Commercial-Industrial Cleaning, by Pressure-Washing, Hydro-Blasting and UHP-Jetting: The Business Operating Model and How-To Manual for 450 Specific Applications

Commercial-Industrial Cleaning, by Pressure-Washing, Hydro-Blasting and UHP-Jetting

Wolfgang Maasberg

Commercial-Industrial Cleaning, by Pressure-Washing, Hydro-Blasting and UHP-Jetting The Business Operating Model and How-To Manual for 450 Specific Applications

123

Wolfgang Maasberg IPAC Solutions Salt Lake City, UT 84101 USA e-mail: [email protected]

ISBN 978-0-85729-834-8 DOI 10.1007/978-0-85729-835-5

e-ISBN 978-0-85729-835-5

Springer London Dordrecht Heidelberg New York British Library Cataloguing in Publication Data A Catalogue record for this book is available from the British Library Ó Springer-Verlag London Limited 2012 Editing by Jill Maasberg and Corey Buxton IPAC Solutions Salt Lake City Utah 84101 Pictures and drawings courtesy of: Hammelmann Maschinenfabrik, Oelde Germany, Wolfgang Leifeld IPAC-MIS, Salt Lake City Utah, USA, Wolfgang Maasberg Kärcher GMBH, Winnenden Germany, David Wickel Sewer Equipment Company of America, Glenview Illinois, Dan O’Brian WOMA GMBH, Duisburg-Rheinhausen, Germany, Theo Sausen. Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced, stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers, or in the case of reprographic reproduction in accordance with the terms of licenses issued by the Copyright Licensing Agency. Enquiries concerning reproduction outside those terms should be sent to the publishers. The use of registered names, trademarks, etc., in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant laws and regulations and therefore free for general use. The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made. Cover design: eStudio Calamar S.L. Printed on acid-free paper Springer is part of Springer Science+Business Media (www.springer.com)

Delivering the promise of high-pressure waterÓ

v

Acknowledgments

I would like to thank the following individuals for providing technical reviews of this manuscript or portions thereof: Jorge Rankin, President and Founder of Aqua-Dyne Lydia Frenzel, Executive Director WJTA, Advisory Council Mike Bulard, Parts Marketing, Jetstream of Houston Pat DeBusk, Co-Chairman WJTA, and Vice President of Inland Industrial Services Travis Mecham, C-Tech-Kärcher-North America Theo Sausen, President WOMA, GMBH Tom Pritchett, CEO, Champion Industrial Services

vii

Quick Guide

Commercial: Industrial Cleaning 1. In Chap. 1 introduction, categorize the industry or business, its area and/or hardware, exposing the specific application criterion, customer contacts, resources and detailed safety regulations

ix

x

Quick Guide

2. Document customer contacts, the industry resource criterion and safety curriculum to the application review form, followed by a jobsite risk assessment allowing for the particular job location and its circumstance

Quick Guide

xi

3. Decide on the required job entity and its correlating core number provided within manuals application ‘‘Register’’ (2)

xii

Quick Guide

4. Evaluate the recognized core application curriculum, (primary–secondary numbers)

Quick Guide

xiii

5. Choose the primary and/or secondary gear-list authorization form to classify and document necessary tooling (jobs gear up-list)

xiv

Quick Guide

6. Track paperwork (job-walk) through jobs conclusion

Contents

1

Introduction: Succeed in Residential, Commercial and Industrial Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Agricultural Environment, Cattle-Hog-Poultry Operations, Kennels-Zoos-Aquariums, Veterinary Facilities. Bacteria, Pest and Corrosion Control, Biological Security Program, Various Cleaning Applications, Customer Contacts, Business Resources, Safety Guidelines . . . . . . . . . . . . . . . . . . 1.2 Asphalt-Tar-Mastics Industries, Bituminous Compound Manufacturers, Waterproofing Applications, Manufacturing Hardware and General Equipment Cleaning Procedure Industries Technical Resources, Customer Contacts, Safety Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Automotive Manufacturers, Automotive Suppliers-Industries, Hydro-Blast History, Industrial Cleaning Applications for Manufacturing Hardware and Machine Shops, Vehicle and Trucking Facilities, Mobile Vehicle Washing Applications, Important Customer Contacts and Trade Resources . . . . . . . . . 1.4 Airports, Aviation Industries and Their Municipalities, Hydro-Blast History, Servicing Shop Environments, Coating and Rubber Removal Applications, Introduction to General Surface and Equipment Cleaning Techniques, Customer Contacts and Technical Resource Information. . . . . . 1.5 Battery Manufacturers’ Process and Recyclers’ Plant Hardware Cleaning Applications, Services to Industry Suppliers, Industry Resource Info, Customer Contacts, Safety Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Beverage, Bottling Facilities, Breweries, Distilleries, Juice Processing, Equipment and Area Cleaning, Specialized Tooling, Specific Safety Requirements, Customer Contacts. . . .

1

1

9

16

22

29

32

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xvi

Contents

1.7

1.8

1.9

1.10

1.11

1.12

1.13

1.14

1.15

Butchers-Slaughterhouse Operations, General Processing, Cattle-Hog-Poultry and Animal Rendering Facilities, Equipment and Area Identification, Hygiene Requirements, Customer Contacts, Technical Resources and Safety Stipulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Building Washing, Exterior-Interior Surface-Prep., Graffiti Removal, Restoration, Coating-Removal, Water-Proofing, Specialized Tooling, Scaffolding Procedures, Industry Resources and Safety Requirements, Various Customer Contacts . . . . . . . 44 Commercial-Industrial Structures, Demolition-Rehabilitation Procedures, Construction Clean-Up, Surface Preparation, Equipment Resources, Safety Issues and Resources, Customer Contact Information . . . . . . . . . . . . . . . . . . . . . . . . 54 Refinery-Oil-Polymer-Chemical-Epoxy-Resin-Vinyl-Latex-Paint Manufacturing Environments, Area and Manufacturing Hardware Identification, Psi-Gpm Performance Requirements, Hydro-Blast Background, Customer Contacts and Industry Resources, Plant Safety Stipulations and Training for Contractors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Coal Mines, Coal Gasification Plants, General Mining and Mineral Extraction, Hydro-Blast Equipment History, Customer Contacts, Contractors Resources and Safety Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Coffee, Tea, Cocoa, Seeds-Leaves-Herbs, Process-Extraction Hardware Cleaning Services, Hydro-Blast History, Contractors Customer Contacts, Resources and Safety Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Cement-Lime Manufacturing, Ready-Mix Concrete Industries, Prefab Assembly Lines, Pipe, Brick, Block Manufacturing Equipment Cleaning, Hydro-Blast History. . . . . . . . . . . . . . . . 86 Dairy Foods, Byproduct and Derivatives, Milk Processing, Industries Hazardous Analysis and Critical Control Point System (HACCP), Customer Contacts, Establishing a Sanitation Program Incorporating Hygiene and Safety Principles Recognized by USDA and FDA . . . . . . . . . . . . . . . 93 Fish Hatcheries, Aquatic Farm Environments, Tropical Marine Livestock Centers, Balancing Lake & Pond Ecosystem (Dredging), Recognizing the Hazardous Analysis Critical Control Points, Various Pressure-Washing and Hydro-Blast Applications . . . . . . . . . . . . . . . . . . . . . . . . 101

Contents

1.16

1.17

1.18

1.19

1.20

1.21

1.22

1.23

xvii

Food Service Industry, Restaurants, Healthcare Organizations, Corporate Kitchens, Custodial Kitchens, etc., Produce Retailers, Food Processing Companies, Trucks-Tankers and Rail Cars, Pressure-Washing Applications, Hydro-Blast History, Customer Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foundries, Steel Mills, Forging Shops, Nonferrous Metals Industries, Pelletizing and DRI Plant Services, Numerous Pressure-Washing and Hydro-Blast Applications, Necessary Equipment Hydro-Blast History, Customer Contacts and Resources, Industry Safety Procedures . . . . . . . . . . . . . . . Glass, Porcelain, Ceramic and Enameled Product Industries, Various Low and High-Pressure Cleaning Applications for Wastewater Treatment Facilities and Air Emissions Hardware etc., Customer Contacts and Trade Association’s Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maritime Vessels, Offshore Oil Platforms, Shipyards, Harbor Facilities, Piers, Recreational Boating, Various Low and High Pressure Water Cleaning Applications, Including Underwater Jetting Operations, Hydro-Blast History, Customer Contacts and Resources, OSHA Safety Standards and Shipyard Competent Person Training . . . . . . . . . . . . . . . . . . . . . . . . . . Municipalities’ Wastewater Treatment Facilities, Shopping Zones, Parking Facilities, Exhibition and Sport Arenas, Highway-Road Services, Sewer-Cleaning, Vacuum Sludge-Debris Removal, Coating Removal, Various Low and High-Pressure Water Cleaning Solutions, Safe Work Practices, Customer Contacts and Resources . . . . . . . . . . . . . . Pharmaceutical, Cosmetic, Drug and Dietary Supplements Industries, Low and High-Pressure Water Cleaning Applications for Biological Separation-Extraction and Chemical Synthesis Process Equipment, Process Area and Equipment Decontamination, Customer Contacts-Resources-Safety . . . . . . Pulp-Paper, Paperboard, Cellulose and Engineered Wood-Lumber Industries, Hydro-Blast History, Various Nozzle and Tool Configurations, Low and High-Pressure Cleaning Applications for Plant Hardware, Customer Contacts and Resources, Safety Procedures in Pulp-Paper Plant Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power-Plant Services, Coal-Oil-Natural Gas Combined Cycle, Biomass, Hydro or Nuclear-Powered, Hydro-Blast History, Low and High-Pressure Cleaning Application for Boilers, Heat-Exchangers, Condensers, Stacks and Cooling System, Compressor Oil Lube Services, Customer Contacts and Operational Safety Guidelines . . . . . . . . . . . . . . . . . . . . .

108

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131

137

157

170

176

185

xviii

1.24

198 212

. . . . . . . . .

212 212 214 214 214 214 217 217 220

Application Register. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Example: Identify a Job Criterion and Create its Job Specific Gear-List . . . . . . . . . . . . . . . . . . . . . . . . . . .

231

Application Core Curriculum . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Brick-Block-Stone-Stucco and Masonry Façade Cleaning, Structuring, General Surface Preparation and Restoration . . 3.2 Surface Pasting, Airborne Dust Suppression, Applying Extended Service Non-Film Forming Seal Applications, Biosecurity, Sanitizing, Deodorizing, Decontamination, Chemical-Concentrates-Proportioning-Metering, Foaming, Flash Rust-Corrosion-Inhibitors, Use Of Acids, Bleach and Fungus-Mold Inhibitors . . . . . . . . . . . . . . . . . . . . . . 3.3 Clinker-Slag-Coke Removal, Kiln-Boiler-Furnace Cleaning, Thermal-Hot Scale Removal (Cracking) . . . . . . . . . . . . . . 3.4 Condensers or Small Tube Heat Exchangers, Large Tube Heat-Transfer Units, After Coolers, Steam Generators, Three Drum Water Tube Boilers, Ring Exchangers, Plate and Frame Type Exchangers, Bayonet-Tube Exchangers, Dryers-Incinerators, Heat Transfer Hardware. . . . . . . . . . . 3.5 Coating-Paint-Graffiti Removal Techniques on Surfaces such as Asphalt, Concrete, Masonry, Structural Steel and Aluminum, High-Temp Industrial Coating-Insulation Deletion Methods, Surface Flash-Rust Corrosion-Oxidation Control . . . . . . . . . . . . . . . . . . . . . .

...

247

...

250

...

272

...

285

...

290

...

303

1.26 1.27 1.28

1.29 1.30

3

Railroad-Commuter-Light Rail Maintenance Yards, Railway Historical Associations, Theme Parks, Rail-Bridge, Steel-Concrete Rehabilitation, Rail Accident, Site-Emergency Response, Hydro-Blast History, Applications, Customer Contacts Resources and Safety . . . . . . . . . . . . . . . . . . . . . . The Business Operating Model . . . . . . . . . . . . . . . . . . . . . . 1.25.1 Retain and Safeguard Corporate Application Itinerary . . . . . . . . . . . . . . . . . . . . . . . Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application Core Curriculum 1,000–55,000 psi . . . . . . . . . . . 1.28.1 The Gear-List Authorizations . . . . . . . . . . . . . . . . . 1.28.2 GEAR-LIST Authorizations’ for . . . . . . . . . . . . . . . Application Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29.1 Develop the Trade Curriculum, ‘‘Introduction’’ . . . . . Compile Application Register Catalog . . . . . . . . . . . . . . . . .

. .

1.25

2

Contents

231

Contents

3.6

3.7

3.8

3.9 3.10

3.11

3.12

3.13

3.14

3.15 3.16 3.17

3.18 3.19

xix

Concrete-Aggregate, Cleaning-Cutting-Scarifying, Demolition-Restoration and Finishing, Concrete Removal-Cleaning Procedures on Industrial Equipment and Vehicles Utilizing the UHP-Hydro-Blast Equipment. . . . . . . . . Dry-Wet Vacuum Applications, Dredging, Emulsifying Sludge, Hydro-Excavation, Gravel Cleaning, Pumping Fluids, Dust-Refuse or Bio-Product Loading, Transfer or Removal of Industrial Product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duct-Work, Canopy Hood Installation Cleaning, Acid and Sanitary Treatment, Cleaning and Chemically Treating Pipe Prior to Installation of Liner Systems, and the Coating of Interior Steel-Iron Pipe () . . . . . . . . . . . . . . . . . . . . . . . . Directional-Horizontal Underground Pipe Installations, Water Well Cleaning, Water Jet-Grouting, Pile Driving . . . . . . Expansion-Control Joint Cleaning on Rigid Pavement, Sidewalks, Decking, Tank and Pool Construction, Grout-Membrane-Plastic-Rubber-Elastic Removal (New Product Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . Filters, Screens, Felts, Bag-House Units, Trays for Catalytic-Cracking, Vacuum Suction Rolls, Radiators-Fin-Fan (Exterior), Air-Preheater Baskets, Staggered Channel, Wire Mesh-Plate-Vane Mist Eliminators (Centrifugal, Basket, Vane-Type), etc . . . . . . . . . . Flatwork-Surface Cleaning, Gas Stations, Banks, Restaurants Drive-Thru, Machine Shops, Warehousing and Parking Garage Areas, Airport Runways, Jet-Bridge and Hangar Facilities, Vehicular-Pedestrian Tunnel Surface . . . . . . . . . . . . . . . . . . . Hazardous Industrial Waste Recovery and Soil Treatment, Asbestos, Radioactive Trace Element Remediation, Vehicular Accidents and Cleanup of Crime Scenes . . . . . . . . . Hydrostatic Testing of Boilers-Steam Generators, Gas and Vacuum Vessels, Towers, Tanks and Nondestructive Leak Testing of Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . Mold Remediation, Disaster Cleanup, Water Damage-Sludge Removal, Insect-Pest Suppression Odor-Stench Control . . . . . . Oil-Lube Systems (Industrial), Tanks, Oil Compressors, Hydraulic Equipment Services, Light-Oil Jetting . . . . . . . . . . . Ornamental-Statuary-Monuments, City Fountains, Theme-Amusement Parks, Hotel and Municipal Pools, Aquatic-Marine Pools and Tanks . . . . . . . . . . . . . . . . . . . . . . Polishing, Etching, Metal Burr-Flash Removal, Weld Seam Polishing, Surface Modulation . . . . . . . . . . . . . . . . . . . . . . . . Sewers, Laterals, Culverts, Sumps, Industrial Pipe Cleaning, Pipeline Cleaning and Cutting Applications. . . . . . . . . . . . . . .

327

342

361 371

378

384

391

409

421 429 435

441 450 452

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Contents

3.20

Steam-Vapor-Gas-Flue Stacks, Industrial Elevator Shafts, Laundry-Garbage Chute Cleaning and Sanitizing . . . . . . . . . . . Stationary-Portable, Industrial-Commercial Equipment, Vehicle Fleets, Rail-Car, Truck-Trailer-Tanker Trucks . . . . . . . Tanks, Vessels-Autoclave, Precipitators, Container Cleaning, Volatile Substance Removal and Effluent Separation . . . . . . . . Hydro-Abrasive Blasting, Steel Cutting-Demolition Applications, Underwater Hydro-Blasting and Dredging . . . . . . Wash Water Control, Recovery, Filtration, Recycling, Wastewater Reclamation Technology, Evaporation, Hazardous Materials Cleanup, Chemical Rinse Aids . . . . . . . . Wood Structures-Roofs-Decks-Landings-Fencing, Wallboard Cleaning, Facilitating Coating Painting-Preservation Procedures, Vinyl and Aluminum Siding Cleaning, Tile-Asphalt Roof Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

532

4

Associations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

549

5

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Contractor’s Basic Safety Information Bid and Paperwork Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Application Register Catalog . . . . . . . . . . . . . . . . . . . . . . . . .

557 557 560

About the Author . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

577

Glossary of Acronyms, Abbreviations and Symbols, Industrial Language Discovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

579

Trade Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

615

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

617

3.21 3.22 3.23 3.24

3.25

470 477 488 507

522

Chapter 1

Introduction: Succeed in Residential, Commercial and Industrial Environments

Abstract The introduction and documentation encompasses over 500 distinctive service identities within the agricultural, marine, industrial and commercial environment utilizing tools energized by high-pressure water. Portrayed are the industry specific application diversities and its established correlating safety requirement. The business and technical introduction offers the research and ground work to support and shore-up services-sales, tooling and equipment choices by presenting the correct application approach to customers within 24 commercial-industrial sectors. The introductory business model establishes independently the confidential procurement procedures and narration of application methods, technique and processes to safeguard corporate application itinerary voiding the loss of application technology and know-how to various and often repetitive circumstances.

1.1 Agricultural Environments, Cattle-Hog-Poultry Operations, Animal Pounds, Horse Stables, Kennels-Zoos-Aquariums, Veterinary Facilities The great number of animals held in today’s confined production, transportation, holding or display facilities situated often in remote or isolated locations, result in distinctive pressure-washing and hydro-blast application varieties and services. The encountered acidic and highly humid environment generally poses a specific threat to humans and animals alike, accelerating bacterial growth, pest development, corrosion, coating and concrete deterioration. In this atmosphere, contractors and service providers must establish a biological security program encompassing operational exterior–interior cleaning requirements for buildings, equipment and surfaces in feed storage facilities to protect W. Maasberg, Commercial-Industrial Cleaning, by Pressure-Washing, Hydro-Blasting and UHP-Jetting, DOI: 10.1007/978-0-85729-835-5_1,  Springer-Verlag London Limited 2012

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.1 On demand chemical metering pump

Fig. 1.2 Flock breeding facility

animals and humans alike (biosecurity, Fig. 1.1). This also includes and involves the controlled behavioral requirement of contractor’s labor force, tooling and pressure washing equipment introduced to the jobsite. A contractors’ biosecurity program can only be successful when pooled with the customer’s operational circumstances, on-farm-facilities compulsory HACCP system (hazard analysis and critical control point) which incorporates the existing integrated pest-bacterial management programs. Visiting and conferring with local veterinarians in regards to past history and possible conclusions of flock pest-infectious-disease control requirements pertaining to the job site and general surrounding areas is a welcomed and necessary practice to support a qualified bid procedure. Suitable future or rotational chemistry applications, specifying disinfectants, biodegradable soaps, bacterial-pest control products and the availability for adequate tested blast water (bacterial-Salmonella) should also be discussed with the customer and his veterinarian. A contractor entering the egg, broiler and chicken stock breeding industry does best (Fig. 1.2) when it is understood that he intends to operate within the food manufacturing industry (animal to food), which also encompasses FDA, EPA and OSHA guidelines. Due to the multitude of encountered applications, jobsites, human and animal conditions, a standardization of a biosecurity program in ‘‘one size fits all’’ cannot be established (Fig. 1.3). Most bird infections-pathogenssalmonella or respiratory diseases can be spread by multiple incoming or outgoing routes. The biosecurity program will include standard operational procedures (embracing food safety guidelines) to eliminate the risk of exposure to organisms,

1.1 Agricultural Environments

3

Fig. 1.3 Cattle feeder unit

Fig. 1.4 Grain and feed silos

therefore protecting animal health. A constant review-updating process identifying and prioritizing the potential sources between, during and after facility visits and designing adequate application techniques is vital to the program. Further, it is only of value in written form, and treated equal to a job-bid report, when signed off by all involved to gain legitimacy. Contractors must also guarantee that equipment is sterilized, warranting no possible cross-contamination from neighboring farms, their herds, equipment, or prior job sites. As veterinarians sterilize-sanitize themselves between farm visits, so must also be the contractor’s crew and their equipment. The service provider may also encounter mandatory quarantine restriction periods (3–7 days) between visitations to primary flock breeding facilities, a minimum of 4–5 weeks for bird houses, and 6–7 weeks for laying houses. Needless to say, technical capability and versatility in applying pesticides and disinfectants correctly during an application processes is mission critical and must be verifiable. No producer or exhibitor is willing to put thousands of animals at risk due to contractor’s negligence or incompetence. Once flock replacement schedules are confirmed, facilities clean out schedule and necessary maintenance procedure is established in written form. Contractors may offer interior or exterior cleaning and pest-bacterial control measures on concrete floors, plastic curtains, ceilings, walls, feeders, drinkers, feed drums and all other production equipment (Fig. 1.4). This includes cleaning and

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.5 Wastewater recovery shoe

decontaminating-sanitizing flock placement vehicles, feed container silos (Fig. 1.5) water supply equipment, etc. Once on-site and cleaning operations are in progress it is important to work closely with flock supervisors and laboratory personnel (veterinarian) that will evaluate and perform bacterial counts on cleaned areas to determine a ‘‘passing’’ status before restocking. Cleaning schedules in hog operations, furrowing and finishing houses may provide a one to four day window in their production cycles. Zoos and safari parks provide cleaning schedules during fall and winter seasons. Aquariums, kennels and racetracks may offer contracting possibilities, seasonal, biannual or annually. In these environments, offering an established biosecurity program integrated to contractor’s application varieties will greatly enhance business opportunities. Most operations own in-house hot or cold pressure washing equipment, performing at 1–3,000 psi, 1.5–5 gpm. The available application range (90%) to the contractor requires between 3 and 8,000 psi at 5 to 35 gpm, hot water 200 Fahrenheit plus and/or cold water equipment. In slurrifying or dredging organic waste, cleaning and sanitizing, decontaminating or sterilizing, the contractor must streamline his hydro-tool variety to the application encountered and may require the following: On demand chemical metering accessories (Fig. 1.1), dehumidifying equipment, hydro vacuum-dredging tools (Fig. 1.5) that are often fitted to a vacuum box; for flat work spin jet equipment with vacuum support, foam nozzles and rotary nozzles; manual or exterior automated tank cleaning equipment, sewer and pipe cleaning nozzles, water-filtration-recycling equipment and/or water abrasive blast gear. Due to ambient temperature conditions (Fig. 1.6) and possible atomizing water jets in agricultural application environments (misting), equipment operator’s pressure-washing or hydro-blasting in confined agricultural areas quite typically experience visibility problems. The possible creation of barn, silo or tank fog within an otherwise routine cleaning application must always be considered.

1.1 Agricultural Environments

5

Fig. 1.6 Milk parlor

According to the specific application, adequate ventilation and/or dehumidifying equipment will therefore be considered. Some applications encounter methane gas environments or chemical-burn-fireexplosion hazards demanding safety procedures to protect structures and involved personnel (pulverized or pressurize-humid grain-organic products). Major applications include: Cleaning grain elevators, feed mill equipment, silos and flour bins, harvesting machinery, vessels, including dredging sedimentation ponds, regenerating water wells and preparing wooden fencing, decks or buildings for staining and/or painting applications. Most high-pressure water cleaning applications may also be offered or are an intricate part to production in orchard, potato, rice, soybean, tobacco including catfish fish farming environments. When out there in God’s country, one must never underestimate the variety of products manufactured. Alfalfa grass is not only used for feed, but also converted into nutritional supplements or added to pharmaceutical products. The sugar cane-root harvest season promotes the seasonal business in sugar refineries. These plants are also often found in sugar beet growing areas as are fuel (ethanol) and power producers, utilizing agricultural product and waste products (Fig. 1.7). Grain production, their mills (Figs. 1.8, 1.9), storage facilities, rail and truck transportation equipment must also be considered. Farming cooperatives may service their equipment in large machine shop facilities in need of periodic cleaning services. There are many opportunities to justify activity in the agricultural environment. Veterinarians and red meat producers may disagree on the best practices for pest or bacteria control procedures. Some prefer the chemical method, others the hot water method or a combination of both. Therefore, applying higher pressures with hot water at 200 plus Fahrenheit and up to 9,000 psi, deep cleaning cracks, bug

6 Fig. 1.7 Feed silos and loading facilities

Fig. 1.8 Grain silos

Fig. 1.9 Cattle feeder

1 Succeed in Residential, Commercial and Industrial Environments

1.1 Agricultural Environments

7

holes and fissures in concrete slabs applying pesticides, killing pest eggs, larvae and bacteria should be sufficient in convincing either veterinarian or producer. Further applications include: Coating-paint removal on steel or concrete surfaces in aquariums, sedimentation vessels, pools of all types, animal exhibition and holding areas; Cleaning and treating pedestrian areas, fountains, ponds and public exhibitions; Decontaminating, cleaning, restoring aluminum or stainless steel equipment, tractor trailers, tanks, etc. with acid treatments; Sterilizing and sanitizing animal operating rooms, recuperating cells, and holding areas; Routinely sterilizing, sanitizing and treating production equipment in poultry hatcheries, cattle and hog facilities. Contacts. Your local veterinarians and associations, avian contract breeders, zoo curators, purchasing and maintenance superintendents, dog pounds and kennels, breeders and farmers, truckers and feed lot operators (Fig. 1.10), dog and horse racing facilities. Resources. Equipment and materials; WJTA, PNA, CETA, SSPC. On the Internet. Veterinary associations, farmers and livestock cooperatives. Principles of disease prevention in commercial broiler integrated operations. Research requirements for biosecurity, cleaning or decontamination-disinfecting poultry equipment and housing; contact the American Association of Avian Pathologists, University of Pennsylvania. Safety. On the Internet. Research sanitation performance standards compliance guide, FSIS-USDA best practices for equipment maintenance by pressure washing, http://www.cfsan.fda.gov/*lrd/hccp.html, Competency in agricultural hygiene. Safety procedures vary, depending on application and may include establishing confined space entry procedures, air monitoring devices, electrical or mechanical equipment lockout procedures. Establishing a step in/out area, where disinfectants are applied to boots, protective clothing and tools, or an all in/out decontamination procedure. A multitude of industrial safety regulations may be required.

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1 Succeed in Residential, Commercial and Industrial Environments

APPLICATION REVIEW Da

Customer, Company:

Date:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail:

Maintenance

Safety

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Concrete cleaning, feeders, tanks, production equipment, silos.

WORKSHEET- PURCHASING - SALES

1.2 Asphalt-Tar-Mastics Industries, Bituminous Compound, Manufacturers

9

Fig. 1.10 Tar-pitch-product facilities

1.2 Asphalt-Tar-Mastics Industries, Bituminous Compound Manufacturers, Solvents, Emulsions, Adhesives Environment In the mid 1950s, plant maintenance personnel invited Wolfgang Maasberg Sr., founder of WOMA corp., to design and develop specific tooling for coal producers’ hardware, taking into consideration the difficulty of cleaning tar-pitchproduct and treatment facilities (Fig. 1.10). Supported by the pump’s quickexchange plunger capability in manipulating the crucial gpm–psi ranges deemed necessary for product cutting or scaling applications, Otto Teufer, a WOMA employee who was considered a bona fide high-pressure water application technician in the developing Hydro-blast market designed an array of nozzles, lanceflex-lance equipment and combined them with tank and pipe cleaning techniques, applying 7,000 psi at various gpm-hp ranges. It was obvious to all involved that his discipline and work ethic as a submarine captain during World War II had given him great insight and intuition to correctly develop high-pressure water tooling. This in particular where the visual performance confirmation of a nozzle pattern, water-jet product penetration and tool interaction with scaled refuse manipulated in a confined space (sewers, pipes, flue-exhaust duct, etc.) was unknown or technically–physically not manageable. The ingenuity of Otto’s techniques are today utilized by service providers with sophisticated equipment or application methods and are still steadily employed by asphalt emulsion-solvent manufacturers, bituminous roofing, vinyl flooring production facilities, coating manufacturers, asphalt recycling plants and asphalt paper-felt manufacturing processes only to name a few. He also constantly stressed that in an emerging hydro-blast market, manufacturing processes-technology-hardware and possible fouled product characteristics must be understood before a correct hydro-tool selection, safety procedures and necessary supplies could determine a successful

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.11 Refinery

Fig. 1.12 Gravel mill for asphalt-concrete

job completion. Regardless of previous successful cleaning or scaling methods, tooling and pump fluids applied (water–emulsions–oils) the behavioral product characteristics of bituminous, viscous-sticky products such as tar, pitch, bunker seed or liquid mastics must always be taken anew into consideration. Tar is derived by the destructive distillation of coal or the cracking process of petroleum (refineries Fig. 1.11). Straight run asphalts are distillates resulting from the evaporation of the volatile constituents of crude oil in a vacuum in the presence of steam. The further the distillation is carried, the harder the product. Blown asphalts are produced by blowing air through soft asphalt or heavy bituminous oil at high temperatures. These asphalts have a higher softening point, lower ductility and are less affected by temperature than comparably hard straight run asphalts. Emulsified asphalts are emulsions of asphalt cement and water that contain a small amount of an emulsifying agent. Cut back asphalts are asphalt cements that have been liquefied through blending with petroleum solvents. They are used as binding agents in cold mixed asphalt-concrete or as a penetrating prime coat surface treatment applied, for instance, on water dams, bridge or building foundations. The industry provides five penetration grades indicating the hardness of asphalt cement (Fig. 1.12) before mixing and at surface temperature; AC. original viscosity, AR. viscosity after hot mixing (40–50, 60–70, 85–100, 125–150 and 200–300).

1.2 Asphalt-Tar-Mastics Industries, Bituminous Compound Manufacturers

11

Fig. 1.13 Asphalt plant

Penetration and adhesion parameters of asphalts or coatings must be known when cleaning procedures are defined. Porous, cleaned or reconstituted surfaces (anchor profile) which receive a new product or coating system should preferably receive a compatible product, producing and guaranteeing correct adhesion effectiveness. The contract cleaner servicing a tar manufacturer’s distillers, tanks, heaters, condensers, pipe systems or their containment areas should consider the vast array of products manufactured elsewhere utilizing tar in one form or another. To name a few corporate identities; Weather-control-protection-roofing products, irrigation pipes, insulation foils, pavers, adhesives-mastics, and paint-coating manufacturers. These can be serviced applying the existing knowledge base and equipment-tool variety. Removing asphalt residue or tar appearing in bulk (Fig. 1.13) or thin layers has in the past been achieved by vacuum, steam, chemical cleaning or sandblast methods. Heated product behavior can be quite controversial when attempting to achieve the desired cleaning objectives. Steam composed of heated water/air droplets in a highly compressed stage leaving the nozzle orifice will create an ultra-high velocity when expanding into the atmosphere, thereby diminishing the mechanical energy rapidly by becoming a compressible blast medium. This process will not allow efficient bulk product removal above 1/8 in. Asphalt products softened by heat will move and generally then again adhere to surfaces yet to be penetrated by heat and steam velocity. This situation can be frustrating. Some contractors will apply chemical agents or emulsifiers to lubricate loose material in an effort to eliminate cleaning surfaces twice, creating quite a mess. The Hydro advantage is relatively low water compressibility, at approximately 0.5% at 10,000 psi, allowing a great nozzle standoff distance to the material being removed with minimal mechanical energy loss, moving the bulk material quickly and in a comparatively controlled fashion. Against popular belief, viscous tar, bituminous or bunker-seed products can be removed, pumped and emulsified with much higher efficiency than generally known by applying either water or emulsifying agents as the pump fluid medium. This is noticeable especially when the application is combined with a Hydrovac system operating in dry mode, removing the material from the jobsite.

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.14 Asphalt-gravel chute

Abrasive blast techniques are successful in removing thin layered asphalt, tar and mastic products (Fig. 1.14). The sandblast system’s energy can be transmitted to the product and surfaces quite well. Air velocity will accelerate the abrasives extremely high, creating a better nozzle standoff distance compared to steam systems. However, the problems are evident. Continually adding blast material to the product is considered undesirable as this will increase overall volume, removal and transportation costs. Adding a porous profile (Fig. 1.15), especially where soiling reoccurs, will certainly hamper future cleaning attempts. When porous base surfaces are present (anchor profile), sandblast, steam or chemical techniques are slow and cumbersome while hydro-blasting, pressure washing procedures surpass and excel in time management, equipment mobilization and environmental protection. At times, on an existing structure where an anchor profile must be added or reestablished, hydro-blast and abrasive blast techniques (air-slurry-water-abrasive) are combined, preparing base surfaces for future coating procedures. There are also some applications where ice blasting techniques can be employed in a stepped combination with high-pressure water (2,000–3,000 psi) producing accelerated bulk removal times due to the products low temperature (coal-tar-mastics). Recently developed industrial ice blasting equipment is in its infancy, but promising, especially where distances between equipment and jobsites (trigger gun operator) could exceed 50’. Establishing a controlled, measurable or adequate anchor profile for most coating applications is limited. Contractors apply high-pressure water to clean or prepare production facilities in asphalt stills, processing raw asphalt into a roof grade product or offer their services to companies converting glass and organic felt into asphalt-bituminous mats, insulating siding, coal tar emulsions, asphalt mastics or powder goods and to manufacturers of general construction and weather sealing products such as mineral asphalt-shingles etc. Services include cleaning heat exchangers, boilers, polymer tanks (Fig. 1.16), vacuum suction roles, flue systems, water treatment

1.2 Asphalt-Tar-Mastics Industries, Bituminous Compound Manufacturers

13

Fig. 1.15 Asphalt plant loading tracks, heater and baghouse

Fig. 1.16 Asphalt polymer tanks

Fig. 1.17 Rock quarry sorting plant

facilities and so forth. Rock quarries producing gravel, sand or concrete may also manufacture asphalt-bituminous products utilized in (hot) road surfacing applications. These plants are open to hydro services in a multitude of environmentsmanufacturing hardware du to a great product variety manufactured combining the composition of oil or coal tar (Fig. 1.17). General water pressures throughout this industry range from 3,000 to 20,000 psi at various gpm performances.

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.18 Asphalt loading facility

Surface cleaning and surface preparation methods for re-installment of paint and coatings will provide an outstanding adhesion factor. Deep penetrating highpressure water can prepare rock foundations, fissures, expansion joints, etc. Expert tool configuration permits surface preparations of soft underlay substrate such as rubber, plastic, wood and wallboard, or hard concrete and steel surfaces. Above and below grade, structural water proofing applications, architectural restoration and mold remediation are all business facets important to the pressure washing and hydro blasting contractor. Contacts. Purchasing, maintenance superintendent in distribution facilities, municipalities, related trucking, transportation (Fig. 1.18). Asphalt-mastic-coating, waterproofing companies, restoration, demolition, quarries and construction industries, equipment rental companies etc. Resources. Technical ‘‘SSPC–WJTA’’. Trade papers, bid and contracting information on specific job descriptions provided for contractors and subcontractors by corporate web sites. National association of waterproofing and structural repair contractors, http://www.nawsrc.org, Water-Proofing contractor Association, htpp://www.the waterproofers.org Bitumen Waterproofing Association, http://www.bwa-europe.com, Web info: ‘‘Asphalt-tar-mastics-manufacturing’’. Safety requirements. Dependent on application, confined space entry permits, hazardous awareness training, competency in scaffold primary access (PAT), and supervisory competent person training (CPT). Hazardous waste management, EPA-OSHA-CWA-HUD compliance. Numerous applications frequently require a combination of controls.

1.2 Asphalt-Tar-Mastics Industries, Bituminous Compound Manufacturers

15

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

Purchasing

Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering

Tel: e-mail: Area:

Maintenance

Tel: e-mail: Area:

Safety

Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Tar and asphalt related production equipment, tower distiller, tanks, tub heaters or condensers, suction rolls, waterproofing, faults and fissures profiling.

WORKSHEET- PURCHASING - SALES

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1 Succeed in Residential, Commercial and Industrial Environments

1.3 Automotive Manufacturers, Automotive Industries, Suppliers Before World War II, the versatile industrial complex in the USA required high volume fluid transfer processes at comparatively elevated pressures (1,200 psi plus). Applying a massive horsepower input, Allis Chalmers, Gardner Denver, Ingersoll-Rand and F.E. Myers etc. provided the know-how and manufacturing capacity to develop and deliver enormous high-volume reciprocating pumps operating within their industrial environments. Necessary maintenance and cleaning cycles on in-plant hardware in these environments utilized a variety of mechanical and chemical cleaning procedures which starting in 1956 Europe were uncompromisingly displaced with tools manipulating high-pressure water. These tools replaced chemical circulation-purging and flushing methods, surface cleaning or product removal by steam cleaning equipment, rotary-flex lance brush and drill pipe operations servicing fouled boiler, condenser and heat-exchanger tubes. As water powered abrasive-blast equipment proved functional, rust, including paintcoating removal and establishing or reestablishing an anchor profile by applying air or electric driven needle-chisel-guns and in numerous industrial environment abrasive sandblast techniques were increasingly replaced or reduced to a supportive maintenance role (1959). Also, in light of the newly discovered application variety, Europe witnessed in the late 1950s, an accelerated hydro-blast equipment and tool development phase geared to Western, Mid and Far-Eastern industrial markets substantially surpassing technical development criteria and equipment sales in the United States. The introduction of high-pressure water in early 1960 as a cleaning, scale removal, abrasive-blast or vacuum tool proved cumbersome on US soil. Entrepreneurial efforts in the US converting the existing reciprocating pump equipment by reducing fluid volume and raising operating pressures to hydro-blast performances was the preferred norm and proved awkward. Also quite unexpected was the skepticism and disbelief in high-pressure water tool capabilities by plant maintenance personnel, competing service providers, pump manufacturers and engineering identities alike. Skepticism stubbornly prevailed into the mid 1960s. Surprising, as in the past high-pressure water already gained prominence in hydraulic mining procedures, steel slag removal-quench-methods, washing concrete slurry off newly poured structures on construction sites or applying low-volume pressurized water to clean in agricultural environments (Fig. 1.19), slaughterhouse facilities, pulp, paper and cardboard industries and servicing vehicle fleets. In Germany mid 1956’, founder Wolfgang Maasberg, WOMA Corp., in the early 1950s Paul Hammelmann, Hammelmann Corp. and Alfred Kärcher, Kärcher Corp., all three in somewhat similar positions after the war, believed in Wolfgang Maasberg’s idea and concept ‘‘water as a tool’’. Alfred Kärcher repaired US military steam cleaning equipment which resulted in the development and manufacturing of Kärcher hot and cold pressure washing units and tooling.

