But you don’t find newspaper articles about the smell anymore. That’s because the pump division of Baltimore County Utilities has installed an odor control system based on hydroxyl radical fogging technology. Operational since last August, the OHxyPhogg V250 system from Parkson Corp. has eliminated hydrogen sulfide odors that used to prompt calls to county council members from neighbors and negative publicity in the local news media.

“We don’t hear anything now,” says John Guido, operations supervisor for the pumping and treatment division. “And that’s a good thing.”

Close to neighborhoods

The Baltimore County sewage system handles 40 billion gallons of wastewater a year and includes 3,000 miles of sewer pipe and 60,000 manholes. Guido’s division operates and maintains 224 pumps at 117 pumping stations, one community treatment plant, three treatment and water distribution systems, and 2,500 grinder systems at individual homes.

The Gray Manor location is surrounded by homes and commercial establishments and is one of the largest pumping stations in the system. On average, it handles 6 to 8 mgd, and the flow can run higher during storms. The wet well pumps are driven by 700 hp motors.

“Hydrogen sulfide odors had been persistent at the site,” says Guido. For the past few years, his team of mechanic III Mike Cooper, mechanic II Jay Tawes, and mechanic I Justin Yokubinas had used a masking agent with little impact.

“We had tried using a misting system that sprayed an orange blossom scent around the pump station,” says Guido. “It had a marginal effect, and the misting system was costly and maintenance-intensive. When the orange blossom agent ran out, we’d have to go out and install a fresh 55-gallon drum of it. If the system ran dry on a holiday or weekend, the odors went unmasked until our crew came back on the job. It knocked down some of the odors, but not all.”

The odors were even worse during an upgrade of the pumping station, prompting the calls from neighbors.

“At first, we considered replacing the orange blossom scent mister with ozone, but then Parkson introduced us to the OHxyPhogg system,” says Guido. The company gave a 30-day pilot test at another pumping station in November 2010.

Fast response

OHxyPhogg systems use an air atomizing three-fluid nozzle developed by Vapex Environmental Technology that combines ozone with a rapid application of micron-sized water droplets. The result is a hydroxyl radical fog that can be dispersed throughout the odorous air space, generating a large reaction surface area and oxidizing the odors.

The technology is being used successfully in lift stations, wet wells, covered sludge thickeners and holding tanks, and other odorous spaces. The systems require only a potable water source and a 110 VAC or 220 VAC electrical connection.

The pilot study was designed to determine the ability of the technology to reduce or eliminate hydrogen sulfide odors inside the wet well structure. A second aim was to test the effectiveness of the fogging system in reducing or preventing grease buildup and corrosion on the structure walls.

The results were excellent. Monitors recorded average hydrogen sulfide levels of 22 ppm in the wet well, and even higher levels in the diverter box, before operation of the fogging system. Once the system went online, the hydrogen sulfide dropped to 0 to 3 ppm at various points in the wet well. The test showed a reduction in grease and corrosive gases, as well.

“The pilot test station is out away from populated areas, and odors can be very bad,” says Guido. “I thought if the fogging system worked there, it would be a good solution to the Gray Manor situation.”

Easy installation

Under direction of superintendent Mark Thiess, the utility bought an OHxyPhogg V250 unit and worked with Parkson to install it. A utility crew handled the piping. The unit was positioned in a separate small room in the pumping station and connected to electrical service and water. Then Guido’s team ran the fogging pipes into an adjacent room, drilled holes in the floor, and routed the pipes into the wet well below, positioning the fogging heads so they would completely cover the wet well area.

“We made one change by using schedule 80 PVC pipe instead of the schedule 40 that was specified,” says Guido. “It stands up better and is harder to break if something hits it.”

The piping installation took about 12 hours. “We actually did such a good job that Parkson tells us they want to use us as a model,” Guido says.

The system was activated the next day, and the results were evident immediately.

“We could not detect any hydrogen sulfide odors around the pumping station,” Guido says. “The nose is one of the best odor monitors we have. Our operators didn’t smell anything.”

Maintenance has been minimal, and the negative media coverage has ended. “You never hear about a job well done,” Guido says. “As long as the neighbors don’t smell the pump station, we don’t hear anything.”

The reasons include enhanced maintenance, spill-response training, and greater general awareness of the problem among wastewater agencies. Some agencies, including the Leucadia Wastewater District in Carlsbad, Calif., have gone further, adopting formal operation and maintenance programs, publishing design and performance provisions, updating overflow response plans, and developing capacity assurance plans that include monitoring and measurements — elements specified by the U.S. EPA’s proposed Capacity, Management, Operations, and Maintenance (CMOM) program.

Leucadia’s efforts also include use of technology, including SmartCover monitoring and alarm systems that detect potential spills in locations such as known trouble spots on the collection system and pipes in difficult-to-access easement areas. The devices are helping the district prevent spills, reduce easement inspection frequency and document sewer performance history.

Easy problems first

Like most agencies implementing new SSMPs, Leucadia addressed the easiest sewer problems first, leaving more challenging and costly work ahead. To sustain its Internet-accessible compliance record, the district also conducted an external audit of its performance and adherence to the SSMP to identify areas for improvement.

That effort revealed two areas of concern: Trouble spots (especially where overflows had occurred) and off-road easement areas difficult to access because of canyon topography, protected biological resources and floodplains. Furthermore, large-diameter pipes, surcharge flows and long distances between access points affect the district’s ability to clean and inspect parts of the collection system.

The district deploys easement inspectors to monitor assets in remote areas.

The inspections mean sending an employee (or a team of employees using the buddy system) into canyons and other unpaved areas to locate manholes, inspect the manholes for deterioration or vandalism, and observe the flow for short periods.

