank because you don’t have to rehab them every few years. Because they are durable and reliable, you won’t be caught blindsided by regulators during inspections, either.

The right wastewater tank can keep you compliant and avoid downtime that may result from a bad outcome from an inspection. While wastewater isn’t a profit center, you want to be sure you manage costs well, so that waste doesn’t ruin your bottom line. Be proactive with regular inspections and invest in a tank that will protect you and the local water supply for decades to come.

The wastewater industry is full of general rules of thumb and best practices, often ignored within these is selecting the right storage tank with the right coating for the application. As the term ‘wastewater’ represents a broad cross-section of constituents, waste stream makeup, compounds, origin and strength it is no wonder that the general rule of thumb is just that, too general. Wastewater streams vary widely, especially in the industrial sector, as do the options effective in their treatment. Just as careful selection of the right process and technology is a necessity to achieve successful (i.e., permit-driven) treatment results, so too is the tank in which the initial storage and eventual treatment process takes place.

The success or failure of any tank is largely dependent on its coating. While there are generally two main albeit different types of steel storage tanks on the market today, welded steel and bolted steel, they are relational in they both rely on a steel substrate for structural integrity (steel sheets welded together, steel sheets bolted together) and a coating system (field-applied paint, factory applied glass or epoxy) in order to effectively store liquid.

The storage and treatment of wastewater, in all of its variations and sources is some of the hardest liquid to store. The components that make up strong waste streams often produce heavy corrosion-causing conditions that challenge storage tanks of all types. The “right tank” in the wrong application carries monetary and operational consequences, commonly referred to as time & money.

Welded Steel

Welded steel tanks are the oldest of all storage tank designs, which includes ground storage tanks commonly used for wastewater treatment. The design of a welded steel tank includes the application of a field-applied coating, the success or failure of the coating is largely reliant on two things; the applicability of the coating (‘paint’) being used and most importantly the proper application of the coating. Even the best coating system will fail if not properly applied, field conditions often change quickly allowing environmental conditions to affect the application process. The true weakness in field-applied coating lies in the fact that they are carbon-based systems, meaning they can and will chalk, fade and eventually fail due to corrosion. Additionally, while there are various types of custom or heavy-duty coating systems available the costs associated with coatings themselves and the stringent nature of their application often make them too costly to consider.

Bolted, Powder-Coated-Epoxy-Steel

Bolted, powder-coated-epoxy-steel tanks are some of the most widely used in wastewater storage and treatment operations. Their low initial cost compared to field welded and bolted, glass-fused-to-steel tanks often give them an advantage. Additionally, bolted, powder-coated-epoxy-steel tanks are quick to erect and can be built on small sites with limited space around the tank in which to work. This is due to modular building techniques unique to bolted tank construction. As with all coated steel tanks, the bolted-powder-coated-epoxy-steel tank relies on its coating system to provide the protection against the harsh environment found in wastewater. While the powder-coat epoxy is a carbon-based, the advantage bolted-powder-coated-epoxy steel tanks have is in the actual application of the coating; bolted-powder-coated-epoxy-steel tanks are factory-coated, this allows ever-changing environmental factors that adversely affect field-applied coatings to be eliminated. The coating process is fully automated, using state-of-the-art robotic applicators and the latest in steel sheet preparation ensure the epoxy coating is evenly applied, in precise thicknesses and properly cured in order to achieve a robust coating system. This results in a ready-to-build product that is fully coated and ready for service once it is delivered to the site.

Bolted, Glass-Fused-to-Steel

Bolted, glass-fused-to-steel tanks have become a viable and sought after technology for wastewater storage and treatment. Although higher in initial cost compared to bolted, powder-coated-epoxy-steel tanks, it is a truly unique product that uses a factory applied glass coating (porcelain enamel) to protect the steel against corrosion. The glass is “fused” to the steel, this “fusion” process is only achieved at > 1,500° F and produces an inert coating that is mechanically and chemically bonded to the steel. The result of this “fusion” is a coating system that is impermeable to most liquids, eliminates undercutting caused by corrosion, will not chalk, fade or rust and will never need recoating. Glass-fused-to-steel is more than twice as hard as any field-applied paint/coating system and has a bond rating 12.5 times stronger than factory-applied, powder-coat. Similar to the powder-coating process used on bolted epoxy tanks, the application of the glass coating is fully automated, using robotic spray guns and applicators that ensure consistent, uniform liquid glass coating is applied to every sheet. Glass-fused-to-steel tanks are erected using modular construction methods that allow the tank to be constructed on small sites with limited work space. This form of specialized construction utilizes lifting jacks, designed specifically for Aquastore® glass-fused-to-steel tanks provides safe, OSHA-friendly construction with quick and efficient erection time.