1.3 Automotive Manufacturers, Automotive Industries, Suppliers

17

Fig. 1.19 Early twin piston pump

Fig. 1.20 Left, Oskar and Wolfgang Maasberg, Sen

Wolfgang Maasberg (Fig. 1.20), operating out of a car garage at his father’s business Oscar Maasberg in Duisburg, sold to slaughterhouse operations and dairies the F.E. Myers reciprocating pump line, operating up to approximately 1,200 psi. To overcome the lack of applicable water pressure he then sometimes found it necessary to substitute or return to chemical cleaning methods. This led him to specifically design and manufacture the first hydro-blast pump series, (starting at 75–150 then 45 hp Fig. 1.21) founding as a result WOMA Corp. At this time his pump design already featured quick exchange plunger configurations. The Pump head incorporated a manual pressure regulator permitting a gun-valve design, achieving the all important water shutoff capability operating above 5,000 psi. Paul Hammelmann followed immediately by designing and improving available hydro-blast tool configurations converting his existing industrial Ruck-Zuck pump identity to hydro-blast equipment. Today Hammelmann Corp. is known worldwide and noted for their successful upright packing-less pump designs. In the US, George Rankin, founder of Aqua-Dyne, Houston, Texas, also a pump engineer and one of the first to develop hydro-blast pumps, gear and fluid ends within a comparatively compact design structure avoiding competitor’s habits (US) to convert fluid transfer pumps to hydro-blast equipment.

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.21 75 hp, quick exchange plunger and pressure regulator

Fig. 1.22 43,000 psi Hp-gun

In the early 1970s, Flow Research of Renton, Washington was sponsored by the US government to develop hydraulic powered intensifiers, achieving water pressures of an astonishing 60,000 psi plus. ADMAC, a partner of Flow Research, followed to develop and produce, in the USA, the first mobile contract cleaning, paint stripping and steel-concrete cutting UHP units. In-house stationary UHP pump intensifying equipment developed into two and three dimensional component cutting systems. These units incorporated abrasive or nonabrasive water jets in conjunction with NC, advanced CAD and robotic equipment and were integrated in a wide area of industrial manufacturing processes to enhance conventional product cutting methods. For instance, the equipment produces precision cut instrument panels, carpets, headliners, bumper parts and a multitude of composite component products. This is not to say that the automotive industry inspired engineers to develop equipment in the UHP pressure range. Challenging application requests from the marine and industrial environment, application specific parameters, required tooling and operational effectiveness (efficiency), are the forces spurring high-pressure water tool designs (Fig. 1.22) and applicable pump pressures to 55,000 psi. Hydro-pump manufacturers (reciprocating) strive to achieve operating pressures at 55,000 psi plus, redefining tool development anew (hoses, nozzles, rotary seals, etc.) for service providers, equipment designers, and their customers. Accommodating the car and industrial vehicle manufacturer, automated or manual service requirements seldom exceed 40,000 psi operating pressure. In their

1.3 Automotive Manufacturers, Automotive Industries, Suppliers

19

Fig. 1.23 a, b Coating removal

respective foundries, the global car manufacturing industry, starting with Mercedes, GM, Ford and VW began in the late 50s to experiment and clean their engine motor blocks. Casting sand and protruding metal flash were removed in oil and water passages with approximately 5,000 psi, at about 5 gpm. Ever since, high-pressure water cleaning applications have found their way into manufacturing environments, providing successful service solutions. In the early 1960s, as equipment durability and water pressures became adequate, the paint removal application expanded into automotive paint facilities (Fig. 1.23a, b). Manufacturers, in their pursuit to apply superior paints to their products, benefit with today’s available pressure–volume ranges and tool capabilities. Through the years, paint and coating development for impact and abrasion resistance, adhesion parameters and thermal durability in structure, led to a slow but constant rise in necessary water pressures regardless of a specific tool utilization or water volume configuration. Combined with application specific tools, the UHP low water volume cleaning method offers a superior controllable product penetration. While in operation, comparatively lower tool recoil forces result in the laborer’s extended physical endurance and safety. This permits the manual cleaning of vehicle transport equipment, paint booth surfaces and so on. Substantial flat work and grid-iron surfaces may also be cleaned with hand held or mobile spin jets. Contract cleaning companies offering their service capabilities to the automotive industry may approach their clients with a multifaceted sales strategy. Most manufacturing plants have their in-house equipment and unionized labor force involved with specific turnaround schedules and maintenance procedures. The marketing strategy can, but should not be, based on turnaround schedules when streamlining an entrance to this field. Contractors do well in constantly educating maintenance engineers and purchasing identities in their specific areas, offering new application technology and equipment capabilities which cannot or

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1 Succeed in Residential, Commercial and Industrial Environments

will not be challenged by the in-house labor force. Aggressive competitiveness, technical superiority, a close relationship with contractor’s equipment engineering departments and a superior emergency response capacity will provide contract possibilities when in-house inoperable equipment, union strikes, a newly developed product line or manufacturing necessities arise. When all other business parameters, such as insurances, labor force status, equipment durability and accessibility is guaranteed, routinely upgraded and reviewed by customer’s maintenance and purchasing department’s, employment is plausible. Contractors operating hydro-blast equipment offer in-house applications for automotive manufacturers to include: tank cleaning procedures, paint removal on grid flooring, paint spray booth surfaces, cleaning chassis transport units and their related manufacturing equipment. Heating ducts and air-conditioning systems, bag house, flue-stack and heat exchanger or boiler services may also be offered in a subcontractor status to specific hardware suppliers and erectors. Cleaning floor surfaces in machine shop and warehouse facilities with a minimum 20,000 square-foot per hour surface cleaning rate (36 hp plus), which includes the recycling of blast water, is also an important facet. Manufacturing and warehouse facilities’ pipe-sewer systems, and followed by servicing the water treatment plant again is a further aspect one must consider. Service providers operating hot or cold pressure washing equipment (3–5,000 psi.) clean the following: Loading docks, industrial-commercial warehouse facilities, air-conditioning, heating and duct systems or equipment, in-house cafeterias, wash and change rooms. Smaller machine shops are cleaned by utilizing floor spin-jets with water filtration recycling and oil water separation equipment. This equipment can also be useful when cleaning parking lots and car garage structures or when providing chemical spill and storm cleanup services (Fig. 1.24 a–c). Tractor trailer fleets, cars for dealerships and vehicle rental companies, tractor trailer manufacturers, their engine and drive train repair facilities, trailer axle rebuild and service companies are all corporate identities to be considered. Contact. Engineering, housekeeping, purchasing, maintenance superintendent for car truck-rental companies, engine-transmission-drive train rebuild operations, automotive part manufacturers, automotive paint shops, vehicle dealers, warehousing, vehicle shipping and trucking facilities, automotive foundry and metal works. Resources. Yellow Pages, Trade papers, Internet. Automotive plant maintenance facility contracts through engineering, purchasing and maintenance superintendents. Automotive trade associations, such as AWDA the warehouse distributors association http://www.awda.org, or manufactures, distributors and dealers association and general automotive trade identities http://www.ashop.org, their machine shop facilities, purchasing and maintenance personnel. Safety requirements. According to application encountered, combinations of controls are frequently required.

1.3 Automotive Manufacturers, Automotive Industries, Suppliers

21

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering

Maintenance Tel: e-mail: Area:

Tel: e-mail: Area:

Tel: e-mail: Area:

Safety

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Warehousing, trucking, loading docks, machine shops, paint shop facilities, chassis transport equipment, Garage structures and bag house units.

WORKSHEET- PURCHASING - SALES

22

1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.24 a–c Fleet washing, water recovery-recycling

1.4 Airports, Aviation Industries and Their Municipalities, Suppliers The aviation industry always offered a wide variety of flat work (horizontal), serviceable equipment, buildings and business identities. This fact accelerated in the early 1960s development of application possibilities which today contractors and equipment manufacturers do specialize in. Service companies do well when competing throughout the private, commercial and military aviation industry, applying pressure washing, hydro-blast and UHP technologies. Take into consideration the thousands of runways and landing pads within the continental USA and their subsequent necessary service support. Pressure washing contractors clean private and commercial aircraft utilizing wash water recycling procedures, a variety of specialized tooling and polishing techniques to remove engine exhaust stains, oil and insect splatter from wing (Fig. 1.25), aircraft cowlings and discolored or soiled fuselage areas or the concentrate on servicing hangars, machine shops, freight facilities, restaurants and parking garage structures and their floors (Figs. 1.26, 1.27, 1.28). Industrial hydro-blast services may remove rubber on runways, service b heat exchangers and chillers in air-conditioning and heating systems, clean lube oil and fuel tanks as well as removing industrial coatings on hangar floors and structures.

1.4 Airports, Aviation Industries and Their Municipalities, Suppliers

23

Fig. 1.25 a–c Wing surfaces Fig. 1.26 Pedestrian areasbefore

Fig. 1.27 Pedestrian areasafety cones

This environment also holds a vast application array within surrounding support businesses. Staying abreast of newly developed application varieties, subsequent tool and equipment changes, the aggressively changing technology provided by the pressure washing and hydro-blast manufacturing industry demands the constant education of purchasing agents, maintenance superintendents, contractors and their labor forces alike. Competition is stiff; therefore contract cleaners cannot sit back and wait for contracting opportunities provided by walk-in customer contact. To gain experience in this field, smaller corporate service identities or entrepreneurs may pursue a subcontractor status with larger established companies. Approaching the industry’s hardware suppliers, commercial building management identities, building contractors, their coating and painting companies may accelerate the learning curve substantially. A job specific superior hydro-tool variety enhancing productivity is also important to establish prominence within this field. Service providers pursuing contracting bid status should research the FAA’s (Federal Aviation Administration) compliance regulations when involved with aircraft or air carrier companies. They familiarize themselves with airport

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.28 Pedestrian areasafter

authorities’ runway maintenance schedules, requirements and guidelines, the proper containment and filtration or recycling practices of blast-wash-waste water today also established by airport authorities, city, state or the Environmental Protection Agency (EPA) and learn to comply with labor safety standards guided by the Occupational Health and Safety Administration (OSHA) (Fig. 1.28). Providing adequate insurance is a business strategy amid a wide ranging price variance. A runway cleaning contractor will pay a substantial higher annual rate than the service provider cleaning airport parking structures. Due to the application variety, which may start with servicing airport restaurant kitchen exhausts (hood systems), airline catering food storage-manufacturing and receiving areas to rubber or coating removal on runways and in jet bridge areas renders the insurance question an important, sometimes decisive one for competing contractors. Within the constant landing process of aircraft a tremendous mechanical friction between runway and aircraft tires results in a gradual rubber build-up, decreasing effective braking performance in adverse weather conditions. In the past this rubber build up was removed through a sandblasting process or chemical treatment. Needless to say this was inadequate. In the mid 1960s WOMA Corp., West Germany, designed and developed a runway cleaning (test) unit operating between 150 and 600 hp. Much of their technical base knowledge applied then was derived from the manufacturing of street washing (Fig. 1.29) and sewer cleaning equipment sold throughout European municipalities. This street washing equipment operated in combination with a standard rotary brush supported by a curbside mounted vacuum shoe featuring a high-pressure water jet spray bar. A hydro vacuum injector (Hydrovac-system) delivered refuse and water to the onboard mounted water filtration recycling unit. This wash or blast water recycling capability is now a must for competing service providers. In 1967, while cleaning and removing rubber build up on runway surfaces at NATO airports, such as the Husum air base near the Danish border, it became obvious that environmental changes, runway structure (Fig. 1.30) and surface friction coefficient, (asphalt-concrete-rubber) were not the only parameters for a correct cleaning and rubber removal solution by high-pressure water. The following parameters were then established: Necessary pressure and water volume configurations on a multitude of runway (asphalt-concrete structures,) considering the multiple ambient temperatures and surface conditions, followed by adequate nozzle designs, their standoff distances, rigid and/or oscillating spray bar configurations, their width and horsepower requirements. Consolidating all

1.4 Airports, Aviation Industries and Their Municipalities, Suppliers

25

Fig. 1.29 a–c 1963 Street washing equipment

technical variables became measurable-recordable by outfitting the unit with a manually metered, onboard hydraulic drive system powered by PTO. The elimination of the driver clutch and gas pedal operation provided precise measurements in cleaning, rubber removal times and nozzle performance criteria while guarding against surface polishing or otherwise possible concrete or asphalt surface damage. Today, operational changes are obvious. Pressure and volume configurations have altered due to technical developments, environmental considerations, runway design and surface testing procedures. Cleaning intervals are determined by aircraft weight, landing frequency, temperatures and general runway surface conditions. High traffic runways are generally serviced bi-annually. Airport maintenance may also resort to optical, physical, friction and texture testing procedures on the affected pavement before and after cleaning (mu-meter, grease- smear technique, ultrasonic thickness gauging). Coating or paint removal on taxiways and runways, Jet Bridge and plane parking areas (Fig. 1.31a, b) are next on the list of possibilities. Constant construction cycles and multitude of approaching aircraft types in service areas produce a necessary, quite lucrative and specialized field in itself. Epoxy coatings, plastics, bituminous paints found in the above-mentioned areas as well as in aircraft hangar’s general aircraft production lines and paint facilities belong to this application group. Blasting expansion joints clean of existing rubber or bituminous systems found on runways and taxiways can be achieved at any necessary width, depth or length.

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.30 a, b Runway layout

Fig. 1.31 a, b Jet bridge area

One must be cautious in determining why the need to do so arises. Maintenance operations vary extensively in their reasoning, due to changing weather, environmental conditions, normal-abnormal aircraft tire wear during the landing process, concrete surface and subsoil conditions including expansion joint service b history or general construction procedures. Corrosion-rust accumulations removed by various high-pressure water blast techniques followed by chemically cleaning and painting or coating procedures in air conditioning, heating systems, vacuum ducts, tanks and pipes below or above ground can effectively be offered and performed as an competitive and save alternate solution. Aircraft engine parts operating at extreme high temperatures are the most difficult to clean and strip of their soiling or coatings. Coating processes, materials, operating temperatures in their specific engine locations are parameters a UHP manufacturer considers when supplying automated equipment to the aviation industry. This field is quite specialized and does not directly compete with a contractors’ business environment. Nevertheless, in some areas, developments in coating removal practices are applicable to the industrial field. Cleaning an airports heating and air-conditioning system, their condensers and chillers (Fig. 1.32) or jet fuel and oil tanks including their pipeline systems are more or less industrial applications performed by experienced service companies.

1.4 Airports, Aviation Industries and Their Municipalities, Suppliers

27

Fig. 1.32 a, b Condensersheet

Fig. 1.33 a–c Before-after and source

Airport parking-garage structures, airline catering and foodservice facilities, pedestrian and employee traffic locations, exterior building cleaning, truck loading docks, freight distribution centers, machine shops and so forth are applications providing great growth opportunities for the successful commercial pressure washing service company (Fig. 1.33).

28

1 Succeed in Residential, Commercial and Industrial Environments 1.4.18 APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Fig. 129. c. 1963 Vacuum-jetting apparatus for mobile self-contained and water recycling street washing equipment, later converted for various surface cleaning applications including rubber removal,( second patent draft).

Safety equipment and procedures:

©

Expansion joint services, food catering facilities, warehouse services, epoxy and paint removal, concrete cutting, tank cleaning, sewer cleaning.

1.4 Airports, Aviation Industries and Their Municipalities, Suppliers

29

Fig. 1.34 Aircraft coating removal unit

A multitude of equipment is available operating at 3–55,000 psi with water volumes varying by applications encountered (Fig. 1.34). Water filtration and recycling units will greatly enhance contracting possibilities, especially when combined with a vacuum recycling capability, separating and isolating debris. Achieving acceptability as a subcontractor with construction, restoration, industrial maintenance, and coating/paint companies is of vital interest to the new comer. Contacts. On the Internet Airport Management Associations, Purchasing, engineering, maintenance through airport authorities, air carriers, includes air freight carriers, corporate fields for contracting policies and procedures, aviation insurance carriers, requesting vendor’s application form for annual contracting opportunities and contact, Airport pavement maintenance management. Resources. Equipment-technical support. WJTA–SSPC. General information; Air Transportation Association (ATA) offers an online database, aviation marketplace, also contact the Federal Aviation Administration’s acquisition’s policy and contracting departments, craft dealers, brokers and private clubs. Safety requirements. Customers requirement, specific to applications encountered.

1.5 Battery Manufacturers, Recyclers, Suppliers, Process Equipment Battery manufacturing and recycling processes and their chemical, plastics and metal suppliers are an obvious customer base for the industrial contractor. The major battery groups are nickel–cadmium, nickel–zinc, nickel–alkaline, nickelmetal-hydrate, lithium–ion and commercial or industrial lead acid deep-cycle batteries most commonly found in cars, boats, forklifts and the industrial environment. In the last 20 years a multitude of custom battery packs, lead acid

30

1 Succeed in Residential, Commercial and Industrial Environments

hybrids, rechargeable micro batteries were developed and are found in the computer, aviation, auto and medical environments. The recycling process starts by the removal of combustible materials such as plastics. Plastics are melted and forced through an extruder, producing pellets for reuse in the battery manufacturing process. Separating plates, alloys and acids are the next step. Lead parts and lead oxides are melted in smelting furnaces producing ingots at 65 pounds, or hogs at 2000 pounds. This lead again is recycled for the manufacturing of new batteries. Acids are either processed or converted into sodium sulfate which is applied in detergents, glass and textile manufacturing or neutralized with a baking soda like compound, resulting in treatable water which is then restored to clean water standards. The variety of base products found in the battery manufacturing and recycling process are plastics-polypropylene-vinyl, polymers, carbon graphite, nitric acids, sulfuric acid converted to hydrochloric acid, lead–lead oxides, nickel hydrate, zinc, lithium, titanium, platinum alloys and an array of insulation materials. Considering all these battery components, it is obvious that the industry is highly regulated by local, state and federal agencies which inspect manufacturing and recycling plants periodically to verify the compliance to required standards. Contractors and service providers research this environment and do best by obtaining all necessary permits and licenses to adequately perform and promote their business possibilities. Gaining knowledge in industrial lead abatement procedures, labor hygiene, air filtration and clean air work practices is of significance, as is the awareness of technical or circumstantial fugitive potential lead emissions. For instance this may include poorly cleaned and dried surfaces introduced to air turbulence or cross winds resulting in unacceptable air lead contamination. A contractor and customer may be surprised that past cleaning efforts were only visually successful. Other lead dust sources can include dry sweeping, deferral-suspension by water mist, fumes, and burning. Also, when providing mobile vacuum, water filtration and recycling equipment procedures the components such as carbon, phosphoric or otherwise filtration (HPAC) systems must operate within regulatory standards. Competent contractors provide proof of equipment capabilities, which can result in laboratory test procedures sampling for contamination on equipment surfaces, collected effluent and air exhaust streams. Submittal of federal-state licenses and the capability of adhering to customers’ plant safety procedures are necessary in achieving a bid status. Manufacturing facilities and recycle plants install interior and exterior air monitoring equipment to provide verification as to the permissible airborne activity within regulatory laws guarding against potential lead overexposure. Labor forces operating within these areas are informed in writing of the potential harmful effects when exposed to lead. Contaminated clothing cannot leave the jobsite and must be handled in accordance with company and OSHA regulations. The correct use of personal protective equipment (PPE) is imperative. Respiratory protection, positive or negative airflow situations are encountered and have to be correctly dealt with. In general, manufacturing plants submit and

1.5 Battery Manufacturers, Recyclers, Suppliers, Process Equipment

31

enforce safety regulations vigorously and are supportive when contractors adhere to them, especially when in-house safety classes are provided to contracting forces. The contractor’s labor force may also be required to produce certification from a blood lead laboratory prior to job or bid execution. The entry-level entrepreneur will find this industry quite stimulating. He is advised to research EPA and OSHA requirements, and enrolls in necessary training courses to gain competency status through testing, acquiring hazardous material removal training and confined space entry procedure training. It sounds more difficult than it actually is. The acquired education will help tremendously in choosing the right equipment and work method necessary to compete in this field. Plant shutdown or turnaround schedules allow for the cleaning of the spent battery reclaim, repair, receiving, assembly, plate processing, oxide and grid production areas, followed by services to the plants environmental pollution control system as is the cleaning of under floor pipe ducting and filtration equipment, employee change rooms, truck loading docks, general storage facilities and the cleaning or preparation of concrete containment areas for coating procedures in areas where acid or chemicals are manipulated. The utilization of vacuum supported spin jets and water recycling/filtration systems are of great benefit. Industrial contractors also service battery crushing equipment, separation and desulphurization units, their piping and conveyor systems, tanks, water treatment facilities, sodium sulfate crystallization plant hardware, furnace flue gas heat exchangers, their piping and bag house systems, including rotary furnaces, crystallizer towers, hoppers, condensers and stacks, lead smelter equipment, wet and dry scrubbers and so forth. Contacts. Purchasing Departments, maintenance superintendents, plant laboratory personnel, plant engineers in manufacturing, distribution, transportation, and recycling facilities. Resources On the Internet ‘‘Battery council.org’’, ‘‘A–Z industry groups, associations and organizations’’. Battery recyclers waste prevention, storage-fuel cell, and battery engineering departments. ‘‘Battery manufacturers-processesequipment’’. WJTA for equipment specifics, SSPC for supervisory and competent person training for ‘‘DELEADING of industrial structures’’. Safety requirements. Hazardous waste management and awareness, EPA-OSHA-CWA regulations. OSHA provides an interactive web-based training tool on lead exposures in battery manufacturing environments, safety and health topics, http://www.osha.gov. In-plant training of specific corporate and plant safety requirements, respiratory protection and medical surveillance, identifying potential sources of exposure, Supervisory and competent person training (CPT). Many applications frequently require a combination of controls. Individual state laws may be more stringent than federal laws.

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1 Succeed in Residential, Commercial and Industrial Environments

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing Tel: e-mail:

Engineering Tel: e-mail:

Maintenance Tel: e-mail:

Safety Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review: Safety equipment and procedures:

©

Receiving and pollution control areas, truck loading docks, condensers, heat exchangers, tanks, crystallization plant equipment, bag house units.

1.6 Beverage Bottling Facilities, Breweries and Distilleries, Juice Processing In this global industry at virtually every production level one will find successful application technology applied. The vast variety in product or produce converted into digestible liquid substances is unlimited. Service providers must study and understand the process and process equipment necessary to convert raw materials into finished products. Raw material processing differentiates dramatically between product identities, seasonal schedules and is paralleled only occasionally in manufacturing, for instance within the bottling, packaging and shipping method. Plant layouts and manufacturing hardware also vary between product identities and age of the plant encountered. Beer, wine and distillation processes have been with us for ages. This industry was one of the first to apply pressure washing and hydro-blast applications in the early to mid 50 s. Equipment manufacturers supply mobile and stationary equipment integrated into specific and continuous workflows, generating pressures from 1,500 to 5,000 psi, 180 plus hot or cold water, chemical metering devices applying suds-soaps, automated tank (Fig. 1.35) or barrel cleaning equipment and product recovery systems which include workstations with multiple gun operation capability situated on hotspots in the production line.

1.6 Beverage Bottling Facilities, Breweries and Distilleries, Juice Processing

33

Fig. 1.35 Telescope fixture

In the last 35 years this industrial complex advanced enormously in plant automation, encompassing all production lines. In only one regard has nothing changed and that is expressed in producing continuous good and extremely taste neutral clean water. Companies may utilize two water supply systems for lesser and higher-quality potable water resulting in large water purification systems featuring filtration, reverse osmosis, boilers, heaters, condensers and evaporation units where periodic hydro blast services are necessary. When production plants are located in remote regions where water access may be a problem and water conservation is a given, a coarse solid waste grouping of production materials and byproducts is performed utilizing cross filtration units, centrifugal separators, etc. The constant cleaning, sanitizing, sterilizing and pasteurization process and sometimes unavoidable occurrence of product spill

34

1 Succeed in Residential, Commercial and Industrial Environments APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing Tel: e-mail: Area:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Fig. 1.36 3D Nozzle

Safety equipment and procedures: Cooling tower, evaporators, fermentation tubes, refrigeration systems, cold storage facilities, tanker trucks,

WORKSHEET- PURCHASING - SALES

Fig. 1.36 3D nozzle

1.6 Beverage Bottling Facilities, Breweries and Distilleries, Juice Processing

35

requires large effluent treatment plants to control waste streams delivered by pipe systems, floor drain, pits and trenches. This effluent, or better said, waste stream, must be chemically neutralized with a pH correction procedure in place to avoid overloading the treatment plant and its equipment, again providing hydro-blast and pressure washing applications. In any case, most companies are not permitted to incorporate the storm water system within their operation, demanding tight controls from in-house laboratory quality control managers, enforcing hazardous and critical point inspection procedures. Byproducts may be separated, dried and milled supporting secondary product identities in medical, pharmaceutical or for instance in feed and fertilizer manufacturing operations. This provides the next layer of equipment services to be considered by contractors. The service provider must assure his future customer that he is aware and understands that fruit, vegetable and grain processing, not only in the fermentation procedure, but also in manufacturing method, storage and transportation environments, may create a substantial safety hazard in oxygen deficiency, combustibility and toxic nature. All industrial safety procedures may be encountered, including confined space entry, correct respiratory protection, egress methods, scaffolding, fall protection requirements, hardware lock out-take out procedures, and in plant safety-hygiene education just to mention a few. The challenge is to plan and design an effective service agenda integrated with plant shutdowns individual maintenance schedules. This includes taking into consideration customer’s hygiene and safety requirements, delivering a high degree of initiative to work within maintenance issues provided by maintenance planners, schedulers, maintenance superintendent and laboratory personnel (Fig. 1.36). The pressure washing service provider has many opportunities, especially in smaller production facilities where processes may vary substantially from larger plants. Services start with loading docks, trucking facilities, dry goods storage units, silos, refrigeration, cold storage facilities, maintenance machine shops utilizing water filtration and recycling equipment, cleaning corporate buildings and parking areas. Further, servicing equipment, hardware in fabrication-restoration locations (turn around yard), as in filter component, suction-roll equipment repair and cleaning procedures. Professional behavior, incorporating and understanding safety requirements found in prospective environments, providing flexibility in service schedules and maintaining an educated labor force will set a contractor apart from others, creating opportunities for the future. Also consider that recently many microbreweries (Fig. 1.37) have established businesses in restaurant identities, permitting a multifaceted business strategy that introduces kitchen exhaust hood cleaning, general area and building cleaning procedures, including trucking and loading docks in the

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.37 a–e Various brewer vessels

food receiving location. Utilize hot or cold water with or without corrosion protective or sanitizing additives. Specialized equipment may be necessary, such as automated tank cleaning equipment (Fig. 1.36), vacuum units, surface spin jets, vacuum assist water recycling and product recovery equipment, non marking food grade high-pressure hoses, disposable raingear, etc. The manufacturer’s environment, process, process knowledge, hygiene, sanitation and sterilization procedures must be studied, understood and followed. Contacts. Purchasing, maintenance superintendents, engineering, brew masters, product laboratories, grain, sugar, fruit manufacturers, distilleries and wineries, frozen juice or soda pop manufacturers and their storage and transportation facilities. End-users such as microbreweries and restaurants. Resources. Companies and product manufacturers by name, Internet resources, ‘‘Wineries, breweries, distilleries and juice processing companies’’, http://www. brewersadvocate.org. Area Yellow Pages, product and process specific trade papers, and their trade associations for instance. ‘‘Brewers Associations of America’’ Safety requirements. USDA, FDA, EPA and OSHA requirements are enforced. Many applications frequently require a combination of controls. Individual State laws may be more stringent than federal laws and can be process oriented or a combination of.

1.6 Beverage Bottling Facilities, Breweries and Distilleries, Juice Processing

37

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Hop strainers, incubating dryers, production settling and separation tanks, storage vessels, heat exchangers, boilers.

WORKSHEET- PURCHASING - SALES

38

1 Succeed in Residential, Commercial and Industrial Environments

1.7 Butchers-Slaughterhouse Operations, General Processing, Cattle-Hog-Poultry, Animal Rendering In the mid 1950s pressure-washing and hydro-blasting applications were successfully introduced to slaughterhouses-abattoirs, their meat processing facilities, animal rendering plants, storage, packaging and trucking identities. Today’s equipment manufacturers provide in-plant units slated mainly for production oriented cleaning cycles (Fig. 1.38). As in the agricultural sector, controlled cleaning procedures, well executed sanitation programs concerning all machines, production rooms and manufacturing hardware are in place. It is important that the service provider understands the slaughterhouse ‘‘code of good practices’’. This code will introduce him to all areas of importance. Plant hardware and cleaning necessities may also vary between type of animal slaughtered and product manufactured. Daily volume of animals slaughtered is also a parameter to consider. One must reflect on specialty food manufacturers which may utilize carcasses in small numbers or large operations which slaughter and process in the hundreds, if not thousands of animals. Slaughterhouse and production lines have a never ending consumption of steam, ice, cold/hot utility water or apply water regenerating plants for product manufacturing needs, creating application identities service providers should feel at home with. Animal rendering facilities require another set of operational cleaning guidelines. They differentiate between the manufacturing of edible byproducts fit for human consumption and manufacturing of products such as fats, proteins, bone meal etc. utilized in animal feed, industrial applications, pharmaceutical and medical products. These facilities can be situated in remote locations or within the slaughterhouse environment and feature a wide variety of applications available to the service provider. Obvious applications include the cleaning of condensers, heat exchangers, cooling towers, boilers and evaporators, stacks, bone mills, support equipment such as tanks, product conveyors, etc. The feed silos, animal holding areas and the livestock transportation environment can also be considered. Permanent and itinerant personnel must be trained in in-plant operational and safety procedures. Contractors will seldom be offered a cleaning opportunity within the meat or product processing cycle. The principal in modern processing is that clean and unclean operations are efficiently separated. Contractors’ personnel will not be permitted to enter clean areas during production cycles that start, in most companies, with the scalding/hair removal facility, inclusive of the poultry environment. Manufacturers clean the following areas: Evisceration room, chilling and hanging facility (Fig. 1.39), cutting de-boning area, cooking and smoking, canning rooms, packaging, cold storage and freezer units which include delivery and dry storage facilities. Nowadays, most floor surfaces are concrete based, but one will find food grade nonporous tile as well as asphalt stabilized brick (Fig. 1.40).

1.7 Butchers-Slaughterhouse Operations, General Processing Fig. 1.38 Hot hp-water through heat-exchanger (steam)

Fig. 1.39 Animal fat-blood removal before

Fig. 1.40 Animal fat-blood removal after

39

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1 Succeed in Residential, Commercial and Industrial Environments

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing Tel: e-mail: Area:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures: Heat exchangers, boilers, cooling towers, kill floors, autoclaves, water treatment facility.

WORKSHEET- PURCHASING - SALES

1.7 Butchers-Slaughterhouse Operations, General Processing

41

Due to the corrosive environment and hygiene requirements, most production equipment is manufactured from stainless steel, aluminum, food industry graded plastics and does not necessarily include plant hardware. The service provider will deal with strong to medium alkaline detergents (sodium carbonate, sodium hydroxide), strong to medium acidic detergents (phosphoric acid, sulfuric acid) and anti-corrosive agents or inhibitors. When chemicals and disinfectants are used in a cleanup procedure it is recommended that the contractor finish his work cycle by thoroughly rinsing the entire area with water, then applying a water wash down under low-pressure with 200 ppm chlorine or otherwise recommended solution. Residue encountered on production floors, equipment and slaughter slabs include carbohydrates, sugars, fats, protein, salts, soy protein, glutei, amino acids found in animal tissue, etc., or a mixture of all. In house cleaning crews find that denatured proteins are very difficult to remove. Fat smear accumulations developed from proteins, mineral salts and other components turn into a wax like consistency and are often encountered in plant turnaround procedures. A contractor must be qualified and adept to apply all necessary detergents, inhibitors and acids on demand. Plant maintenance and hygiene departments are most often the best information resource for these products. They will determine required solution ratios. A prerequisit may exsist that the contractor’s equipment or tooling is designed to operate under food manufacturing standards. High-pressure water hoses must be fat-acid resistant limiting hose streaking on floors which cannot be permitted. This includes providing boots, gloves, raingear and hair dress designed for this industry. When working with a wand and/or hydro trigger gun, plant maintenance or inspectors may demand that over-spray or misting be eliminated (Fig. 1.41a, b, c). In this case, hand operated spin jets and surface floor units (Figs. 1.42, 1.43) with vacuum assist recycling and water filtration can be used. Due to waste encountered, the Hydro-vac method may be employed in grease pits, pipe and sewer cleaning and general product or waste recovery. 80% of work found in this environment will require 3–10,000 psi, at 5 to 35 gpm hot (200F.+) or cold water. Contacts. Slaughterhouses, poultries, their purchasing and maintenance superintendents, including management in processing and hygiene departments, refrigerated warehousing, distribution facilities, trucking and rail companies. Food safety consultants and inspectors may be of help. Resources. Technical: WJTA–SSPC, USDA–FDA, Internet food safety links, butchers, poultry business directories and associations. Retail distribution trade associations, North American Meat Processors Association, Meat traders associations, specialty meat producers found in area Yellow Pages and on the Internet. Safety. Sanitation performance standards and compliance, personal hygiene. USDA-FDA standards. Clean Water Act, OSHA regulations. Food processing plants operate under tight State and Federal regulatory controls. Step-in/out area procedures, lock-out/takeout procedures, Awareness in hazard analysis of critical

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.41 a, b, c Surface cleaner

Fig. 1.42 Wastewater recovery

Fig. 1.43 Floating surface prep. equipment

control points in the manufacturing process are of an advantage (HAACP). Customers appreciate contractor awareness and compliance. Applications require a combination of controls.

1.7 Butchers-Slaughterhouse Operations, General Processing

43

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review: (b)

(c)

Fig. 1.41 b. c. Various jetting spray-bar configurations intended to reduce misting (fogging), also operated with mobile hydro-vac water recovery, filtration and recycling equipment. First patent draft 1964

Safety equipment and procedures:

©

Silos, loading docks, grease pits and pipes, product conveyors, tanks.

WORKSHEET- PURCHASING - SALES

44

1 Succeed in Residential, Commercial and Industrial Environments

1.8 Buildings, Washing Exterior–Interior, Surface Prep, Graffiti Removal Restoration, Waterproofing, Stone Care, Wood Care The maintenance of properties generates a never ending application variety. The industry vigorously develops new tooling to support the demands in cleaning, maintaining or restoring high-rises, industrial-corporate buildings (Figs. 1.44– 1.47), churches, monuments, hospitals, hotels, duplexes, rental and residential housing markets. When considering today’s available pressure washing and hydro tool configurations, combined with the industry’s specialization in necessary support equipment to accommodate the forever changing job environment, experienced safety minded employees and subcontractors in their specific fields are essential. Maintaining and developing the labor forces educational path in safe access, fall protection, jobsite safety procedures, behavioral habits’, including achieving the all important awareness of how to apply hydro-tools in adverse job locations and conditions, is considered a cost of this business. In a bidding process, professionals strive to foresee the unknown, leaving nothing to chance and minimizing the results of possible customer suggestiveness or wishful thinking. Meticulously recording all related job specifics will build and enhance an entrepreneurs’ business identity. Service providers that record job successes and their shortcomings add to their overall classification and provide a certain amount of accountability and controllability in gathering corporate hands-on application knowledge. It also enhances management costing methods in application variety, flexibility and possible labor or equipment employment strategy. The paperwork trail begins with the salespersons worksheet when visiting the future jobsite and ends with checking of the equipment gear-up list when returning to the yard after job completion. This is absolutely necessary to establish corporate statistics. The job gear-up, break-down times must be estimated and may include scaffolding-tarpaulin-sidewalk canopy procedures. Pedestrian-vehicle traffic control and the customers’ working hours are considered when coordinating job access and performance schedules. Applicable, hazardous waste identification, its removal, transportation, disposal, safety equipment, and essentials like duct-tape, signage and traffic cones are just some of the obvious costs to consider in the bidding process. Support equipment technical-legal status, practicality, availability and cost are established. Scaffolding and tarpaulin methods have developed exponentially, accommodating pressure washing and hydro blast methods not only in confinement, but also in load classifications, permitting loading of equipment to crash floors. Availability in labor access equipment has improved dramatically. Jobsite waste or product removal systems may be integrated into the work process.

1.8 Buildings, Washing Exterior–Interior, Surface

45

Fig. 1.44 a, b In-situ repair

Fig. 1.45 In-situ wall repair

Confined space, vacuum assist filtration and water recycling-debris separation equipment is today an equipment identity necessary for flat, vertical and overhead work in a multitude of situations. Limited water access may also introduce filtration and water recycling equipment to the jobsite. These evolving technical application elements must be realized and studied as they represent the entrepreneurial vehicle to service providers, moving their potential into the commercial and industrial environment. Future marketing strategy and completed job history is of utmost importance when deciding on equipment combinations or when to purchase them. Too often,

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.46 Aggregate before

Fig. 1.47 Aggregate after

equipment, although powerful, is not flexible enough in mobility, tool utilization or requires too much water which may hamper filtration and water recycling efforts. It can also be assumed that the lack of application knowledge is visually identifiable when visiting a contractor’s yard. The need to work within EPA, OSHA, state, city regulatory laws and guidelines providing sound environmentally correct cleaning methods is not to be looked upon as a hindrance but as a generator in application specialization efforts. Service providers committed to do so create a vast variety in business opportunities. When servicing the private sector, major applications include: Fire-disaster cleanup; Cleaning, disinfecting, sanitizing contaminated areas; Exterior–interior mildew, fungus, moss control and cleaning procedures; Removing masonry coatings, paints and surface deterioration to prepare for painting, water-proofing or

1.8 Buildings, Washing Exterior–Interior, Surface

47

Fig. 1.48 Construction site cleaning

Fig. 1.49 Building restoration

construction needs; Removal of deposits such as concrete spatter (Fig. 1.48–1.50), graffiti and hydrocarbons, soot, fly-ash, loose paint, grease deposits, bird droppings and/or organic growth. Starting out, the entrepreneur can consider roof and house washing applications, learning to protect the flower and foliage environment in his vicinity, masking possible openings and protecting windows, window frames, in particular when chemicals are applied, as well as cleaning, staining wooden structures, fences, terraces, concrete driveways and so forth. When entrusting vital project decisions to a contractor, private home owners are quite suspicious, reluctant or simply nervous deciding on how to clean their home. A beginner wishing to compete in the residential property cleaning application is best advised to study and research the general criteria building and façade inspectors utilize. Building inspectors’ standard practices in building site access, periodic inspections of building façades for unsafe conditions, recognizing

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.50 Building washing prior to tuck-point procedures

previous maintenance justifications, repairs, modifications and façades performance issues can help dramatically in correctly analyzing job necessities. A vast variety in building designs and construction materials are encountered in the house washing application. Concrete, masonry, wood maintenance, paint and coating knowledge will further enhance the marketability to the home owner. To further their course, aggressive entrepreneurs may acquire experience, technical knowledge slowly incorporating building demolition-restoration and construction site cleanup procedures. Specializing in supporting high-profile restorations on buildings, monuments, including working on intricate, creative, and architecturally historic structures, providing cleaning methods designed not to damage or alter surface profiles encountered, and where expertise in a wide range of trades must be combined and coordinated with innovative pressure washing and hydro-blasting techniques. This can include offering the installation of bird control fixtures on exterior façades after cleaning and substrate treatment measures are completed. To ensure a successful bidding process, application related preferable tool configuration must be explained and demonstrated in detail, as a practical solution to the available nondestructive pressure washing-hydro blast cleaning method. Conservationists, architects, chemists, structural engineers, construction superintendents, masons and carpenters alike will demand this attention to detail. Cleaning the exterior of high-rises and monuments is not for the faint (everything above four floors) of heart or inexperienced. Restoration, building enhancement (Fig. 1.51) and water proofing needs are the most likely generator for a job-bid walk. Close attention and cooperation in developing a job strategy between the customers’ architect, trade contractors, scaffolding company and building-façade inspector is a requirement. A well insured and equipped service provider supplies a safety minded and where applicable, a licensed, educated labor force operating on swing stages, boatswain’s chairs, scaffolding systems and access lifts. Besides cleaning and water proofing applications, a contractor may be asked to perform a controlled hydro excavation of structural steel joints, rebar systems,

1.8 Buildings, Washing Exterior–Interior, Surface

49

Fig. 1.51 Brick wall washing

Fig. 1.52 Brick patina before washing, after tuck-pointing

removing concrete, masonry structure, architectural stone on high-rise exteriors and interior surfaces. The enlightened service provider, who maintains contracts cleaning sidewalks, drive-thru and parking areas for convenience stores, restaurants, banks, gas stations, hotels, office units and garage facilities is prudent to consider the

50

1 Succeed in Residential, Commercial and Industrial Environments APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing

Engineering

Tel: e-mail: Area:

Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Job Description:

Safety Tel: e-mail: Area:

Job Site Risk Assessment:

Specify:

Job Location: Jobsite Review: Concrete interface prep: a

Fig. 1.53 Abrasive-blast injector

b

Fig.1.54 a.b. Concrete interface before-after

Fig. 1.55 Concrete form-boards

Fig. 1.56 restored balcony structure

Trade Related Publications: 6. Jonathan M. Whitt (1999) Power-washing 101, A manual for operating a residential and light commercial, pressure washing business, Advantage publishing company, Little Rock Arkansas 72205-3823, Tel. 501-280-0007 http://www.adpub.com [6.28.406] 7. Master Painters Institute (2002) Maintenance Repainting Manual, by MPI, exterior systems evaluation, surface preparation, http://www.mpi.net [6.28.406] Safety equipment and procedures:

©

Pipe and sewer cleaning, high-rise laundry - garbage chute cleaning and disinfecting, sidewalks, oil-debris removal.