However, these inspections involve hazards that include encounters with snakes, poison ivy and wild animals, along with the chance of injury during foot travel on rough terrain. Thus there were risks to offset the benefits of putting eyes on a given manhole for five minutes per year or per quarter.

Automating inspections

In seeking an alternative to labor-intensive inspections and a way to monitor trouble spots more closely, the district installed SmartCover monitoring and alarm systems from Hadronex. The devices, attached below manhole covers, continuously monitor water levels in the sewers and provide user-defined alarm notifications to impending overflow events and to intrusions by unauthorized parties.

The battery-operated units install in a few minutes. Batteries typically last one year. The devices provide two-way wireless communication, allowing the district to interrogate them from anywhere. Data is downloadable for insertion into spreadsheets. Alarms are sent directly to specified district personnel for timely response.

The devices can be easily maintained or traded out by inspection personnel. Thus they provide continuous real-time information for the same level of effort as periodic inspections. Additionally, data from the monitors has given the district an improved picture of sewer lines’ capacity and dynamic performance over longer periods than previously available.

Analysis of the data has allowed the district to target capital improvements more effectively and gain the benefit of each asset’s full useful life. Managers and regulators also appreciate the more detailed data available during spill investigations.

Finally, the alarm function demonstrates the district’s commitment to proactive spill prevention and limits risk exposure in less-traveled and more environmentally sensitive service areas. By installing several SmartCover units and adding more each year, the district has achieved efficiencies in easement inspection. F

About the Authors

Leo Schempp is former field services manager and Jeff Stecker is field services superintendent with Leucadia Wastewater District, based in Carlsbad, Calif. Both hold California Water Environment Association Collection System Operator IV certification.

That’s how it is in the magazine publishing world: January could be March, or June, or even the following January. It can be hard to keep straight, and it’s not uncommon for an editor to have a very skewed sense of time. But that illustrates my point. It’s February, but for you, as you read these pages there aren’t piles of snow outside the window and the mercury is being much more liberal in its movements up the scale.

Everything here at COLE Publishing is always a few months ahead. Our deadline for the July issue, for instance, will have passed by the time you read this. We were wrapping up the March issue when I stepped into the editor’s chair, and much of the material for the April edition was already in the can, as we say in the business. That’s why we’re just now getting a formal introduction in May, even though I stepped into my role at MSW in January.

I’ve already visited a CIPP lining project in Madison, Wis. The project was the first of its kind on a potable water main in Wisconsin. You’ll be able to read about the project in an upcoming issue of MSW. I’ve also sat down with Rob Molskie, conveyance system manager for the Stevens Point (Wis.) sewer and water utility. The utility has come a long way in the past five years, and you’ll also be able to read about how they’ve made drastic improvements in their system in an upcoming issue.

There are other great stories coming up in MSW as well. Bethlehem Township (Pa.) has just begun an ambitious lateral lining project that will likely make a big impact on the municipal sewer system. Nashville, Tenn., will also grace these pages in a story detailing the work the municipality has done to build green stormwater infrastructure. Those efforts have been recognized by the Natural Resources Defense Council, and we’ll bring you the full story in August.

Of course, there will also be plenty of stories on new technology, new solutions to common problems and new ways to serve your customers better.

My hope is that you won’t notice any significant changes as the balance of the load shifts each issue from work that was done prior to my arrival to the work done under my watch. I assure you the focus and quality of this publication won’t waver, because a lot of dedicated people put a great deal of hard work into putting together a product that speaks to your industry and its place among the vital services we all depend on.

As we move forward, I’ll do my best to make sure MSW continues to deliver information of value to the industry, including profiles of the people and departments that are shaping the future for sewer and water utilities. If you have comments, suggestions or story ideas, please feel free to email me at editor@mswmag.com. I hope to hear from you.

Sioux Corp., manufacturer of pressure washers, steam cleaners and steam generators, redesigned its website, www.sioux.com, adding videos, slide shows and related content.

East Jordan Iron Works consolidates under EJ brand

East Jordan Iron Works Inc., East Jordan, Mich., and its affiliated companies Norinco in France, Cavanagh in Ireland, McCoy Construction Castings in Canada and HaveStock in Australia have consolidated under the EJ brand. Products include cast manhole frames and covers, hinged assemblies, adjustment risers, drainage castings, grates and gate valves.

ISCO Industries founder dies

Jim Kirchdorfer Sr., founder and chairman of ISCO Industries, passed away Feb. 3. Kirchdorfer started the Louisville-based pipe supply and custom manufacturer of HDPE pipe company 50 years ago in his father’s hardware store. The company now has 25 locations with 300 employees worldwide.

Goddard named TRB emeritus member

James Goddard, who retired as chief engineer from Advanced Drainage Systems, was named member emeritus of the Transportation Research Board committee on subsurface soil-structure interaction.

This past year, the Infiltration Control Grouting Association (ICGA), a division of NASSCO, developed a standard specification for the use of chemical grout in sanitary sewers, laterals and manholes. The specification, originally drafted by environmental consulting firm Malcolm Pirnie, was reviewed and revised by many dedicated ICGA members. It was also peer reviewed by professionals from the Water Environment Associations of New England, Florida, Kentucky-Tennessee, Virginia, Chesapeake and California. The peer reviews were critical to the development of a quality chemical grouting specification.

The ICGA also developed a white paper to educate utility operators on the appropriate use of chemical grouting in sanitary sewers. This document, titled The Role of Chemical Grouting in Wastewater Systems, will be translated into a training program that can be used by chemical grouting professionals to train operators and engineers throughout the country. The white paper can be found on the ICGA website: www.sewergrouting.com.