The Right Economics, The Right Tank

The investment in waste treatment and storage is a necessity, driven by EPA-mandated regulations and enforced by local municipal and utility agencies that serve the public trust. This investment in is seldom a small one, requiring capital expenditure and operational impact that constantly move the bottom-line, profitability needle. The economic comparison for selecting the right tank, the right coating, the right technology for waste treatment and storage can be summed up like this;

• Welded Steel: High capital cost, long range life with potential for high maintenance costs, dependent on skilled field craftsmanship (construction and coating).
• Bolted, Powder-Coated-Epoxy-Steel: Low capital cost, short to mid service life with recoating potential and eventual replacement, engineered product – manufactured sheet materials with factory-applied coating.
• Bolted, Glass-Fused-to-Steel: High capital cost, long service life with minimal maintenance required, engineered product – manufactured sheet materials with factory-applied coating.

The reality in any and all of these tanks is they will require significant investment; time, money, resources, operational impact and will become another piece of the plant’s infrastructure. They also become another line item on the maintenance list that will affect the company’s bottom line in some capacity. The money will get spent on capital investment in the tank itself and over the life of the tank in scheduled/routine maintenance costs. The decision on where and how to spend that money will be affected by the technology chosen – a company will spend less in capital costs on a bolted, powder-coated-epoxy-steel tank but will eclipse that initial cost with maintenance (repair/recoating and eventual replacement) costs. Conversely, a company will spend more in capital costs on a bolted, glass-fused-to-steel tank but will achieve overall cost reduction in maintenance (minimal repair, no recoating or replacement) savings over the life of the tank.

The improvement in the plant’s waste treatment process will provide peace of mind for regulatory compliance and a good name in the community, the storage tank used in that process is an integral part – both economically and operationally. Let Southeastern Tank, Inc. help you select the right tank with the right coating with the right technology for your waste treatment application.

How often do you think about your industrial wastewater tank. If you’re like most people, you don’t want to have to think about it, because thinking about it generally means you’re staring down a problem. Wastewater is inevitable in production, and caring for that wastewater is your responsibility under the law. Choosing the right tank today can mean the difference between dealing with the EPA and local regulators, or focusing on growing your business.

Tank Cost Vs. Tank Quality

The quality of a wastewater tank is essential. The most advanced and thorough treatment processes in the world mean nothing if you’ve got a tank that’s deteriorating or costing you an arm and a leg in ongoing maintenance.

There are two philosophies when it comes to buying a tank. You can spend the money upfront on a high-quality tank with a long lifecycle that can handle the demands of your waste, or you spend less and pay for ongoing rehab and maintenance for the next several decades.

That decision depends a lot on the way in which your company’s leadership feels about spending money, but if you’re going to make an investment in a tank soon, it’s worth it to explore glass Aquastore tanks. They are extremely durable even when continually exposed to chemical-heavy water, and they have a proven lifecycle of 20-30 years, vs. epoxy tanks that require rehab as early as eight years in. Remember, too, that unscheduled downtime on an offline, damaged or out-of-compliance wastewater tank will impact production.

Business Today vs. Business Tomorrow

Every business wants to grow, and if your company is on the path towards expansion, your future development may be impacted by your ability to manage wastewater. Your discharge permits may be impacted by an increase in production or an expansion or change in product lines, and no CEO wants to hear that growth is being slowed by something like wastewater tanks.

If you’re faced with rehabbing or replacing the tank you have today, consider the direction the business is going in. You want to be sure that your waste management processes are as agile as your production processes. Therefore, you want to be able to choose tanks that can be erected quickly and efficiently, and providers that understand the importance of compliance while meeting the needs of a fast-paced business.