WORKSHEET- PURCHASING - SALES

Figs. 1.53–1.56

1.8 Buildings, Washing Exterior–Interior, Surface

51

Fig. 1.57 10,000 ft2 plus per hour flat-work

Fig. 1.58 Hydro-vacuum result while cleaning

commercial-industrial market as their equipment should be capable of performing in this environment. Commercial buildings, their business identities and manufacturing processes offer the widest application range and growth opportunity to the service provider. Their businesses encompass most industrial cleaning procedures, facilitating and accelerating the contractor’s necessary experience and confidence required when engaging the industrial environment. Servicing the commercial sector, major applications are: Cleaning and surface preparations for painting-coating on masonry structures, cleaning production hardware, equipment and vessels, steel preparation facilitating painting-coating procedures in support of fabrication and/or maintenance work, providing 10,000 ft2 plus per hour general surface cleaning capacities on manufacturing and warehouse flooring during vacation or maintenance turnaround schedule utilizing vacuum assist water recycling and filtration capabilities. The contractor’s professionalism in cleaning large exterior and interior surfaces may open the door to entertain a bid status supporting manufacturers’ processes or routine equipment cleaning requirements (Fig. 1.52).

52

1 Succeed in Residential, Commercial and Industrial Environments APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing Tel: e-mail: Area:

Engineering Tel: e-mail: Area:

Job Description:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Site Risk Assessment:

Specify:

Job Location: Jobsite Review:

Fig.1.59 a.b.c.d Bird repel system

A fixture to repel birds, straightforward installation to susceptible building areas Trade Related Publications: 3. Cyril Harris (1993) Dictionary of Architecture & Construction, McGraw-Hill, Inc., http://www.mhprofessional.com [6.28.406] Safety equipment and procedures:

©

Graffiti removal, masonry coating removal, paint and coating removal, emergency spill remediation, aluminum siding.

WORKSHEET- PURCHASING - SALES

Fig. 1.59 a–d Bird repel system

1.8 Buildings, Washing Exterior–Interior, Surface

1.8.1

53

Application Capacities

A. Washing exterior–interior surfaces including dust removal in high access cleaning procedures with effluent and debris recovery techniques employing the hydro-vac, filtration, water recycling or evaporation methods. An extensive surface variety is encountered. This equipment configuration can lead into criminal, accident and disaster clean-up opportunities, and is often overlooked by salesman prowling for business opportunities. B. In combination with high-pressure water cleaning methods, employing water filtration, recycling and HEPA vacuum procedures, dehumidification equipment in mildew-spore and fungus remediation applications is considered a vital up-and-coming application. Due to application diversity, a high degree of knowledge must be gathered in how and why mold-fungus-spore-moss grows. Before finding an adequate remedy, a consultation with area chemists, building inspectors and possible coating specialists is advisable (Figs. 1.53–1.56) Environmental conditions found indoors and or outdoors, such as dark and damp surroundings, poor ventilation, nourishment in construction materials, indoor environments with high transient humidity or structural microclimates and their favorable surface temperatures are obvious research points that remedies must be found for. Accidents and natural disasters are also generators of this application. Specializing in this field requires applying today’s equipment correctly in combination with job specific support equipment and tooling. Job circumstances can lead into the hazardous material removal business as well. C. Paint and coating removal on commercial, industrial structures applying environmentally correct cleaning methods, adhering to all necessary safety procedures, supervisory competent personnel implementing effective controls in paint-coating identification, if necessary, exposure control, environment monitoring, including product recovery and disposal. This application may evolve into lead or asbestos abatement practices, chemical spill clean-up and accidental product recovery procedures. D. Demolition and restoration applications throughout the commercial environment. This is a facet with no limitations of specialization and growth. The water blasting specialist is capable of removing surface deposits from architectural sand stone without damaging or altering surface profile. He may clean and prepare wood structures for painting or staining procedures. High-pressure water can be applied to ready marble-granite slabs minimizing scarring or scratching by foreign objects in the polishing procedure, providing savings in time and materials. Wear vibration or surface damage by air hammer or other mechanical means is not acceptable; the demolition capability of high-pressure water may lead into restoration specialization of historical structures. When applying the non-destructive cleaning method in historical architectural restoration and preservation applications, the pressure washing and hydro-blasting

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specialist is virtually indispensable. The investigative phase, deconstruction phase and desired preservation method is accommodated and supported by a wide variety of applicable tool configurations, including the hydro vacuum method (Fig. 1.57) with adjustable vacuum-airflow performances and job specific tooling (Fig. 1.58) Contact. Purchasing, maintenance, engineering, housekeeping commercial and industrial business identities. Municipalities to receive funds from HUD for façade improvement programs and their published and detailed guidelines for businesses interested in participation of a bid status. Also building owners requiring funds for restoration CDBG, which are HUD funds. Resources. Condominium associations, real estate holding and management companies, insurance companies, building and façade inspectors, architects, restoration, waterproofing and painting companies, Yellow Pages, Trade papers and consulting companies or the Internet. Industry resources. WJTA, SSPC, PNA, IWCCI, ISSA, IICRC, ASTM E227003, Standard practice for periodic inspection of building façades for unsafe conditions. ASTM E06.55, Water leakage of building wall’s. ASTM D5107-03, Preparatory surface cleaning of architectural sand stone. Safety requirements. Hazardous awareness training, environmental compliance EPA, OSHA, and state regulations. Clean Water Act, Scaffold primary access training (PAT), http://www.scaffold.org, competent person training in applicable field (CPT), Traffic control laws and regulations, work zone-pedestrian-traffic safety regulations. SHAFACT Sheet, http://www.osha.gov (Fig. 1.59)

1.9 Commercial–Industrial Structures, Demolition-Rehab. Procedures, Construction Industries, Surface Preparation The forever growing variety of dilapidated or deteriorating surfaces encountered on marine, commercial and industrial structures in need of rehabilitation, restoration or structural changes will expose the hydro-blast journeyman to a constant learning and seamless job recording process. Further more, customers and contractors estimating performance and time requirements will include surface roughness or anchor profile parameters, guaranteeing not only paint-coating adherence stipulated by manufacturers, engineers and coating inspectors but also an estimation of how much coating material is needed to achieve required strength or coating-liner thickness. Necessary tool selection, pressure and water volume configuration may vary substantially and must be chosen not only in accordance to scale or product removal requirements but must also be adapted to the jobsite, considering safety, effectiveness and accessibility when applying the hydro-tools. Following are a few possible concerns that pressure washing and hydro-blast journeyman, service providers and their customers must consider:

1.9 Commercial–Industrial Structures, Surface Preparation

55

Fig. 1.60 Gravel-aggregate before-after

1. Product-effluent removal and transfer procedures to the recycling and filtration unit, correctly installing supply and transfer hose systems maintaining work related mobility, which includes controlling and confining water-effluent runoff. 2. Correct identification, declaration, packaging and removal procedures to a licensed hazardous waste site. 3. Construction sites safe access requirements and their educational, procedural necessities. Engineering must provide scaffolding with correct structural weight classifications, in particular when equipment placement on crash floors and effluent transfer reservoirs are utilized. 4. Testing the job environment for possible contamination before, during and after job completion. 5. The correct placement of laborers break, shower, toilet, and staging facilities, establishing step in–out areas. 6. Traffic control and overall job-site security necessities. These aspects are compounded and are rarely the same between jobsites. Pressure washing and hydro-blasting environments may be found underwater, between, below ground or at ground level in confined spaces and naturally, above ground locations situated at any imaginable height. In the mid 1950s hydro-blast equipment manufacturers supplied and integrated the first units into concrete product manufacturing and process hardware services. Applications then concentrated on removing installed paper adhering to aggregate, controlling cement drying processes surrounding gravel material on pavers and prefab concrete slab modules intended to show open gravel-aggregate structures (Fig. 1.60). High-pressure water replaced the sandblast or brush technique. Soon thereafter plant maintenance personnel discovered an abundance of applications which spread throughout the entire Portland cement and concrete component manufacturing environment. In the mid 1960s high-pressure water extended cement kiln operating times with clinker removal procedures utilizing the thermal

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.61 Rebar corrosion

Fig. 1.62 Concrete carbonation

shock method on clinker rings while the kiln rotated during production, minimizing Remington cannon shell usage and down times due to clinker build up. Much has since changed in the cement plant operating environment, rendering some of these application procedures to the past or elsewhere applied in industrial environments. In 1967 concrete scarifying, removal and demolition applications gained prominence both overseas as well as in the USA. Handheld and mobile equipment attained a level of dependability suitable for most facets of concrete cleaning and rehabilitation methods. This includes demolition applications on bridge decks, pylon structures, building façades and on a multitude of industrial structures. The equipment does not necessarily need to be purchased as it can be rented nationwide. Engineers and contractors alike have gained valuable experience and are able to estimate performance schedules successfully. Damaged concrete structures are most often visually identifiable and submitted to physical failure analysis (Fig. 1.61). This involves laboratory testing prescribed by engineers and concrete specialists throughout the marine, industrial and commercial environment. Basic test requirements include recording overall visible defects, including cracks, their length, width, depth, depth of concrete carbonation, presence of chlorides, chloride profiles, which include sulphate levels, concrete delaminating measurement in depth (Fig. 1.62) and area, degree of rebar reinforcement corrosion and existing efflorescence on concrete surfaces, possibly lime or salt deposits etc. Before a removal procedure is described and submitted inspectors and engineers involved in nondestructive testing of concrete surfaces will resort to an array of available tooling and work methods. They may include concrete pull-off test procedures, core drill tests for moisture and saturation, determining the extent of

1.9 Commercial–Industrial Structures, Surface Preparation

57

Fig. 1.63 Hydro concrete mill

structures internal damages by applying ultrasonic-pulse-impact-echo equipment and laboratory testing for chemical contamination status, etc. The structure’s environment and the chemical mechanism of concrete deterioration found is only one parameter necessary to establish a hydro-tool selection and work method. It is crucial to be correctly informed on the impending rehabilitation method and procedure to deliver a tool selection generating measurable adhesion parameters in surface roughness, desired porosity (anchor profile) and cleanliness to support new product installation and product warranty guidelines. The rehabilitation process starts with the removal of deteriorated concrete material above and/or below the rebar structure, in the process neutralizing carbonation-salt-rust or acid damaged surfaces, checking periodically for surface roughness or anchor profile. This is done by utilizing a digital unit which provides the important readout. The contractor will establish cleaning and drying times of concrete structure before the painting-coating-liner resurfacing procedures commence. The concrete scarifying method (Fig. 1.63) is also employed on new or existing structures where conversions, add-ons, load enhancement or coating and painting is required. Here again, a measurable surface treatment in porosity or surface roughness (anchor profile) is provided by the hydro technique, eliminating sand blasting, acid etching or mechanical equipment requirements. Concrete bridge decks in need of an asphalt road deck installation may be prepared with a mobile hydro concrete mill. Aircraft hangars requiring a new coating system may utilize similar equipment, removing a partially measurable amount or a total removal of deteriorating coating when repairs are essential. Fish tanks, pools, fountains, concrete holding ponds and water tanks in need of coating procedures are all essential locations for the pressure washing, hydro-blasting and UHP service provider. Coating removal practices on oil rigs, piers, water dams, their spillways, or steel–concrete bridges and water tanks require an educated, competent workforce. Access methods to these work sites are engineered by scaffold system manufacturers and rental companies of such equipment. With each access development, special attention must be given to environmental conditions, including prevention

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.64 Vacu-coating removal

of overspray, denying a positive air pressure situation in confined work spaces, correctly assessing and engineering the scaffold systems life load qualifications. Scaffolding engineers must be made aware of incorporating water runoff containment and weight of effluent transfer units. At this time journeymen will decide on the necessary tool variety to access the surfaces in question. A scaffold designer will also incorporate all other necessities required by painters, welders, electricians, inspectors, etc. Needless to say, the complexity is staggering requiring engineering and practical experience. (CPT) All involved must provide certificates attesting to their capability in these specific areas. Hazardous waste removal experience is also a must, most likely a practice necessary within a job description to provide water recycling, filtration and decontamination capabilities. To support the pressure washing, hydro-blasting-UHP journeyman the SSPC and NACE Society for Protective Coating and Corrosion established standards with a written and visual comparison. These visual guide references also provide a standard in evaluating the degree of rusting on painted steel surfaces depicted in general rusting, spot rusting and pinpoint rusting. Due to their visual comparison in cleanliness and surface conditions the standards are a great help in sales, engineering and application oriented endeavors. For the experienced, a guideline is established providing an approximate comparison when estimating a job by drawing from personal experience when comparing before and after with these references (photographs). Paint and lead rich coating removal (Fig. 1.64) on elevated city water tanks also presents a prominent application, minimizing environmental concerns. The Hydro contractor will work in unison with painting contractors when a total removal of existing dilapidated coating system is necessary. Often, over coating procedures are desired, permitting a vacuum assist wash down utilizing approximately 4–12,000 psi. Pressure ranges in over coating procedures vary depending on paint conditions. Throughout the chemical, oil, metal, food and produce manufacturing processes one will find secondary containment structures. The presences of destructive, aggressive or environmentally dangerous substances often accelerate the deterioration process on concrete and steel surfaces. These surface preparation needs and sheer business volume are often underestimated by pressure washing and hydroblasting-UHP contractors. Surface treatment, demolition and scarifying methods are employed to facilitate relining, specialty coating, and hybrid concrete installation needs (Fig. 1.65).

1.9 Commercial–Industrial Structures, Surface Preparation

59

Fig. 1.65 Manual coating removal

Fig. 1.66 Manual surface prep

For that matter, all construction sites are of interest to the entrepreneur, especially when a recycling and water filtration with refuse separation capability is available. Opportunities are plentiful. As always, there are facets where lesser experienced service providers may gain knowledge in a subcontracting status, for instance, by providing services to ready a site for inspectors and engineers in their preliminary investigation phase. The hydro demolition company preparing a deteriorating concrete structure in excavating the rebar system to ready the site for concrete gunning or ‘‘Shot Crete’’ applications may not be interested to perform the construction cleanup phase. Therefore, removing possible concrete overspray and spatter is another sub-contracting possibility (Fig. 1.66). Contacts. On the Internet, ‘‘masonry associations’’, Rehabilitation, restoration and construction firms, their project managers, architects and field supervisors. Consider city engineering, waterproofing companies and painting contractors. Also inquire for service bids in cement, brick, masonry and structural cement component manufacturing plants. Many cement or masonry manufacturers will have their in-house equipment for specific application needs. This does not mean a service provider should ignore upcoming plant shutdowns and service schedules. Resources. WJTA–SSPC. Internet, ‘‘national contractors’’ Bid and/or request for proposals generated by product manufacturers, architects, cities, housing projects, also all varieties of commercial contractors and property owners. Safety. Specific requirements for subcontractor ‘‘construction safety’’, Construction site varieties, their locations, structural circumstances or processes demand a keen safety oriented perception and operational qualification. For information OSHA’s A–Z index pages for construction safety, http://www. osha.gov. The Pressure washing, Hydro-blasting or UHP service provider must notice all necessary elements, not only for the important human safety aspect but also in providing a correct bidding process, taking into account all operational circumstances that may change during the contracting period. States, cities, or companies may require a contractor’s license for specific jobs or in general.

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1 Succeed in Residential, Commercial and Industrial Environments APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

P.O. Box:: ZIP Code:

State:

Purchasing

Engineering

Tel: e-mail: Area:

Tel: e-mail: Area:

Job Description:

Maintenance

Safety

Tel: e-mail: Area:

Tel: e-mail: Area:

Job Site Risk Assessment:

Specify:

Job Location: Jobsite Review: Concrete removal at 43.000 psi

Fig. 1.67 Concrete removal-demolition

Trade related publications: 1. Andreas W. Momber, (1998) Waterjet applications in Construction Engineering, by A.A. Balkema, Rotterdam, NL http://www.balkema.nl [6.28.406-1] 2. ACI- American concrete Institute and, BRE, ICRI (2003) Concrete repair manuals volume 1 and 2 published jointly [6.28.406-2] http://www.concrete.org (Fig.1.67) from Page 61 Safety equipment and procedures:

©

Concrete scarifying, under water surface prep, dike repair, bridge deck concrete demolition, water tank cleaning.

WORKSHEET- PURCHASING - SALES

Fig. 1.67

1.9 Commercial–Industrial Structures, Surface Preparation

61

Fig. 1.68 Self-propelling nozzle

Fig. 1.69 Product cutting nozzles

Applications frequently demand a combination of controls, including a trained and licensed labor force, providing for instance, confined space entry permits, scaffold primary access training or supervisory and competent person training-certification in specific application environments. City, state and federal laws must be considered and applied. (EPA-OSHA-CWA, etc.)

1.10 Refinery-Oil-Polymer-Chemical Manufacturing Environments, Epoxy-Resin-Vinyl-Latex-Paint The development of compact triplex pumps enabled commercial sewer cleaning professionals (1956) to apply the self propelling nozzle technology incorporating the necessary high-pressure hose assembly. This technology developed and patented by Wolfgang Maasberg Sr. enabled the cleaning of pipe and sewer systems in remote locations. The pumps compact design and comparatively low psi performance, (1,600 psi. plus) but high water volume output and a hydro-vacuum jet pump configuration, accelerated the development of truck and trailer mounted sewer-pipe cleaning equipment, featuring hydraulic operated hose reels, waterwaste tanks, and so forth. In Germany in the late 1950s to early 1960s, equipment manufacturer WOMA Corp. developed the 10,000 psi, approximately 22 gpm pump capacity utilizing 150 hp. air cooled diesel engines or stationary electric motors. This performance level facilitated the introduction of the tube-bundle cleaning method by highpressure water. The development of adequate nozzles (Fig. 1.68) and steel wire reinforced hoses, basically manufactured then for the oil-hydraulic environment, permitted the self propelling of flex lance assemblies throughout a condenser or liquid product transfer tube (pipes) with horsepower inputs and high-pressure-water volumes that were new to this era. Product cutting nozzles (Fig. 1.69) were designed and employed on rigid steel lance assemblies wherever extensively fouled or solidly plugged tubes were

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.70 Hydro-lance unit

encountered. The reaction and possible hydraulic forces developed by multiple nozzles pointing forward, concentrating the waters energy directly towards product and surrounding tube surfaces can be dangerous to a novice rigid lance operator. Product behavior and physical structure throughout a condenser or heat exchanger system may vary extensively. Hydraulic forces may develop, adding to already existing reaction forces upon the lance operator. When permitting product to collect behind the nozzle mount, then forming a seal between the tube wall and rigid lance body, can develop an explosive hydraulic piston situation towards the operator. This cleaning practice is now more often semi-automatically performed (Fig. 1.70), avoiding the otherwise physically challenging and when incorrectly applied, dangerous product removal method for a hydro-lance operator. Depending on the product this may also occur with a flex lance operation when one forward jetting nozzle is, for instance, incorrectly sized or manipulated, penetrating too quickly through the product in question, possibly creating a hydraulic product piston, which reacts upon nozzle head surfaces thus blowing backwards towards the operator. In the late 1950s to mid 1960s durability of hydro-blast equipment was marginal. V. packing, packing glands, O-rings, suction and pressure valves, pistonplunger configurations and their water sealing surfaces were subject to mechanical failure. Existing job reports of this period bear witness to the constant changing or replacement procedures of vital parts before, during, and after a job assignment. It was not only the pump’s water and gear end side which needed consideration. High-pressure hoses adapted from the hydraulic environment were not suited in necessary durability and flexibility when applied to changing application varieties encountered. Nozzle flow technology (Bernoulli theory), and metallurgy had to be studied and researched, taking into consideration the tremendous water velocities, necessary water cleanliness, filtration procedures and manufacturing methods. Operational stand times of pressure regulators, high-pressure guns, dump guns and rotating cleaning heads were also in their/or infancy and not very dependable. Engineers needed to understand metal stress parameters, packing glands and

1.10

Refinery-Oil-Polymer-Chemical Manufacturing Environments

63

Fig. 1.71 Hydro-cutting and demolition

O-ring installations, applying correct metallurgy and understanding cavitations influence on parts introduced to high pressure, high velocity water. In short, a never ending development and engineering process began. Initially, cooperation and unified thinking habits between plant maintenance, engineering and purchasing allowed hydro manufacturers to design and further develop or test available and emerging technologies. Superior surface cleanliness, drastically reducing cleaning times, replacing costly alternative cleaning methods, such as employing rotary brush techniques, drilling and chemical cleaning procedures justified the engineering and development necessities to solve these mechanical weaknesses. Today’s chemical, plastic and refinery environments will utilize pressures between 3,000 and 55,000 psi, with horsepower requirements ranging from 20 to 600 hp, determined by application necessary psi-water volume configuration. In refineries 90% of the available job variety is performed between 4,000 and 35,000 psi and does include demolition work (Fig. 1.71). More often than not, they also operate in-house automated equipment like tube bundle cleaners and rotating hydro-coke drum cutters manipulated by a drill gantry structure. Experienced hydro service providers classify the refineries available application variety more or less as a standard operational procedure, however, this cannot be assumed when servicing chemical and plastic processing hardware. The journeyman not only considers the arising and sometimes stringent safety requirements due to product encountered, but must also understand the product behavior when it is introduced to pressurized high velocity water and solvents. Necessary water volume and pressure configurations, combined with an expert tool selection may vary between job assignments due to product manufacturing processes. Products adhesion to surfaces and its tensile strength-elasticity-stickiness, systems process and operating temperature or void of, accidental product molecule changes due to manufacturing failure, or preparing hardware for product changeover requirements, to name just a few of the parameters considered, may alter cleaning and removal techniques greatly. If this would not be enough, the journeyman must also

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Fig. 1.72 Chemical-abrasive injector

be aware of cleanliness requirements which can be extreme. Generally, contractors do best when they understand that within the chemical and plastics environment, ‘‘clean’’ means cleaning to an absolute degree of cleanliness, eliminating all traces of prior existing residue. The final inspection process or method and inspection equipment applied by maintenance departments should be known to the journeyman, eliminating possible and nasty surprises before a job completion is recognized. The newly developed UHP low water volume cleaning method offers, in combination with application specific tools, superior controllable product and corrosion penetration parameters. While in a cleaning operation, a lower tool reaction force generally developed by 2–3.5 gpm with a vacuum assist technology will remove debris and hot or cold water, benefiting the laborer’s extended physical endurance and safety. Heated water and refuse is simply cooled utilizing a vacuum chill box, eliminating the need for long, high-temperature vacuum hose runs. When incorporating the hydro-vac system, a secondary air cooling cycle may be provided to lower emerging temperatures to acceptable operating exhaust levels. If lead coating-asbestos removal procedures are encountered, an air filtration system (HEPA) may be of essence. This controlled cleaning or removal application technique of industrial coatings is therefore not only possible on large surfaces (remote vacuum assist equipment), but also in confined areas including corrosion removal on liquid transfer pipes, tanks of all designs and equipment protected by industrial insulation. Steel surfaces with deteriorated paint-coatings will most likely reveal a prior anchor profile procedure (wet-dry abrasive blasting). On raw steel, high-pressure water can not alone provide a satisfactory anchor profile. Depending on a coating specification, a correct garnet (abrasive) must be metered to the high-pressure water injector (Fig. 1.72) producing this all-important anchor profile, facilitating the desired coating adherence. Concrete surfaces, new or deteriorated, may be pressure washed, hydro-blasted (Fig. 1.73) or prepared with the UHP method, to eliminate the use of abrasive materials and achieve a variety of desired anchor profiles (surface roughness). Inspectors verifying a correct anchor profile or surface roughness (Fig. 1.74) will verify coating manufacturers recommended guidelines requiring the correct operation of surface gauging equipment.

1.10

Refinery-Oil-Polymer-Chemical Manufacturing Environments

65

Fig. 1.73 Defective coating

Fig. 1.74 Defective coating removed

Before commencing with high temperature surface preparations, inspectors must test the structural integrity of the hardware in question. Where insulation systems are present, inspectors will survey the hardware after the removal of possible asbestos laden insulation. Where metal wall thicknesses are insufficient, resulting either from external pitted corrosion or internal wear typically found on elbows or the lowest point of an inlet pipe component, a replacement or metal patching procedure must first be considered. In any event, the service provider and UHP tool operator must be the final inspectorial link, especially when blasting commences while plant or hardware is in operation. Controlling the possible heat-exhaustion of the labor force involved is best overcome with a rotation procedure of the workforce (in–out), providing adequate breathing gear and work area environment (area air-conditioning, negative air space, etc.). When working in confined spaces such as in the interior of tanks, etc., the ambient temperature must be controlled to minimize flash rusting (exhaust fans, dehumidification equipment, etc.). Federal, state and customer awareness in striving to perform a correct and safe environmentally sound maintenance procedure accelerated the development of equipment and the marketability of the coating or corrosion removal method by high-pressure water. Further, the arising environmental obligations to the contractor are more manageable in water recycling, filtration, debris separation or possible evaporation procedures, which today are recognized by structural

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.75 Tarpaulin shrink wrap

engineers working in unison with paint and coating manufacturers, scaffoldingtarpaulin providers (Fig. 1.75), maintenance departments and contractors alike. They have begun to understand the available tool capability of high-pressure water equipment, therefore trying to accommodate service providers with technical necessities when involved in their design strategy and the endless pursuit to develop new heat resistant, elastic or hard scratch and chip proof coating systems which may require removal pressures of 20,000–55,000 psi. To acquire bid status in refineries and chemical plants, contractors must provide adequate insurance, past and present performance standards, safety education and certification for their employees, possible and necessary equipment capabilities, prior extensive verification in similar job activities, access to qualified hydroblasting or UHP journeyman and professional supervisors with a track record in safety, quality in scheduling, planning, job execution and in meeting their past contracting time lines. Proof of enduring relationships as contractor or subcontractor in similar plants can help greatly. Service quality, budget control and timely completion may create a preferred contractor status (Fig. 1.76). Refineries and chemical plant maintenance departments include an array of standard must do hydro-blast applications in maintenance and plant turn-around bid procedures. By identifying plant locations, plant hardware-equipment and product manufactured in these areas, it becomes obvious that a great variety of specialized or technically refined hydro-equipment can be employed. Some of the product or by products manufactured in chemical plants and refineries are: Ammonia, sulfur, synthetic rubber, latex, base feed stock for chemical fibers, organic or inorganic fertilizers, paint base products, all varieties of fuel, coke, waxes, aromatics, graphite, lubricants-oil, asphalt-tar base stocks, pharmaceutical base stocks, etc.

1.10

Refinery-Oil-Polymer-Chemical Manufacturing Environments

67

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review: Trade related publications: 9. NASSCO (206) Jetter Code of Practice, WRc Swindon, Frankland Road Blagrove, Swinden, Wiltshire SN5 8YF, England, [6.28.406] http://nassco.org 10. Raymond E.F. Weaver (2003) Practical Math for the Protective Coatings Industry, The Society for Protective SSPC, [6.28.406] http://www.sspc.org 11. The Society for Protective Coatings (2004) Surface preparation and coating of concrete, surface preparation and considerations for concrete substrates, SSPC, http://www.sspc.org [6.28.406] 12. The Society for Protective Coatings (2002) Good painting practice, Painting manuals volume 1 a. 2 SSPC, http://www.sspc.org [6.28.406] 13. The Society for Protective Coatings (2001) The inspections of coatings and linings, SSPC, [l6.28.407] http://www.sspc.org 14. The Society for Protective Coatings (2000) Protective coatings, fundamentals of chemistry, corrosion and its control, [l6.28.407] http://www.sspc.org 15. The society for Protective Coatings (2004) The fundamentals of cleaning and coating-concrete, Common mechanisms of concrete deterioration SSPC, http://www.sspc.org [l6.28.407] Safety equipment and procedures:

©

Product removal services in secondary containment areas, lube oil system cleaning, heat exchanger - boiler cleaning, sulfur condenser services.

WORKSHEET- PURCHASING - SALES

Plant-area (Fig. 1.77), hardware-equipment and general services or cleaning applications include: Hydrostatic test procedures (Fig. 1.78) which can be performed on all forms of vessels (Fig. 1.79), related production equipment and fluid transfer systems (pipelines); Cleaning new or rebuilt high velocity turbine lube oil systems (flushing), this includes debris, corrosion-rust and scale removal in

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Fig. 1.76 Refinery plant

Fig. 1.77 Refinery plant area a, b

Fig. 1.78 Hydro test-block

1.10

Refinery-Oil-Polymer-Chemical Manufacturing Environments

69

Fig. 1.79 Hydrostatic test vessel

compressor housings, oil tanks and oil supply lines; Cleaning refinery towers’ internals, fractionation trays and liquid distributors, mist eliminators, including the coke stripping on valves and related equipment or servicing atomizers, evaporators, autoclaves, reactors, and air pre-heaters, or boilers on water and fire side are standard applications and include the sulfur condenser’s service (OD-ID-cleaning practice), vertical or horizontal fin fan cleaning practices (cooler-exchanger), in short, all fluid feed lines and product handling equipment can be considered subject to the hydro-blast cleaning method. Servicing smoke stacks, cooling towers, sludge removal in settling ponds above or below water level, tank cleaning and bulk product removal services in tank farms or the correct preparation of containment areas and secondary containment facilities such as loading docks where caustic soda, hydrochloric acid, spent sulfuric acids are handled and concrete coating procedures are deemed necessary; demolition-cutting on concrete and steel structures in refineries is also considered a vital and necessary application. Contact. Plant purchasing, engineering- maintenance and maintenance superintendents in their specific areas, general service providers such as insulation and coating companies, their inspectors for subcontracting possibilities, including specialty fabrication contractors supplying hardware and fluid transfer equipment. Resources. http://www.goliath.ecnext.com, Petroleum refining company profiles, WJTA–SSPC, OSHA–EPA. On the Internet, ‘‘petroleum refining processes’’ Oil–petroleum–gas, petrochemical associations, consulting and engineering services. Mechanical contractors associations. Safety. NPRA, national petrochemical and refiners association for safety training and requirements, http://www.npradc.org. The successful candidate will have the ability to understand and comply with regulatory requirements such as OSHA–EPA compliance of in-plant safety procedures, which includes safety training in customers’ specific environment and areas. When a reactive chemical hazard possibility exists or must be eliminated, some applications demand spill prevention compliance or training and knowledge in necessary pre-job area preparation. A hit or miss strategy is under no circumstances acceptable. Clear for entry, tank degassing procedures, confined space entry permits and procedures, electrical and hardware lockout-takeout procedures, managing a gas detector program, hygienically maintaining and managing breathing apparatuses-egress systems and their use. Competent person’s operating air monitoring devices, and

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1 Succeed in Residential, Commercial and Industrial Environments

enforcing emergency response procedures and/or training, competent persons for scaffolding access, access equipment and tool rigging requirements are all necessary must-do basics in this application environment. APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box:: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Bag house services, insulation removal, paint-coating removal, hydrostatic testing of tanks and product vessels, flu-stack services.

WORKSHEET- PURCHASING - SALES

1.11

Coal Mines, Coal Gasification Plants, Mineral Extraction, General Mining

71

Fig. 1.80 Hydraulic-area pasting pump station

Fig. 1.81 Open pit coal mining

1.11 Coal Mines, Coal Gasification Plants, Mineral Extraction, General Mining Light-weight, compact reciprocating pumps developed in the mid to late 1950s, ranging between 45 and 150 hp, benefited the coal mining industry immediately and resulted in the delivery of WOMAs underground hydraulic and area pasting pump stations (Fig. 1.80), operating on a 24 h, 365 day schedule. Introduced industry wide, the pump design featured a quick exchange plunger-piston configuration, accommodating water-emulsion-oil capacities required for hydraulic roof shoring gear and similar equipment. In confined spaces, gpm–psi performance criterion provided superior water-emulsion deployment when directives were given by mining and maintenance engineers for area pasting requirements (Fig. 1.81), suppressing movement of coal dust caused by underground weather (air-velocities). In sensitive areas where water accumulations must be kept to a minimum, general hardware cleaning operations where now possible due to high pressure water jetting techniques at comparatively low water volumes. It can be noted that for scientists and engineers alike, the performance capability of equipment spurred and enhanced the growing awareness of high-pressure water characteristics within coal-rock stratospheres, energizing experimental developments in coal-rock drilling (Figs. 1.82, 1.83) and general mining assist applications. Long underground distances between pump stations and confined work areas forced WOMA Corp. to immediately develop pneumatic-hydraulic pressure

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.82 Rock-bore operation

Fig. 1.83 Rock mining operation

regulators, semi and automatic bypass valves, high-pressure oil-emulsion accumulator systems and fluid vibration-shock absorbing hp-hose fixtures to prevent wall breakouts. The correct application and installation of fluid pulsation dampeners was necessary due to the forever extending hp-hose and hydraulic line runs. In this confined but vast environment, with widespread distances between confined spaces in need of service, it became clear that the existing spring loaded hp-gun designs were inadequate due to psi range and fluid velocity–volumes–mass. The dump gun valve and its operational requirements were impractical because of subsequent product loss or unnecessary water accumulation in the work area. This prompted the design of an hp–gun incorporating a labyrinth valve configuration (Fig. 1.84), which in operation decreases the fluid-volume’s energy shock and/or loading, controlling the valves impact to its sealing surface and sealing components. WOMAs unique invention minimized component fatigue and facilitate a safe continuous manual gun operation. When actuating the trigger gun, pressure drops reducing hydraulic forces upon the top labyrinth valve body (Fig. 1.84), forcing an open gun position. When releasing the gun trigger into off position, the necessary hydraulic forces are reestablished, moving the valve body into a closed position (Fig. 1.85).

1.11

Coal Mines, Coal Gasification Plants, Mineral Extraction, General Mining

73

APPLICATION REVIEW Customer, Company:

Date:

Nr:

Address: City:

Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing Tel: e-mail: Area:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures: Surface cleaning, tank cleaning, sewer cleaning, concrete cutting, pasting procedures.

WORKSHEET- PURCHASING - SALES

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.84 Valve in open position

Fig. 1.85 Valve in closed position

Fig. 1.86 Piston pressure stroke

The labyrinth technique was developed in this era (1967-WOMA). WOMA engineers and application technicians, managing high velocity water within a given tight gap (labyrinth valve), was transferred to a plunger–piston design. Today this technology is successfully utilized in equipment featuring packing-less plunger–piston configurations. In simple terms, the plungers reciprocating action (Fig. 1.86) produces an alternating fluid drag force (glide surfaces), utilizing in delay time the low velocity labyrinth cavities (turbulent) thus slowing the water’s velocity and therefore pressure to a near zero level within the suction or pressure stroke of a plunger. Water emission is reduced to a minimum, providing adequate lubrication and cooling for plunger operations (Fig. 1.87). Competing service providers and their crews must understand or be familiar with modern technical basics of industrial mineral extraction and process methods. Companies differentiate in how they apply separation chemistry or electrical (cathode–anode) and mechanical extraction from random rock (Fig. 1.88), coal, earth, and a variety of organic matter by crushing, grinding, smelting or liquid to liquid extraction. The latter can be a mass transfer operation, in a liquid solution (feed) and is contacted with an immiscible or nearly immiscible liquid (solvent) that exhibits preferential affinity or selectivity towards one or more of the

1.11

Coal Mines, Coal Gasification Plants, Mineral Extraction, General Mining

75

Fig. 1.87 Piston suction stroke

Fig. 1.88 Rock mining operation

Fig. 1.89 Gold extraction unit

components in the feed. Two streams result from this contact, the extract, a solvent rich solution containing the desired extracted minerals (Fig. 1.89) and the residual feed solution containing the leached waste. Regardless of which extraction method employed, the pressure washing and hydro-blasting industry will find an endless supply of applications in production cycles maintaining and cleaning equipment, plant hardware or production areas (Fig. 1.90). Within this environment, qualified service providers may be called upon to prevent catastrophic equipment failure.

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Fig. 1.90 Copper smelter

Fig. 1.91 Truck services and wastewater treatment

The equipment encountered in typical mineral extraction processes include mixers, settlers, static, agitation and packed columns with random liquid distribution structures, centrifugal devices such as high-speed multistage rotary machines, product crushers, grinders and water treatment facilities. Static extraction may be performed in settling tanks (combined with axial mixing autoclaves) or cement, asphalt and plastic lined settling ponds, high heat evaporation systems or chemical processing facilities providing solvent extraction. Extraction processes substantially differ, as does the equipment in need of service. Companies may utilize boilers, heat exchangers, solvent extraction tanks, lime silos, acid wash vessels, carbon conditioning tanks, drying ovens and general feed processing hardware. Others may require sewer-pipe cleaning applications for water supply and discharge lines, including servicing waste water treatment centers and their storage tanks or evaporation facilities (Fig. 1.91). Another facet could include servicing mineral transport equipment such as trucks, railcars, conveyor equipment, transport cages, maintenance shop facilities or process machinery, including rotary disk and drum filters, trolleys, grinders, blowers, etc. Coal washing facilities require cleanup of coal dust in confined or open spaces. Utilizing the hydro-vacuum system eliminates costly air filtration methods. This includes sludge or slurry pumping from tanks and settling ponds (tailings-limeetc.) below or above effluent-water levels, protecting sensitive pond liners in the process. This industry utilizes point source dust collection equipment incorporating fume scrubbers, air ducts and bag house systems, all in need of periodic cleaning.