The International Pipe Bursting Association (IPBA), another division of NASSCO, recently published the Guideline for Pipe Bursting. This guideline is designed to assist owners, designers and contractors involved in pipeline replacement and/or rehabilitation projects to evaluate the capabilities of pipe bursting as an existing trenchless pipe replacement method.

Another training initiative is the development of NASSCO’s Introduction to Sewer Cleaning with Jetting Equipment, a newly released 55-minute video that provides fundamental information about the safe and efficient use of sewer cleaning equipment. It also provides a basic overview of sewer jetting for beginners and can serve as a reminder of proper and effective practices for more experienced workers.

We are also developing documents and training materials that provide overviews of other rehabilitation and assessment technologies, including CIPP liner installation and inspection and lateral and manhole rehabilitation.

NASSCO would like to work more closely with local WEF member associations and other organizations such as local Rural Water Associations. Our goal is not only to assist with training, but to provide a two-way line of communication between NASSCO and local sewer professionals for feedback concerning programs like PACP and the Inspector Training Certification Program (ITCP), and also to learn how we can better serve the industry.

NASSCO has served the sewer industry for 36 years and continues to move forward with new and exciting initiatives. Over the past year, more than 100 organizations have joined NASSCO to help set industry standards for the assessment and rehabilitation of underground pipelines and assure the continued acceptance and growth of trenchless technologies. If you would like to get involved in the myriad of opportunities that NASSCO offers, please feel free to contact us and discuss how you can participate. F

Ted DeBoda is executive director of NASSCO. He can be reached at director@nassco.org. NASSCO is located at 11521 Cronridge Drive, Suite J, Owings Mills, MD 21117.

Catch basin risers from American Highway Products eliminate debris falling into collection systems causing backups, reduce costs, and streamline the adjusting of utilities to the new grade when paving roads. Heights start at 3/4-inch rise and increase in 1/4-inch increments. Inclined risers are available. The type 1 and type 2 risers are easy to install, and will not break from installation forces or uneven manhole frames. Custom designs are available. 888/272-2397; www.ahp1.com.

I&I barrier

The I&I barrier from AP/M PERMAFORM is designed to stop water from leaking into manholes through grade rings. The weather- and puncture-resistant unit is made of polyethylene, and forms an interior wall that stops water from infiltrating. Once installation is complete, there is no need for further adjustments. No adjustable bands are used to hold the unit in place. 800/662-6465; www.permaform.net.

Battery-operated meter

The M5000 mag meter from Badger Meter delivers flow measurement information for general-purpose detection. The battery-operated unit comes in a low-maintenance stand-alone package and is suitable for a wide range of utility and industrial applications. It can be used to measure well water, wastewater, reclaimed water and bidirectional flow applications that have minimal electrical conductivity. Built for field verification testing with the use of a simple handheld device, the meter can achieve an accuracy of ±0.5 percent and a flow range better than 300:1.

The meter combines a detector and an amplifier. The flow detector has no moving parts in the flow stream, which prevents pressure loss and keeps maintenance to a minimum. The amplifier can be integrally mounted to the detector, or it can be mounted remotely. Housed in a NEMA 4X (IP66) enclosure, the amplifier targets a variety of applications. 800/876-3837; www.badgermeter.com.

Multiple-path flowmeter

The Model 7720 Transit-Time flowmeter from Accusonic Technologies addresses difficult installation requirements common to large UV disinfection systems. The maximum 10-path capability allows the unit to measure with accuracy and repeatability, even in the presence of distorted flow profiles. The pipe section length required for installation is less than for other flow measurement technologies, according to the manufacturer. Measurable pipe and channel sizes range from 8 inches to 600 feet. Using multiple-path, chordal, transit-time technology, accuracy is ±0.5 percent in full pipes and ±2.0 percent in partially full pipes and channels. 508/273-9600; www.accusonic.com.

Leak correlator

LeakFinderRT from Echologics is a Windows-based acoustic leak noise correlator that pinpoints quiet narrow-band leaks on water and wastewater mains of all materials including ductile iron, pre-stressed concrete cylinder pipe (PCCP), plastic (PVC) and asbestos cement (AC). Its advanced hydrophones and enhanced correlation function improve municipalities’ ability to accurately identify and locate narrow-band leak noise. The system is well designed for plastic pipes, multiple leak situations, and scenarios where there is a large amount of background noise or where leak sensors have to be closely spaced. 866/324-6564; www.echologics.com.

Multiple velocity flowmeter

The FlowShark Triton flowmeter from ADS Environmental Services offers multiple velocity and depth measurements for accuracy in standard and challenging hydraulics. It is a fit-for-purpose monitoring device, with intrinsic safety as the standard. The unit offers simplified software with Qstart, which can be downloaded from the company website. It allows setup, activation and collection in a few minutes, and has viewing options that enhance data accessibility. The flowmeter sensors offer versatility, redundancy and multiple technologies for continuous running of comparisons and tolerances.

Options include the peak combo sensor with peak Doppler velocity, an uplooking ultrasonic depth, and pressure depth all-in-one housing for versatile, economical measurement across a wide range of hydraulics. The surface combo sensor includes surface velocity, downlooking quadredundant ultrasonic depth, pressure depth, and surcharge continuous wave velocity. An all-in-one housing stores the four technologies, allowing all measurements of depth and velocity to take place without the need to install a separate sensor. The quadredundant ultrasonic sensor is also available as an option. 800/633-7246; www.adsenv.com/triton.

Chlorine dioxide analyzer

The CDA-22 chlorine dioxide (ClO2) analyzer from Electro-Chemical Devices includes a panel mounted plumb-and-play design and automatic flow control in a low-maintenance complete measurement system. The unit measures ClO2 concentrations from 0.05 to 20 ppm. Easy to install and maintain, the analyzer incorporates a ClO2 sensor, automated flow control device and analyzer/controller mounted on a PVC panel.