Space can be a determining factor in this process. Most companies keep their wastewater tanks somewhere behind the facility, because no one really wants to think about them. That space can be restrictive when it comes to growing, replacing, or adding new tanks. There are ways to make limited space work, but you need to choose a partner who can work efficiently in small spaces. Keep in mind that glass tanks do not require the cranes, scaffolding and other heavy equipment that some other types of tanks require, and they can be an ideal solution when you need to expand but you don’t have much land to work with.

Spend Now Vs. Spend Later

When you get down to brass tacks, you’re going to either spend a lot of money today on a high-quality, long-lasting glass tank or you’re going to spend a lot of money down the line worrying about maintenance and compliance standards on an epoxy tank.

The truth is, only your organization can determine which approach is best. Given your unique financial situation, it can make sense to spend less today and worry about the rest later. There are pros and cons to each approach. The key to making the right decision is to gather enough information as you can from potential tank providers and weigh it against your budget and priorities.

What About Water Used For Production?

Most business leaders want to spend more time thinking about the water that makes them money, rather than their waste water. If you require tanks for the water you use to produce your goods, the same principles really hold true. Investing in a durable, high-quality tank with a long lifecycle upfront can save dollars down the line, and budgets might be more free here, since the water tank is an asset for production, rather than a cost center.

No matter what business you’re in it will ultimately be your priorities, the chemical makeup of the water, and the company’s financial situation that will really determine what type of industrial water and wastewater tanks to choose.

Wouldn’t it be nice if, in the event of a fire, you could simply rely on your municipality to feed your sprinkler system? Some businesses are lucky enough to have that luxury, but for many others, a fire protection tank is necessary in order to meet the National Fire Protection Agency (NFPA) standards and to keep the business, its assets and its employees safe.

Fire protection tanks are one of those line items that you know you need, but you don’t want to think about. Dealing with these tanks can often feel like more hassle than it’s worth. Here’s how to help make that process move smoothly and quickly so that you can get back to the business of making money.

About Those “Pesky” NFPA Standards And Specs

Someone on your staff probably knows the basics when it comes to NFPA standards, but it is rare to find someone who is truly familiar with the requirements. This can spell trouble when shopping for a fire protection tank. If you aren’t 100% sure of exactly what is required for your business, you could waste a lot of money going back to the drawing board after an inspection or attempting to file an insurance claim.

Unfortunately, laypeople with good intentions can waste a lot of time chasing down and attempting to making sense of NFPA specs. If you hire a general contractor to manage your tank project, there is no guarantee that they will understand the ins and outs of the rules governing tank you must install. This can lead to one of two negative impacts. One, you could end up with a tank that is not able to meet NFPA specs, or two, you could get a tank that is way too big or powerful for your specific needs, resulting in wasted dollars.

Navigating Compliance And Cost

You have a fine line to walk when it comes to fire protection tanks. You want to be sure that in the event of a fire, the system works properly, but you also have to manage costs. Many people tend to gravitate toward the cheapest tank because the purchase does not add value to the business, but cheaper isn’t always smarter.

When shopping around, pay close attention to each bid you collect. Cheap is ideal, but you have to make sure that you’re getting exactly what you need. On the flip side, you don’t want someone to scare you into buying far more than you would ever use. Always choose to work with an expert in fire protection tanks who will help you walk the line between compliance standards and your budget. Providers that know NFPA specs can ensure that you get and pay for only what you need, when you need it.

Avoiding Business Disruption

When you have to buy a fire protection tank, you want to get the whole thing over with quickly. As you collect bids, pay close attention to process. Look for a company that can give you an accurate price quickly and who can work with you on efficient installation that will not disrupt your operations. While most businesses understand the importance of fire protection, they also have deadlines to meet and money to make.

Since dealing with these tanks can be a headache, always consider the tank’s durability and lifecycle when making a final decision. Choosing the most durable tank can give you decades of peace of mind, even if it might cost a little bit more to install upfront. It’s better to pay now and not have to think about that tank, then be stuck updating it over and over again.

When you are faced with NFPA specs that require a tank, work with a provider that will give you a long-lasting and durable tank that meets requirements and can be installed quickly and with as little disruption as possible. Buying a fire protection tank isn’t nearly as exciting as buying new production equipment. Most companies do it because they have to, not because they are gung-ho about buying a sizeable water tank they may never use. However, you want to be sure that in the unlikely event that you do have to use that tank, that it will protect your property and the lives of your employees.