1.11

Coal Mines, Coal Gasification Plants, Mineral Extraction, General Mining

77

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing Tel: e-mail: Area:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures: Coal washing facilities, evaporation facilities, bag house systems, maintenance shops.

WORKSHEET- PURCHASING - SALES

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.92 Coal gasification plant

Coal gasification plants require services on all major plant hardware components during the shutdown-turnaround procedure (Fig. 1.92). Water chillers, wash towers, vaporizers, steam drums, coolers and sour water-condensers, heat exchanger deck hardware for low temperature heat recovery, sulfur condenser, reactor equipment, quench and condensate degassing columns, scrubbers, stacks, all up and downstream equipment pipelines which includes turbine oil delivery systems and compressor gear-end or their oil tanks (when catastrophic failure has occurred), water cooling tower and water treatment facilities are some of the equipment service providers consider in a job procurement. Applications such as cutting tank-pipe steel plate or support structures (steel, concrete, wood) in volatile environments are further possibilities. Also, one should consider water abrasive lasting or UHP services (without abrasives) as specified by maintenance departments, providing rust, paint coating or insulation removal applications. Adding the potential of delivering a necessary anchor profile or concrete roughness enhances job variety when surveying applications in the mineral mining and extraction industry. Maintenance needs and turnaround schedules are specified by purchasing and maintenance superintendents. A pressure washing contractor wanting to break into this industry should concentrate marketing activities on the housekeeping departments of administrative buildings, their change-washrooms and building hygiene needs, cleaning exterior and interior surfaces, fleet washing, or cleaning parking garages. Maintenance shops may also provide specific applications for in-house vacuum assist surface cleaning, or the hydrostatic test method of vessels and pipe systems (Fig. 1.93). These can be offered with equipment ranging between 1,500 and 5,000 psi (pressure washer), supplying a simple water charge pump, certified pressure relief valves for pressure washer and equipment being tested providing a mechanical or electronic certified chart recorder to establish important vessel–pipe test record by utilizing a converted dumb gun as the manual control charge valve. These types of activities may open the door for a smaller service company to gain bid status for tank cleaning applications, as well as drain, pipe and sewer cleaning jobs. There are absolutely no limitations to your marketing efforts.

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Coal Mines, Coal Gasification Plants, Mineral Extraction, General Mining

79

Fig. 1.93 Hydrostatic test block

Contacts. Geological or mining engineers supervising construction, processing or plant operations of open pit, quarry, underground mining environments or engineers that are involved in the direct mineral processing operation of separating minerals from dirt, rock or other materials. Plant-purchasing or maintenance engineering departments for solvent extraction and leach plant processes, waste water treatment management and facilities, storage, packing, trucking and rail identities. Contact coal gasification plants; purchasing, engineering, maintenance departments and plant hardware manufacturers, or industrial coating companies for subcontractor status. Resources. National Mining Association http://www.nma.org, Mining and mineral associations, http://www.onemine.org, WJTA–SSPC, industrial and commercial mining consultants, mechanical engineering and manufacturing facilities for upgrades and hardware design, metallurgical engineering services and their process engineering departments associated with gold, copper, zinc, uranium, tungsten, nickel, tin, etc. Safety. A multitude of safety procedures will be encountered in this industrial environment and requires an in-plant safety training obligation for the contractor’s crew and can include a ‘‘Hazard-Awareness Assessment Program’’ for surface and alternative mines. A mining safety engineer will always be present or involved in one form or the other. They are responsible for labor safety, monitoring-verifying mining environment, operational-performance in safety and equipment-hardware compliance. Oxygen deficiency, explosive atmosphere and exposure to toxic gases and vapors are possible. All federal-state and in-plant safety requirements are enforced (OSHA–EPA). Frequently applications require a combination of controls.

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APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering

Maintenance Tel: e-mail: Area:

Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Servicing Pelletizing plant, water treatment facilities, rail and field services.

WORKSHEET- PURCHASING - SALES

1.12

Coffee, Tea, Cocoa Seeds, Leaves, Herbs Extraction-Processing

81

Fig. 1.94 Coffee roasting unit

1.12 Coffee, Tea, Cocoa Seeds, Leaves, Herbs Extraction-Processing In 1954, the founder of WOMA Corp., selling chemicals, disinfectants and pump equipment to dairies, concentrated and/or granulated milk producers,realized the opportunity to develop and manufacture mobile and stationary plant equipment. Heating hardware and related plant equipment (boilers, condensers, evaporators, cyclones, tanks, etc.) developed excessive hard, stubborn or bulk contaminants in milk concentration, powder operations and pasteurization processes. By applying high-pressure water as a tool he realized the great reduction in cost compared to manual and chemical cleaning methods then standard within this industry. Municipal sewer and pipe cleaning methods, also in their infancy, applying the high-pressure water hose propulsion technique (water jetting equipment), combined with the emerging oil-hydraulic high-pressure oil transfer hose technology (external steel wire reinforced), enabled him to adapt these technical developments for the cleaning method with high-pressure water, and in doing so, delivering application techniques as the pressure washing and hydro-blast industry identifies these today. For contractors already involved in the food or beverage industry it is a natural to consider the specialization of their service capability for manufacturing plants of heat sensitive and aroma based consumer products. The extraction, centrifugal separation, concentration, filtration, aroma preservation, drying, spray drying, agglomeration-granulation and powder handling procedures (Fig. 1.94) and their subsequent process hardware are all individual identities in need of pressure washing or hydro-blasting services. Extraction methods found in these environments may differ with seeds, leaves or plant identity, which may include the extraction and isolation of major food additives, pharmaceutical or industrial base byproducts. The coffee, tea and cacao bean extraction process and their evolving byproducts may show some similarities in manufacturing hardware being serviced (heat exchangers, filters, evaporators, tanks, process pipes, etc.).

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Fig. 1.95 Process containertank

Decaffeination of coffee-tea or the spice and herbs extraction process (pulping) can also be achieved through a water extraction method, in which, for instance coffee beans are soaked, steamed and rinsed allowing the caffeine to defuse from the beans into the water using no artificial chemicals. Application variety and tooling will change in the direct solvent extraction method. The decaffeination is accomplished by direct application off ethylene chloride, ethyl acetate or carbon dioxide to the coffee beans. The beans are then steamed to remove the residual solvents, dried and roasted. Plant hardware differs from the water extraction method. Cocoa derived from the cocoa plant (cocoa-beans), and utilized for cocoa milk, chocolate, confections, but also for the extraction of Theo-bromine, a light central nervous system stimulant as well as Theo-philene, a mild stimulant derived from the tea leave and applied in pharmaceutical products, will differ only slightly in tooling and gpm–psi requirements. Considering only a few extraction processes it is obvious that there are vast application varieties and service possibilities available to the high and low-end service provider. Health, sport or boutique oriented products requiring plant extraction processes belong within this category and must be considered by the low-end service provider in smaller commercial business identities (Fig. 1.95). The growing specialty product market, such as the development of the micro brewery industry, opened the door for the low-end contractor (3-5,000 psi), especially when acquiring knowledge in industry safety standards, hygiene and technical expertise.

1.12

Coffee, Tea, Cocoa Seeds, Leaves, Herbs Extraction-Processing

83

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Evaporation facilities, bag house systems, maintenance shops, boilers

WORKSHEET- PURCHASING - SALES

As in the food and beverage category, coffee, tea, cocoa and herb extraction methods vary and offer a wide variety of process machinery (Fig. 1.96): Boilers, heaters, heat exchangers, evaporators, mixers, box driers, cyclones or centrifugal separators, vacuum drying equipment such as distillation equipment, air–gas– liquid filtration systems of all types, freeze driers, roasters, grinders,–refrigeration

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.96 Pasteurizing equipment

and cooling environments, bag house units, smoke stacks, wet and dry storage tanks and so forth. The low-end contractor concentrates his service capability on in-plant cleaning schedules, specializing in machine shop cleanups, cleaning of transportation equipment such as delivery and product supply trucks, manufacturing equipment, product storage facilities, silos, tanks, conveyor belt systems etc., or sterilizing and possibly chemically treating production floors and production equipment, which may include the hygiene areas for the plant labor forces, servicing exterior administrative offices, parking facilities, truck loading docks and so on. Researching the extraction plants technical environment is of vital importance for future service possibilities. Contracting opportunities may be seasonal. The high-end service provider will find most industrial application identities within this field. Acidic-corrosive environments can be encountered and require metal preservation procedures within boiler, condenser and tank cleaning operations. Food grade paint-coating removal and installment applications in secondary containment areas and production floor environments are also not unusual. Servicing water treatment facilities, their storage tanks and filtration units is a reoccurring application criterion. It is an advantage to understand the multiphase operating systems encountered, which may incorporate natural raw material extraction and separation technology, atmospheric process systems, reflux or heat elevated pressure processes. Contacts. Manufacturer’s engineering, purchasing, maintenance superintendents for contracting status and possibilities. Process engineers specialized in food drying–freezing and hardware such as air suspension drying equipment, atomizing, fluidized bed drying facilities, flash drying and rotary or spray drying procedures. Consulting services for roasting companies involved in business start-up and expansion. Manufacturers producing artificial sugars, herbal oils and ointments

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Coffee, Tea, Cocoa Seeds, Leaves, Herbs Extraction-Processing

85

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

©

Safety equipment and procedures: Condenser, box driers, tanks, centrifugal separators, stacks.

WORKSHEET- PURCHASING - SALES

utilizing supercritical fluid extraction and pharmaceutical-bio chemical extraction processes, the beverage industry producing organic teas, coffees and juices, etc. Resources. On the Internet, ‘‘Coffee extracts, decaffeination process’’, much of today’s manufacturing and product extraction specifics can be researched and

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studied, plant hardware manufacturers, plant engineering departments, Specialty Roasters Guild of America, the directory for coffee marketing database (Associations), the National Food Processors Association, for contractor’s equipment, WJTA, PNA, CETA, SSPC. Safety. In addition to understanding and enforcing state and plant food safetyhygiene regulations (FDA compliance), a multitude or combination of controls may be necessary, including confined space entry permits, lockout-takeout procedures, hazardous material handling capability and so forth. Permitted in food for human consumption (bulk chemicals) are food additives, microorganisms, chemicals and polymer substances which are present in specific containers and/or fouled manufacturing equipment identities and may pose a threat to the labor force in a condensed, liquid or gaseous state. Code of federal regulations: 21 CFR173 secondary direct food additives http://www.foodsafety.org.

1.13 Cement, Lime Manufacturing, Ready-Mix Concrete Industries, Prefabricated Building Assembly, Pipe, Brick and Block Manufacturing The Portland cement and lime manufacturing environment, a relatively small industrial identity in the late 1950s, was a significant contributor, not only for service opportunities in a wide variety of power washing and hydro applications but also in its support of practical how-to demonstrations within specific experimental tool development stages. In this environment, working with water seemed ludicrous. Introducing high-pressure water jets to dolomite lime (hydration) or cement dust encrusted equipment, including layered deposits on roof structures, plant structural framing, and hardware was not yet heard of. This created a farreaching skepticism with maintenance superintendents. Sentiments have changed within the last 40 years. Understanding the environmental pressures, air emission standards, control practices-equipment and hydro tool developments, the safety oriented service provider, knowledgeable in plant operations, familiar with wet or dry production processes and aware of the possibility of high or low reactivity of cement or lime dust to moisture, has changed this sometimes adverse opinion. The successful manipulation of large (dry-wet) product volumes or product-scale behavior, adherence parameters, tensile strength and product solubility when introduced to high-pressure water are today well documented fact. Traditionally, to maintain a kiln in operation, the clinker ring buildup fragmentation in problem areas was performed via an externally mounted Remington cannon or other mechanical means. The hydro-method is based on thermal shock fragmentation, applying high pressure, low-volume bursts directly to the clinker buildup (Fig. 1.97) within a 75–100 feet distance from the inspection apertures while the kiln rotates in a semi-full production cycle, thus maintaining necessary

1.13

Cement, Lime Manufacturing, Ready-Mix Concrete Industries

87

Fig. 1.97 Cement–lime kiln

internal kiln temperatures. While in rotation, correct nozzle-lance configuration (angulations) prohibit structural and fire brick damage (refractory). Comparatively minute or necessary water volumes will keep developing gases within operating guidelines while effectively cooling the hp-lance and nozzle assembly. Initially, the fracturing process with high-pressure water was developed by utilizing technical experience gained in clinker removal services performed by contractors in fossil fueled (coal) steam boilers during the early 1960s with WOMA Corp. equipment. The sheer length of modern cement–lime kilns (60–980 feet) and today’s operational efficiency may render this clinker removal method inadequate, except in areas where hydro lance access to clinker build-up can be provided (control-inspection aperture). There are approximately 250 cement–lime manufacturing operations within the continental USA to be pursued by contractors. Lime manufacturing facilities are not necessarily part of a cement plant. Lime production or lime reclamation can also be found in the pulp-paper industry, sugar refineries and so forth. They burn calcium and or magnesium carbonate, calcareous materials as coral, chalk and shells or a mixture of liberating carbon dioxide to obtain the derived oxide. The calcium oxide product from the kiln is generally crushed, milled or screened and stored in silos. From storage, the burned lime is delivered to the end-user in the form of quick lime or transferred to a hydrating plant where it is reacted with water to produce slacked lime. A contractor’s technical and sales force must study the integrate pollution prevention and control mechanisms and their necessary plant equipment identities. Fugitive dust emissions and debris buildup are comparable to cement kiln operations and therefore abatement and hydro-blast cleaning procedures are similar. Job set-ups differ between kiln type and size, wet or dry process, plants’ product volume manufactured and vertical shaft kilns found in antiquated or smaller companies producing specialty products. Depending on the job description it may also be

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Fig. 1.98 Kiln bag house and air filtration

important to be familiar with the energy type utilized within the clinker burning process. The hydro-blasting service provider will navigate his potential to air filtration systems to clean bag house units (Fig. 1.98), stacks, flues, electrostatic precipitators-scrubbers (wet or dry scrubbers), closed-loop water treatment facilities, removal of sludge-lime-dust deposits in settling ponds, gravel bed filters, cooling towers, silos, tanks and agitators. The hydro vacuum unit either directly employed or fitted with a mobile product recovery box of 20–40–60–80 yard capacity, will always be of advantage within these types of applications. Especially where increased water usage must be kept to a minimum within the destruction of semi solid concrete waste, or where lime-cement dust and silica buildup, filter cake sedimentation must be dredged below or above water, liquefied, pumped, moved or loaded. Removal applications of tough scale or sedimentation found on internal in-plant hardware, produced by the closed loop plant water which is laden with calcium carbonate, chloride, magnesium, iron, silica traces and enriched with sulfuric acid to balance water (ph-seven) are of a general nature. This includes hydrostatic test procedures with turbine oil or de-mineralized water on pressurized plant equipment, tanks or cleaning plant’s oil lube systems, oil-compressors, fuel storage and transfer equipment, etc. High or low temperature paint and coating removal applications may be required when a premature brick failure (refractory) occurs on a pre-heater kiln, main kiln, clinker cooler, or refractory lined vessels, resulting in a localized shell deformity, forcing a unit shutdown. During the 16–20 h cool down period, plant masons and maintenance superintendents will coordinate refractory or partial refractory repair strategies. Hydro-blasting or UHP jetting procedures, removing brick’s adhesion material from the interior shell reduces not only the overall replacement cost but is environmentally friendly. Replaced steel can quickly be water-sandblasted on site, creating the crucial anchor profile. Not all kiln plant environments employ their own bricking masons or equipment (bricking robot

1.13

Cement, Lime Manufacturing, Ready-Mix Concrete Industries

89

Fig. 1.99 Blending equipment

Fig. 1.100 Ready mix plant

equipment). It is advisable to locate kiln, maintenance identities involved in this work for business opportunities. The power washing contractor (3–5,000 psi.) should consider servicing equipment in maintenance yards (over 8000 quarry operations exist), their equipment and shop facilities, conveyor systems, crushing, grinding, milling, proportioning, blending equipment or areas (Fig. 1.99) and loading ramps, load towers, product packaging equipment labor hygiene areas, etc. Power-washing companies do best when including water pick-up, filtration and recycling equipment capabilities in their general services. Following the cement–lime product trail into ready mix plants (Fig. 1.100) paving plants, concrete reclaim facilities and portable mobile batch plants will greatly enhance marketing perspectives.

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Fig. 1.101 Concrete batch equipment

Fig. 1.102 Concrete precast yard

The ready-mix concrete industry exploded in the last few years to over 5,000 plus batch plants (mobile-stationary) throughout the continental USA offering power-washing, hydro-blasting and UHP contractors a wide variety of opportunities. Concrete batch equipment (Fig. 1.101), identified as low profile-central, transit mix plants and paving plants, must be serviced before, during and after job completion. Tilt mixers, hoppers, tanks, cement silos, conveyor equipment, cement and concrete mixer trucks are the service targets. Primarily their function consists of mixing water, cement, sand, gravel or crushed stone and delivering it into a customer’s construction site in an unhardened state. Today’s entrepreneur specializing in this field will justify the necessary equipment investment by providing application flexibility, versatility with his hydro tooling and support equipment, demanding a wider customer base within a construction cycle or throughout the general construction and maintenance environment, including offering services to heavy equipment rental yards and used construction equipment suppliers. Stationary pre-cast companies and their batch plants (Fig. 1.102) which manufacture pipe, brick, block, architectural components and hollow core concrete extrusion products such as building panels (Fig. 1.103), bridge girders, underground tanks etc., also belong to the customer base of a quality contractor servicing the cement, lime, and concrete industry. Their tooling requirements also permit offering services to pottery, ceramics and plumbing fixture manufacturers engaged in shaping, molding, glazing and firing ceramics. This also includes the glass product, glass fiber manufacturing industries, where again, a high temperature conversion of various raw materials (milled quarry products, recycled glass),

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Cement, Lime Manufacturing, Ready-Mix Concrete Industries

91

Fig. 1.103 Building panels

Fig. 1.104 Brick-block and building composite’s yard

predominantly borosilicate, is the prime process requiring services, such as cleaning refining equipment, heat exchangers, boilers, condensers, flues, tanks, water, air filtration equipment and last but not least, their specialty equipment producing the end product. Contacts. Quarry supervisor, engineer maintenance personnel, yard foreman (Fig. 1.104). Cement process consultants, Cement–lime plant purchasing, maintenance and waste management personnel. Concrete batch plant operator, maintenance supervisor and concrete transportation identities. Pre-cast companies, plant purchasing, maintenance superintendents, construction planning, construction site’s project engineer, project specifying personnel, architects, field engineers, field superintendents, etc. Resources. Cement and Concrete basics (http://www.cement.org). Equipment, WJTA–SSPC–CETA–PWNA. Manufacturing locations, quarry-cement–lime manufacturing associations, the area chamber of commerce, all other identities applying high heat processes to quarry and industrial byproducts, PCA—Portland Cement Association, NPCA—National Precast Concrete Manufacturers Association, http://www.precast.org. Safety. Guard against eye, skin and respiratory tract irritation from exposure to cement dust, heat exertion, awkward work posture, chemical burns, incorporate safety gear for caustic-gaseous environments, possible oxygen deprivation and provide slip-trip-fall protection. Oversee safety meetings before job commencement and tailgate meeting with the labor force. Study safe practices in cement and

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lime plants (Internet). Request details from specific trade associations. In general consider all industrial, OSHA and in-plant must-do safety regulations. Most environments and applications require a combination of safe practices, safety gear and safety training and may differ between job assignments. APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance

Safety Tel: e-mail: Area:

Tel: e-mail: Area:

Job description: Job location: Jobsite Review:

Landfill, other uses Limestone Clay, Shale, Sandstone, Iron Ore

Raw materials Finishing Mill Slag’s, Fly-ash Bottom-ash Alumina, Mill scale

Gaseous Emissions

Product crushing and grinding

Storage & blending

recovery

Kiln & preheater & precalciner & clinker cooler

Finished product Portland & blended Masonry cements Fuels Natural gas Coal, Coke Fuel oil Liquid-solid Waste

Storage crushing & blending

Safety equipment and procedures:

fine grinding

Packaging

Storage & Loading

Additives Gypsum 3 to 7% Fly-ash, Pozzolanes, GGBFS for Blended cements

Customer

Limestone, lime as plasticizers Masonry cements

©

Product manufacturing equipment, flues, precipitators, stacks, conveyor belts, trucks, heat exchangers, cooling towers, kilns, water treatment facility.

WORKSHEET- PURCHASING - SALES

1.14

Dairy Foods, Byproducts and Derivatives, Milk Processing, Concentrates, Powders

93

1.14 Dairy Foods, Byproducts and Derivatives, Milk Processing, Concentrates, Powders, Refrigerated-Frozen Dairy Products In the early 1950s compact reciprocating pumps featuring low water volume at comparatively high pressure configurations (1,200 psi) were introduced by FMC Myers Corp., USA. The commercial and industrial versatility of this equipment proved valuable to Mr. Wolfgang Maasberg Sr. the founder of WOMA Corp. Subsequently, surprising Myers Corp. by his modifications and add-ons, transforming their equipment to then unknown commercial-industrial identity introduced to the USA as Hydro Blast Equipment, or today referred to as Water Blasting Equipment, in Europe-England (WOMA-England) as Water Jetting Equipment and in Germany as Hochdruck-Wasserstrahl-Gerate, later registered as ATÜMAT (High Pressure Water Jet Equipment). In 1954 Wolfgang Maasberg’s company, in its infancy, was selling industrial pumps, chemicals and chemical cleaning solutions to the dairy and general food industry. It became apparent that after a dairy’s high heat processing cycles, most hardened product residue and bulk material adhering to the disassembled manufacturing hardware could be removed with available water pressures, manually administered with a rudimentary spring controlled valve assembly, similar in appearance to that of a pistol, hence in German ‘‘hochdruck wasser strahl pistole’’ (high pressure water jet gun). In avoiding equipment disassembly or reducing obvious chemical, time and labor costs to the customer, the need to provide specialty tooling designed to manipulate water jets in hard to reach or distant internal equipment areas spawned WOMAs future. This prompted aggressive business and engineering commitments by persistently developing new tool capabilities for application procedures not yet available to the general industry. The pressure washing contractor, cleaning and sanitizing the dairies free or tie stall barns (Fig. 1.105), tunnel ventilation systems, automated and gravity flow manure gutters, feed storage silos, tractors-animal trailers and farm equipment, etc. or making use of his pressure washing equipment’s hydro-vacuum system in servicing settling ponds or underground tanks (sludge-sedimentation removal practices, etc.) which includes cleaning water treatment facilities and regenerating water wells, could consider expansion of his service capabilities to the milk parlor environment. In researching this possibility he will realize quickly that hygienic work habits, sanitation, hygienic support equipment, hydro tool design and the use of chemical applications differ greatly when compared to livestock areas and equipment cleaning operations. Regardless of the contractor’s prior quality in labor hygiene practices and general sanitation programs, when in job solicitation or cleaning operation, he must incorporate and perform a series of protocols and personal equipment cleaning procedures, aimed to eliminate possible prior exposure possibilities (feed

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Fig. 1.105 Dairy feed stall

Fig. 1.106 Dairy milk parlor and equipment

and livestock area) to avoid a cross contamination into the milk parlor or dairies product manufacturing environment (Fig. 1.106). The possibility of spreading foreign organisms and bacteria, including unidentified soil and microbial product residue from prior jobs. or human viral influences cannot be permitted. When involved with dairy purchasing and maintenance departments, it is especially important that one adheres strictly to the established controls that prevent, reduce or eliminate problems from occurring. Contractors are under intense scrutiny to avoid any possible introduction of foreign micro-organisms such as bacteria, mold or yeast to the milk processing environment which also results in poorer product quality and shelf life.

1.14

Dairy Foods, Byproducts and Derivatives, Milk Processing, Concentrates, Powders

95

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location: Jobsite Review:

Safety equipment and procedures:

©

Tanks, tanker trucks, loading docks, cooling towers, water treatment facilities.

WORKSHEET- PURCHASING - SALES

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.107 Dairying plant

When establishing a sanitation program, the plant’s (Fig. 1.107) maintenanceprocess engineer and laboratory personnel must be involved to identify and prioritize remedies against the possible introduction of harmful organisms. The contractor should advise or design with the customer the necessary chemical resources, composition and ratios to be applied with high-pressure water before, during and after cleaning requirements. This includes identifying adequate blast water for areas or equipment in question, equipment changeover to various plant locations, equipment breakdown, sanitation and correctly discarding job essentials such as gloves, coveralls, tarpaulin, earplugs, spent eye wear, empty containers, etc. after a job completion. To be effective, every service provider’s employee must know that it is part of his or her job description to eliminate the risk of contamination possibilities to the area, equipment and product by effectively implementing established sanitation guidelines. All written procedures and statements must be signed by maintenance-laboratory personnel, providing the job history. The validated program is added to the bid paperwork, gear-equipment-job report folder and must be saved for possible inspections or verifications. It is of an advantage to be knowledgeable of the plants hazardous analysis, critical control point system (HACCP) and guidelines, providing the operational quality assurance within specific production-equipment-hardware (Fig. 1.108) or plant areas to by serviced. This does not necessarily rely on testing the final product manufactured but concentrates more specifically on internal hygiene, laboratory tests of all milk products and their contact surfaces, plant operating temperatures and equipment operating parameters throughout all storage—sterilization–pasteurization—manufacturing cycles and plant maintenance processes. Today’s milk processing environment and product cycle is highly automated and features a clean-in-place system (CIP) and procedure, accommodating the industry’s necessary cleaning ordinances or better cleaning intervals for raw or heat treated milk storage facilities, including all inline milk contact surfaces (Fig. 1.109) of plant processing equipment.

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Dairy Foods, Byproducts and Derivatives, Milk Processing, Concentrates, Powders

97

Fig. 1.108 Dairy product vessels

Fig. 1.109 Cream pasteurization equipment

Milk contact surfaces may feature a variety of scales (milk stone, powders, fats, etc.) and differ not only by product being manufactured and transferred, but also vary do to CIP flushing or cycling of specific dairy detergent-wash solutions. These may be chlorinated alkaline or hot-acid-caustics, low or high temperature fluids and are designed for plants specific process and hardware requirements. The solution is circulated throughout the system with a relatively high fluid velocity and then returned to the holding reservoir.

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APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location: Jobsite Review:

Safety equipment and procedures:

©

Water pretreatment plant, boilers, condensers, evaporators, filtration systems.

WORKSHEET- PURCHASING - SALES

1.14

Dairy Foods, Byproducts and Derivatives, Milk Processing, Concentrates, Powders

99

Fig. 1.110 a Chillercondenser, b condenser tubes

Offering cleaning procedures and application technologies with limited or non misting side effects (overspray), utilizing available hydro vacuum systemsequipment and recycling the necessary blast water within the dairy environment will find a positive response from maintenance superintendents, laboratory personnel and purchasing-management alike. Elevated water pressures are mainly necessary in the high heat producing part of the plant. Cleaning milk powder equipment, their product lines, conveyors, boilers, heat exchangers (Fig. 1.110a, b) water and milk evaporators, cooling towers, filter housings and waste water treatment centers, sewers and drainage pipes are some more of the general hydro-cleaning varieties encountered. Typically, a service provider will gain access to the milk reception, processing, product manufacturing and storage-distribution areas only when a facility malfunctions or a routine plant shutdown is imminent. Modern dairies feature an abundance of welded and continuous product transfer pipes (Fig. 14.7), tanks and silos, hopefully with strategic access ports, permitting the application of flex lance technology and equipment. To achieve high velocity water access to all hidden or cumbersome internal areas, gasket, flange and possibly inaccessible pipe surfaces are in need of special attention when hydro-tool selections are considered. In large plants, milk tank trucks are cleaned and sanitized internally. Maintenance departments verify and tag each time the tanker is cleaned and perform a log book record for each procedure. This does not mean that external truck cleaning operations cannot be offered. Ice cream and frozen yogurt manufacturing facilities are another opportunity for service providers. The conversion of skim milk, milk fat, milk solids, sucrose, corn syrup, emulsifiers and specialty ingredients into ice cream or yogurt by fermentation, blending, mixing, pasteurizing, homogenizing, aging, freezing, hardening, packaging, storage and distribution offers numerous application varieties. Milk, milk byproducts, fruit, chocolate and a diverse variety of ingredients added to the variety of manufactured products demand the same diligent operational integrity, applying hygiene, sanitation and biosecurity guidelines. Product transfer pipes (Fig. 1.111), silos, tanks, filtration equipment, heat exchangers, boilers, cooling towers, refrigeration-freezing equipment, waste water or water treatment centers, trucking and warehousing are all points of interest. Contacts. Farm-Dairy-operations, unit managers, feed managers, veterinarians, feed suppliers, Artisan cheese and ice cream manufacturers, farm equipment

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1 Succeed in Residential, Commercial and Industrial Environments APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location: Jobsite Review:

Safety equipment and procedures:

©

Feed silos, silo cleaning, mist eliminators, general building sanitation.

WORKSHEET- PURCHASING - SALES

1.14

Dairy Foods, Byproducts and Derivatives, Milk Processing, Concentrates, Powders 101

Fig. 1.111 Dairying transfer pipes

repair-maintenance and dairy product storage (refrigeration) and transportation facilities, etc. Resources. Equipment, WJTA, CTA, PNA, for coatings SSPC, dairy industry resources thru the Internet, dairy breed associations, local dairy associations, local, national and international dairy foods associations, states milk inspection services, etc. Safety. Milk and dairy food safety guidelines, US-FDA, USDA, a multitude of industrial safety, sanitation, hygiene, operator training and supervision procedures are required. http://www.cfsan.fda.gov.

1.15 Fish Hatcheries, Aquatic Farm Environments, Tropical Marine Livestock Centers, Secondary Fish Processing Plants, Lake and Pond Management, Fish Processing Marine and freshwater aquaculture can be as the growing of fish and shellfish to supplement natural supplies for recreational, tribal, commercial and scientific purposes. At this point, everyone understands that during the last 40 years oceans suffered unsustainable harvesting practices. Overall counts of many species are dangerously low and cannot be expected to maintain their existence by natural procreation alone. Global seafood consumption, national-international fishing fleet’s offshore production capabilities, combined with the degradation of ocean and landlocked spawning habitats by human populations, growth-activities and subsequent ecological changes are the major forces which accelerated research, development and construction of marine-freshwater aquatic farm environments.

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Fig. 1.112 Fish farm ponds

The maintaining of fish health and their procreation in large numbers in a confined space was the number one research-development question, which today results in the aquaculture product penetration to markets in the millions of tons. Fish-farms, hatcheries–nurseries rearing (Fig. 1.112), donor, brood fish pond design-structures and commercial holding facilities differ by species (cold-coolwarm-water), as do the water recirculation-treatment facilities and their possible leach field layouts. The fish farm water source may also vary and could be ocean, lake, stream, spring, surface or deep well water. In the early 1960s, with the growing consciousness of biologists to better manage bacterial and biological controls in the fish farm-hatchery environment, maintenance personnel began utilizing a 150 hp hydro-blast unit, displacing the sewer jetting technique. This resulted in a more effective rust, algae and bacteria removal practice of offshore salt water supply and discharge lines operated by land-based marine hatcheries. Ever since, power-washing and hydro-blast applications have been administered in the aquatic farm environment. Hot water above 190, at 3–8,000 psi removing bulk contamination (aquatic growth, sedimentations, various scales, etc.) in its wake neutralizing harmful bacteria not only on surfaces but also in otherwise difficult to penetrate crevices, reset gasket areas, concrete fissures, etc. also results in a chemical cost reduction when final startup prep procedures of equipment and related structures are performed. Cleaning feed equipment and silos, tanks, commercial holding facilities, interior or exterior race ways (Fig. 1.113) degassing units for catfish hatcheries, packed column aerators and water treatment center equipment, including pipes, filtration equipment and chillers, are considered general pressure washing applications. Fish farm or hatchery laboratories will advise as to the correct application of disinfectants, for instance, applying a nonselective germicide (1% active iodine) as is often utilized in laboratories and veterinarian facilities. Balancing fish pond ecosystems and water quality standards are a vital management facet in farming operations. Service companies should be able to perform water chemistry analyses and interpretation to support ongoing application endeavors.

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Fish Hatcheries, Aquatic Farm Environments, Tropical Marine Livestock Centers

103

Fig. 1.113 Race way facility

Fig. 1.114 Fish pond environment

The hydro-vac dredging method can be utilized in several ways and is preferably applied as a preventive pond cleaning procedure, removing fish-waste-feedalgae controlling ammonia and nitrite levels, etc. before a fish kill occurs, or in a prime dredging operation servicing pond bottoms (Fig. 1.114). Dredging operations can be performed at or below water levels, not disturbing or damaging sensitive soil-clay-plastic pond liners. Gravel beds can be pulled, gravel cleaned and returned to pond bottom and the effluent can be pumped directly to leach fields, tanker trucks and water filtration-recycling systems. In this application the hydro-vac method is far superior, providing application versatility, tool variety and cost effectiveness in comparison to other dredging operations. Expansion or renovation of existing hatcheries, spawning facilities, concrete raceways, etc. may call for partial-total concrete or coating removal, construction site or prep-cleanup. Serious contractors will pursue and qualify for a subcontractor status with all structural and equipment manufacturing identities involved within the aquatic farm industry. A variety of hydro blasting and pressure washing techniques found in the aquatic farm environment can also be transferred to the tropical marine rearing, holding and exhibition environment. Lake and pond

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Fig. 1.115 Processing equipment

management companies also share similar job opportunities, but most likely are not driven by the high priority sanitation concerns fish farms-hatcheries-processors must consider. Developing national and international industry trends, incorporating processing capabilities adjacent or within a fish farm environment expands the overall application variety and business opportunity into the processing (Fig. 1.115), packaging and transportation field. On-shore seasonal or periodic manufacturing schedules, species variety and the variation in processing systems in today’s conversion of raw materials for human consumption, revolves around or includes freezing, drying, smoking, spicedmarinated (pickled) products, cooking, frying-breaded, canning, vacuum packing, cold storage, etc. Most large canneries also operate a fish meal and/or fish oil production facility, applying high heat and vacuum, drying, grinding processes. The hazardous analysis critical control point system (HACCP) and specifications varies between processors and is tailored to their specific production needs. Opportunities for pollution prevention, odor control, bacteria-decontamination procedures, cleaning process equipment, production areas and so forth between seasonal or product manufacturing cycles, differ from most at sea processor environments. Studying spawning facilities within the food industry segment encountered will quickly enlighten a service provider of possible application opportunities. Following the in-plant water usage trail, which includes water for refrigeration systems, washing of raw materials and process equipment, conveying products from one process area to another, dissolving and extraction processes, steam generation for cooking-heating, evaporators and turbines, etc. ending with cooling towers and water treatment facilities is a clear indicator to the abundance of application possibilities Fig. 1.116.

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Fish Hatcheries, Aquatic Farm Environments, Tropical Marine Livestock Centers

105

Fig. 1.116 Spawning facilities

Soiled boilers, condensers, heat exchangers, cooling towers, refrigeration equipment, wastewater treatment facilities, manufacturing floors including receiving-distribution areas provide standard application identities to contractors. A bacteria free environment is essential to shellfish producers. The service provider may offer scale removal-cleaning of water supply pipelines over extensive distances, under water cleaning of shellfish breeding surfaces, removing barnacles on stock pylons and separating kelp from base material-surfaces. Within this environment 90% of applications are performed with hot or cold water between 3 and 12,000 psi. Offering an expert chemical application procedure by providing a precise chemical-water ratio metering control is also of importance to the customer. Fresh, round or dressed, frozen fish, fillets, shellfish and crustacean products are highly susceptible to texture breakdown, decomposition, discoloration and flavor changes caused by a multitude of natural and circumstantial factors. Supervisory and maintenance personnel striving to minimize spoilage, maintaining their product integrity, desired palatability and shelf life, demand that a contractor or service provider perform his operation within all specified plant ordinances, varying by species and subsequent products manufactured. The FDA’s food hygiene requirements and guidelines concerning personnel and equipment utilized by service providers are always enforced. Contacts. State fish hatchery complexes, Fish and wildlife services (USFWS), state water conservation districts, licensed and authorized commercial and private hatcheries, consultants for design, construction of fish hatcheries, aquaculture consultants for shellfish and marine fish farming, fish feed manufacturers, the laboratories involved with fish health, environmental monitoring and technology, fisheries-fish-farm biologist and supervisor. Aquaculture water treatment facilities and reclaim systems, engineering and design-management identities. Fish stocking operations, and transportation companies, fish processor, their purchasing-maintenance departments, specialty products operations, canneries, etc. Resource. For equipment, contractors, coatings, WJTA, PNA, CETA, SSPC, plant’s HACCP system identifying FDA’s critical inspection points.

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Safety. FDA’s and OSHA regulations are enforced, according to application encountered, many applications frequently require a combination of controls and all industrial standards can be expected.

1.15

Fish Hatcheries, Aquatic Farm Environments, Tropical Marine Livestock Centers

107

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Boilers, condensers, chillers, cooling towers, production facilities.

WORKSHEET- PURCHASING - SALES

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Fig. 1.117 Briggs and Stratton

1.16 Food Service Industries, Food Processing Companies, Produce Retailers, Suppliers, Trucks-Trailers-Tankers-Railcars The question as to who was first to utilize, ‘‘high-pressure water as a tool within 1,500–3,000 psi at 5 gpm or less, is probably related more to when cost effective and reliable engines were available to withstand the demands triplex pumps require in performing pressure washing operations. In the mid 1960s to early 1970s Italian and Japanese firms developed and subsequently mass-produced affordable compact pumps. They were, for all purposes quite similar to their big brothers, operating at 25–150 hp., featuring a V. packing design, ceramic plunger sleeves, caged plate valves, manual pressure regulation combined with a pressure relief function for manual trigger-gun operations (avoiding the dump-gun service), controlling water usage and undesirable side effects. At this time engine manufacturers including Briggs and Stratton (Fig. 1.117), Honda (Fig. 1.118), Kohler (Fig. 1.119), Kubota, etc., developed suitable engines (5–20 hp.) by taking into account the operational rigor reciprocating pumps may undergo within a service application. This engineering and design event facilitated adequate pump drives, revolutionizing the new-age pressure-washing industry. Some ask why hydro-blast equipment manufacturers were slow to respond or passive to the existing pressure-washing market. One answer is that they actively pursued the complexity of the emerging industrial potential in operating above 25–150 hp, providing application specific water volumes and tool combinations (interchangeable piston-plunger combinations). Or, one can also theorize that within the constant quest to produce higher pressures and water volumes above 25 hp. (capping out in the mid 1960s at 150 hp), application varieties below 25 hp. were all of secondary interest and only important to service providers capable of operating multiple hydro-tool combinations of one triplex pump in a specific job environment. I speculate that service providers and manufacturers alike did not anticipate an adequate amortization or return on their investment in emerging markets at 2–5 gpm and 1,500–5,000 psi. This is most surprising considering the vast amount of jobs available within this performance criterion.