Installation is complete after connecting the sample and drain lines, power and outputs. It can run for up to one year between electrolyte/membrane changes. The unit features a polarographic gold/silver PTFE membrane amperometric ClO2 sensor, which is flow-sensitive. Output is almost flow-independent at values greater than 0.5 ft/s. 800/729-1333; www.ecdi.com.

Level measurement

The Prosonic S FDU90 ultrasonic level sensor from Endress+Hauser is designed for small measurement ranges up to 100 feet of liquid depth, and is used for measurements in open ponds, flumes, and sewer system weirs. The low profile and reduced blocking distance allows use in confined spaces. An optional submergence shield protects the sensor membrane from contamination and provides a reliable evaluation of flood events in conjunction with the unit’s evaluation. A separate transmitter makes the sensor suitable for harsh environmental conditions. Setup can include an active flooding alarm. It is designed for level measurement at rain overflow basins. 888/363-7377; www.us.endress.com/level.

Electromagnetic meter

The WATERFLUX 3070 electromagnetic water meter from KROHNE offers a flow sensor construction with a rectangular, reduced cross section and efficient coil construction. The coils provide a strong homogeneous magnetic field, leading to an improved signal to noise ratio. The measurement is independent of the flow profile and measurements are very stable.

The mean flow velocity and flow profile are optimized within the rectangular and reduced cross section, reducing uncertainty for upstream disturbances. The meter can be installed directly after an elbow or reducer in the pipe without straight inlet or outlet lengths. A reduction of inlet and outlet sections means smaller measurement pits. The unit also offers low power consumption of the signal converter. 800/356-9464; www.krohne.com.

Data management

FACE (FlowWorks Advanced Calculation Engine) from FlowWorks is a one-stop data management platform. The system offers real-time data analysis across multiple hardware platforms, and a complete suite of graphical editing QA/QC tools. FlowWorks collects data from all SCADA systems and from USGS and NOAA environmental stations.

FACE is a set of real-time data calculation tools, allowing users to create new data channels from incoming channels using advanced algebra, statistics and logic equations. The editing tools combine real-time data manipulation with an easy-to-use graphical interface. Analysts can highlight data directly on time-series or scatter graphs, or in tables, and then flip to a simple editing screen to make short work of common editing functions. 206/859-6999; www.flowworks.com.

Velocity flowmeter

The FH950 portable velocity flowmeter with electromagnetic sensor from Hach simplifies the velocity measurement process for stream discharge measurements, primary device calibration and sewer spot-check measurements. Step-by-step instructions guide the user through the flow profiling process, and field time is shortened with the ability to log velocity and entered depth information within the meter. Real-time discharge calculations are available, and collected flow data is downloaded to a computer via USB connection, eliminating post-site visit manual data transfer and calculations.

The electromagnetic sensor can be disconnected from the meter, has no moving parts and never requires mechanical maintenance or calibration. The meter is a direct replacement for USGS type mechanical meters. 800/368-2723; www.hachflow.com.

Double clarification

The BIOACTIFLO system from Kruger USA combines contact stabilization and microsand ballasted clarification to produce high-quality treatment of wet-weather flows. Return activated sludge (RAS) from the existing clarifiers is combined with the excess flows into a solids contact tank. A targeted mixed liquor suspended solids (MLSS) concentration is maintained in the contact tank to facilitate rapid uptake of soluble biological oxygen demand (BOD) via contact stabilization followed by ACTIFLO clarification.

The combination of the two results in total BOD removals in excess of 85 percent, 95 percent TSS removal and total phosphorus levels of less than 0.15 mg/L. Existing ACTIFLO installation for wet-weather flows can be converted to BIOACTIFLO and the ACTIFLO train can also be used for tertiary treatment during dry-weather flows. 919/677-8310; www.krugerusa.com.

Submersible level transducers

TruBlue submersible level transducers from Measurement Specialties measure water level and quality. The transducer has an 8 MB internal memory and can store up to 55,000 level and temperature measurements. Its internal 3.6-volt lithium battery with onboard surge protection has a 5-year lifespan, based on four readings an hour. Sampling modes include linear, linear averaging and event, with programmable sampling rates of up to five per second. The transducer is available in full scale water level ranges from 0-11.5 to 0-658 feet (5-300 psi) and has an operating range of 32 to 122 degrees F. 800/328-3665; www.trubluemonitor.com.

Full-profile flowmeter

The FPI Mag (full-profile insertion) flowmeter from McCrometer with hot tap installation is a scalable solution to measuring and monitoring variable runoff flows. The flowmeter installs without interrupting service, dewatering lines, cutting pipe or welding flanges. The unit is an economical flow metering solution for medium and large line sizes.

The meter is available for line sizes from 4 to 138 inches, and features accuracy of ±1 percent of reading ±0.03 ft/s zero stability from 0.3 to 20 ft/s velocity range. The flow sensor is pre-calibrated in the company’s NIST traceable calibration lab and requires no field recalibration. Applications include wells, booster stations, filter balancing and backwash, pumping stations, UV dosing and potable water distribution. 800/220-2279; www.mccrometer.com.

Portable sludge detector

The Sludge Gun from Markland Specialty Engineering is a portable sludge level detector used to find the sludge/sand interface in stormwater pretreatment systems. It can also be used in primary and secondary clarifiers, DAFs, settlement tanks and lagoons. Power intensity is adjustable for sludge densities ranging from light flocs to thick blankets. No calibration is required.