1.16

Food Service Industries, Food Processing Companies

Fig. 1.118 Honda

Fig. 1.119 Kohler

109

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Fig. 1.120 Prison facilities

This was not the case with steam vapor-hot water equipment manufacturers who understood the added application advantages in the commercial servicecleaning industry. Incorporating or outfitting the available hot water or steam technology with these pumps (5–18 hp.) resulted in a variety of high-pressure water-steam equipment combinations, followed by the birth of the modern mobile and stationary hot–cold water pressure-washer and systems (1,500–9,000 psi). The successful downsizing of existing hydro-tool varieties (5–10,000 psi) was also of benefit to service companies. Today, the industry supplies manually adjustable pressure regulators, pipe cleaning nozzles, abrasive injectors and tank cleaning heads, spin-jets for flat or vertical work, hp-gun-wand-flex lance combinations and their nozzle technology. Industrial vacuum heads-equipment, product separation techniques and up-down-stream chemical metering equipment, etc., accommodating gpm–psi ranges associated with the pressure-washing industry, were also modified and successfully applied. These events quickly created application marketability for cleaning private, commercial and industrial environments. In the USA, leading equipment manufacturers (1,500–5,000 psi) with foresight, at their own time and expense, accelerated the design and development of closed looped water recycling-filtration-evaporation and reverse osmosis systems. These systems are today readily available in stationary and mobile form, supporting the service industry’s application marketability, in particular where environmental constraints and liquid waste disposal regulations require detailed attention. The food service industry established compliance requirements regulating fire hazard control, air quality-temperature and food safety within the transportation, produce-storage-handling and assembly areas, identified as produce receiving area, cold-storage, refrigerated walk-in facilities, product prep-rooms and kitchens. These requirements are well documented and competing service providers should familiarize themselves with them. In their constant daily routine and effort to eliminate the introduction of food borne illnesses and possible fire hazards, restaurant owners, chefs and custodial management in institutions such as prisons (Fig. 1.120), healthcare organizations, schools and corporate kitchens expect service providers and their labor force to submit appropriate certification in

1.16

Food Service Industries, Food Processing Companies

111

Fig. 1.121 Fast food industry

kitchen exhaust cleaning procedures. This includes incorporating the practical relevance or variety between cleaning and sanitizing objectives, correct waste removal practices and if necessary, implementing closed looped water-refuse filtration recycling methods. Alkaline-detergents-acids-solvents-disinfectants their implementation-concentration and neutralization within a job requirement must be governed by health department’s sanitary guidelines and FDA approved. Product containers must visually identify contents by displaying up-to-date material safety data documentation (MSDS). Jobsite access where nonessential personnel traffic could occur may also require this visual warning or identification of hp-washing operations and potentially hazardous products in use. As for over the road transportation, MSDS documentation must identify and accompany chemical-powders and liquids. Drivers must display a visual warning-identification sign on the back of the vehicle in question. For the most part, within their business-theme and on their premises, the fast food industry (Fig. 1.121), designed and developed exhaust hood-duct and fire prevention equipment to better facilitate services and cleaning procedures. Services and oil-grease removal-pickup schedules are determined by operating time and the product volume manufactured. They further present a wide variety of job opportunities. Their premises require periodic attention, which could include cleaning restaurants drive-thru (flat work), exterior customer window assemblies, parking or pedestrian areas, children play facilities, produce receiving areas (loading docks), garbage-refuse locations and dry storage surfaces. Oil recycling areas and equipment, which can include an incinerator environment in need of services, or graffiti removal applications, are all further possibilities for a contractor. State and County health and fire departments are not yet nationally unified in a standardized inspection curriculum for restaurant hood-duct systems. The decision to incorporate adequate cleaning intervals is mostly left to the judgment of facility operators. Therefore, commercial duct-hood cleaning-sanitizing schedules and their service complexity may vary drastically between business locations and their

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Fig. 1.122 Fire extinguishing-suppression equipment

Fig. 1.123 Denatured fat contaminated surfaces after cleaning

management. Today, they can prove in large measure similar in intricacy to hydro blast operations. This is in part due to cuisine variety, product volume, type of cooking oil-fats-moisture and temperature utilized in the production process. Furthermore, exhaust systems efficiency, oil-grease filter type (grease removal devices), the design of fire extinguishing-suppression equipment (Fig. 1.122), their location and a duct systems age-structural integrity or accessibility are all constantly changing factors playing a part in these challenges. Chemical applications within a kitchen (approved acids, solvent, soaps) and the wide variety of high-pressure water tools, their jetting characteristics manipulating oil-grease or denatured fat contaminated surfaces (Fig. 1.123), demands effective tarpaulin-covering procedures (splash proofing) to minimize and direct waterrefuse overspray into the nearest containment area, always keeping food safety

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Food Service Industries, Food Processing Companies

113

Fig. 1.124 Roof duct installation and fan assemblies

regulations and overall cleanliness in mind. This requires practical experience and incorporating application oriented flexibility within every encountered jobsite. Incomplete or mediocre cleaning procedures may also present a liability factor to a service provider. Most hood-duct fires are due to burning foodstuffs. According to state-county enforced fire codes, when performing grease extraction procedures on hood canopies, grease-traps, grease filtration-extractors and their kitchen exhaust duct system, including duct risers, roof installation and fan assemblies, a service provider must be properly trained, certified and qualified to recognize different types of commercial kitchen exhaust systems and components (Fig. 1.124). Identifying a noncompliant system, often found in older establishments (grandfathered), and when restaurant ownership changes sporadically, demands proper recording-reporting of non compliance for tool inaccessibility, blind spots and possible oil-grease leak or pooling situations. In short, reporting the overall status before, during and after a system is serviced is a requirement. With proper technical authority, this may also involve the installation of grease proof, air, fire and water tight service access doors to inaccessible areas of a system. Basic plumbing, sheet metal fabrication skills, knowledge of electrical circuitry and performing lockout-takeout measures is a necessary prerequisite. The contractor is expected to test the system after job completion, guaranteeing and making ready for proper functionality before any restaurant activity or function continues. Training and employing an educated labor force is very important. Labor dress codes, safety and hygiene methods should also be responsibly guided and not seen as a negative criterion, rather as a necessary professional, safety oriented function, resulting in the customer’s ease of mind and supporting management in their sales efforts. When scheduling services, take into account a kitchens natural operating and down times, which might include operations in produce receiving, storage and prep areas. Having proper education and experience in ventilation control, fire-protectionprevention and or equipment supply industry for commercial cooking facilities offers further opportunities. This includes servicing and, if necessary, charging fire

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Fig. 1.125 Food-produce retailers

suppression systems to guarantee their functionality and upgrading exhaust systems to current (NFPA) fire code requirements. Technically well versed contractors or entrepreneurs can also expand their potential into the grease interceptor business. In general, their sizes are determined by product volume-usage and existing uniform plumbing codes or otherwise local standards. Externally situated, these grease interceptor units hold a minimum of 650 gallons plus effluent. Pumper truck employment (hydro-vac system) and possible microbial treatment procedures are of essence. Cleaning the air-conditioning system’s (duct work) evaporation coolers, etc. is also an important facet. Food-produce retailers (Fig. 1.125) offer obvious application varieties, starting with cleaning shopping carts, floor surfaces in produce receiving or warehousing facilities, refuse locations, pedestrian and parking areas. Employing the closed loop high-pressure water cleaning method is ideal, in particular in equipment service areas or suppliers-customer vehicle parking locations where dirt and oil accumulations are likely. Federal and most local laws will not permit the introduction of created effluent by pressure washing operations into the storm water conveyance systems. Due to the intensive use of disinfectants, harsh cleaning solutions, acidic produce, heavy human and equipment traffic, coating renewal or removal applications in warehousing, cold storage and produce display areas are also common job descriptions. Some retailers also operate in-house restaurant or kitchen style food service, requiring periodic hood-duct cleaning applications. Besides operating highly sophisticated computerized distribution centers, giant national supermarket chains often maintain bread, milk, cheese or ice cream manufacturing environments (Fig. 1.126) where standardized high-pressure water cleaning solutions are of necessity. All food processing-manufacturing activities, including packaging, storage and transportation, are conducted under conditions and controls necessary to minimize the potential for growth of microorganisms or other possible contamination. The industries complying with these requirements monitor physical factors such as time, temperature, humidity, pH, pressure and product flow rates in manufacturing

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Food Service Industries, Food Processing Companies

115

Fig. 1.126 Dairying plant

processes such as freezing, hydration, dehydration, heat processing, acidification and refrigeration. The industries risk assessment for possible product contamination led to establishing critical control points (HACCP) throughout the manufacturing process. Plant cleaning schedules challenging suspicious food or edible product contact areas accelerated the design and manufacturing of stationary hot and cold pressure washer systems. They are placed in production facilities supporting sanitation standing operational procedures (SSOP). This fact does not add to or diminish the business potential for a contractor. Most service opportunities are created during production line shutdowns or product changeover procedures which can be seasonal or when starting up a new product line requiring cleaning of contaminated hardware components. In the food retail-processing environment a prerequisite might exist that the contractor’s equipment or support tooling be designed to their industry standards. The aspiring entrepreneur does well when realizing the type of energy and hardware applied within specific manufacturing processes. Boilers and steam generators, heat transfer equipment (condensers, heat exchangers), cooling towers, pumps, air compressors, their pressure and discharge product lines, water treatment facilities, refrigeration, freezer hardware and areas, are often the heart of a process environment. Bakery, candy, confectionery processes, beverage and cannery environments, dairy products, dressing and sauces, vacuum packed frozen-refrigerated fruit and vegetables, grain and cereals, meat, poultry or seafood products, snack foods, etc. are all manufactured with production equipment and areas in need of periodic services. Ovens and driers, precipitators, tanks, mechanical-centrifugal or bag house filtration units, accumulators, mixing-blending or fermentation vessels, product forming, sorting, grading equipment, packaging machinery or product conveyors are only a few equipment identities. It can be noted, as within the produce retailer’s environment, that acidic activities of foodstuffs, thermal conditions and mechanical forces by loading equipment, etc. to floor coverings accelerates wear and tear demanding frequent removal and installation procedures of FDA-USDA

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.127 2D nozzle carrier

Fig. 1.128 2D nozzle carrier extended

approved floor systems. Working with paint-coating installers can be a viable subcontracting possibility. In the mid 1960s the first nozzle carriers with an automated rotary function were developed, operating at 7,000 psi delivering 36 gpm (Fig. 1.127) and pressed into industrial services for evaporator, tanks, autoclaves, rail tankers and tanker truck cleaning applications. Rotary nozzle carriers outfitted with various accessories drastically improved the industrial application potential. This type of equipment was engaged throughout the commercial, industrial and military sector, including smokestack maintenance (Fig. 1.128), sewer, horizontal-vertical

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Food Service Industries, Food Processing Companies

117

Fig. 1.129 Rail-tanker telescoping fixture

Fig. 1.130 3D Tank nozzle

industrial pipe cleaning operations, container and casing decontamination procedures (Fig. 1.129). In the mid 1960s, the first high pressure 3D nozzles (Fig. 1.130) became functional, producing further enhanced cleaning methods, operating at 7,000 psi up to 89 gpm. This profound nozzle technology often eliminated the otherwise customary confined space entry method found necessary in square-round-elongated tanks or spaces by permitting water jets to reach all problem corners and areas. At that time, this type of equipment was temperamental, nevertheless, an industry benchmark in its performance criteria and today is an industry standard for performing cleaning and product scaling operations within most available low to high pressure gpm–psi ranges. Since the conception of water as a tool, refrigerated trucks, trailers, tankers and railcars, the major movers of foodstuffs, have been cleaned with hot or cold

118

1 Succeed in Residential, Commercial and Industrial Environments APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering

Maintenance Tel: e-mail: Area:

Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

©

Safety equipment and procedures: Food service industries, food retailing, suppliers, food processing companies, tanks, trucks, trailers, railcars, and mechanical equipment.

WORKSHEET- PURCHASING - SALES

1.16

Food Service Industries, Food Processing Companies

119

Fig. 1.131 Fleet washing

high-pressure water in one form or another. As well as mobile foodservice units, this type of equipment is today cleaned only by incorporating EPA (Clean Water Act), state and city guidelines, regulating industrial and commercial wash water discharges. The continued cleaning with high-pressure water and sometimes necessary chemistry, in rural and industrial areas, of trucks, trailers and for this matter all other mechanical equipment on unprotected permeable grounds, is deemed environmentally an unacceptable work method. This includes not only the illegal discharge of waste or wash-water to open ground-soils-gravel surfaces, but also into storm sewers and septic systems. Regardless of the job in question, qualified and conscionable service providers will always first consider the possible environmental impact by the downstream blast water refuse. In these service areas, past inappropriate precautions resulted in gradually accumulatively developing leach fields containing high-levels of pollutants which contaminated surface-soil-ground-aquifers and subsequent well or potable water sources for decades to come. Responsible for this are the possible pollutants in turbid wash water. Liquid waste containing total dissolved solids in excess of 400 mg/l or containing a chemical oxygen demand in excess of 45 mg/l, detergents and materials causing foaming or frothing, acids or alkaline substances having a pH value lower than six or higher than 10., traces of emulsified oilsgrease and/or toxins such as benzene, cadmium, chromium, toluene, mercury, copper, lead, metals, etc. must never be introduced to the separate storm water conveyance system. EPA, state, county and city drainage utility authorities under the national pollution discharge elimination system (NPDES) controlling storm water discharges from sites of industrial activity, prohibit all non storm water discharges to the municipal separate storm water conveyance systems. In researching all necessary regulations, a service provider is best advised to consider the closed loop non discharge cleaning method to avoid the obvious, but also possible implications resulting from past activities by unknown violator. This no discharge reality, in itself, presents a terrific business opportunity. Fleet washing (Fig. 1.131) demands a high degree of trade flexibility. Engaging in weekend and night work, having emergency response capabilities and tooling

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Fig. 1.132 Wash-water recovery

befitting the multitude of a fleet owner’s equipment and location varieties, means maintaining a qualified labor force, planning and organizational skills. A ‘‘one size fits all’’ equipment and tool selection must be viewed with skepticism. Primary cleaning considerations are; 1. The type of road film encountered and remaining waste of previous products transported; 2. Vehicles or equipment purpose, seasonal circumstances, fleet location, scheduling requirements, location of possibly necessary electric power and water sources; 3. Ground, refuse runoff conditions or circumstances must conform to EPA, state, county-city-locality wastewater discharge regulations. For the most part, variables will likely change between jobsites. Local municipal ordinances can also be more stringent than federal regulations and can include heightened discharge policies regarding sanitary sewer systems by limiting the liquid volume introduction (gpm) of non-hazardous wash water. Varying in cost, municipal waste water discharge permits can be a requirement regardless of the wastewater volume in question. Concentrating any liquid waste stream on a customer’s site can result in a hazardous product. In general, only when service providers remove unidentified hazardous materials from a customer’s location, will he become partially or fully responsible for the correct disposal of such materials. In addition to EPA and FDA regulations, most city and counties offer internet resources for non-storm water discharges, providing waste water treatment links. Some incorporate best management practices for mobile pressure washing services. Once these parameters are understood, qualified equipment and tool selections can be determined. The savvy service provider will find professional products-tooling and chemical rinse aids specifically designed for closed loop wash water pickup (Fig. 1.132), incorporating removal of fine solids and pollutants such as oil and grease manipulated by vacuum, water filtration-recycling-compacting and/or possible evaporation methods. As well as fleet and equipment washing, justifying the investment in such equipment is a matter of the company’s entrepreneurial growth and future potential. Mobile integrated mat and vacuum boom systems, sewer-pipe

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Food Service Industries, Food Processing Companies

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APPLICATION REVIEW Customer, Company:

Date:

Nr:

Address: City:

Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing Tel: e-mail: Area:

Engineering

Maintenance Tel: e-mail: Area:

Tel: e-mail: Area:

Tel: e-mail: Area:

Safety

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Kitchen hood canopies, air duct exhaust cleaning, grease filtration-extractor services, fleet washing, and drive-thru’s.

WORKSHEET- PURCHASING - SALES

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drain covers, tarps, wet-dry vacuum equipment with an internal sump-pump function, converting pressure washing-hydro blasting equipment to hydro-vac technology and most importantly, choosing job specific tooling-essentials, keeping application flexibility in mind, enhances the contractor’s application potential and overall marketability. Most equipment can be utilized for disaster cleanup or servicing parking garage facilities, gas stations, bank drive-thru, building restoration work or, for instance, in general area decontamination of crime scenes and accident sites, floor and equipment services in machine shops, warehouse facilities, and in most other in-house surface cleaning operations. Contacts. Hotels, restaurants, institutions, food-produce retailers, food processing-manufacturing, process engineers, maintenance-services, purchasing departments, product transportation environments, their purchasing-maintenance personnel or facility managers. Resources. Refrigerated Transportation and Warehouse Association, http://www.IARW.com, Areas ‘‘Food Processors Association,’’ for possible customer info, http://www.mwfpa.org. Internet; ‘‘Storm water management and discharge control’’, Best management practices for mobile cleaning’’, EPA, state, city or county wastewater discharge departments, local fire departments for existing regulations and fire prevention codes (restaurants), etc. Safety. FDA, and OSHA regulations within the specific commercial or industrial environment.

1.17 Foundries, Steel Mills, Forging Shops, Nonferrous Metal Industries, Pelletizing (DRI) Plant Some consider the hydraulic mining method the first high-pressure water application within the mining and metals industry. That is highly debatable, considering the prerequisite of an industrial pump, wire braided reinforced hoses, suitable 4,000 psi plus pressure gauges and highpressure water a. tools, all of which had not yet been developed. The washing and removing of ore from a prospecting site by a concentrated high-volume low pressure water jet ended as a controversial mining technique. First by gravity flow, later by steam engine-pump combination, developed water pressure and on the hillside manually operating mounted nozzle contraptions provided the mechanical force. Some applied Bernoulli’s nozzle design criteria, expediting dislocation of mineral aggregate in the millions of tons, leaving much of the affected environment in shambles. In the early 1900s, quench procedures performed on red hot metal surfaces applying a thermal shock with water (spray bar over rolling stock) is also referred to by some as one of the early high-pressure water application techniques. Again, this is suspect as this technique did not represent a new method

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Fig. 1.133 a DRI plant, b Smelter, c Foundry

of slag scale removal within the industry (Fig. 1.133). The notion that anyone in the 1800s to mid 1900s produced the necessary psi and gpm configuration has never been confirmed. What’s more, today it is known that high-pressure water methods, including UHP performances present certain limitations in removing such slag. In 1956, at his father’s business location, Wolfgang Maasberg developed the fundamental equipment identities for WOMA Corp., promoting and manufacturing high-pressure water tools operating within the 75–150 hp. range. Applying high-pressure water above 5,000 psi at various gpm performances within foundry, non-ferrous metal smelting and refining industries developed more or less by chance. Situated in Duisburg Germany, the heart of not only intense coal mining, iron foundries, nonferrous metal smelting and refining operations but also the cargo industry with their Rheine-Ruhr river ship yards, did encourage tool design criteria for these industries. Able to apply his newfound technology, which he coined ‘‘water as a tool’’, and equipment identified as ‘‘ATÜMAT’’ supporting these tools, delivering correctly the all important application oriented water volume-pressure configuration, he introduced hydro-blasting or water jetting techniques to these industries. In Germany in 1958, water blast techniques performed by WOMA for foundry processes supporting the mold recovery, shakeout, shot blasting and mechanical core removal application in large motor castings with various interchangeable hp-gun lance extensions, were not transferable to the Japanese market. Kobe and Kawasaki steel works therefore automated (1964–1968) their engine casting division by remotely controlling high-pressure water guns. Impacting casting sand and filaments within a cast motor block (Fig. 1.134) on a remotely controlled rotary platform, providing a successful cleaning procedure was then an astonishing achievement and not thought of by burly hydro-blast operators. Damage control to casting from knock out procedures, such as chisel, shot or abrasive techniques, reducing the caustic solution and disposal costs, operating in a dust free environment and permitting the recycling of core and shell materials was an obvious benefit. Yet, this method, protecting the operator behind a glass screen or better, in an operator cubicle was later downsized to support the development of enclosed automated casting cleaning systems, ‘‘CASTÜMAT’’, providing similar attributes Fig. 1.135.

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APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering

Maintenance

Tel: e-mail: Area:

Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Sand and core removal, machine shop cleaning, washroom services, sewer and pipe cleaning, gas flue cleaning, electro static precipitator services.

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Fig. 1.134 Cleaned engine castings

Fig. 1.135 Casting sand removal

Fig. 1.136 1963 Sewer cleaning nozzle

In mid 1958, adding a substantial power capacity (75–150 hp) to the newly developed sewer jetting technology proved especially successful when cleaning blast furnaces horizontal and vertical gas flue systems having diameters of 50 plus. Sewer jetting heads incorporating crudely drilled nozzle orifices were exchanged for a nozzle carrier arrangement integrating individual, exchangeable hard-hitting nozzles (Fig. 1.136). Designed and guided by Bernoulli’s strategy for compressing, accelerating and focusing a fluid jet over the longest possible standoff distance penetrating adhered scale or refuse proved successful. These nozzle carrier designs also accommodated encountered pipe circumferences (Fig. 1.137) to deliver the necessary gpm performance to drag in or lift the high-pressure hose assembly while cutting and flushing debris. Besides the emerging nozzle carrier technology, hoses providing the necessary gpm performances when operating at 5,500 psi plus ushered in the high-pressure cleaning era for large industrial pipe and tube cleaning applications. It can also be noted that debris accumulating in designated or accidental waste collection areas permitted the first employment of hydro-vac systems, still in their

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Fig. 1.137 Low profile sewer nozzle

infancy, but proving extremely effective in the pickup of dislodged refuse, water separation and filtration or product pumping and lifting capacities over vertical elevations of 600 –900 feet plus. The iron and steel making process usually starts with converting coal to coke, also called coking. Baking coal in a battery of large coke ovens in the absence of air preventing combustion, will release a variety of volatile byproducts and chemicals including tar, light oil, ammonia-ammonium sulfate, sulfur-sulfuric acid and others. In the past, the by-products and chemicals were of high value but are today more economically manufactured using such technologies as those of oil refineries. Some of these byproducts are recovered to power waste heat boilers (coke oven gas, light oil, etc.), converting energy to high-pressure steam, in turn generating electricity, otherwise likely rendered harmless by an expensive pollutant control and recovery system. The byproduct recovery plant area and its process equipment such as tar separator units, electrostatic precipitators, wet-dry scrubbers, the tar and liqueur plant equipment, still-tower and ammonia scrubber systems or waste water treatment facilities are all standard location and equipment identities serviced by high-pressure water and-or pressurized emulsion or light oil blast techniques. In the past, blast furnace operations in steel mills and foundries produced a multitude of product, creating subsequent frequent processing difficulties. The resulting application variety is nowadays considered a standard in the service industry. Responding to these applications requires pressures ranging from 3,000 to 45,000 psi at 2.5 to 60 gpm. Approximately 75% of the available application criteria can be managed within the 3,000–12,000 psi range at 2.5–36 gpm. Services may include cleaning heat producers, boilers, converters, heat exchangers, sulfur condensers, kilns, gas pipes, steam or fog tunnels, blast furnace’s air cooling baffles, filters, cooling towers (Fig. 1.138), stack and bag house units, water treatment facilities, etc. (Fig. 1.139). Sales departments (services) do well in identifying sub-industry’s maintenance needs, which may vary from the primary metal manufacturer’s application criteria. Starting with the steel pipe and tube divisions, to the aluminum, copper, zinc, titanium, nickel and lead divisions, an extensive application variety can be mobilized. The pressure washing contractor also offers his services to this industry’s giant open pit mining operations which are generally located in faraway desolate areas. Numerous application possibilities exist permitting a gradual introduction to

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Fig. 1.138 Foundries cooling tower

Fig. 1.139 Water treatment facility

industrial services by cleaning colossal mobile plant equipment, interior machine shop areas or exterior maintenance yard facilities which can include bath-house conveniences, interior or exterior office structures, dust removal and pasting applications, servicing field laboratory environments, visitor center and so forth. Due to the physical locations of most mining operations, adding hygienic oriented cleaning methods to the available application palette is of great advantage when offering 3,000–5,000 psi cold or hot high-pressure water services. With disinfectants or chemical assist applications, especially when spin jets and water-refuse removal operations with vacuum capabilities are offered, application varieties can greatly be expanded for an existing or possible new customer. Industrial service providers utilizing 5,000–14,000 psi high-pressure water equipment may also enter into the mining environment, especially where taconite rock, bentonite and-or limestone aggregate is produced and delivered to an on or off-site pellet plant. Pellet types manufactured are numerous and based on customer specs. Product change over procedures sometimes results in fouled equipment. In-plant services include cleaning concentrate’s gravity spiral lines, disc

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Fig. 1.140 Flew and bag-house renewal

filters, concentrate storage tanks and distribution units, product conveyors, various screens and vibratory machines, pellet kiln, burner and cooler assemblies, stacks, and bag house units, water treatment facilities and their settling tanks or ponds, pellet loading and transportation-rail identities. DRI technology, providing the direct reduced iron pellets from iron ore (taconite aggregate) to the melting process, also offers an application variety. Cleaning DRI top gas scrubbers, cooling gas scrubbers, ejector stacks and flues, bag house equipment, etc. are common applications found throughout the industry. Newly developed and changing manufacturing processes or the closure of many blast furnace operations in their existing locations are not necessarily product quality oriented activities. Blast furnace operation’s smelting and refining iron ore, bauxite, copper, tin, scrap metal and in some instances, uranium ore, etc., have produced an indefensible pollution burden, forcing and accelerating an environmental control criterion, which today manages and guides the general ferrous and nonferrous metal manufacturing technologies. This also led in some areas to a decentralization of the steel industry and the development of so-called mini-mills, which are found in numerous rural areas. Mini-mill-plants (Fig. 1.140) make every effort to maintain the smallest possible footprint regarding pollution to the environment. Contract work includes cleaning of metallurgy stations, their fumeparticulate filtration equipment and bag house units, centrifugal separators, flues and stacks, scrubbers, dust collection bins, water treatment facilities, soundproofing equipment and their voids, exterior and interior tank cleaning applications, heat exchanger services, etc. Plant operators monitor air quality for compliance during plant operation and cleaning schedules. Due to their rural location, pressure washing operations between 3,000 and 5,000 psi are common and not only performed within the interior of buildings or manufacturing areas, but often mobilized for external building and roof structure cleaning applications to maintain an aesthetic appearance befitting their rural environment. Exterior hot corrugated roof structures and walls are cleaned during plant operation with temperatures ranging from 90 to 160F. Staging, rigging and access, scaffolding and operating man lifts while plant is in operation demand a tight collaboration with mill’s safety planners and control personnel. Bauxite mining and crushing equipment, washing or wet screening hardware, bauxite transportation-rail and shipping identities require general pressure washing

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and hydro-blast services up to 8,000 psi. Plant hardware in alumina refining operations such as digesters, filters, precipitators, rotary kilns and the calcination equipment producing the hydrate for the aluminum smelting process can require in or on some equipment, water pressures up to 40,000 psi. Modern primary aluminum smelting operations manufacture a variety of specialty alloys integrating not only iron, silicon, magnesium and their alloys, zinc and zinc alloys or copper, etc., but also blend recycled aluminum into their final product composition requiring prior stripping-cleaning and possible paint removal processes. Regardless of the foundries’ melt process, type of energy consumed or type of furnaces in place (electric arc and induction, crucibles, iron foundries cupolas, etc.), scrap and bone yards supplying a specific metal grade or scrap waste to the melting process also depend on high-pressure water for maintenance solutions. Today cleaning equipment in scrap metal production facilities which control emissions from shredders, combustion facilities, their particulate scrubbers, bag house systems and flues, tanks and storage facilities for volatile and toxic substances or their areas, is of essence to any modern scrap yard operation. The effective guidelines and continuous controls to prevent air and soil pollution or excessive emissions when in the dismantling, burning, grinding, compacting, storage and transportation processes are tightly regulated by state and-or the EPA. Soil-earth remediation is also an operational aspect service providers should make available to this industry. Hydro-blast equipment with a few tool add-ons and filtration-chemistry is most cost effective in these operations. Aluminum smelting is an electric, energy intensive process offering power-washing and hydro-blasting marketing opportunities in nearby hydro electric, coal, natural gas or nuclear power plant operations. Contacts. Purchasing and maintenance superintendents in steel mills, forging, foundries and Pelletizing plants. Mining engineers supervising construction or plant operations and processing facilities. Purchasing, engineering and maintenance departments for gravity-evaporation extraction, leach plant, solvent extraction and the treatment for the plant process water. Manufacturers of plant hardware for emission control equipment such as precipitators, scrubbers, bag house units, etc. Purchasing, maintenance and emission control department in scrap and bone yards. Resources. The Steel Manufacturers Association, representing primarily electric arc furnace producers and operating mini-mills, http://www.steelnet.org, American Iron and Steel Institute comprised of producer member companies and suppliers to the industry, http://www.steel.org, On the Internet: Iron scrap, bone yards and the general recycling industry. CISPI member directory, pipe institute, http://www.cispi.org. Safety. Steel mills, steel pickling facilities, foundries and nonferrous metal industries utilize or produce a variety of hazardous gases, fluids, fugitive dust and toxic substances which can be found in confined spaces or open areas and on contaminated plant hardware (coke oven gases, hydrochloric acid, chlorine, sulfur, phenols, fuels, etc). Study the National emission standards for hazardous air pollutants for integrated iron and steel manufacturing facilities (NESHAP) 68 FR 27646. Traffic hazards by heavy mobile industrial equipment, including overhead

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1 Succeed in Residential, Commercial and Industrial Environments APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Gravity spiral line cleaning, pellet kiln services, gas scrubber cleaning, tank cleaning, pickling facility cleaning and soil remediation services.

WORKSHEET- PURCHASING - SALES

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Foundries, Steel Mills, Forging Shops, Nonferrous Metal Industries

131

cranes, high heat areas, below and high above work locations with or without unwarranted heat-dust-fume levels, or oxygen deficiencies, excessive noise or distances between contractor’s equipment and job location, open unprotected electric and mechanical equipment, etc., are all factors considered when a bid walk is performed. It can be required that salesmen be trained, which can include a specific safety criterion in areas or process environments encountered in a specific in-plant job location. A contractor’s crew submits to a plant safety awareness course, possible blood testing for existing lead-asbestos levels, etc. Further a safety meeting before work commences and a daily tailgate meeting of the crew should be the professional standard. A combination of safety controls and methods are always likely and coordinated with plant personnel.

1.18 Glass, Porcelain, Ceramic and Enameled Products Industry In the early 1960s, the newly developed pressure washing and hydro-blast technologies were quickly custom tailored and introduced to plant maintenance requirements found in glass, ceramic and porcelain trade environments referred to as the non-metallic mineral product manufacturing industry. Long gone are the times where maintenance departments of production facilities creating tableflatware, cable-insulators, glass containers, kitchen and washroom or commercial window products delivered the bulk of cleaning services performed at 25–150 hp. Product volume requirements and the specific product oriented manufacturing process and its equipment utilized by glass fabricators, takes today advantage of incredible hydro-blast tool capabilities operating at pressures ranging between 3,000 and 55,000 psi. Production facilities manufacturing flat glass, including industrial plate and architectural, glass tile-brick products, automotive glass, pressed and machine blown glass, light bulbs or television tubes and specialty products such as wire glass, textured glass, heat resistant glass, safety glass, glass fiber products, etc., support a multitude of application varieties geared specifically to the product and product change over procedure, eliminating most application identities past glass manufacturing processes required. Services include cleaning of vitrification furnaces, ash furnaces, revolving furnaces and glass kilns, Penn-Vernon Drawing machine and equipment, down draw and re-draw process equipment, production molds, air blowers, heat exchangers, air-fume control equipment, conveyor and fabricator lines, storage tanks, sewer pipes, etc. Today, the glass melt is prepared from pellets (Fig. 1.141) silica sand, lime, dolomite, soda and recycled glass waste. Besides silica sand (Fig. 1.142), large optics, precision optics, fiber-optic, specialty glass for instrumentation, commercial,

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Fig. 1.141 Glass pellet feed

Fig. 1.142 Silica sand prep

analytical, laboratory and technical applications may also incorporate potash, lead oxide, zinc and a variety of other metal oxides depending on the product manufactured. The service provider must be aware of possible hazardous and/or chemically contaminated areas and confined spaces with oxygen deficiencies, possible hazardous-contaminated equipment which can include the utility water provided by plant maintenance being too aggressive (pH value), abrasive or otherwise chemically and/or bacterially contaminated requiring appropriate attention to protect the labor force and/or equipment operations. Generally, four types of air emissions are generated. Those from the combustion of fuel for operating the glass melting furnace and fine particulates from the vaporization and re-crystallization of materials in the glass melt and airborne or windswept particulate from storage facilities and transportation equipment and last but not least, from cutting, grinding and honing operations. Emissions generated provide an excellent business opportunity for commercial and industrial service companies utilizing an array of pressure washing and hydro-blast tool combinations. The pollution prevention hardware and control equipment or method differs due to product manufactured, the type and size of furnace encountered, fuel utilized and composition of the feed material. Not to worry, the emission control equipment is of standard commercial or industrial design, starting with exhaust blowers, smokestacks, flues and air ducts, centrifugal cyclone separators, bag house units, tanks, cooling towers, water treatment facility area and equipment, filter systems, evaporators, silt settling ponds, etc. The jobsite bid procedure and

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Glass, Porcelain, Ceramic and Enameled Products Industry

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APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing Tel: e-mail: Area:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Exhaust blower, bag house units, smokestacks, flues, air ducts, tanks, cooling tower.

WORKSHEET- PURCHASING - SALES

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necessary safety methods demand prior identification of possible hazardous emissions, encountered hazardous products and/or accumulated total volume of generated waste within a service operation before the correct price, job procedure and labor safety requirement can be established. Main emissions may include sulfur oxides, nitrogen oxides and particulates which can contain heavy metals such as arsenic, boron and lead. Specialty glass can produce and release hydrogen chloride, hydrogen fluoride, arsenic, boron and lead from raw materials and must be considered specifically if the job requirement calls for raw material or waste removal practices. Liquid effluent from float glass processes, coating and electroplating operations may also vary substantially. Therefore, on a prospective jobsites, the employer’s labor department, regulating plant safety, engineering and laboratory personnel controlling plant environments and operations, which generally includes the wastewater treatment facility, will always provide the best or safest information base and criteria to a service provider. Purchasing identities sometimes miscalculate job oriented safety issues concerning a possible in-plant work order or services description. The varieties of ceramic products machined or molded by industrial identities may also incorporate some metals within their structural composition. Companies applying high-heat, high-pressure and chemistry in their manufacturing processes always rely on water as a specific maintenance tool. Air pollution, effluent filtration-control equipment, waste water treatment facilities and equipment are the first line of any company’s environmental defense and therefore of immediate interest to a contractor. Today’s manufacturing facilities for advanced ceramics or engineered ceramic products can be found in rural, urban and industrial areas. They produce armor protection systems (plating-fabrics), ceramic filters, membrane filters, ceramic coatings for military industrial and medical applications, or components for air frames, aircraft engines, power generation equipment, oil field equipment, fiber optics and optical lenses. Also and vital to contractors offering high-pressure water as a tool are manufacturers of ceramic capacitors, transducers, superconductors, etc., servicing the electronic industry. This is also accurate concerning facilities which manufacture enameled products. The enameller utilizes dense mineral powders and metals for his coating process, producing laboratory and industrial equipment, household goods such as kitchen and bathroom fixtures. Further, the ceramic-porcelain-tile industry, which can be of industrial or decorative nature, applying high heat processes utilizing industrial furnaces, driers, silos, conveyor belts, tanks, autoclaves, boilers, heat exchangers, etc. Taking all this into consideration, the non-metallic mineral product manufacturing industry should always be seriously pursued by a service sales force. A contractor can offer his capabilities starting on the silica quarry production site (Fig. 1.143), to the glass recyclers’ facility and the transportation environment to production facilities applying the high heat glass melt processes. Contact. Glass Association of North America, http://www.glasswebsite.com. Product manufacturers, purchasing, laboratory, engineering, maintenance personnel, product specific manufacturing associations acquiring a customer base, air

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Fig. 1.143 Silica grain sorting equipment

Fig. 1.144 Silica storage bins

pollution engineering and waste management control identities, mineral miningquarry operations and their product transportation and storage facilities (Fig. 1.144). Resources. Trade associations as the NGA—National Glass Association, http://www.glaas.org, GMIC Glass Manufacturing Industry Council, http://www. gmic.org, and includes automotive, Fiberglas, flat glass, glass container, hollow glass, optical glass fiber, pressed and blown glassware and safety glass manufacturers. Safety. Due to the variety of manufacturing environments and diversity of energy, raw materials or chemicals utilized within the industry, a single set of safety recommendations for an external plant labor force is not possible. The environmental health and safety guidelines for the glass manufacturing environment, describing emissions to air, wastewater and solid waste is the best guideline and source besides the specific plant, plant area and product handling requirements encountered with every jobsite. This will likely be a requirement produced within a job description provided by purchasing and maintenance identities. Some applications require thermal protection gear, eye protection, confined space entry qualification, and so forth. Excessive long distances between a jobsites and equipment–equipment operator can be encountered. Most job applications require a combination of enforced in-plant safety requirements.

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APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing

Engineering Tel: e-mail: Area:

Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Water treatment facility, settling ponds, evaporation beds, autoclaves, boilers, condensers.

WORKSHEET- PURCHASING - SALES

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Maritime Vessels, Offshore Oil Platforms, Shipyards

137

1.19 Maritime Vessels, Offshore Oil Platforms, Shipyards, Harbor Facilities, Piers, Recreational Boating In 1968, to support their growing customer base, WOMA Corp. of Germany established a subsidiary in Linden, New Jersey, introducing their products, hydroblast techniques and services to the US market. At this time with sales, distribution and manufacturing facilities in over forty-seven nations the company felt at ease to undertake this endeavor. In the US the majority of foreign customers that were aware of cleaning with hp-water and its application varieties, a exploited this techniques first. The New Amsterdam, a Dutch liner for example, stranded in 1968 in the New York Harbor on pier 48, was such a customer. Her fouled boilers were cleaned on the fire, water and high-pressure steam side applying hydro-flex and rigid lance technologies. Power, steel, chemical and refinery plant identities servicing their equipment with high- pressure water in European, East and Far Eastern industries were to some extent also educated in the utilization of hydroblast technologies. Abroad, in their subsidiaries, US refineries and chemical plants were already accustomed to industrial high- pressure water cleaning services for approximately a decade. In no small measure did this support the US industry and or initiated the rapid development of hydro-blast equipment and services by local engineers and industrial entrepreneurs calling b the technique ‘‘water blasting’’… As indicated in 1975 reports, US start-ups (Fig. 1.145a, b) encountered problematic equipment dilemmas. This included poorly functioning hp dump-gun designs, excessive pressure drops in hp-hose assemblies and nozzle designs creating internal streak patterns. The applied corrosion inhibiting technology also proved quite ineffective. Pump valve and/or packing failures appeared most likely when equipment operated over extended times above 8,000 psi. Notorious flaws in nozzle design criteria, pitiable machining processes, and little consideration to equipment-cleaning method, and created shortcomings application oriented gpm/psi configuration concerning hp-hose by poorly designed knock-off tooling and nozzle criteria and tool assemblies, which often failed to produce or replicate an expected cleaning rate or surface a appearance and more shocking, these nozzles are still peddled to the unsuspecting novice, reminding us of this not so happy hydro-blast era. It is also noted that a decade earlier, technicians flirting with similar problems in European and Far Eastern markets introduced a far more adequate, but no doubt more expensive design and manufacturing technique avoiding these obvious and in some cases, persistent problems. Besides heat exchanger, condenser, boiler, ship-hold or tank cleaning applications, the superstructure or ship-hull above or below the water line was first manually washed or hydro-blasted with hp-guns applying fan-jets. Working from a powered platform on the ship-hull’s water line (Fig. 1.146a, b) offsetting tools recoil forces produced the immediate b development of balanced underwater hp-guns which were then pressed into service by industrial divers (1959). The effective manual method quickly evolved into the practical application of rigid and

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Fig. 1.145 a, b Navy introduction to 1968 Hydro-blast equipment-cleaning method, and created shortcomings by poorly designed knock-off tooling and nozzle criteria

oscillating nozzle carriers (OCR) also designed and intended for street cleaning equipment and rubber removal by runway cleaning equipment. Jetting equipment was first affixed to mobile crane or hydraulic staging (Fig. 1.147), gear operating from the pier side of a vessel or mounted to a miniature tractor in service on the interior of dry docks. Shipyards realized immediately the advantages of a fixed and distant controlled jetting device. In streamlining this application, it became obvious that a remote controlled nozzle assembly would be of an advantage by eliminating staging equipment and minimizing the labor force. In a group effort WOMA engineers and an affiliate shipyard (1967–1971) designed a unit called MAGNOMAT (Fig. 1.148), operated by one man utilizing the ship’s railing or shipyards crane. The bond of the nozzle carrier to the ship hull and offsetting the nozzles recoil forces while providing remote controlled mobility, guaranteeing the correct overlapping of previously cleaned surfaces, is achieved with three powerful electro magnets. An array of plastic sheeted wheels will provide the necessary nozzle standoff distance and remote steering necessity. Today the MAGNOMAT is still of interest, especially in washing or advanced cleaning situations where algae barnacles or general marine growth must be removed from hull surfaces. This avoids the contamination of lake or seawater by

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Fig. 1.146 a, b Offsetting tool recoil forces

Fig. 1.147 Rigid nozzle carrier

eliminating within the cleaning process the introduction of paint chips, excessive rust or other scale deemed a contaminant to the water’s environment. A 150 hp drive input produces up to 4000 yd2 per hour. The hourly cleaning rate can be doubled by adding horsepower. Today’s coating removal equipment (Fig. 1.149a, b, c) may appear somewhat similar, but operational and technical comparisons can not be found. Vacuum gear blowers are responsible for equipment bond to hull surfaces and the subsequent controlled refuse transfer to a pier side or floating water filtration assembly. The

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Fig. 1.148 Magnomat

Fig. 1.149 a–c Various coating removal equipment

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Maritime Vessels, Offshore Oil Platforms, Shipyards

141

Fig. 1.150 a Wastewater separation, b vacuum ring pump

UHP vacuum Spin-Jet technology utilizing low water volumes for the coating and a rust removal process is replacing standard abrasive blast applications and earlier water-blast techniques common to spin-jet assemblies applying high pressure– volume water to remove paints, concrete surface slurry, etc. b The industrial low pressure, high volume rotary tank cleaning nozzles manufactured by companies such as Butterworth (1925) and Sugino in Japan can nowadays be found in most shipyards. High volume-high pressure rotary nozzles (5–22,000 psi.) are more or less in operation with manufacturers periodically cleaning their tank and autoclave vessels. Contractors–-subcontractors will operate high-end mobile equipment in a variety of c industrial or commercial tank cleaning applications. With great success some service providers are also qualified to exploit the variations of hydrovacuum systems within the maritime industry (Fig. 1.150a, b). Developed for culvert and street cleaning equipment, the simplicity, unmatched performance and physical practicality on a jobsite is indisputable and its business potential totally underestimated. In oxygen deficient or enriched, b explosive, flammable or toxic atmospheres, this equipment provides superior functionality, ease of operation and decreased operating costs in comparison to equipment customarily put into service under similar job conditions. Powered by high-pressure water at 7,500 psi, the ‘‘hydro-vac’’ component producing at any altitude continues maximum theoretical vacuum, consequently transferring super high air volumes (Cfm) throughout a vacuum system results in a specific job criterion which cannot be challenged by equipment powered by means of fan and mechanical vane or gear pump-blowers. Vacuum fan pumps (impeller)

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Fig. 1.151 Hydro-vac barge loading

are naturally restricted in vacuum performance. Vane and gear-blowers (direct displacement) quickly tend to wear and are more susceptible to performance reduction, most noticeable when operating in elevated altitudes. More importantly, they also generate tremendous heat on their internal meshing and exhaust surfaces which can be a notorious fire hazard by misinformed or unintentional incorrect work procedures. Volatile or flammable, combustible and toxic products in liquid, viscous, gravel-rock like, granulated or powdered form are simply and cost effectively loaded while separated and filtered from transferring air or water to any degree desired. Mobile Vacuum-box containers designed to facilitate a maximum airflow throughout a vacuum system and operating at max-vacuum standard (32 Hg–10 m at 4,500–6,500 Cfm), taking into consideration various material separation and filtration techniques including HPA filtration, are nowadays custom manufactured and readily available nationwide. Regardless of available hydro-blast or UHP equipment on hand, competent service providers must produce a multitude of trade certifications directly related to the marine environment. These certifications will permit bidding processes applying all available equipment identities utilizing pressure-washing or hydroblast techniques. An incredible job variety is considered, therefore requiring a

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143

Fig. 1.152 Equipment barge

complex tool selection or availability, substantial safety equipment and established verifiable safety procedures. Service providers with rivers and lakes in their vicinity should consider the barge cleaning, repair and breaking industry. Often a barge must be cleaned between loading dissimilar cargoes (Fig. 1.151). The reasons can differ and be seasonal or production and product related and may involve the interior removal of trace chemicals, flammable or combustible liquids, dry bulk or powdered industrial-commercial granulated or gravel like materials. These cleaning or preservation requirements must not necessarily be performed in a dry dock or shipyard. Mooring can be found adjacent to production or loading facilities, beached or at anchor and in lonely dock facilities situated in rural areas. A barge cleaning process can and will involve many hazards. The most important hazards are due to combustible, flammable materials, inhalation or by skin contact from inadvertent chemical exposure. The flammable–combustible cargo barge cleaning process is the removal of the residual cargo by cleaning the tanks on the barge. OSHA guidelines are precise and involve pre-planning and preparing to clean, set-up for cleaning, cleaning and completion criteria, hazard communication, personal protective equipment and exposure limits, which should be evaluated throughout the barge cleaning process (Fig. 1.152). There is much more to consider when identifying the cargo’s remaining residue within a tank structure. Hopefully, this is verifiable through MSDS identification aboard the vessel (Top side mailbox) and includes the internal areas of product transfer pipes and inaccessible tank voids. OSHA also provides guidelines for the most typical hazardous barge cargoes found throughout the marine environment.

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APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering

Maintenance Tel: e-mail: Area:

Tel: e-mail: Area:

Tel: e-mail: Area:

Safety

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Heat exchanger, condenser, boiler, ship hold cleaning.

WORKSHEET- PURCHASING - SALES

1.19

Maritime Vessels, Offshore Oil Platforms, Shipyards

145

Preparing steel surfaces on the vessel’s superstructure and hull for coating– painting procedures or removing specialty coatings, as for instance on submarines, is currently a routine application performed by contractors servicing naval and industrial–commercial shipyards. Remotely operated UHP crawlers or vacuum supported manually controlled UHP spin jet equipment and guns are commonplace. This should include abrasive blast techniques using hp-water above and below the water line. Service and sales forces often dismiss this straightforward tool capability. Often, while Hydro-blast services are conducted near hot work, performing specific limited structural changes or spot repairs to a hull or superstructure will require a final coating procedure. Prior to, or while services are in-house, the shipyard’s purchasing, maintenance superintendent, including the vessel’s chief mate, should always be made aware of the nearby capability. The need arising to produce or reestablish a necessary anchor profile can be lucrative. Often, the motivation to force an unsuspected work order is the negated or otherwise difficult job set-up procedure, arising air hazards and area contamination usually associated with abrasive air blast techniques. To avoid typical suggestiveness or varying opinions on a steel surface condition before, during and after a water-blast or UHP procedure, the reference guide and photographs for ‘‘Steel Surfaces Prepared by Water-Jetting’’ developed by the society for protective coatings and NACE can be practical. ‘‘SSPC publication 01-05, NACE, international corrosion association item Nr.22016, ISBN1-88906056-9.’’ The photographic guide is a valuable tool for any bidding and inspection process of a job criterion. Levels of cleanliness and flash rust of prior deteriorated multiple metal conditions and their final appearances are portrayed. This possible surface comparison is also important when considering various coating characteristics or their specific future installation methods. Coating manufacturers, coating inspectors, painters and vessel owners alike are most likely willing or accustomed to utilizing this visual guide. Confirming specific anchor profiles and reference surface appearances, before and after preparation by water jetting procedures, considering climate changes, application of possible chemical corrosion inhibitors, timing priorities for surface preservation, drying time and maintaining readiness for coating operations and their various applicator provisions is this guides support function. Salespeople intending to sell services correctly must educate themselves to a vessels physical interior structure. Compartment or tank designation system and identification differs between industrial-commercial and naval vessels. Navy vessels apply a three part number. Example 02-116-2. First digit before dash indicates the deck level. Decks start at ‘‘0’’ being main deck, 01 level being first deck above main deck, 02s, etc. Single-digit 2 designates second deck below main deck level, 3 designates third deck, etc. The middle digits indicate forward most frame number of the compartment. The third digit indicates side of the vessel, 2 = port side, 1 = starboard side.

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1 Succeed in Residential, Commercial and Industrial Environments

The Navy method for identifying compartments is also a three part number. Example; B-10-3 F. The first letter designates part of the ship, A = forward of the engine space, B = engine spaces, C = aft of engine spaces. Second series of numbers indicate the number of tanks in that area of the ship. The third indicates the type of product that space is used for, and whether the tanks are located (2) portside or (1) starboard side. F = for fuel oil, W = water or ballast, J = jet fuel, L = lube oil. The commercial method normally identifies frames numbered from forward to aft, except some tankers in reverse. Tanks and spaces are also numbered from forward to aft; # 1 cargo hold, # 1 double bottom. Tanks are also marked port, STBD or centerline, # 2 doubled bottom port, # 2 double bottom center, # 2 double bottom STBD. Generally, compartments are not numbered, but designated by their function as engine room, steering gear room, anchor chain compartment, etc Fig. 1.153. When offering to clean or perform surface area preservation, a salesperson must take into consideration necessary safety procedures within any specific location, configuration and description of the interior, possible restrictions to physical movement and so forth. The onboard competent person’s practical job experience and know-how within a specific area must be considered and never underestimated. Adapting hydro-blast tools to tank and cargo hold (Fig. 1.154a) configurations demands close working relationship with either the equipment manufacturer’s engineering department or a distinguished supplier specialized in providing custom accessories, enabling tool operators to reach all essential areas deemed necessary in surface preparation. Cleaning double bottom framing, longitudinal girders, their angles and brackets, or the interior of forepeak, deep, settler, bunker, day, after peak and potable tanks, heating grids in fuel oil tanks, surfaces in anchor chain rooms, bilge wells, shaft alley, cofferdams and so forth are the job descriptions a contractor will pursue. In general, when working in these confined areas a service provider must be able to read and calibrate oxygen deficiency meters and accurately measure combustible gases, handle the instruments with appropriate care, be proficient in managing and training the labor force in the correct use of air supply equipment, continuous flow respirators, pressure demand respirator with egress unit and general protective respirator equipment. Often safety belts, harnesses, lanyards, drop lines and lifelines are essential. Their use and condition is guided by the National Safety Council’s standard. Most often, hydro-blast personnel will work alongside multiple job descriptions performed by other crews and are not related to either their company nor within their specific job description. It is very important, that hydro-blast personnel are independently capable to ensure that their workspace is at all times adequately ventilated, maintaining a gas free and oxygen sufficient condition. There is an established criterion for the correct ventilation (Fig. 1.154b, c) for double bottom tanks, cargo hold, barge tank, tanker cargo tanks, fan and duct arrangements, etc. Specified are the correct installation procedures of air supply and exhaust hoses and necessary explosion proof equipment. Explained in detail are the prevention tactics for an

1.19

Maritime Vessels, Offshore Oil Platforms, Shipyards

147

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Fig. 1.153 Vacuum-assist coating removal

Trade Related Publications: 16. The Society for Protective Coatings (2001) Paint Film degradation, mechanisms and control, failures related to particular substrates SSPC, [l6.28.407] http://www.sspc.org 18. The Society for Protective Coatings (1992) Maintenance coating of weathering steel, field evaluations and guidelines, [l6.28.407] http://www.sspc.org

Safety equipment and procedures:

©

UHP abrasive blasting, coating-paint removal on superstructure.

WORKSHEET- PURCHASING - SALES

Fig. 1.153

incomplete air circulation or dangerous recirculation of exhaust air and or short circuiting of exhaust air, possible also by the obstruction of designated escape routes by venting hoses and equipment such as fans, air-compressors, and Venturi blowers ventilating the hazard away?

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.154 a Cargo hold, b ? c, tank-vessel exhaust plan

Proving operational proficiency in naval or commercial shipyards on piers supervised by Coast Guard and OSHA guidelines is a must. Enforced or established safety and Health regulations designed for the shipbuilding, ship repairing and ship-breaking industry is the criteria. Various certified companies however have their own set of competence; a standard based on an approved task analysis and/or any set of performance criteria specific within a pressure-washing or hydroblasting job description and includes the step in–out procedure to the work location. Successful service companies develop a contracting strategy based on pre-qualification by achieving an approved contractor status with prospective customers. Verifying competence for an entire crew, a contractor bidding on annual job descriptions, covering all stages of a contracting cycle can be taxing and must be routinely validated by management. Contractors hiring a labor force should also be very diligent in proving or verifying the individual competency status in checking IDs and the origination of certifications. Job planning and establishing a permanent location for hydro-units and support equipment, such as vacuum box containers, trucks, tooling and safety equipment can only be executed by coordinating with the shipyard’s designated supervisory staff. Fire department personnel will provide designated hydrant water supply and permit. Dry dock operations may vary due to traffic and equipment applied. In naval and commercial yards, a vessel’s owner, captain or chief mate and shipyards NFPA certified marine chemist will most likely control or confirm the contractually stated and applied technique to adequately discharge the treated hp-wash waters (Figs. 1.155, 1.156). Contractor’s designated competent person

1.19

Maritime Vessels, Offshore Oil Platforms, Shipyards

149

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing

Engineering

Tel: e-mail: Area:

Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Fig. 1.155 Onboard coating removal

Trade Related Publications: 19. The Society for Protective Coatings (20002) Surface preparation and cleaning of metals by Waterjetting prior to recoating, Joined surface preparation standard SSPC-SP 12/NACE No. 5, http://www.sspc.org [l6.28.407] 20. The Society for Protective Coatings (20004) Supplements to systems and specifications, SSPC painting manual volume 2, cleaning metals by Waterjetting, surface cleanliness requirements, dehumidification and temperature control during surface preparation, http://www.sspc.org [l6.28.407] Safety equipment and procedures:

©

Clean and preserve fuel oil tanks, steering gear and shaft alley areas

WORKSHEET- PURCHASING - SALES

Fig. 1.155

must be capable of writing a detailed work report, and record in depth in place safety procedures which are adhered to by all involved before a hydro-blast operation commences, confirming a flawless work-application solution, followed after the daily job completion by a recorded tailgate safety meeting. 80% of the

150

1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.156 Coating removal in progress

Fig. 1.157 Coating removal

available application load can be handled in this field between 3,000 and 14,000 psi at five to 60 gpm and includes rubber removal on aircraft carrier runways, servicing boiler tubes, heat exchangers, oil lube systems and compressors, hydrostatic testing of boilers, condensers, pipes, pressurized vessels and tanks. Degreasing and preservation applications are considered extensive and require a knowledgeable labor and management force. Shipyards often require that visiting contractors, subcontractors, including their sales forces, undergo an in-house safety course and awareness training to limit the possibility of accidents and fires in their workplace. The type of alarm systems, how to evacuate in specific or differing emergency situations, location of designated assembly areas, primary exits, location of fire extinguishers, etc., are the primary functions explained to visitors. Working offshore demands another set of competency in personnel training which is specifically designed for oil–gas platforms and their supply vessels, drill rigs, submerged work methods and emergency response procedures. The logistics of working in confined but highly visible areas on offshore structures (Fig. 1.157), job planning and equipment mobilization procedure are a critical function, as is the communication between owners, coating inspector and paint crew. Offshore hydro-blast or UHP equipment and accessories must be functional under any and/ or imaginable circumstance.

1.19

Maritime Vessels, Offshore Oil Platforms, Shipyards

151

Fig. 1.158 Ballast tank coating removal

Equipment down times due to mechanical, technical or labor induced criterion is unacceptable. Naturally, ongoing work procedures can be interrupted by weather. Service providers do well when offering alternative job descriptions. Cleaning tank and ballast tanks (Fig. 1.158), mist eliminators, heat exchangers, condensers, oil lube systems, heaters or performing the coating removal on a helicopter pad, etc., are some of the possibilities that should only be offered while in the job procurement phase. The continuous corrosion protection efforts necessary on offshore oil and gas production facilities, including the floating production, storage and off loading vessels (FPSO) and may consist of servicing stripped-down decommissioned oil tankers rebuilt and re-equipped to perform oil storage, separation or drilling processes, provide a constant business potential for qualified entrepreneurs. There are several types of drill rigs, jack-ups, which are towed to their drill locations where the legs are lowered to the seabed and the operating platform is lifted above sea surface. The drill ships appear somewhat like seagoing vessels, except they feature a drill derrick above their deck line with a hole through the center of the hull, accommodating the drill pipe assembly. Submersibles are drill rigs floated to shallow water locations and ballasted to sit on the seabed. The semi-submersibles have their superstructure attached onto pontoons or a hull and are ballasted below the water surface. Large production platforms vary in size and provide long-term accommodations for the operating crew and varying maintenance personnel. Production equipment and processes differ according to product quality, extraction process of oil or gas and the necessity to make products ready for transport. They can be anchored or tethered to the sea floor and are considered a floating-production, storage and offloading facility (FPSO), or tension leg platforms (TLP) typically built from steel or concrete and are likewise anchored to the sea floor by vertical ‘‘tendons’’. Often services are performed while platform is in production. At all times and regardless of environmental circumstance, a contractor must protect the platforms operating environment. This includes protecting the crew from possible physical

152

1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.159 UHP gun, coating removal at 43,000 psi

harm by high-pressure water, maintaining the job vicinity free of static spark possibilities, fire hazards, accumulation of dust, abrasives or any other wind-swept refuse which compromises mechanical seals, lip seals, packing glands, etc (Fig. 1.159). This includes protecting rotary equipment such as pumps, compressors, turbines, ventilation equipment, the water desalination environment, etc. The effective implementation under severe weather conditions of rigging, scaffolding, hydraulic man lifts must always be considered within the job description and criteria, which includes the correct transportation and positioning of hydro-blast equipment on a supply boat, barge or platform. Water supply can be taken from the desalination plant or ballast water, guarded by filtration equipment and considering pumps operating requirement. Offshore main process equipment for separation of oil, liquids and gas, including the utility system such as seawater desalination components, heating and cooling system, vent and drain systems are of general nature and serviced by hp-water application techniques adapted from refinery-gas or industrial applications. A relatively new equipment identity providing the ultra high-pressure abrasive blast capability (UHP-AB) is nowadays a somewhat standard coating and corrosion removal technique found superior in its cost effectiveness and operational procedure (speed), especially on offshore oil rigs and equipment. Minimal dust emissions due to minute abrasive expenditure, delivering an excellent coating adhesion (anchor profile), and comparatively low fuel consumption can provide the competitive edge. A prerequisite when applying corrosion control coatings in the splash and title zone or below is to perform a multi-level inspection including visual, ultrasonic and radiographic methods verifying, for instance, weld seam-fusion or corrosion levels on pipeline or any other structural integrity. The hydro-blast technique performed by industrial divers is therefore essential (Fig. 1.160). Submerged applications performed by underwater abrasive blast techniques since 1962 were first thought of by maintenance crews servicing floating dry-docks, piers, locks and dams in Germany’s extensive shipyard facilities. In the late 1960s industrial divers utilized floating hydrostatically balanced abrasive pots operational

1.19

Maritime Vessels, Offshore Oil Platforms, Shipyards

153

Fig. 1.160 Underwater abrasive container and diver a, b

at any depth they were accustomed to. Hp-gun-abrasive-injector combinations with recoil of set were then powered with a 75 hp drive. At this time the system outperformed any other available method producing an anchor profile on steel surfaces to customary abrasive blast standard S.A. 2-1/2. It can also be noted that the French navy in the late 1960s through early 1970s, were the first to actively prepare ship hulls by applying experimental coatings specifically designed for installation below the water line with various successes on their vessels. The superior surface modulation effects achieved with abrasive hp-water on concrete surfaces resulted in the immediate support of concrete repair procedures on concrete piers, dikes, spillways and water dam structures in marine harbor, river and lake environments. Commercial and recreational boating, their marinas, harbor and pier structures, vessel maintenance environments, workshops and storage facilities, etc. are all business identities important to a service provider. Required pressures are 3,000 psi plus, hot and cold water preferably with a pump drive starting at minimum with 18 hp. plus, facilitating the utilization of water, abrasive blast injectors, 200 vacuum equipment with filtration and water recycling equipment, applying pipe and sewer cleaning nozzles, floor Spin-Jets producing 10,000 ft2 plus per hour, chemical metering and foaming attachments for confined space cleaning and preservation applications. Most often, in this ecologically vulnerable environment where a pollutant of any type, including generating water turbidity is viewed with suspicion and therefore cannot be introduced to the river or lake water. This includes the indiscriminate cleaning of submerged surfaces bearing aquatic growth, creating turbidity (Fig. 1.161). It is of importance within most job requirements to recommend water recovery and filtration capabilities when services are provided on vessels, piers or interior jobsites such as machine shops, tanks, storage facilities, loading docks, etc.

154

1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.161 Recreational facilities

Fig. 1.162 Manual algae and coating removal

Barnacles, algae and general marine growth can also be removed below or within the water splash zone of any water bound surface structure or vessel applying the simplest filtration methods (Fig. 1.162). Contractors working with full-service marinas should always first inquire on their developed regulatory criteria and restrictions which identify the storm water discharge requirement. A spill prevention response plan, maintenance and good housekeeping program, customer established best management practices and the correct implementation regarding materials-chemical storage, machine shopengine and maintenance-cleaning (Fig. 1.163) area and their methods are a prerequisite for a water discharge permit. This includes oil water separation equipment or their underground facilities, approved abrasive air–water blasting or pressure-washing operations which can include coating-painting procedures in dry docks or above ground facilities (Fig. 1.162). These areas, location, products or work methods also require regulatory approval before a general storm water discharge permit is granted. Contact. Shippers, integrated barge owner companies transporting raw materials, independent barge brokers, barge owners transporting grain, lumber, iron ore, barge rental and shipyard facilities, tugboat towing services, their maintenance and purchasing departments, barge rebuild companies, marine chemists and coating inspectors, marine salvage companies, Naval, industrial–commercial shipyards

1.19

Maritime Vessels, Offshore Oil Platforms, Shipyards

155

Fig. 1.163 Ship-hull washing

management or commercial and private marinas, their engine and vessel repair facilities. Resources. Shipper associations, AWO, American Waterways Operators Associations, 801 N. Quincy St, Suite 200, Arlington, A 22203, http://www. americanwaterways.com. Maritime Law Associations. Inland Rivers, Ports and Terminals, IRPT, 204 E. High St. Jefferson City, MO 65101. Transportation equipment cleaning guidelines. Superintended of Documents, US Government Printing Office Washington, DC 20402, Ph. (202) 512-2250. On the Internet ‘‘barge cleaning guidelines’’. Safety. OSHA standards for shipyard competent person training, which includes atmospheric testing, confined space awareness, confined space attendant, ‘‘monitor-hole watch’’, confined space entry/rescue, confined space entry/attendant supervisor. Identify and define confined spaces, recognize hazards, entry requirements, proper use of equipment, understanding signs or systems, and consequences of exposure, maintaining accurate count of entrance, how to monitor activity inside and outside of space to determine if it is safe, verify that rescue services are available, train to perform none entry rescue, filling out and verifying entry permits, ensure regularly that all tests specified by permit have been conducted. Perform safety meetings-tailgate safety meetings, lockout-takeout procedures, fall protection, competent person or awareness and preferably provide a hazardous communication course (HAS-COM). When working in these environments, always be aware of possible hot work down line from confined spaces, especially on product supply lines (fuel). Coordinate your actions with hot work permit procedures. ‘‘Safety standard for marine vapor control’’ by US Department of Transportation, United States Coast Guard, http://www.purgit.com/navic1_96.html.

156

1 Succeed in Residential, Commercial and Industrial Environments

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City: Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Trade Related Publications: 21. SSPC (2000) Standard Method of Evaluating the Degree of Rusting on Painted Steel Surfaces, [6.28.407] http://www.sspc.org 22. SSPC-NACE (2001) Guide and Reference Photographs for Steel Surfaces Prepared by Waterjetting, [6.28.407] http://www.sspc.org 23. SSPC-NACE (2001) Guide and Reference Photographs for Steel Surfaces Prepared by Wet Abrasive Blast Cleaning, The Society for Protective Coatings, SSPC, http://www.sspc.org [6.28.407] 24. SSPC (2002) Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning, The Society for Protective Coatings, SSPC, [6.28.407] http://www.sspc.org 25. SSPC (2004) Guide and Reference Photographs for Steel Surfaces Prepared by Power and Hand Tool Cleaning, The Society for Protective Coatings, SSPC, http://www.sspc.org

Safety equipment and procedures:

©

Clean and preserve floating docks, fueling and maintenance areas.

WORKSHEET- PURCHASING - SALES

1.20

Municipalities’ Water–Wastewater Treatment, Shopping Zones

157

1.20 Municipalities’ Water–Wastewater Treatment, Shopping Zones, Parking Facilities, Exhibition and Sport Arenas, Highway-Road Services The business potential generated in city or county municipalities should not be avoided by informed and successful service providers. The assortment of work encompasses all applicable tool varieties in performing a surface preparation or cleaning application found throughout the commercial and industrial environment. In his daily endeavors a successful and well-resourced entrepreneur is accustomed to provide, within his job criterion and description Worker’s Compensation insurance, covering his employees and complying with all applicable state-federal laws and regulations and offers to his customers comprehensive liability insurance ($500.000–1,500.000 property damage umbrella). He further guarantees equal opportunity employment and customarily provides possible subcontractor certification and necessary insurances or performance bonds. These general requirements are not enough to successfully participate in a governmental business setting. Challenging, the municipal milieu can be very competitive, intense and sometimes confusing. Some cities may give preference to companies owned by women or minorities, which may require performing services in a subcontractor status. Waiting or down times, bidding terms and conditions, excessively high insurance requirements or excessive liquidated damage amounts, resulting in bonding requirements favorable difficult to obtain, can be a hurdle. Variable safety standards and procedures, work scheduling considering ambient conditions for the coating installation, restrictive working hours and weekend limitations are all factors only a well rounded service provider is likely to stomach. Encountered paper work necessities developed by county or city purchasing departments concerning vendor registration processes can also be taxing. Pre-qualifying for purchasing departments’ source lists covering the applicable category or possible services provided by an entrepreneur is essential. Providing an educated labor force and the best possible equipment for a job description, combined with established and safe environmentally correct work methods may positively sway purchasing and maintenance-superintendents decisions, but by no means never, ever, should one consider this a given. The contractor’s service repertoire in wastewater treatment facilities is categorized into four major identities, as follows: A. Cleaning the interior of failed process equipment and digesters by removing compacted organics, snails and sewage utilizing the Hydro-vacuum system shared with mobile vacuum containers, or pumping the effluent directly through the injector assembly over long distances to alternative tanks, settling-evaporation ponds and tanker trucks is a standard practice. As is cleaning, pumping and safely removing caked sedimentations from evaporation-settling ponds (Fig. 1.164) by slurrifying or emulsifying waste into a semi liquid form conveying the mass by the Hydro-vacuum technique. This enables a job completion avoiding usual and likely

158

1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.164 Evaporation-settling ponds

Fig. 1.165 Wastewater plant

damages created by mechanical equipment to susceptible pond membranes consisting of clay, asphalt or plastic liners. Pulling plastic or gravel filtration media through the injector assembly is also a quick and unsurpassed cleaning method of the filter media itself, while in process returning the media to its vessel or clarifying location. B. Applying enhanced hydro-horsepower for pipe or sewer jetting applications achieving industrial performance standards, or offering prior to coating procedures a blast cleaning with the HP water-abrasive or jetting method on steel purifying vessels (charcoal filter), filter presses, lock-gates and sliders, including mechanical scrapers which remove scum, grease and other floating debris from wastewater, mixing tubes in settling basins, effluent weir plates, weir troughs’ and in operation submerged aeration pipes which are under constant corrosion attack as are cat walks and ladders belonging to the second application identity. C. Nationally deteriorating at an alarming rate, the aging wastewater plant infrastructure (Fig. 1.165) offers to pressure-washing, hydro-blasting or UHP service provider, several opportunities inherently ideal and far superior to familiar cleaning, neutralizing, abrasive blasting and concrete rehab-breaking techniques. Trying to stay abreast of or controlling ongoing deterioration in wastewater treatment facilities where hydrogen sulfide gases (H2S) and sulfuric acid (H2SO4) eat away or attack large aggregate and erode exposed interior-exterior concrete surfaces, steel fixtures or essential equipment, chemist and maintenance departments operate within a continuous maintenance procedure. Today, advanced coating systems designed for waterworks and wastewater treatment facilities

1.20

Municipalities’ Water–Wastewater Treatment, Shopping Zones

159

Fig. 1.166 Wastewater clarifier

require the best possible surface-substrate preparation, therefore the UHP and hydro-blast abrasive blast technologies are called upon. In older facilities, deteriorated coal-tar coatings are usually present and are replaced with coating systems designed for specific plant locations and process oriented performances, not only to inhibit but also in some cases to stop the deteriorating erosion processes altogether. Coatings are identified for exterior weathering, UV and mild chemical exposure for steel or concrete surfaces, interior environment exposure for steel, concrete walls and ceilings, immersion for wastewater collection (Fig. 1.166), primary treatment and/or secondary b treatment on steel and concrete surfaces in immersion-tertiary treatment facilities and/or secondary concrete containment areas. The identification and classification of a deteriorating area, and its necessary substrate removal volume must be determined before a correct hazardous waste disposal classification and method can be suggested. When working in a pretreatment sewage process area or confined spaces in the presence of live flowing sewage water, uninterrupted monitoring for the possible presence of highly toxic hydrogen sulfide gases must be a given. In particular where the removal of grit-sand, gravel and other heavy solids and/or organic particulates that have settled out by gravity from the wastewater stream are removed before the frayed concrete-coating removal application is introduced (Fig. 1.167). Confined space entry procedures, continuous air breathing apparatus, egress gear, and correctly wearing full face respirator gear are fundamental to the job description. Work areas will include the facilities closed influent and effluent channel areas, grit chambers, primary sedimentation basins and the channels between them. In primary clarifiers, also referred to as primary sedimentation basins, where construction joints are highly susceptible to erosion by developing gas above the operating waterline, including the interior roof services and exposed walls, deteriorating concrete is generally always recognizable. This includes the interior digester’s roof structure and when in operation the exposed settling basin walls. Damaged coatings on older structures most likely consist of coal tar heritage and are easily removed. Coating failures on cat walks open primary-secondary clarifiers, at times also called primary and sedimentation basins, occur mainly to steel anchor-fittings, and the submerged aeration piping including their scrubbers. Services are probably required when a major unit shutdown is in progress.

160

1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.167 a Neutralized aggregate, b restored aggregate surface

Fig. 1.168 Classic concrete deterioration

Wastewater facilities are humid environments in which surfaces can or will be saturated with moisture, therefore work methods must be quick in concrete removal (Fig. 1.168) and coating drying-curing times, especially in areas where plant operations cannot be shut down for extended periods of time. Where structural integrity must be reinforced on walls, splitter and chamber boxes or roof structures, etc., the available UHP and abrasive hydro-blast technologies provide, in combination with modern cementitious application and

1.20

Municipalities’ Water–Wastewater Treatment, Shopping Zones

161

Fig. 1.169 In situ manhole-sewer repair in progress

coating systems, unsurpassed specific bonding and pull off parameters (Fig. 1.169). This becomes especially obvious when testing concrete for essential surface profile parameters, concrete acidity-pH value, and moisture content prior to commencing trowel or spray on coating procedures. D. The harsh operating environment and the exterior chemical conditions (Fig. 1.170) buildings are often subject to a demand for a continual cleaning and maintenance process designed to protect existing coatings, concrete and steel structures and are ideal application requirements for pressure washing entrepreneurs. Maintaining machine shops, control and laboratory buildings, change rooms, and the general interior hygienic environment, exterior building aesthetics and publicly visible structures or surfaces such as parking facilities, belong within this fourth application requirement. The sewer and pipe jetting technology developed in the mid-50s, today again gained prominence by its unsurpassed scaling, cleaning and flushing capacities. The ever-expanding, and in many communities a deteriorating infrastructure of pipe and sewer systems susceptible to catastrophic failure which also burdens a wastewater treatment facility, accelerates the need for complete isolated bypass rehabilitation procedures. The industrial high-pressure water jetting-cleaning and abrasive blast application, combined with a hydro-vacuum debris removal routine is preceding to a high-load composite insert installation requirement. Generally, these locations include sewer manholes and shafts, pipelines, tunnels, lift stations, junction boxes and wet well structures. Cleaning procedures and providing

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1 Succeed in Residential, Commercial and Industrial Environments

adequate surface roughness is also necessary prior to resurfacing sewers interior concrete and/or brick walls, followed by a troweled or spray on high-performance coating application. The industrial jetting capability is especially of interest when exterior remote installations of flexible tubular lining systems to a sewer-pipe system are planned and performed. The service provider intending to increase profit margins with sewer and drain cleaning applications must be aware that the potential customers’ sense of urgency requires a response criteria not to be compared to a customers scheduled bubble gum removal application. County, city or communities providing sewer-pipe cleaning or vacuum truck services cannot always be available in an emergency. Pre-qualifying with city purchasing and maintenance services is done by identifying the service provider’s technical application capabilities into the cities purchasing source guide, which can result in a standby position for possible emergency work. This only works if the responsible city employees are convinced of service provider’s advanced equipment status, technical know-how, labor qualifications and highly developed safety curriculum. County-city water towers or storage tanks, etc., require periodic exterior or interior coating removal applications. This is always a corrosion-aesthetics, leak or contaminant preventive measure and can turn into a visually pleasing exterior art form. Today’s remote-controlled UHP coating strip-mill technology permits a cost effective coating installation. Savings occur not only in reduced scaffolding and tarpaulin expenses. Coating applicators follow UHP mill in a stepped sequence similar to exterior fuel tank or ship hull coating removal and installation techniques. When flash rust inhibitors are not utilized, the coating applicators performance solely depend on full surface dryness, after the scheduled UHP stripping, weather or ambient temperature and time flash rust development exceeds the inspector’s guidelines or coating instruction. Regenerating gravel and sand formations, surrounding a tired shallow or deep water well which includes the cleaning of the well’s sump and the submerged suction side of pump stations and the discharge piping is an application that was introduced in the mid 1960s. The technique itself is applied today in the US mainly as a soil stabilizing application (Fig. 1.171) and represents an added entrepreneurial capability. In the mid 1970s Nozon Corp. of Germany successfully serviced throughout the African continent hundreds of plugged-silted gravel-soil formations in the vicinity of solid or corrugated well spears, generally in a radius of 200’ and down to 90’ plus depth. The process often provided a better than new well performance history. High velocity water is introduced to gravel and important soil formations by hydraulically operated high-pressure water rigid-lance assemblies (Fig. 1.172) with a nozzle configuration, producing a high velocity turbulence forcing silt into the wells negative system where the sewer cleaning and hydro-vacuum method is applied to clear and clean all gravity areas. Shopping zones and their parking facilities and hopefully abundant car and foot traffic, holiday and special event businesses strive to maintain a functioning, environmental friendly and aesthetically pleasing environment. Providing a

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Municipalities’ Water–Wastewater Treatment, Shopping Zones

163

APPLICATION REVIEW Customer, Company:

Date:

Nr:

Address: City:

Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing Tel: e-mail: Area:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

a

b

d

c

e

Fig. 1.170 a. b. c. d. e

Typical deterioration of an concrete and coating matrix:

©

Safety equipment and procedures: Evaporation pond, purifying vessels, coating removal on lock gates, tank cleaning, primary and secondary digester cleaning, Sewer-pipe cleaning.

WORKSHEET- PURCHASING - SALES

Fig. 1.170 a–e Typical deterioration of an concrete and coating matrix

diversified service capability achieved by quickly convertible equipment to a multitude of application varieties encountered can often be of an essential business survival strategy.

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Fig. 1.171 Soil stabilizing application

Fig. 1.172 Corrugated well spears-pump station

Introducing a blast-water filtration and recycling capability for coating removal or surface cleaning applications on plaza areas or parking deck facilities, including removing oil residue from parking lot surfaces, proves to be a successful sales strategy, especially when combined with a concrete seal installation or general deck maintenance in preparing and sealing concrete damage resulting from stress or freeze cycling. This also includes the repairing of expansion joint systems, as is the bubble gum and graffiti removal technique servicing restaurants and shops in their vulnerable areas. The sales potential can naturally be expanded to exhibition and sport arenas, schools, public golf courses, tennis court resurfacing applications and so forth.