A spring-loaded trigger turns on the gun, and a thumb-adjustable sensitivity control compensates for thin or thick sludge. A tone is emitted as the optical probe enters the bed, varying in volume and pitch depending on concentration of solids. By observing the depth markers on the cable, the operator establishes the location of the sludge blanket and the overlying unsettled cloudy layer. After use, the cable is wound at the self-storing spool at the front of the gun. 905/873-7791; www.sludgecontrols.com.

Monitoring software

Telogers Enterprise software and Ru-33 remote telemetry unit from Telog Instruments offer a complete monitoring, data collection and reporting solution. The telemetry unit provides real-time monitoring and alarming of instruments and sensors, even in the harsh environments of sewers and underground water vaults. It forwards data wirelessly to a host computer over 1xRTT or GPRS networks, so no telephone lines are required. The Ru-33 can operate for six months to a year on a 6-volt lantern battery, eliminating hard-wired power sources.

Once the data reaches the host computer, Enterprise provides users with immediate access to the information for analysis and reporting. Real-time information and easy-to-use templates help users create reports. The software also aids in the use of modeling programs, helping municipalities predict CSO events and their potential hazards to adjacent waterways, beaches, and public or private lands. 585/742-3000; www.telog.com.

The low volume, valveless metering pump from Fluid Metering Inc. is made for the precise dispensing of air sensitive, crystal forming fluids. The H Series pump heads are available with an isolation gland to provide a fluid barrier between the pumped process fluid and atmosphere. 800/223-3388; www.fmipump.com.

Omega event data logger

The OM-CP-Event101A event data logger from Omega interfaces to tipping bucket rain gauges and other devices with TTL pulse or contact closure output. Features include 10-year battery, 4 Hz reading rate, multiple start/stop function, high-speed download, 406,323 reading storage capacity, optional memory wrap, battery life indicator and optional password protection. 800/826-6342; www.omega.com.

Scantek clamp-on ultrasonic flowmeters

Keiki UFP-20 clamp-on ultrasonic flowmeters from Scantek Inc. feature two pairs of transducers on the outside of pipes. The meter can measure heat energy at two different systems or two different circuits in a system at the same time. By using three different types of transducers (small, medium, large), the meter can measure pipe diameters from 13 mm to 5,000 mm. The main unit’s inner memory can provide long-term storage of instantaneous flow rates and totalized data in digital form, which can be transferred to a PC through USM memory under CSV format and modified for statistical analysis. 410/290-7726; www.scantekinc.com.

Universal Flow Monitors vortex shedding flowmeters

Coolpoint vortex shedding flowmeters from Universal Flow Monitors Inc. have no moving parts, eliminating the potential for clogging and feature Intrinsic Safety on 1/4-, 3/8-, 1/2-, 3/4-, 1-, 1 1/2- and 2-inch meters. The 4-20 mA three-wire transmitter features brass body with Viton seals and PVDF sensors. Available in pipe sizes from 1/4 to 4 inches, the meters have a 10:1 turndown ratio and three-digit LED readout, selectable alarm state (N.O. or N.C.) set point or pulse output and choice of gpm or lpm. 248/542-9635; www.flowmeters.com.

RIDGID manual hydraulic benders

Manual hydraulic benders from RIDGID are designed for precise cold bending of standard gas pipe (DIN 2440), black steel Schedule 40 (ASTM A53) and stainless steel Schedule 40 pipe. Bending shows in real time the angle the pipe is bent, reducing the number of starts, stops and pipe removals to take measurements. Durable piston seals prevent premature leaks and maximize uptime. User fatigue is minimized due to handle design, which minimizes the number of strokes to advance the piston. Benders are available in two models: 3/8- to 2-inch capacity (Model HB382) and 3/8- to 3-inch capacity (Model HB383). 800/769-7743; www.ridgid.com.

General Speedrooter 92 drain cleaner

The Speedrooter 92 drain cleaning machine from General Pipe Cleaners features the Flexitube spring distributor tube that allows cable to feed and retract more smoothly for enhanced machine durability, even if the frame has been damaged. A cord and foot pedal wrap on the handle makes it easier to store. Made to feed and retract 3/4-, 5/8- and 1/2-inch cable, both large and small drums have a see-through inner cage to determine how much cable remains. Other features include a braced frame, heavy-duty 1/2 hp motor and Flexicore cable. 800/245-6200; www.drainbrain.com.

Subsurface Supply industrial vacuum system

The IVAC PV500 sand, sump, rock, slurry and water handling industrial vacuum system from Subsurface Supply Inc. is capable of moving materials in industrial and environmental cleanups. The skid-mounted unit weighs 1,800 pounds, is 72 inches long, 36 inches wide and 74 inches high. The system delivers up to 100 psi, 500 cfm and 25 inches Hg. Discharge pressure is fully adjustable (1-100 psi). It has a vertical vacuum lift up to 150 feet, vertical discharge up to 500 feet and horizontal vacuum of 500 feet, horizontal discharge up to 10,000 feet. The control panel can be powered by a 12-volt DC or an intrinsically SAFE option is available for hazardous environments. 605/838-8384; www.subsurfacesupply.com.

Honda industrial series generator

The EB1000 industrial series generator from Honda has a maximum output of 10,000 watts, narrow-shaped design and centralized exhaust. The generator operates at 72 decibels at 23 feet. The digital auto voltage regulator (DAVR) holds voltage stable within 1 percent during standard operation. The i-Monitor digital operation system offers at a glance total used hours, generating voltage (when error detected), battery condition, Oil Alert and AVR (auto voltage regulator) error code. 678/339-2600; www.powerequipment.honda.com.

McLaughlin truck-mounted Mega Vac

Mega Vac truck-mounted vacuum excavation systems from the McLaughlin Group feature tank capacities from 1,600 to 3,000 gallons. Power options include a 67 hp Kubota diesel engine with 1,025 cfm blower or 99 hp Kubota engine with 1,200 cfm. Both options produce 15 inches of mercury. A deep vacuum power plant with 99 hp engine, 1,200 cfm and 24 inches of mercury is available. The three-stage filtration system allows for both wet and dry excavation. 800/435-9340; www.mightymole.com.

JWC Environmental vertical screening system

Auger Monster model AGV from JWC Environmental is a vertical screening system that fits inside pump stations to provide protection against rags and debris. The system mounts to the wall of the pump station next to the inlet pipeline, capturing rags, wipes, plastics and trash. The custom built system can screen up to 1 million gpd. It also can be installed as a headworks screen for a package treatment plant or lagoon system. 800/331-2277; www.jwce.com.

“The Big Shot typically runs off an air compressor,” says Dan Ferguson, Footage Tools president. “There’s a piston that runs inside the barrel of the tools; it’s the inertia of the piston striking the nose of the tool that moves it forward in the ground. What you’re doing is displacing the earth as you move along. In an ideal situation, you have a nicely formed, compact hole left behind where you can pull your cable, water service or gas line through.”

The tools can be run by a portable compressor. The 2-inch model requires 25 cfm at 80-100 psi, while the 4-inch model requires 75 cfm at 90-110 psi. Ferguson says the pneumatic tools offer an economical alternative to pipe bursting and other trenchless methods when replacing 30- to 60-foot-long service lines, two inches in diameter and smaller.

The tools’ pistons are designed to withstand high-impact conditions and are treated with an anti-corrosive coating. Features include an easily replaceable cartridge-style shock absorber and a flexible air tube assembly to minimize internal deflection.

“They’re lightweight and require a fairly small entrance and exit pit (4 to 6 feet, depending on tool length),” Ferguson says. Expander heads (4.5-inch diameter for the 3-inch U300 model and 5.5-inch diameter for the 4-inch U400) are available for bursting clay tile pipe and pulling in new lines. Other accessories include a cutting head for the U300 model, pipe puller extension, tailpipe pulling cable and tailpiece wrench.

Ferguson says the tools require minimal maintenance.

“The biggest nemesis of piercing tools is corrosion,” he says. “Because of the water molecules in the compressed air that enters the tool, it’s important that the tool is well lubricated. We treat our pistons with a phosphate coating to help minimize corrosion that can happen inside the barrel. If you keep the tool well lubricated and stored properly there generally isn’t a problem.” 888/737-3668; www.footagetools.com.

To serve the new facility and provide for more growth and development, the city needed to ensure adequate pressure throughout its water distribution system. Some of the infrastructure is over 100 years old. City officials knew some areas of town had much different pressure than would be expected based on maps of the system.

Addressing these issues required a thorough understanding of the whole system, and the best way to develop that was through a systemwide hydraulic model. An initial data collection phase provided information for the model, which accounted for known water system attributes such as pipe sizes and materials, valve locations, fire hydrants, and elevated water tank levels and sizes.

The model identified areas of low pressure and inadequate fire flow, but that was far from the only benefit. It also helped the city find infrastructure it didn’t know it had, and identified closed valves in the system, solving mysteries about low pressure. Finally, the model highlighted areas where opening or closing valves would improve pressure, and where new or upgraded pipes would be needed to accommodate future demand.

Incomplete information

Americus, known as the “Shining City on a Hill,” is located in Sumter County in southwest Georgia. It is home to the headquarters of Habitat for Humanity International, the century-old Windsor Hotel and the Rosalynn Carter Institute for Caregiving. It is also a popular tourist destination, being near the birthplace of former president Jimmy Carter and the site of the Civil War’s infamous Andersonville prison.

Out of sight from the wandering tourist, beneath the city’s roadways and historic buildings, lie old water pipes, some dating back to the early 20th century. As challenging as it is to run an aging water system, it grows much more difficult when information on the infrastructure is outdated, inaccurate or missing. The lack of information is accentuated when water mains break and it is nearly impossible to fully isolate the system for repairs.

Building the model

The Americus water distribution system consists of 134 miles of 2- to 20-inch pipe spread over nearly 11 square miles. To serve its 17,000 people, the city has two water treatment plants fed by groundwater and eight elevated storage tanks. The city now supplies an average water demand of 2.85 mgd, but future demand has been estimated at 3.34 mgd by 2030, a 17 percent increase.

To develop the hydraulic model, Americus hired consultants Woodard & Curran to examine infrastructure maps and information, including Geographical Information System (GIS), record drawings and water maps.

Engineers entered the data into the Bentley WaterGEMS hydraulic modeling software to create an initial infrastructure schematic for the entire city. They extracted residential, commercial, industrial and institutional water consumption data from the city’s utility billing system, and then accurately located the data within the model to represent varying daily and seasonal demands on the waterlines at any given location.

As a better picture of the system emerged, officials chose nine strategic locations for fire hydrant tests that calibrate the model and replicate how the system worked in reality. During a fire flow test, flows from an open hydrant are recorded, along with initial (static) and final (residual) pressures on neighboring hydrants, to document the system’s reactions to high flows.

These tests aid in refining pipe roughness values, a factor that contributes to pressure. Well-calibrated roughness values result in a model that accurately represents field conditions. In addition to fire flow testing, engineers installed five pressure data loggers throughout the system to record pressure over a 24-hour period.

The pressure loggers captured the behavior of the system at specific points before, during and after the fire flow tests. The data gave the team a better idea how the system reacted to the fire flow tests and provided information on how the system performed over time, from daytime high demands to nighttime low demands.