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Municipalities’ Water–Wastewater Treatment, Shopping Zones

165

Fig. 1.173 Rigid-lance assembly at saturation depth

Large stadiums or arenas are especially of interest due to their physical size. Horsepower requirements are low (18 hp-plus), producing high-pressure hot-water at 3,000 psi plus. Chemical and disinfectants application knowledge is important as are managerial skills combined with systematic high energy hp-hose positioning tactics supporting but not impeding the gun operator in his jetting endeavors, producing a speedy job completion. Food concessions and their areas wash and restrooms or sometimes competitors’ facilities where environmentally correct cleaning procedures are a marketing consideration, ground keeper’s maintenance, service and shipping-receiving areas are potentials identified by aggressive sales tactics. A Restoration project on historical buildings is another facet pressure washing and hydro-blast services must consider. Specializing in stone masonry and concrete restoration, which include soil and stain removal applications on fountains and city art deco pieces or historical statues, is lucrative. Highway road services, cleaning toll plazas, their booths and road surfaces from oil, grease and carbon contaminants and providing services to highway rest areas facilities are also essential. Salesmen in consultation with highway departments must not forget to offer the removal of provisional road markings on construction sites avoiding depressions in road surfaces common to grinding or abrasive blast techniques Fig. 1.173. Contacts. Maintenance and Purchasing for municipal solid waste management, consultants for organic waste management. Municipal engineering for source development concerning utilities infrastructure, wastewater system upgrades in

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Fig. 1.174 a Recreational area and competitors shops, b, c concession-public washroom facilities

pumping stations, digesters, etc., including their storm water collection, retention and conveyance systems. Contact purchasing, maintenance and consultants for building infrastructure concerning administration for municipal buildings, recreational facilities (Fig. 1.174a, b, c), City municipal swimming pools, library buildings, maintenance garages and storage facilities including engineering departments for curb, gutter and sidewalks, as well as supervisors for the sewer storm water management program. Resources. Municipal Management Associations, Municipal Management Consulting Association, National Association of Purchasing Management, The National Contract Management Association, National Institute of Governmental Purchasing, Inc., Federal Regulations, State Regulatory Authority, County Regulatory Authority, Municipal Land-Use Regulation and Control, storm water permitting, information, Water and irrigation conservation ordinance. Safety. The labor force providing services in wastewater treatment facilities must be trained to identify plant area and its specific potential hazards. Tightly adhere to preventive measures for a multitude of possible volatile and somewhat unpredictable conditions occurring in these facilities. There are responsible safety officers and competent plant operators controlling the written plan for a permit required in the confined space entry procedure, explaining materials, equipment and methods used during the cleaning process, evaluating and possibly verifying functionality of personal protective equipment, guarding from exposure to raw sewage, gases, oxygen deficient voids, fire and explosions due to formation of flammable gases, dust and so forth. A continuous recording and identifying of atmospheric conditions for toxic gases such as hydrogen sulfide and carbon monoxide, oxygen levels-deficiencies and oxygen rich atmospheres, including testing for flammable atmosphere caused by methane and other gases or vapors is

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167

necessary. At all times, ventilation equipment must be capable of replacing airborne hazards with verifiable atmosphere in a continuous function, controlling the atmosphere for a safe confined space entry and fluid job procedure. Take-out, lockout procedures for electrical and mechanical devices, including flow bypass or diversion equipment is also a required capability, independent but in unison with plant operators and their procedure. Never follow a fallen comrade into a confined space for rescue. Activate the in place rescue procedures by immediately notifying designated trained rescue personnel and ensure all required equipment is present before a rescue into the confined space is activated. More people die in failed rescue attempts than those who needed rescuing. Always check for water flow bypass or diversion mechanisms in case of rain or flash flood conditions. Establish emergency communications procedures and know how to immediately contact medical response and plant rescue services. By no means are these the only guidelines and regulations necessary to perform within wastewater treatment facilities. Besides the wastewater treatment plant’s operational handbook, OSHA’s second edition manual for safe work practices in wastewater treatment facilities is a great information source for regulations, codes, safety standards in areas concerning pressure washing and hydro-blast (UHP) application requirements. ‘‘Safe Work Practices for Wastewater Treatment Plants’’ http://www.OSHA29 CFR1910.146. Sewer, pipe and manhole cleaning or rehabilitation can be a potentially hazardous undertaking. Safety regulations, requirements and labor force training differ from wastewater treatment facilities. There is no one individual culprit, but more or less a combination of dangerous possibilities often underestimated by either too confident or complacent attitudes. Preferably, sewers and pipes are cleaned by utilizing the natural gravity flow of a system. This automatically introduces traffic either vehicular and/or pedestrian to the work site of the service provider’s labor force and equipment. Protection of pedestrians, vehicles, and labor force alike, which includes every part of equipment operation, is performed by utilizing signage, safety cones, barricades and possibly a traffic control supervisory team. Regulations can vary by state for signs, signals and barricades. The OSHA traffic control safety workbook for the construction industry is also of great help, as is the American National Standard (ANS) for traffic control supervisors. A storm water and sanitary sewer entrance demands a confined space entry permit as the labor force is likely to be exposed to hazardous atmospheres. Never, ever retrieve an accidentally dropped tool, nozzle, flashlight, etc., from the bottom of a manhole which constitutes a confined space entry (Fig. 1.175a, b). Personal protective clothing and equipment, adequate personal hygiene practices, no eating, drinking or smoking within the work area and open sewer-pipe are a commonsense ‘‘must adhere by’’ behavior ritual to limit or avoid exposure to biohazards. OSHA hazardous exposure and risk assessment, standard regulations for bacteria, pollutants, toxins, chemicals, and blood borne pathogens common to the content of sanitary sewer refuse must be closely followed. Also, in specific applications, precise, detailed written safety requirements and procedures are always practiced and enforced by supervisory staff. Contractors that find themselves inserting nozzle assemblies (Fig. 1.176)

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Fig. 1.175 a 1958 Sewernozzle design, b 1960 Sewermulti nozzle carrier design

Fig. 1.176 1961 Interior bottom profile, sewer flushing heads

within an excavated trench area more than 4’ deep must make sure that there is a qualified competent person present as explained in OSHA regulation 29 CFR 1926, responsible for the excavated or trenched job site. Besides the remaining dangers of a correctly secured trench location, water or high-pressure water velocity can quickly be a critical destabilizing factor when inadequate cleaning operations are performed. Destabilizing by heavy load, vibrations, pressurizing or removal through water velocity and water saturation of soil formations can immediately endanger labor forces surrounded by weakening structural integrities. This can result from an incorrect nozzle choice with an over and above necessary power input, undetected faulty or damaged sewer-pipe structures where high pressure water jets found cavities or cracks, etc., on interior pipe surfaces. Tunneling effects can occur quickly and are possibly recognized by operators detecting visually changing debris flow and/or substances. This, by the way, is another reason to always work with the natural designed downhill flow of a sewer system to possibly permit a quicker visual recognition (refuse color change) of such a problem by eliminating the pooling effect while flushing (Fig. 1.177), this especially when prior problem detection by camera is not available.

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Municipalities’ Water–Wastewater Treatment, Shopping Zones

169

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Man-hole rehabilitation-sewer cleaning, water well cleaning, toll plaza cleaning, and parking deck coating removal.

WORKSHEET- PURCHASING - SALES

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.177 a 1958 Sewer-pipe cleaning technology by Wolfgang Maasberg Sr., b Modern combination vacuum-sewer cleaning equipment

1.21 Pharmaceutical, Cosmetic, Drug and Dietary Supplement Industry By providing customized cleaning solutions to the pharmaceutical, cosmetic, drug and dietary supplement industries, contractors and hydro-blast equipment manufacturers learned at once that application requests strongly and independently differ with products manufactured. Computerized and automated production is often lot-based. Large quantities of raw materials pass from one process step to the next, leading to final products such as creams, ointments, tablets, capsules, aerosols and inject table solutions. The medical drug and supply criteria for veterinarians can be included within this application variety as does the cleaning of manufacturing hardware, equipment and facilities for surgical gloves, sutures and dressing production lines. Application techniques are best identified when considering a likely natural biological separation–extraction process or chemical synthesis. Operational functions are the separation of medicinal chemicals including but not limited to, antibiotics and vitamins from microorganisms, botanical and biological products thru extraction and purification of organic chemicals from vegetative materials or animal tissues and the not so natural chemical synthesizing or synthetic processes. When synthesizing pharmaceutical products, volatile organic compounds and pollutants (VOC) are contained. Seasonal batch requirements, product changeover, accidental or as a result of equipment failure, therefore possibly emitting contamination to the environment which results in the procurement of pressure washing or hydro-blast services in particular when this is combined with an area or equipment decontamination procedures.

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Pharmaceutical, Cosmetic, Drug and Dietary Supplement Industry

171

Fig. 1.178 Pressure-washers heating element

The following equipment identities and production areas are cleaned and decontaminated by service providers: Autoclave or batch reactors which are often glass lined hosting the chemical reaction and double as holding tanks, mixers, heaters, crystallizers and evaporators or cleaning distillation equipment and their heat producers. Consider as typical the condenser and secondary condenser cleaning application, which includes tray, rotary and fluid bed dryers, wet-dry scrubbers and carbon adsorption equipment. Service providers streamline their safety equipment to avoid any possible contact with pollutants applied in the pharmaceutical separation technology. Solvents of a wide variety are utilized within processes (acetone, amyl alcohol, benzene, ethanol, ethyl acetate, toluene, etc.) therefore specific care must be exhibited, warranting safe working conditions. While in a production sequence, custom-designed clean-in-place equipment systems (CIP) are found throughout most operations, supporting a bio-cleaning process. Manually cleaning and sanitizing with hot high-pressure water can today be a customary maintenance function. Plant generated steam is utilized to continuously heat the pressurized water between 185 and 2258F (1,500–5,000 psi at 5 gpm, avoiding within a hygienic environment the utilization of burner assemblies (coils). Temperature adjustments and levels are precise (Fig. 1.178) and do not fluctuate or spike due to operators on–off jetting procedure (cycling). This characteristic can be of importance where continues high heat sanitizing procedures are a must.

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1 Succeed in Residential, Commercial and Industrial Environments

Fig. 1.179 Chemical metering utility

Service providers must be capable of verifying plant or in-house laboratory identifications of existing waste characteristics, pollution prevention and control methods. Cleaning of manufacturing areas, their exterior equipment, interior walls, ceilings and floors which are usually constructed to withstand repeated aggressive wash downs, or cleaning analytical test lab surfaces, their work bench including containment hoods and isolators can be considered one application faced. These areas are most likely not inclusive of a general industrial services procurement procedure. Laboratory environments demand a specialized application curriculum and will most likely be product specific in specialized safety and technical requirements. Interior surfaces in process areas, similar to the food industry, can feature 100% solid epoxy, epoxy acrylics, polyurea hybrid and advanced resin coatings, etc. and/ or oil–grease–acid resistant brick and tile structures. This application will require extensive wash-down training and an advanced skill level in detergent and chemical application techniques, ensuring an imperative surface cleanliness. Offering or providing with cleaning processes a chemical metering utility incorporating a verifiable fluid volume control function (Fig. 1.179) is imperative.

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Pharmaceutical, Cosmetic, Drug and Dietary Supplement Industry

173

Most always, in-house laboratories will identify or provide critical detergents. They can be low foaming, heavy-duty alkaline detergents as utilized for cleaning lab-ware in parts washers, or low foaming liquid acid cleaners and/or low foaming phosphate free detergents, etc. Often a plant turnaround decontamination, or unit pre-post operational decontamination process which possibly requires removing concentrations of volatile organic, toxic bulk or trace ingredients while executing a predetermined cleaning plan, will include the correct application of such chemicals. Equipment to be serviced include vapor recovery systems, gas wet or dry scrubbing equipment, bag-house units for particular matter and in some cases high efficiency particulate air filter system’s suction (HVAC) and discharge side, including all duct work providing the HEPA filtration for manufacturing floors. Fluid bed equipment performing drying, crystallizing or agglomeration and granulation including dust collectors in tablet manufacturing processes, or dehumidification equipment, freeze-dryer hardware, feeders, extractors and filling or packaging equipment, maintenance shops and cleaning transportation equipment are all identities specifically categorized by customer’s maintenance and procurement department. Preventing cross contamination between equipment and locations during an ambiguous cleaning or decontamination procedure which includes the periodic analytical verification of a successful job completion will be tightly controlled by laboratory-maintenance personnel. Exploiting the customer’s or manufacturer’s available liquids as a blastcleaning, slurrifying, agitating or vacuum-pump drive medium is of significance, in particular when the incentive to return scaled or recovered product back into the production process exists. Also, by utilizing some of the manufacturer’s liquids as blast medium one can avoid the contamination of a production process and the isolation of machinery or its shutdown. This is only possible when liquids’ specific weight, compressibility, viscosity, foaming or lack of, and abrasiveness of liquids are identified to make adequate technical adjustments preventing pump damage or any other mechanical problem. This generally requires equipment rpm reductions and plunger changes, providing the application oriented necessary fluid volume and pressure configuration. Equipment with automated RPM governors most likely must be changed to manual rpm regulation and then supported by an adjustable pressure regulation and pressure relief function. With the exception of operations where expensive or dangerous products can be returned to the production cycle, dump guns are not employed. The pharmaceutical or medical product manufacturer will also need to know hp-pumps fluid-end product compatibility which is most likely a given, since fluid-ends generally are manufactured of high grade stainless steel and contain compatible o-ring or packing materials (Teflon, neoprene, delrine, etc.). Equipment requiring grease fittings therefore grease or any other packing lubrication method cannot be introduced. Pump conversions are best performed utilizing manufacturer’s expertise (pump-fluid-engineering).

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1 Succeed in Residential, Commercial and Industrial Environments

The introduction to operate and clean with purified or distilled high-pressure water and/or light oils found in the pharmaceutical, biotech, and cosmetic process industry may illustrate a comparison to application procedures and methods to the hygienic and bio-safety requirements established throughout agricultural, food, distillation and the general extraction process industries. This includes best cleaning practices and implementation requirements compulsory to the coffee, tea and dairy foods concentrate and powder-granular products manufacturing identities and their plant hardware. Cross contamination is not acceptable under any circumstance. Cleaning procedures are completely isolated between hardware and exterior surface identities, as must cleaning operations between buildings, clean rooms and laboratories. Pipe systems are capped and isolated, which include valve assemblies. Cleaning and removal of calcifications on reverse osmosis equipment and their storage tanks or cleaning wastewater treatment facilities hardware and general surfaces or pharmaceutical containment systems and areas also belong to this application identity. As it is within the food industry, sizing operations, grading incoming raw materials, milling, blending and mixing, compression and performing coating techniques with a variety of equipment is part of the manufacturing step. This is followed by bulk packing and product transportation via railroad, truck or barge, which also offers a variety of service opportunities to the pressure washing specialist, operating at 3–5,000 psi range applying both hot and cold water. The service provider working in the food industry can simply adapt his technique to pharmaceutical quality standards. The food industry’s hp-water equipment is also simply modifiable. Chemical-acid and heat resistant food grade hp-hose assemblies and so forth are again necessary as is all support equipment. Safety-hygienic gear must prove compatible to refuse encountered within a cleaning environment or process. Cleaning product contact surfaces and multiple use production equipment requires the verification of the cleaning process by customers’ analytical method. To avoid problems a contractor best establishes the specific analytical determination for possible residual substance or the lack of. The detection threshold is measured in parts per million or parts per billion. Residual limits after a cleaning process for equipment and diverse surface identities should be guided by practicality, achievability and validated by a test method first established in the contractual procurement phase. This includes maintaining the required timeframe test and verification procedures after a job completion. Also, pharmaceutical outsourcing has grown into a sizable industry. Bulk product manufacturing and packaging requires the same conscientious specialized training for equipment operators and jetting personnel alike and can involve the issuance of PPE fitted closing, which naturally means education in selecting proper equipment, providing records of training routine and regular inspection of the equipment itself and its’ maintenance. Area contamination and emissions consisting of potentially accumulative volatile organic compounds can be found in unsuspecting areas or within equipment identities, especially when services are provided to pharmaceutical contract manufacturers with, now and then, not so stringent safety guidelines or

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Pharmaceutical, Cosmetic, Drug and Dietary Supplement Industry

175

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

©

Safety equipment and procedures: Slurrifying, agitating and pumping sedimentations or products, wastewater treatment facility, tank cleaning

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enforced controls. Small-scale pharmaceutical manufacturing facilities, their water systems, waste water treatment facilities, particulate bag house units and critical utilities ‘‘clean rooms’’ are ideal entrepreneurial business entry-level identities. The US Food and Drug Administration (FDA) has categorized this field into various and obvious topics: Food, including dietary supplements, drugs, medical devices, vaccines, blood products and other biologics, cosmetics and veterinary medicines. Contacts. Pharmaceutical and biotech laboratories and manufacturing facilities. Chemical, mechanical and process engineers, analyzing product quality and equipment status in sizing, milling, blending, compression and coating operations in the dietary supplement industry. Contact bulk manufacturers (agriculture, mineral mining and chemical industry), operations of pharmaceutical chemicals (BPCs), their purchasing, maintenance and shipping departments, etc. Resources. Pharmaceutical Research and Manufacturers of America (PhRMA), Pharmaceutical Drug Manufacturers Association (PDM). Independent Cosmetic Manufacturers and Distributors, http://www.icmad.org. Best practices from Bayer’s, Johnson & Johnson, Glaxo in implementation of various compliances in FDA 21CFR. Industry good manufacturing practices, in production and process control, packaging and labeling, CFR Code of Federal Regulations, industries manufacturing practices for human and veterinary pharmaceutical products 21CFR 210-211, biological product-21 CFR 600 and 21 CFR 620. Safety. All industrial and commercial safety procedures and equipment classifications, including choice of respiratory protection may vary between installations and areas or products manufactured. Specialized personal protection can be required guarding against toxic and volatile conditions. Confined space entry, lock out-take out procedures and a substantial job related combination of controls can be mandatory.

1.22 Pulp-Paper, Paperboard, Cellulose and Engineered Wood-Lumber Industries Visualizing and developing a variety of cleaning solutions by means of a water-jets genetic impact and velocity to soiled and/or contaminated surfaces in the dairy food industry, Wolfgang Maasberg Sr. focused and applied much of his acquired powerwashing technology to the pulp–paper–cellulose production processes. In 1956, Senior and his father Oscar Maasberg delivered maintenance solutions with pump equipment operating at 800–1,200 psi within the pulp-paper fabrication, in particular pertaining to the wet side of pulping processes and their equipment. However, application criterion did not parallel or correspond to cleaning requirements, horsepower-input, tooling, and jetting performances previously found satisfactory when servicing fouled or contaminated dairy-food manufacturing hardware.

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Pulp-Paper, Paperboard, Cellulose and Engineered Wood-Lumber Industries

177

Fig. 1.180 In-place nozzle spray-bar

Fig. 1.181 Traversing nozzle equipment

Essential water volume–pressure configurations to overcome the scales’ tensile strength, adherence or bulk accumulations varied substantially but nevertheless were not the only factors concerning an adequate equipment performance. The continuous distribution and pulp dewatering–drying process required the design and manufacturing of fixed in place (Fig. 1.180, or traversing equipment (Fig. 1.181) operating electric or pneumatic fan nozzle assemblies. The periodic and automated cleaning of rotating disk filters, suction rolls, bottom-top felts and screen assemblies dramatically enhanced plant operations. Furthermore, outfitting and/or converting cross-longitudinal paperboard cutting equipment with hp-water cutting nozzles abolishing typical knife assemblies presented the first product cutting application instantly formative to industries specific tool design criteria. Various nozzle and tool configurations, especially in the chemical Kraft or secondary sulfite pulping process required a variety of pump and tool development efforts which resulted in an equipment umbrella recognized as ‘‘ATÜMAT’’. Companies exploiting the recovered black liquor by-product to support paper mills steam generation (recovery boiler) were immediate beneficiaries of this equipment capability. Mechanical pulping processes utilizing refiner disk plates, etc. shared with the chemical pulping method where wood chips are pretreated with sodium carbonate, sodium hydroxide or sodium sulfide and cooked in high-pressure single or multiple continuous digesters dissolving the lining by separating it from woodchip fiber strands, also required specific tool designs. This facilitated particular cleaning services, as it did for cleaning of equipment hardware applying chlorine, chlorine dioxide, hydrogen peroxide, oxygen and/or ozone to bleach the pulp fibers. Chlorination towers, screens and screen-suction roles (Fig. 1.182) which dewater pulp stock during the bleaching process (Fig. 1.183), inorganic and organic scale removal in evaporator tubes or vacuum receiver and all fresh and whitewater tanks, including pulp product feed or discharge pipelines are all subject to periodic cleaning procedures.

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Fig. 1.182 1958 Intermittent suction-roll cleaning

General cleaning operations in recovery boilers are performed on all interior surfaces including smelt spouts, smelt tank interior, super-heaters, boilers generating bank and economizer, steam drum, flu-stack, flu-gas wet or dry scrubbers and bag-house equipment. Make ready by cleaning interior and exterior boiler tubes for necessary periodic hydrostatic test and leak detection procedures including hazardous corrosion analysis. These testing intervals vary between 12 and 48 months. Depending on shutdowns or maintenance schedule, flash tanks, blow tanks, chip steamers, sulfur recovery system’s condensers (Fig. 1.184), lime kilns and calcination equipment must also occasionally be cleaned. Contractors adjusting gpm–psi performances by simply changing plunger configurations did then and now accommodate cleaning services on plant hardware which process recycled pulp from wastepaper and paperboard, creating products like newsprint and sanitary paper. This advantage in equipment flexibility was particularly noticed when cleaning Material Recovery Systems (MRF) which continuously process newsprint and wastepaper into a manufacturing route creating insulation products, artificial fibers of all sorts for industrial products, including filter cloth and an array of industrial fabrics, ropes, abrasive materials and protective clothing. Hydro-blast personnel must be careful to correctly identify adequate application technology when servicing MRF recovery systems due to a possible mix of nylon, acrylic and polyester fiber operations. Applied process heat to chemically derived fibers drastically alters scale-refuse adhesion, tensile strength and removal characteristics. Similarities in cleaning procedures of manufacturing hardware can be of a visual nature only. The corrosive paper-pulp mill environment combined with high ambient temperatures and, on a good day, 85% plus relative humidity offer a consistent mixture of coating removal and surface preparation necessities for impending coating installations or concrete repair procedures. These application requirements can be found on the mill’s manufacturing floor, hardware-equipment and structural concrete or steel components which reach up to the crane rail installations and

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Pulp-Paper, Paperboard, Cellulose and Engineered Wood-Lumber Industries

179

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing

Engineering

Tel: e-mail: Area:

Maintenance

Tel: e-mail: Area:

Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

a

b

a 1963 Advanced and quick exchange fan nozzle design, primarily applied for traversing and/or in-place fixed spray-bar equipment b Nozzle fixture and body incorporate Bernoulli’s inside tapering structure

©

Safety equipment and procedures: Suction rolls, disc filters, chlorination towers, evaporator tubes, water treatment facilities, settling ponds, evaporation beds, boilers, condensers.

WORKSHEET- PURCHASING - SALES

Fig. 1.183 a 1963 Advanced and quick exchange fan nozzle design, primarily applied for traversing and/or in-place fixed spray-bar equipment. b Nozzle fixture and body incorporate Bernoulli’s inside tapering structure

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Fig. 1.184 1967 Tube bundle cleaning

mezzanine beam component surfaces, stainless steel or concrete tanks utilized for storing bleaches, liquors and other corrosive liquids, etc. Under constant caustic exposure, cleaning and resurfacing deteriorated structural components within the proximity of a paper machine requires a superbly executed hydro-application and an experienced labor force capable of expert tarpaulin installation procedures. Correctly and without fail protecting the operational integrity of the paper machine is imperative. Providing all necessary access for machine operators and tenders servicing their equipment at will and securing a working relationship providing a high degree of flexibility within the job procedure concerning the machine tenders and contractor’s crew alike is of fundamental importance. Also blocking and drawing steam from the paper machine is essential in numerous ways. This will somewhat control humidity and without fail (erected coverings) protect surfaces of paper equipment from falling debris, chemical or water contaminants. Jobsite’s secondary blast enclosure is mobile, safe and sound, guaranteeing flexibility, avoiding physical restraints to the water-blasting crew and facilitates a secure refuse collection including a possible water filtration-recycling capability. Reinforced polyethylene curtains, plastic sheeting and lumber material is utilized to construct primary enclosures protecting the paper machine, which include secondary enclosures for drive equipment of the paper machine, and most likely will feature it’s own access and separate air filtration system. Ventilation, air-conditioning and dehumidification equipment is employed for most coating applications. This again requires a close working relationship with installers applying elastic urethane coating-liners, epoxy coatings and fiber reinforced lining systems withstanding the aggressive chemical and/or thermal environment. The necessary coating classification and installation recommendation will speak volumes in supporting the appropriate hydro-tool selection and gpm–psi performance. The coating product warranty criterion almost always categorizes and identifies necessary surface conditions within the application subject matter. Verifying adequate roughness, anchor profile, aggregates possible pH and moisture content, essential ambient environmental conditions and curing times is a prerequisite. Coating descriptions for interior dry or wet exposure on concrete walls, ceilings and floors are of a standard nature. They are drastically dissimilar for chemical exposure and in acid-caustic rich interiors or in severe wet-end exposure situations

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on the paper machines concrete floor and steel surfaces and/or wet-submerged concrete-steel substrates. The corrosion control requirement in operating refineries-chemical plants (product transfer equipment, pipes, etc.) where high temperature insulation must be removed before corroding surfaces are cleaned with UHP water, entertain certain application similarities as today’s available high-temperature coatings provide a new application criterion. In today’s strictly controlled wastewater discharge requirement, plant chemists and maintenance managers control a delicate chemical and microbial balancing act. Maintenance prevention necessitates the constant monitoring of effluent characteristics customary to the pulp-paper processes, especially within the highheat and caustic manufacturing atmosphere. By nature concrete and metal corrosion is a predominant occurrence and/or on the colder side of a pulp mill line where microbial activity might cause slime deposits compromising the paper quality and possible damages to alloys. The wastewater effluent carrying a major source of pollutants containing organic trace filtrate, will leave the process water in a high biological oxygen demand situation (BOD). Combine this with dissolved organic carbons (DOC) and a chemical oxygen demand (COD) along with heavy metals, chlorides, alcohols and chelating agents results in a rewarding application variety for qualified service providers within wastewater treatment facilities. This area offers the exploitation of all pressure washing and hydro-blast application techniques, operating stationary and/or mobile equipment identities, utilizing all facets of modern tool technologies while cleaning precipitators, digesters, diversion basins, primary–secondary–tertiary clarifiers, dredging operations in aeration lagoons or settling-evaporation ponds, etc. Dust control and removal on the dry site of a modern paper mill is a possible cleaning requirement and a never ending concern to management maintaining their desired product quality. The cleaning regimen is most likely performed within the duration of a cold plant shutdown. Often forgotten or not addressed by contractors marketing endeavors, but nevertheless it is a very lucrative business identity when applying the hydro-vacuum system with industrial vacuum hose-brush and wandextensions. Within the removal process, dousing airborne debris and dust particles in injector’s vacuum chamber renders removed particles harmless and can be directly transferred to plant’s sewer system or contractors’ water recyclingfiltration unit. Overhead beam structures, air ventilation duct systems and hard to reach structural beam surfaces are cleaned free of flaky deposits, fibers, pulp, dust or other wind-swept contaminants, avoiding the employment of bulky vacuum-track modules and their equipment. Modern paper machines run at 60–80 mph, producing 5–7,000 fpm paper products and can be over 30’wide, situated in a facility as long as a football field. The sheer plant size and elevation of a job location can logistically be challenging. High-pressure water and vacuum-hose runs will vary drastically between jobsites especially compared to older facilities and include long extended sewer-pipe cleaning applications where pressure washing performances (10–25 hp) are most likely inadequate.

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In strategic plant locations where pulp buildup or residue impedes a continuous production process, paper mills operate, since the early 1950s, water jetting tools similar to modern day pressure washing equipment. Today, most companies operate electric motor driven 2,000–4,000 psi pump equipment at 4–24 gpm, cleaning periodically failure prone equipment like rotating suction rolls, filter screens or drying pulp from sensitive areas. This does not necessarily alleviate the presence of customarily centralized pump stations with air equalized and water pressurized tanks feeding super long high-pressure pipe and hp-hose systems. Automated rotating tank cleaning and agitation equipment for storage containers maintaining certain liquidity for pulp and chemical products besides the now and then cleaning application are often also powered by these centralized pump stations. Fine and technical paper, specialty paper and packaging products are straightforward product classifications within the pulp-paper industry. This has changed within the last 15 years. Nowadays forestry and agricultural byproducts, combined with waste products from the reclaim-recycling industry, produce commodities such as specialty plywood, laminated veneer lumber, laminated furniture components, polymer-wood and thermoplastic bio-composites, etc., and has dramatically extended the customer base for service providers therefore again preventing the stagnation of high-pressure water application development criteria. Synthesizing-combining these waste products with polymers, polypropylene, high or low density polyethylene, polystyrene, thermoplastic polyolefin and nylon products, etc., enhance possible application varieties. Maintaining or cleaning manufacturing hardware with high-pressure water as a tool may seem quite comparable to cleaning technologies applied in the chemical plant environment. Except, when there are various applications and work environments which reach into secondary industries such as servicing steam-electric power and fuel producers consuming agricultural products and waste product (biomass). These business identities, starting with waste-product suppliers, waste-product converters, final product manufacturers and their storage and transportation environments are all great customers for pressure washing specialists. This provides a gradual transformation potential into the industrial services environment for pulp-paper and cardboard manufacturing hardware and can also be jump started by offering cleaning services to area sawmill operations (Fig. 1.185). Entrepreneurial desires to compete within this industrial market must convey advanced pressure washing, hydro-blast and/or UHP application knowledge and available equipment identities well suited for this field. Equipment operators must be informed and knowledgeable in paper mills operating environment, safety regulations, product flow, locations including aerial recognition of heavy equipment and electrical circuitry within their job criterion. This includes providing MSDS identification for all chemicals introduced to the company, adequate wash water identification and confined space entry qualifications, confidence in job related lock out-take out procedures and a corporate verifiable safety training requirement.

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Fig. 1.185 Sawmill operation

An excellent safety record and experience modifier rating which applies the OSHA recordable rate within the industry and a variety of delighted customers in similar industries will certainly help to compete as well as does the potential of a substantial equipment yard. With minimal equipment modifications contractors performing within power plants, refineries and chemical plant environments are well-suited for this application field. Contacts. Pulp-paper-cellulose plant engineering and operations management, process engineers, purchasing, contract-subcontract administrators, plant chemists and waste water treatment management. Local-national timber and logging companies, their management in equipment-yards. Engineered wood and Biocomposite-biopolymer product manufacturers’ their engineering, purchasing and maintenance departments. For a subcontractor status, industrial painting and coating companies specializing in resurfacing plant equipment, structural concrete surfaces, steel and tank rehabilitation procedures. Resources. For customers in your area: American Forest and Paper Association, http://www.afandpa.org, Technical Association of the Pulp and Paper Industry, TAPPI (www.tappi.org), Association of Independent Corrugated Converters AICC (www.aiccbox.org), Cellulose Insulation Manufacturers Association (www.cellulose.org), Composite Panel Association CPA (www.cctiwdc.org), Western Wood Products Association WWPA, http://www.wwpa.org, Plastic Lumber Trade Association PLTA http://www.plasticlumber.org, Paper-Pulp conversion industry information http://www.paperonweb.com. Safety. Pulp paper plant environments require in-house company training for the visiting labor force, including their management and sales forces, as they also prefer to deal with contractors, voluntarily acquiring OSHA’s safety protection programs, which can also be area or site-specific. Wearing personal protective gear at all times, and capable of identifying mechanical, electrical and chemical hazards is a prerequisite. OSHA 10 ? Contractors safety program provides an insight of what is essential. http://www.wipapercouncil.org. Managing the safety and health

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criteria for the employed labor force, safety equipment necessities and protecting customers’ labor force and equipment within a job requirement reminds one of the stringent petrochemical plant safety criteria.

APPLICATION REVIEW Date:

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Trade Related Publications: 15. The society for Protective Coatings (2004) The fundamentals of cleaning and coating-concrete, Common mechanisms of concrete deterioration SSPC, [6.28.407] http://www.sspc.org 16. The Society for Protective Coatings (2001) Paint Film degradation, mechanisms and control, Failures related to particular substrates SSPC, [6.28.407] http://www.sspc.org 17. Steel Structures Painting Council (1998) Protective Coatings for Pulp and Paper mills, The Society for Protective Coatings , SSPC, [6.28.407] http://www.sspc.org

Safety equipment and procedures:

©

Tank cleaning, bulk product removal, loading dock and warehouse cleaning services, machine shop floor-grease, oil and coating removal.

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1.23 Power-Plant Service, Coal–Oil and Natural Gas, Combined Cycle, Biomass, Hydro or Nuclear-Powered In 1958, the design criteria for self-propelled nozzles (Fig. 1.186a, b, c) to clean sewers and industrial pipe installations appeared at a glance to be somewhat associated to the boiler tube cleaning requirement. This was at best an optimistic point of view accelerating in 1959 the development of hp-water tools not yet available on the open market. In 1960, solving specific power-plant applications with registered patented nozzle technologies operating at higher than previously promising pressures in generating lower water volumes, while offering various degrees of jet impact angles was the first approach. This facilitated the cleaning of 100 –3‘00 boiler and condenser tubes with 00 , ‘00 , ’00 and 100 hp-hose assemblies at 250 to 500 plus in length. There were technical shortcomings encountered. Operating between 3,500 psi at 45 gpm and 8,000 psi at 20 gpm utilizing up to 150 horse-power engine performances excessively deteriorated every available hose configuration within a few job applications. Hp-hose manufacturers scrambled to improve hose abrasion resistance, flexibility in hose structure-radius, weight reduction for two to four layered spiral steel braided and fiber vulcanized and/or Teflon lined assemblies. Hose armatures were also prone to failure and not yet restructured for emerging hp-washing applications or markets. Most often the available hose products maintained internal restrictive hose fittings that compounded fluid pressure drops often identifiable by a nozzle streak pattern developed on tube wall’s interior and/or unnecessary repetitious, inadequate cleaning procedures. Today the motivation to streamline available high-pressure water tools and accessories is to specialize and supplement contractor’s application palette in response to possible emergencies or unscheduled maintenance requirements. More often than not, this type of expenditure is only feasible when a dual purpose for such equipment exists. For instance, when furnace feed is of an inferior or inconsistent coal quality combined with (flame) temperature changes which can suddenly accelerate the development of a clinker buildup, jeopardizing the furnaces tube structure and heating capacity, therefore or subsequently putting at risk the bottom grinder and its operation. Clinker removal techniques developed for cement kiln operations can be transferred to a coal-fired boiler-furnace. During operation, periodically reducing the clinker build-up volume in all fired furnace areas will protect the bottom grinder from catastrophic clinker collapse and therefore at a minimum significantly prolong the units operation or avoid a general unscheduled plant shutdown. The thermal shock treatment upon a clinker formation does not jeopardize furnace tube or brick-insulation structures. This application demands a close working relationship with boiler operators, especially while establishing removal schedules and permissible temperature fluctuations (boiler) when performing clinker removal applications. Maintenance department and plant engineering will advise to appropriate lance carrier installation and possible locations found transversely from inspection ports, etc., on cat walk

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Fig. 1.186 a Filed 1958 Germany, 1960 USA patent draft, b 1/400 and 1/200 Tube-pipe jetting nozzle 1961, c tube-pipe and sewer cleaning nozzle 1958

railings and structural components. This application can also be considered a standby or crisis management capability. High-heat safety gear and eye protection is also a requirement. The dual purpose for the high-heat lance equipment can be soil rehabilitation, water well regeneration and pipe installation-drilling procedures. Providing jetting applications in coal washing plants and coal tunnels, cleaning conveyor belts, coal grinders and pulverizing hardware including blow pipes or screens are services considered on the furnaces fuel side and include cleaning particulate air filtration systems, their flue-gas filters, bag house units and pulling fly-ash formations from the boiler top side (Figs. 1.187, 1.188). Besides clinker removal in fired furnace areas, the accessing of mud and steam drums while in a general shutdown permit the cleaning of all boiler-furnace tubes (Fig. 1.191). Afterward, or as tube repairs are completed, providing hydrostatic test procedures often conclude the necessary furnace-boiler services. Scheduled are also hp-water cleaning applications within a overhaul process, particularly in servicing emission control equipment and plant hardware concerning the desulphurization process of airborne and liquid waste streams which

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APPLICATION REVIEW Customer, Company:

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Providing restricted travel in to desiccated products this hydraulic tool-nozzle is also ideal to slurry calcium and fly-ash formations within clay, asphalt or plastic lined evaporation-settling ponds. Within this application criterion removing slurry or highly viscose products the utilization of hydro-vacuum equipment and vacuum or open roll-off box containers has proven highly successful and superior to alternative industrial vacuum and pumping methods. Safety equipment and procedures: Cooling tower, bag house unit and mist eliminator cleaning, water treatment facility, boiler and condenser cleaning.

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Fig. 1.187 Fly-ash formations

Fig. 1.188 Boiler top side

Fig. 1.189 Wet/dry interface to scrubber (before)

demand routine and specific attention. Cleaning fixed in place plastic mist eliminator fins on top of the interior scrubber vessel can be achieved and supported by a light metal flex-nozzle carrier. When repair is necessary, cleaning operations are performed on dismantled bundles similar to the in-place air preheater basket cleaning operation. Stack-exhaust shaft cleaning is performed manually or with an automatic hose reel function employing an industrial hp-rotary nozzle and if necessary can be operated with an extended nozzle fixture combined with a water volume configuration accommodating the stacks interior radius. The intake or wet/ dry interface to scrubber vessels (Figs. 1.188, 1.189) interior and vessel floor is cleaned by utilizing jetting operations (to knock down and demolish rock hard debris formations to size (chlorides, sulfuric acid remnants, silt-lime-fly ash and calcium sulfate-crust-gypsum), accommodating clean-out procedures by the hydro-vacuum method. Removing scale accumulations in a cooling tower’s interior adhering to fan blades, louvers and trays or dredging and pumping lime and fly-ash sedimentations below and/or above water in cooling towers bottom channels are applications requiring hydro-blast equipment and tooling operating at

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Fig. 1.190 Hydro-blast operation

Fig. 1.191 Wet/dry interface to scrubber (after)

75–150 hp. Vacuum roll-off box containers or an optional vacuum waste-product separator unit and water trucks are also utilized (Fig. 1.190). Slurrifying calcium and fly-ash formations within evaporation-settling ponds lined with clay, asphalt or plastic, and removing these sedimentations by employing the hydro-vacuum method has proven to be highly successful. The established comparison is to otherwise engage high velocity vacuum tractors producing up to 6,800 CFM in combination with mechanical means such as backhoes or pick and shovel shared with fire hose operations. In contrast, an 80-yard box can be loaded continuously in 10–20 min with the hydro-pump process preventing damage to the evaporation pond’s liner. High velocity water quantity above 800 mph and its submerged nozzle standoff distance to thickened, semi dry or dry material being agitated will most often not exceed 5% of its product volume pumped. This figure of adding 5% water is high and can be less varying on moisture content of product. As of today, no faster or effective dredging and removal method above and below water is available (lime, gypsum, fly-ash) (Figs. 1.192, 1.193, 1.194 and 1.195). On the steam side, cleaning interior main condenser tubes and shell side exterior tube structure, tube shield, including gasket areas (when pulled bundle surfaces are exposed) is today considered a generally matured application identity. Specialized is the flushing, cleaning and preservation of turbine lube oil systems which include cleaning lube oil tanks, compressor housing cavities, pressuredischarge lines and vertical integrated oil cooler units with drip or splash proof equipment facilitating a 4–9 tube per minute cleaning rate (Fig. 1.196). This work

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Figs. 1.192 and 1.193 Coal-fired steam generator (1.192). Cooling tower, mist eliminator, stack (1.193)

Fig. 1.194 Coal-fired power plant

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Fig. 1.195 Oil–gas, Steam generator, steam–mud drum

Fig. 1.196 Condenser cleaning, open splash-proof

Fig. 1.197 Combined cycle plant

is performed with demineralized water or filtered, recycled heated light-lube oil customary to plant operations. The natural gas combined cycle power plant operates gas turbine generators with a heat recovery steam generator, capturing heat from the gas turbine exhaust. The steam produced in the heat recovery steam generator system powers a steam turbine generator to produce additional electric power. Various plants operate gas-oil, dual-fuel fired furnace-boiler hardware requiring light distillate fuel oil as backup fuel, which is often trucked into be stored in adjacent tank farms. Natural gas combined cycle power plans (Fig. 1.197), also require low water volumes between steam and hot water cycles. Water losses consist mainly of steam and water leaks throughout its closed loop system.