Once preliminary data was entered into the hydraulic modeling software, along with elevated storage tank data from the city’s SCADA system, the initial typical values assumed for pipe roughness (originally based on material) were refined based on the results of the fire hydrant tests.

In many cases, because of the age of the system, the roughness coefficients were lower than typical for the pipe material. (The lower the coefficient, the rougher the pipes, and the more potential pressure loss.) Newer pipes, such as large transmission lines installed more recently, had higher roughness coefficients.

Discovering the system

During calibration, the team discovered several anomalies. First, the modeled elevated storage tanks did not accurately represent the filling/emptying cycling seen in reality. In addition, field measurements showed extremely low pressures in some sections of the distribution system where the model indicated pressures should be much higher.

Finally, parts of the system thought to be closed off were still under pressure, and vice versa. Behaviors that did not represent how the system should act based on known attributes of the infrastructure indicated the presence of pipes and valves that were not in the city’s water map or GIS.

To find the “missing” infrastructure, team members changed the model to try to explain why the system was behaving differently than expected. In some cases, the modification required inserting a partially or even fully closed valve in areas where real pressures were lower than modeled.

Insertion of these valves made the model more accurately represent the physical system, and when technicians performed field checks of those areas, they indeed found valves. In one case, simply opening a closed valve provided adequate pressures to an area that had experienced zero pressure during fire flow testing.

To resolve another anomaly, the team added a pipe to the model where the city thought an old abandoned line was located, based on a 1911 map. The model showed that the pipe was, in fact, still in service, and that explained why the city had difficulty isolating parts of the system.

Benefits of knowing

One immediate benefit of the modeling was a better understanding of how to isolate specific areas of the system without affecting other customers throughout the city. In addition, identifying potentially closed valves allowed the city to locate and open them to increase pressure and fire flows to homes and businesses experiencing lower pressures.

In areas where inadequately sized infrastructure was responsible for chronic low pressures and flows, the model supported recommendations for new pipes or pipe upsizing to improve water availability.

For example, the model showed that additional piping would be needed to ensure that developments like the new hospital would receive adequate daily pressures and fire flows during emergencies. The new line would also provide redundancy in the system in case the existing line went out of service.

Team members scrutinized the recommendations for impacts to the city’s historical areas and worked to minimize them wherever possible.

Another benefit of the model was the determination that one of the city’s eight elevated storage tanks could be taken out of service, saving on maintenance costs. The tank was temporarily out of service for maintenance during the fire hydrant testing, and the model showed that the system could meet both existing and projected demands with the remaining seven tanks.

A learning process

Since the final hydraulic model report was issued, the city has continued to collect data and update the model. Tank elevations have been surveyed where estimates had been used previously. The city hired a company to exercise valves, giving a much better idea of their working condition and whether they were open or closed. The city continues to incorporate this information into the model to maintain as accurate a system as possible for emergencies and future growth.

The hydraulic model, with collected field data, helped the city conclusively identify unknown or forgotten infrastructure, from missing pipes to closed valves. It helped the city plan for growth and provided greater certainty in day-to-day operations, leading to better service to customers without unnecessary capital expense.

The city showed foresight in developing the hydraulic model and making a small investment to improve it continuously for the future. F

About the Authors

Bernard Kendrick (bernard.kendrick@cityofamericus.net) is public works director in Americus, Ga. Jennifer Suttles (jsuttles@woodardcurran.com) is a project manager and water resources expert with Woodard & Curran. Lorraine Campagne (lcampagne @woodardcurran.com) is a water resources engineer with Woodard & Curran.

A new 19-mile water intake line from the Cumberland River to the town’s water treatment plant went through hayfields and across the driveways of dozens of rural residents who weren’t very happy with the project at first.

But the sincerity of water systems manager Tim Coffee, and a willingness to make adjustments to the route in response to property owners’ concerns, won the day — and without any messy condemnation procedures.

“We were called names, and there were threats, but we looked people in the eye and promised we wouldn’t leave them with a bad job,” recalls Coffee. “Our contractors did a great job.

“Today,” he says of the property owners, “I count these folks as good friends.”

The Livingston project, completed in 2009, was necessitated by recurring droughts and water shortages in this hilly community of 20,000 people midway between Nashville and Knoxville.

Previously, Livingston drew its water from a shallow 54-acre impoundment behind a local dam.

“We nearly ran out of water several times,” recalls Coffee, who’s been with the utility for 27 years. “We had to shut down car washes; people couldn’t fill their swimming pools.”

He says the leadership of Livingston Mayor Curtis Hayes — then on the city council — pushed the town to develop a more reliable source and build the necessary infrastructure.

“We were tired of the situation,” Coffee says. “Mayor Hayes convinced us to seek a better solution.”

The project

The Livingston waterline was no ordinary project. At first, the town looked to nearby Dale Hollow Lake as a water source, but withdrawal fees that would have been imposed by the Army Corps of Engineers were out of Livingston’s price range.

The next best choice was the Cumberland River, which could be tapped without fees but was nearly 20 miles from the utility’s water treatment plant. Plus, the route ran over hilly terrain and would require high-pressure pumping.

The river intake structure itself presented another challenge. Its location is downstream of the Wolf Creek Dam, which is undergoing extensive repairs. To withstand the possibility of dam failure, the structure had to be anchored to the rock bottom of the river by steel rods grouted into 3-inch-diameter, 9-foot-deep borings.

“It was not cost-effective to raise the electrical systems (supplied by Eaton) the 19-20 feet required to protect them against potential flood levels,” explains the town’s engineer, Roy Wauford of J.R. Wauford & Co., Nashville. “But the structure is designed so it will withstand a dam failure if one ever occurs.”

The intake structure also features intake gates at two levels to allow selection of the best water quality.

Transporting water over long distances at higher than normal pressures may be common in the West, but it’s unusual in Tennessee. “As far as we know,” Wauford says, “there is no system other than Livingston in the Southeastern U.S. transporting water over a like distance with similar pressures.”

A pair of high-pressure pumps from Flowserve do the job. The pumps are rated at 500 and 700 psi, respectively, and provide the 310 psi working pressure necessary to move the water from the intake structure some 50,000 feet to a surge tank located on a high ridge halfway to the treatment plant. Slow-closing, oil-actuated ball valves and specially made butterfly relief valves from the Henry Pratt Co. control the flow, minimize surges and prevent water column separation.

Except when the new waterline went under roadways, contractors used open trench construction to lay 20-inch ductile iron pipe varying from special thickness Class 52 (for 500 psi) down to Class 250. Average trench depth was five feet, and at least 42 inches of soil covers all cuts. The line had to run up and down hillsides with grades as much as 40 degrees. From the river to the ridgeline, elevation rises nearly 650 feet. And with the 54-foot side water depth of the surge tank, static head is 700 feet.

Coffee recalls watching contractors loading pipe onto a sled and winching it up the hill. “Some days we’d barely lay 20 feet (of pipe),” he says. “At one point, we had to dynamite a hillside.” The line also had to cross under a creek bed five times on its way up to the surge tank. Under these conditions, bends were limited to 45 degrees and required the use of specially designed, reinforced concrete thrust blocks.

The surge tank has a capacity of about 300,000 gallons, and water flows by gravity through C905 PVC pipe — also installed via open trench methods — another 50,000 feet to the Livingston Water Treatment Plant. The arrangement enables operators to regulate the flow through the plant regardless of the raw water being pumped, and also allows the plant to continue to produce water during power outages.

Treatment plant

Last expanded in 2006, the water plant now has a capacity of 4 million gallons a day and features pre- and post-chlorination, conventional flash mixing and flocculation, and high-rate sand and anthracite bed filtration.

Supervisor Johnny White, who has logged 39 years of experience at the facility, explains that activated carbon is used to improve taste and odor, and that a seven-chain phosphate is added to the clearwell to inhibit corrosion and scale. He reports that flow averages about 2.3 mgd in the winter, and 2.5 to 3.0 mgd during the summer. The plant also adds fluoride to the product water. High-pressure pumps push the product water to the distribution system.

In order to monitor and control the new water system, an extensive supervisory control and data acquisition (SCADA) system was designed and installed by Southern Flow of Atlanta, Ga. The system uses solar panels where power is not available, and to solve any line-of-sight problems, a 60- foot-high antenna on the top deck of the raw water intake transmits data to a central data acquisition point at the highest elevation in the system.

The system also controls the treatment plant operation, monitoring the filters and exhibiting tank levels around the system in real time. Coffee says the SCADA system is “the biggest blessing we’ve ever had.”

Dead ends

Treated water is distributed to Livingston’s customers through a far-flung network of waterlines and storage tanks. Dead ends are common. Coffee explains that many of the lines go into remote areas and serve only one or two homes.

“You’ll be driving out in the country and you wouldn’t believe there’s a water line out there, but there is,” he says.

Some of these outlying lines were established by small, separate utility districts before the town took them over. The system has 105 dead ends, according to Coffee, and that can lead to problems with flushing and maintaining the water supply and chlorine residual.

“It can be a nightmare,” he says. “We flush every three months, or as needed.”

Yet, none of these issues, including fixing leaks and rebuilding meters (see sidebar) amount to much when compared with the task of getting the 90 or so private property easements required to facilitate the intake line project in the first place.

“A lot of these people had nothing to gain from the new line,” says Coffee. “Some of them were getting their water from another system, yet we had to go across their property.”

Coffee attributes much of the success to plain old face-to-face honesty.

“My grandfather taught me the importance of your handshake,” Coffee says. “We never went onto somebody’s land without asking first. We never drove over people’s property. We looked them in the eye and didn’t lie to them. Now, nobody has come back to us and said we did them wrong. That’s a good feeling.”

Working with Melissa Boner from J.R. Wauford and city attorney Kelly Williams, Coffee was able to negotiate all the easements in a year and a half. He credits the project contractors for cementing the relationships with good performance.

“They made the situation possible,” he says. “It was just the way they worked with people … they treated the hayfields or driveways like their own … they filled holes quickly and if they had to cut down trees, they piled the logs up neatly for the property owner to use.”

Coffee says many times, the easement was carved out along property edges and fence lines rather than going through the middle. “It was more costly,” he says, “but it made people happy and created less resistance.

“Any little thing that was necessary to make it happen, we did that.”

In a compliment to Coffee and the utility, Wauford says, “We never did a project of this size without having to go to court.”

Payoff

Bringing a reliable supply of freshwater to the Town of Livingston has required a lot of hard work and persistence over several years, but today, the effort is paying off.

The town won a prestigious award from the Tennessee Municipal League last year (see sidebar) and is earning high marks from state regulators.

“They do a survey every two years,” Coffee explains. “They check everything — flushing records, cross connections, tapping, leaks, chlorine residuals, flow rates, computer records. We scored 597 out of 599 possible points — or 99 percent.”

And while it’s true that the project has forced Livingston’s user rates to go higher, Coffee believes the investment is worthwhile.

“Our water may be more expensive than that of other utilities, but we’ve bitten the bullet,” he says. “There are other towns near us that still don’t have a permanent water source. Now, they’re looking to buy water from us. We feel we’re ahead of the game.”