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Fig. 1.198 Fin-fan heat exchanger, combined cycle plant

The feed water quality standards for drum type boilers (Fig. 1.195) to control the potential of contamination and deposits and/or corrosives is high. Plant waters necessary and destructive elements are measured in parts per billion (ppb). Control measures are in place to avoid excessive boiler tube and turbine fouling and/or minimizing the potential for stress corrosion and possible cracking of turbine blades. The main source of contamination is corrosion (chemical), mechanical or system malfunctioning and/or contractor contaminating a plant system’s interior due to an inadequate maintenance or cleaning procedure. When in high-pressure water cleaning process, completely removing dislodged contaminants must be a job description as must be the identification of reliable and approved corrosion inhibitors. Main condenser, intermittent and after condensers, air cooled heat exchangers, HRSG fin-fan tube cleaning (Fig 1.198), rotary air preheater baskets, economizer, evaporator, vacuum deaerator and flue gas scrubber services as well as cleaning the make-up water system and it’s reservoir or hydro cleaning by flushing the entire turbine and compressor lube oil system are all service applications performed by today’s qualified contractor. In attempting to reduce our reliance on traditional fossil fuels, fuel manufacturing capacities for ethanol and bio diesel facilities are added nowadays to the agricultural services environment. The current and emerging liquid bio fuel technology converting natural oils to bio diesel or sugars, starches and whole-grain into ethanol, generates more rural business potentials for local service companies. This process utilizes the agricultural waste-biomass (fired boilers) for steam generation supporting processes and/or converting it to electric power which is especially obvious in various sugar-cane, paper-pulp and engineered wood manufacturing industries. The biomass fueled boiler and its turbine arrangements can vary drastically in size, airborne particulate-pollution control and in wastewater treatment facilities’ design specifications. Maintenance necessities vary depending on type of fuel being processed and burned. Hydroelectric power generation (Fig. 1.199a, b) and their natural plant locations yet again favor the rural service provider in a variety of possible applications not necessarily linked to power generation. Hydropower is still the most widely used form of renewable energy. It does not produce carbon dioxide or any other waste which may result in the accumulation of excessive scale or corrosion problems generally considered a service providers life blood. Controlling structural steel and concrete deterioration by supporting a possible concrete restoration or coating-painting application can be a periodic procedure.

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Fig. 1.199 a, b Hydroelectric power generation

Fig. 1.200 Spillway

Cleaning and/or surface preparations prepping the plant water intake, trash racks, penstocks waterline surfaces and cat-walk grates or interior valve assemblies, mechanical control-lock mechanisms on spillways (Fig. 1.200) and sometimes the underground surge chamber can from time to time be an expected service requirement. The multi-use water dams providing agriculture irrigation, flood control, upstream water sport facilities such as pleasure craft services, fishing, camping and general tourist amenities are areas where contractors will find their entry-level application curriculum applying high-pressure water and tooling up to 5,000 psi. Decontamination techniques for nuclear power plant processes and methods are somewhat of a classified nature. There is a broad application range and technologies available. Combining contractors’ possible applications criteria, with plant maintenance and engineering specifications under plant laboratories guidelines requires meticulous planning. Radiation protection, minimizing radiation exposure, working within rules for decommissioning-decontamination of commercial facilities that apply radioactive materials also provide a diverse customer variety. This includes the performance of services in medical institutions as well as universities, non-weapons related government-private laboratories and their manufacturing sites and/or accident locations. Activities in these areas can support and develop necessary qualifications for job opportunities when cleaning-decontamination-decommissioning activities in nuclear power plant facilities are made available. The possible variety of work justifies the training requirement and

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related costs for radiation workers, controlling dose limits and establishing a dose history database for them. Code of Federal Regulations (10 CFR Part19) and (10 CFR Part 20) standard for protection against radiation by establishing the dose limits for radiation workers provides the guidance for all involved. This service activity is most always considered a hazardous waste removal application. Job duties will include the correct disposal of various cleaning materials such as dry or liquid broad-spectrum adsorbent products applied in a decommissioning or decontamination procedure as well as cleaning and decontaminating dismantled structures, equipment and soils which remain minimally contaminated but can be disposed of as low-level radioactive waste. Decommissioning-decontamination procedures can include dismantling equipment and structures and/or an environmental restoration of affected surroundings. This work is performed by qualified and periodically tested hazardous material removal workers which through experience may well become qualified decontamination technicians advancing their capabilities to radiation-protection technician. The periodically tested radiation-protection technician (lead man) is aware of decontamination regulations, guidance and communications, and capable of applying radiation test methods and tooling, including operating survey meters to locate, identify and evaluate possible radioactive materials. The radiation-protection technician also controls the correct high-pressure water cleaning and equipment operation which includes Hydrovacuum equipment, its application and combined HEPA filtration systems when servicing primary and secondary facilities. Performing an exact decontamination procedure and appropriately packaging high and/or low-level radioactive waste materials in primary and secondary containment areas for transportation, controlling the process of verifying disposal treatment, which can include transportation to landfill or storage facilities in dry or liquid form and/or incineration, belong within these application criteria. The manual hydro-blast FGD stack cleaning operation, most likely removing acidic residue, deemed hazardous, adhering to general interior surfaces and various structural cavities including flange exhaust chamber are nowadays displaced by quick-install automated equipment available for this application. This equipment can also be utilized for elevator shaft; laundry and refuse chute cleaning operations in high-rises, etc. The operating longevity of hydro-electric power plants often demonstrates the creeping concrete surface deterioration brought upon by general environmental conditions. Carbonation (salt) resulting in physical damage to various degrees into concrete and possible block surface structures accelerates in-depth the decay during natural weathering cycles. These deteriorating weather cycling events can be effectively slowed and controlled by periodic cleaning and sealing concreteblock surfaces in depth before extensive rehabilitation events are necessary. Often a past neglected maintenance procedure forces the securing of such structures by Hydro-concrete rehabilitation and sealing measures which nowadays present a major business capacity within this field. Besides the Hydro-demolition-rehabilitation or UHP concrete removal application, utilizing the water abrasive blast technique is of an advantage, providing a near zero environmental impact while

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APPLICATION REVIEW Date:

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Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

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Jo Site Review:

Safety equipment and procedures:

©

Scrubber unit and interior stack cleaning, sludge removal in cooling tower channels, plant water and evaporation ponds.

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Fig. 1.201 1960–1967 Patent file Fig. 1.202 a, b Housing and turbine runner

performing an industrial rated surface preparation. Most importantly, this application does not entail more than 75 hp input, which under most circumstances far exceeds essential concrete surface preparation prerequisites. Industrial abrasive water-blast techniques and equipment (Fig. 1.201) were first applied in power plant industries and fine tuned for steam turbine or compressor cleaning operations in the early 1960s by removing the general film fouling and hydrocarbon scale. Aluminum oxide powder admixed with high-pressure water

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APPLICATION REVIEW Date:

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Tel: e-mail: Area:

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Safety

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(a)

(b)

Fig. 1.203 a.b Pipe and Tube-bundle cleaning ½” and ¼” Nozzles 1961

Safety equipment and procedures:

©

Oil lube cooler, oil lube tank, fin fan tubes, hydrostatic testing, cleaning trash rack, cat walks and concrete surfaces.

WORKSHEET- PURCHASING - SALES

Fig. 1.203 a, b Pipe and tube-bundle cleaning ‘’’ and ’’ nozzles 1961

was utilized to remove film like deposits on turbine blades. This application is nowadays more often effectively controlled and performed through applying inhibitors (chemistry) to boiler feed water and/or chemical cleaning procedures.

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Admixing powders and various sized granules to a well designed high-pressure water stream should not be a forgotten tool identity (Fig. 1.202a, b). The often superior surface honing, polishing, rust-paint-coating removal and overall surface preparation potential can support a specialized application itinerary which should never be underestimate in its repetitious profitable business potential. Contacts. Power plant maintenance engineering and purchasing departments, retrofit service companies, providing coating-liner installations and plant hardware for sub contractor status. Area coal mines, and Google for information, ‘‘power generation facilities’’. Safety. Service providers involved in electric power generation facilities will provide a tested labor force qualified in providing clear lines of communication with maintenance and plant safety departments, operating confined space entry equipment, air monitoring and continuous atmospheric testing, identification of potential physical hazards, lockout-tag-out procedures, fire prevention, etc. Hpwater applications generally require a combination of controls in this environment (Fig. 1.203). For nuclear power plant services, US Department of Energy, maintenance management programs and labor force training, 10CFR 830, Subpart B, and DOE G 433.1-1 and DOE technical standards program web sites, http://www.hss. energy.gov/nuclearsafety/nsps/maintenance.html. Office of nuclear safety and environment, establishing requirements and guidance to ensure health and safety for workers which is not a department of OSHA, Interfaces & Liaisons, DNF-SB (Defense Nuclear Facilities Safety Board, EPA (Environmental Protection Agency), IAE (International Atomic Energy Agency), NRC (Nuclear Regulatory Commission), OSHA (Occupational Safety and Health Administration).

1.24 Railroad-Commuter-Light Rail Maintenance Yards, Railways Historical Associations, Theme Parks, Rail Bridge, Steel–Concrete Rehabilitation, Rail Accident, Site-Emergency Response In the early 1900s, pump manufacturers designed and delivered in-house cleaning systems and rudimentary equipment combining a water-steam function to more successfully remove grease, oils and other contaminants from railcars and locomotive surfaces. Early on, manually operated wands applying 2.5 and later up to 25 hp were utilized to clean engine parts, truck-axle assemblies and the exteriorinterior of railcar tanks, etc. There is no doubt this water-steam cleaning capability presented a marvelous tool addition to any rail yard facility. Drive-through wash bays and today’s integrated sumps, separating oil-grease and solids from waste streams, were later incorporated. Regardless of the fact that in 1821 James Boyd patented the first rubber-lined, cotton-webbed fire hose assemblies, and Charles Goodyear discovered in 1839 the

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all-important rubber vulcanization process (1844 Patent) modernizing the emerging industrial hose manufacturing technique and followed in 1878 by seamless cotton woven fire hose units (American Fire Hose Company), the highpressure water hose and nozzle technology above 1200 psi did not yet exist to permit the cleaning of boiler tubes in steam engines. Tubes were manually routed with push rods and later with rotary steel brush systems. The American Fire Hose Manufacturing Company also advertised first in1900 hose-reel and fire hose nozzle assemblies. The reinforced industrial hose construction was made possible by converting yarn braiding equipment. Steal-wire braiding, intended as hp-hose reinforcement, was introduced in the mid 1920s. By 1930, industrial braiding equipment delivered hoses in length of up to 20 m. Textile braiding technologies were tailored to the steal-braiding curriculum and combined with existing vulcanization techniques resulting in production of hose assemblies for hydraulic automotive brake systems, appearing in the early 1930s. These hose assemblies were successful in maintaining semi static pressures only and required a substantial technical improvement before service for reciprocating pumps exploiting the pressure washing, sewer cleaning or hydro-blast cleaning application became possible (500 pump rpm plus). In the late 1950s, the introduction of high-pressure water-jets and nozzles to existing low pressure stationary drive-through facilities (1,250 psi) for exterior locomotive and railcar cleaning procedures (Fig. 1.204a), similar in appearance to today’s car-bus-tractor-trailer cleaning systems, proved contrary to prior belief somewhat futile. The thin-film residue removal application, especially on painted or lacquered glossed surfaces, proved inadequate when safely utilizing highpressure water fan-jets. Only by adding various water temperatures and detergents to the stationary stepped fan-jet assemblies, combined with the introduction of a physical friction to surfaces in question, was the removal of statically adhered and/ or carbon-oil-film deposits successful. These semi automatic cleaning systems operate within the 100–300 plus horsepower range. The labor-intensive washingscrubbing method was finally displaced by incorporating hydraulic-electric driven rotary brush or oscillating rag scrubbing systems. With a combined fleet of 7500 plus locomotives throughout the United States, railroad companies annually perform hundreds of overhaul and repair procedures. So-called ‘‘back shops’’ (Fig. 1.204d, e) of engines. These facilities provide major repair work which generally includes the complete disassembly and rebuilding of engine and power-train assemblies including exterior deteriorated coating removal-installation practices. These activities are also performed while actively reducing prior pollutant loads from their maintenance operations and paint job facilities. Today, waterborne coatings with highly reduced solvent levels (VOCs) combined with a clear coat system find their way onto locomotive surfaces. Under various going-green programs high-pressure water cleaning applications, coating removal techniques and the introduction of wastewater-recycling and filtration methods reducing or eliminating the waste burden to the environment, can be considered an innovative application frontier for modern service companies.

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Rail-tanker cleaning, paint-coating removal, livestock-car cleaning and sanitizing.

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Fig. 1.204 a Fuel station, b Rail yard, c Burn-off after extended engine idle, d, e Back shop

In general, locomotives are the only cars that represent the railroad company itself. The reporting Mark is an identification assigned by the Association of American Railroads (AAR) to rail carriers and other companies operating in North America. They are the letters in sequence of two to four, visually and uniquely identifying the owner of railroad rolling stock (locomotives-cars). Freight cars owned by leasing companies do not necessarily exhibit a Railroad Mark. The type of car in need of cleaning and/or sanitation services and/or coating removal applications will often in itself identify the industry and company it services, as for instance gondolas transporting bulk commodities such as aggregate, coal, minerals, scrap or steel products. Open top hoppers are also designed for bulk commodities, such as coal, coke, aggregate or sand and livestock cars operate between cattle yards and slaughterhouse-meat processing operations and/ or transporting zoo or circus animals to their awaiting fairgrounds. Livestock cars may also require a biologically controlled cleaning procedure. Flat cars transport steel, lumber and other finished heavy industrial products, as auto-rack cars transport vehicles from manufacturing location to their destinations throughout the

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Fig. 1.205 a Paten file 1968, b, c 6500 psi.3D nozzle, patent draft, d 6500 psi.3D stainless steel nozzle, e patent abstract

country. Boxcars accommodate the broadest range of manufacturer or shipper needs. They may transport packaged food, auto parts, appliances, forest products, building materials and so forth and generally require the least attention in cleaning procedures and coating replacements. This differs substantially to refrigerated cars-tankers transporting food-stuffs, liquid and meat and/or volatile dry or liquid chemicals. These railcars specifically fall under the regulatory compliance management for freight and tank cars and demand a variety of cleaning-sanitation options for maintenance inspection and certification (e.g. HM201). Tank car cleaning applications naturally performed one way or the other were automated in the early 1930s, applying low pressure high water volume rotating nozzle equipment (Butterworth 1925). Problems arose more often within delivery and sanitation cycles of foodstuffs and chemical products tending to adhere to interior tank surfaces, or when frequent cleaning intervals due to product changeover and general business growth throughout the industrial environment escalated (Fig. 1.205a, b, c). Equipment manufacturers hustled to develop and manufacture 3D nozzle capabilities, performing with lower water volumes at higher pressures 5–8,000 psi plus and made them available in the mid 1960 (Fig. 1.206). The 3D nozzle technology was quite difficult to develop. There were no technical examples or other expertise to draw from. Fluid seal technology for rotating high-pressure water equipment (5,000–10,500 psi) controlling the required or desired nozzle rotation (rpm) for various application necessities presented a definite engineering challenge. Providing specialized services for rail maintenance departments, independent terminals and private railcar owners can include activity in rail and trucking facilities, or light rail transit yards and their maintenance operations and providing services to subway or similar transportation identities. This includes cleaning underpass and tunnel structures or servicing product holding tanks, fuel tank-farms or wastewater treatment facilities, evaporation-settling ponds often located in rail yards, customer’s storage and loading areas. Cleaning applications require generally 2,000–8,000 psi at various water volumes which permits grasping the bulk of available service work.

1.24

Railroad-Commuter-Light Rail Maintenance Yards

203

Fig. 1.206 a Telescoping 3D tank-cleaning assembly, b Private tank yard, c private fill and maintenance facility

The hydro-vacuum, water-abrasive blast and UHP equipment identities will provide an array of possible applications permitting specialization within this field. Coating and lining removal applications on interior-exterior steel railcar surfaces designed for acid, alkalis, dairy, hydrocarbons and livestock transport is an area where the UHP application rules. This, particularly within the presence of an existing anchor profile which permits an immediate spot coating-maintenance or installation procedure while performing within environmentally permissible regulations. Private railcar owners may also require pressure washing services for their unittrains (Fig. 1.207a, b) in their facilities or on their maintenance tracks. Units are in general comprised of 30–125 rail cars in need of pressure washing services completed within 2–3 day shift assignments. This requires an approved aciddetergent-rinse application cycle and the employment of a secondary spill containment, track pans or a pan system combined with a mobile water filtration and recycling function permitting the removal of waste-water by shifts end. This application can somewhat be compared to tractor-trailer fleet cleaning operations, where a complete unit is serviced between 8 and 12 min. This requires a highly organized and systematic work method, leaving nothing to chance. The timely utilization of an aerial lift, supply and application of acid-detergents including the necessary rinse cycle, blast water replenishment and effluent pickup is precisely choreographed. Simultaneously, a correct rail safety and signage procedure and the wearing of safety gear, respirators, etc., must be mandated. This is challenging due to job location, the graveled rail and unsecured shoulder surfaces, length of railcar units, cleaning equipment turnaround procedures and providing a strong labor force which will most likely vary between job locations as well as the encountered weather. The entrepreneur will find the restoration of locomotives and their respective cars quite educational, in particular due to the fact that restoration work must meet the stringent safety rules (Fig. 1.208) established by the Federal Railroad Administration (FRA). This includes performing a correct confined space entry

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Fig. 1.207 a Rail equipment, b private unit train cars

procedure, providing personal protective gear (PPE), enforcing HASMAT regulations and furnishing MSDS identification for all chemicals introduced to the jobsite. These guidelines are often compromised by overeager volunteers supporting the railroad historical society. Contractors do best when comparing existing volunteer work with prior work performances, showing specific time savings achieved with available equipment capabilities and resulting final surface appearances. Needle gun operations, steam cleaning, and pressure washing

1.24

Railroad-Commuter-Light Rail Maintenance Yards

205

Fig. 1.208 a–e Roof access, c water recovery-filtration-recycling, d locomotive restoration yard

practices conducted with less than 18 hp., including air abrasive blast techniques, are inconsiderate maintenance solutions with environmental impacts unbefitting historical societies, theme park operations, etc. Cold-weather cycling combined with salts and acidic environmental conditions resulting today in advanced carbonation effects (Fig. 1.209) on bridge components, corroding and degrading not only steel decks but also the supporting concrete structure. This again justifies utilizing UHP concrete removal practices in reaching below the rebar structure, avoiding further rebar deformations and the introduction of micro fractures to the remaining robust concrete substrate customarily produced when air-electric operated jackhammers are engaged for concrete removal operations. The rehabilitation of aging rail decks and bridge structures is an ongoing business opportunity with no end in sight. Deteriorating concrete and steel decks beneath the rail rock ballast are a constant maintenance concern (Fig. 1.209a) to specifying engineers, transportation departments and transit authorities. After removing the rail section and rock ballast, water abrasive blasting or the UHP application technique is utilized to remove the cavernous corrosion accumulations

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Fig. 1.209 a Removal of advanced carbonation, b 40000 psi UHP coating removal, c Repaired carbonation damage, d coating procedure, rail bridge deck, e repaired concrete carbonation, f removal of advanced carbonation, g damage removed and repaired

which generally are shared with the simultaneous removal of a failing coating system. Care must be taken to correctly identify the existing coating. Blast water and refuse lead based coatings are rendered harmless by utilizing water vacuumrecycling and retrieval-filtration equipment, separating solids, followed by water treatment through recycling the polished effluent via a phosphoric filter assembly

1.24

Railroad-Commuter-Light Rail Maintenance Yards

207

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Servicing waste water treatment facilities, dredging evaporation ponds, fuel-oil tank cleaning, machine shop services.

WORKSHEET- PURCHASING - SALES

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before discarding or returning the water to the UHP suction side. This operation can be a stepped procedure between UHP blast cycles, general repairs such as welding, and the elastic thick-film coating installation, resulting in the water proofing of rails underlying steel decks. Flagmen will guard and warn crews from oncoming trains. Passing rail traffic can be quite disruptive, producing air pressure and windswept hindrances forcing tie-down procedures of all equipment and expendables (tarps, etc.) Rail safety must be precise and often involves night work without the disruption to rail traffic. Railcar accidents where spill control and subsequent spill removal applications occur are almost always classified as an emergency response application. Streamlining high-pressure water tools to support various emergency response criteria can be of considerable interest, especially given that this tool variety is also employed for far-reaching disaster cleanup procedures (fire, flood and vehicular accident cleanup-remediation-restoration). In the absence of mechanically generated heat, spark and or compression within the product transfer process, the hydro-vacuum equipment characteristics provide a superior industrial product removal capacity under adverse circumstances and isolated conditions. To safely transfer product within a potentially explosive, volatile, flammable, acidic, viscous or powder-granular state is its undisputed performance hallmark. While loading railcars, tanker trucks or industrial transportation containers, adding a HEPA air filtration capability will further be advantageous. Contractors wishing to enter the emergency response field utilize an equipment response unit which also consists of chemists operating a mobile laboratory to identify the nature of a spill and the hazardous classification group of chemicals and products involved. Because of an accidents possible location, fluencies and involvement of various emergency responders and/or catastrophic environmental impact, these operations are not compared to remediation procedures performed on Superfund sites, etc., when cleaning, packaging and transporting the identified hazardous wastes to a designated facility. Contacts. Railroad inspection, construction and maintenance services for subcontractor status. Train, subway and transit car manufacturing industries, their purchasing and maintenance superintendents, railroad companies state transit authorities, railroad maintenance plant (back-shop) and track maintenance superintendents, railcar leasing and management companies, rail freight shipping companies, their warehouse and storage facilities maintenance superintendents, railcar fleet leasing and inspection services. Also contact one-stop railcar service companies performing railcar cleaning, mechanical repairs and interior-exterior finishing services and private industrial railcar owners in agricultural, food, automotive, mining and petrol-chemical environment, etc. Resources. AREMA, the American Railway Engineering and Maintenance-ofWay Association, http://www.arema.org ASLRRA, American Short Line-Regional Railroad Association http://www.aslrra.org, On the Internet, ‘‘Historic railway associations’’, AAPRCO, American Association of private Railroad Car Owners, etc. NARCOA-North American Railcar Operators Association, http://www. narcoa.org, etc.

1.24

Railroad-Commuter-Light Rail Maintenance Yards

209

Safety. Workers complying with the Federal Railroad administration will require training and testing to qualify as a roadway worker. Required safety training involves general safety awareness and understanding the ‘‘ABSOLUTE NO-FOUL situation or activity, FRAs, On-Track safety program, Steel bridge inspection and safety regulations for railroads, bridge worker protection program, roadway worker protection, 49 CFR, Part 214, Subpart C., General safety regulations R920-51, safety regulations for railroads, title 49 Federal Railroad Administration, applying to all private, common and contract carriers by rail. Railroads safety program administrator provides contractors with a source list for available safety training programs. OSHA’s hazardous waste operations and emergency response (HAZWOPER) training, including DOT-HAZMAT transportation labeling and placarding training under 49 CFR 172.704, OSHA, Site Supervisory Training, 29 CFR1910.120, EPA’s Hazardous waste management programs 40 CFR 262.34& 265.16, and HAZCOM, Hazardous communications training, 29 CFR 1910.1200 are next to necessary tool and application capabilities the minimal basic qualifications a contractor will produce or utilize on a jobsite. Most jobs and applications within this field require a combination of safety procedures (Figs. 1.210, 1.211 and 1.212).

210

1 Succeed in Residential, Commercial and Industrial Environments APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

P.O. Box: ZIP Code:

State:

Purchasing Tel: e-mail: Area:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures:

©

Unit-rail car cleaning operations, steel deck coating removal, concrete rehabilitation procedures.

WORKSHEET- PURCHASING - SALES

1.24

Railroad-Commuter-Light Rail Maintenance Yards

211

Figs. 1.210–1.211 a Overhead wood cleaning, b balcony-deck cleaning, c manual Spin-Jet operation, d moss-fungus removal, e wastewater recovery, v-shoe, f flat-work, floating Spin-Jet, g concrete, flat work, h Tank-cleaning, top entrance, i confined space hydro-blasting, j vertical coating removal, k stack interface before, l concrete sacrifying

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1.25 Business Operating Model 1.25.1 Retain and Safeguard Corporate Application Itinerary Protecting service providers managerial and operational business future is essential, as is streamlining the recurring business opportunities within the pressurewashing, hydro-blasting, hydro-vac and UHP application criterion. Confidentially attaining the corporate identity is achieved when correctly accruing past and future job histories, avoiding the loss of application technology and know-how to various and often repetitive circumstances. The software-manual supports commercial and industrial buyers and their corresponding persons in that a final job procurement result, and the narration of an application method, including the billing process is independently produced and processed. Maintenance and civil engineers, paintcoating specialists, architects, restoration or preservation consultants, industrial maintenance superintendents and/or entrepreneurs are provided with a managerial method to correctly record and analyze an application prerequisite within their respective field including the agricultural-aquatic, commercial, industrial and marine environment. The industrial documentation provides general high-pressure water cleaning, hydro-vac dredging or bulk refuse-product removal procedures for settling ponds, industrial tanks, sewer or industrial tube-pipe jetting services, including the cleaning of manufacturing hardware, and paint-coating removal endeavors. Steel cutting, concrete roughening or demolition applications, etc. are techniques also depicted. The software-manual’s commercial environment recognizes the know-how of general surface cleaning applications (flat-work) on vehicle garage, drive-thru, machine shop and warehouse surfaces, etc. and introduces façade cleaning and rehabilitation procedures on various substrates including composite and stone, masonry, concrete, brick or wood surfaces.

1.26 Introduction Applications within the agricultural, marine, commercial, industrial, and residential criterion utilizing tool identities powered and manipulated by high-pressure water. Specific safety measures, contact and resource information has been outlined for all included industries. The trade ‘‘application review’’ form is applied by professionals to revise and upgrade the ‘‘introduction’’ manual with every new application encountered, thus expanding manual’s content. Recording the job analysis will identify and provide a guide to a variety of application methods within the application ‘‘index’’ chapter.

1.26

Introduction

213

Fig. 1.212 a Abrasive UHP cutting, b demolition-manual, c surface preparation manual, d concrete-aggregate demolition, e enamel-coating removal, f tube bundle cleaning, g tank reactor, autoclave cleaning, h reactor, autoclave 3D cleaning, i brick–block–stucco cleaning, j commercial–industrial pipe cleaning, k flat-work, l wood structures, vinyl, aluminum, m sewers and laterals

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1.27 Application Register Corresponding to over 450 specific job entities, more than 25 core applications are described within the commercial, marine, and industrial environment. When a necessary application curriculum is recognized, the revealing ‘‘Register’’ numbers are branded by business and industry identification, manufacturing hardware or process, service industries identity or its practice, type of product to be removed, area identification, or environmental and disaster terminology. The application ‘‘Register’’ is expanded or fine-tuned with successfully completed and not yet registered job performances. Based on an existing job report and its application gear-list, a correlating ‘‘register’’ number is established to identify the primary and secondary application identities in chapter ‘‘Applications’’.

1.28 Application Core Curriculum 1,000–55,000 psi In detail review more than 25 major marine, industrial, and commercial complexes, explaining emerging and existing application techniques. When possible, the pros and cons of prior cleaning or product removal methods, rehabilitation, restoration and demolition practices are compared and referenced. All chapters feature an extensive application ‘‘gear-list authorization’’ which outline the most necessary tools, including support equipment to manage purchasing, sales forces, and operators in their attempt to create a functional ‘‘gear-up list’’. When cross referencing between chapters ‘‘Introduction’’, application ‘‘register’’ and the ‘‘Application’’ core curriculum, everyone involved is equipped to interact with necessary business procedures. The all-important paper trail begins with a job hazardous risk analysis, always followed by a trade ‘‘application review’’, and equipment ‘‘gear-list’’, before a procurement-bidding procedure and work order can be initiated (see Figs. 1.213–1.219)

1.28.1 The Gear-List Authorizations The gear-list authorizations in Chap. 3 provide and identify the necessary tooling and possible support equipment for over 450 applications within specific environments and include:

1.28.2 GEAR-LIST Authorizations’ for 1. Brick–stone–stucco–masonry cleaning, structuring, and restoration 2. Biosecurity, sanitizing, decontamination, chem—concentrate applications

1.28

Application Core Curriculum 1,000–55,000 psi

215

Figs. 1.213–1.219

3. Clinker–slag–coke removal, kiln-boiler-furnace cleaning, thermal-hot scale removal (Cracking-thermal-shock) 4. Condensers, small tube heat exchangers, large tube heat transfer units, tube boilers

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5. Coating-paint-graffiti removal on steel, concrete, stone, brick, and wood substrate 6. Concrete cutting, scarifying, surface preparation, demolition and restoration 7. Dry-wet vacu applications, dredging and emulsifying sludge, transfer, gravel cleaning, 8. Corrosion, grease removal, chemically treating and painting ([) of pipes, ducts, tubes 9. Excavating, drilling, sheet pile driving and water well cleaning 10. Expansion control joint cleaning, sidewalks, tank and pool construction 11. Filters, screens, felts, bag-house units, trays for catalytic-cracking, preheater baskets 12. Cleaning of gas stations, restaurant drive-thru, machine shops and warehousing 13. Hazardous waste recovery, soil treatment, radioactive trace element remediation 14. Hazardous industrial waste, asbestos-ACM product removal 15. Hydrostatic testing of boilers-steam generators, tanks pipelines, gas-vacuum vessels 16. Mold remediation, disaster-sludge cleanup, pest suppression, odor-stench control 17. Oil lube systems, tanks, oil compressors, hydraulic equipment services, light oil jetting 18. Ornamental-statuary-monuments, city fountains, hotel-municipal, aquaticpools-tanks 19. Polishing, etching, burr-metal flush removal, weld seam polishing, surface modulation 20. Sewers, culverts, sumps, laterals, industrial pipe cleaning, pipeline cleaning and cutting 21. Smoke stacks, laundry shafts and garbage chutes 22. Stationary-portable, equipment, vehicle fleets, rail–car, exterior truck-trailertanker 23. Tanks, vessels-autoclaves, precipitators, cleaning, volatile substance-effluent removal 24. Hydro-abrasive blasting, cutting-demolition, underwater hydro-blasting and dredging 25. Wash water control, recovery, filtration, recycling, reclamation technology, evaporation 26. Wood restoration and preservation, vinyl, wood, aluminum siding and roof cleaning

1.29

Application Review

217

1.29 Application Review 1.29.1 Develop the Trade Curriculum, ‘‘Introduction’’ Business complex: Agricultural–Aquatic–Marine–Industrial–Commercial–Residential Trade amendment or a variation to a subdivision in this Chapter, ‘‘Introduction’’: Nr: Application ‘‘Register’’ numbers: in Chap. 2, ‘‘Application Register’’: Nr: Recognize, and compare a possible similar application technique identified by ‘‘Register’’ criterion: Describe and illustrate Describe and illustrate an innovative or undisclosed application criterion in which the environment, product deterioration, a manufacturing process or it’s failure is responsible for equipment fouling, rendering plant hardware inoperable, or is the contaminating source for various surfaces and confined and/or enclosed spaces, predetermining pressure-washing, hydro-blasting, UHP and/or hydro-vac application techniques. This includes, general cleaning applications on vinyl, wood, aluminum, steel and concrete surfaces, the interior and exterior decontamination of surfaces from various biochemical and chemical hazardous particulate, corrosion-paint-coating removal, UHP applications, various surface treatments as roughening, scarifying and anchor profiling techniques, hydro-abrasive blasting, hydro-static testing, liquid jetting other than water, industrial pipe and sewer cleaning applications, dredging and commercial industrial vacuum services, and providing an emergency response capability in industrial–commercial–residential environments to remove waste-sludge-liquids or gravel-granulate-dust accumulations. This application curriculum can be expanded to a HAZMAT response to act on environmental emergencies (storm cleanup), and make available mold-fungus remediation solutions, fire restoration, accident or crime scene mitigation. Contacts. Identify company contacts, purchasing, contracting office, engineering and maintenance departments Resources. Identify customers trade related information base, associations, state and federal government trade oversight departments and regulations: Safety procedures, Jobsite specific. Proof of necessary written, tested licensed trained and/or retrained contractor-crew proficiency and classification for technical, safety, legal and health requirements: Developed by: Date: Authorized by: Date:

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”INTRODUCTION” DEVELOP THE TRADE CURRICULUM - amendment Date: Address:

Customer, Company:

Nr:

City: Web site: e-mail:

Purchasing Tel: e-mail:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail:

Maintenance Tel: e-mail:

Safety Tel: e-mail:

Jobsite specific: safety requirements, equipment-procedures, pedestrian-vehicular traffic control: Atmospheric and physical hazards: Biological or sanitary application criterion: Job Location: Job access requirements: Lock-out and tag-out procedures: Step-in and out area:

Area:

Job Site Review: Previous service methods: Process equipment-hardware identification and failure analysis: Debris identification, and hazardous material classification: Debris-scale, adhesion classification, tensile strength, resilience, viscosity and volume: Required tooling and its performance estimates: Itinerary of proposed service action: Pre-job safety meeting itinerary: Tailgate meeting itinerary:

Labor force-contractor specific: safety equipment and procedures: Developed by: Authorized by :

Date: Date: WORKSHEET- ENGINEERING - FIELD-TECH

1.29

Application Review

219

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

State:

Purchasing Tel: e-mail:

Engineering Tel: e-mail:

P.O. Box: ZIP Code:

Maintenance Tel: e-mail:

Safety Tel: e-mail:

Job Description: Job Location:

Job-Site, Hazard Risk Assessment:

Specify:

Job Site Review:

Safety equipment and procedures: Developed by: Authorized by:

© Date: Date: WORKSHEET- ENGINEERING - FIELD-TECH

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1.30 Compile Application Register Catalog Marine–Agricultural–Aquatic–Industrial–Commercial–Residential ‘‘Register’’ numbers are ‘‘branded by’’ business and industry identification or manufacturing hardware and process, identity of an service industry and particular business practice, type of product to be removed, area identification, or environmental and disaster terminology. When a job conclusion has proven successful by conforming to all safety merits within its performance criteria, the successful application criterion and previously undisclosed job description is amended to chapter ‘‘Application’’. The information includes labor force necessities, and gear/tool selections which are identified and categorized by their ‘‘Index’’ primary numeric number (bold). Secondary ‘‘Index’’ numbers apply either to application similarities or an application criterion necessary within a specified primary job description. With a winning job curriculum derived from an ‘‘application review’’ its ‘‘Gear-list’’, job report, and job cost analysis, the application ‘‘Register’’ is chronologically expandable and/or fine-tuned by establishing a correlating ‘‘Register’’ number to the core ‘‘Application’’ curriculum Fig. 1.220.

1.30

Compile Application Register Catalog

Fig. 1.220

221

222

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GEAR - LIST

Nr.

Job Nr.:

Date:

Customer & Company:

Address: Web site: e-mail:

Purchasing Tel: e-mail

P.O. Box: Zip Code:

City: State:

Engineering Tel: e-mail

Maintenance Tel: e-mail

Safety Tel: e-mail

Job Description: Job Location:

Job-Site, Hazard Risk Assessment:

Specify:

Job Review Performed by: Plant hardware, equipment, surface area:

Hydro-blast equipment:

Establishing a new ”Gear-list” prepared by an actual job walk and its subsequent informative job ”Review” is greatly supported by choosing job criteria from the abundant but specific ”Gear list Authorization” located within the core ”Application” chapter. Identifying labor force safety requirements, and transferring or adding relevant itinerary, and tooling to a gear-list can only be established by a job-walk, qualified application review and a precise up-to-date job recording program to the core ”Gear-list”.

Plant location: Product Encountered: Hazardous Material:

Expendables:

MSDS:

Specify:

©

Describe Application and Work Procedure:

Describe Safety Procedure: Itemize Equipment, Safety Gear, Expendables, etc.:

Developed by: Authorized by:

Date: Date:

1.30

Compile Application Register Catalog

223 GEAR - LIST

Nr.

Date:

Customer & Company:

Job Nr.:

Address: Web site: e-mail:

Purchasing Tel: e-mail

City: State:

Engineering Tel: e-mail

P.O. Box: Zip Code:

Maintenance Tel: e-mail

Safety Tel: e-mail

Job Description: Job Location:

Job-Site, Hazard Risk Assessment:

Specify:

Job Review Performed by: Plant hardware, equipment, surface area:

Hydro-blast equipment:

Plant location:

Expendables: Other:

Product Encountered: Hazardous Material:

Developed by: Authorized by:

MSDS:

Specify:

Date: Date:

224

1 Succeed in Residential, Commercial and Industrial Environments ”GEAR-LIST AUTHORIZATION” - amendment

Date:

Customer & Company:

Job Nr.:

Address: Web site: e-mail:

Purchasing Tel: e-mail

P.O. Box: Zip Code:

City: State:

Engineering Tel: e-mail

Maintenance Tel: e-mail

Safety Tel: e-mail

Job Description: Job Location:

Job-Site, Hazard Risk Assessment:

Specify:

Job Report Performed by:

Establishing a new and innovative Gear-list ”Authorization” or amending an existing one within the ”Application” Core chapter, requires an application review criteria encompassing a dissimilar access to a jobsite, unlike or unknown application histories (job reports), with a dissimilar track record and related narration (gearlist), unequal surface-substrate or location, dissimilar manufacturing process or failure, product or environmental conditions, dissimilar safety requirements, safety equipment and personal protective gear necessities (PPE). The mere fact of obvious product adhesion similarities, and/or comparable product-scale removal application techniques does not justify a gear-list “authorization” procedure or changes to an existing one.

Product Encountered: Hazardous Material: Describe Application and Work Procedure:

MSDS

Specify:

Describe Safety Procedures: Itemize Equipment, Safety Gear, Expendables, etc.:

Developed by: Authorized by:

Date: Date:

©

1.30

Compile Application Register Catalog

225

”GEAR - LIST AUTHORIZATION” - amendment

Date:

Customer & Company:

Job Nr.:

Address: Web site: e-mail:

City: State:

Purchasing

Engineering Tel: e-mail

Tel: e-mail

P.O. Box: Zip Code:

Maintenance Tel: e-mail

Safety Tel: e-mail

Job Description: Job Location:

Job-Site, Hazard Risk Assessment:

Specify:

©

Job Review Performed by:

Expendables: Other:

Product Encountered: Hazardous Material:

Developed by: Authorized by:

MSDS

Specify:

Date: Date:

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Figs. 1.221–226

A job walk identifies application criteria recorded in detail utilizing the ‘‘Application Review Form’’. The encountered application is clarified by engineering and/or industries terminology, manufacturing hardware and/or process, services identity or its practice, type of product to be removed, area identification or environmental and disaster vocabulary (‘‘Register Catalog’’). Identifying the application by its terminology, reveals primary (bold) and secondary numbers (‘‘Register Catalog’’) recognizing the specific core ‘‘Application Curriculum’’ supported by an industry specific ‘‘Gear-list Authorization’’ categorizing necessary tooling, equipment and safety procedures for a ‘‘Gear-list’’ creation facilitating the proposal requirement. Creating a ‘‘Gear-list’’ for a proposal procedure must always involve the ‘‘Gearlist authorization’’ curriculum eliminating time, labor, proposal and technical application irregularities.

1.30

Compile Application Register Catalog

227

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

Purchasing Tel: e-mail:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail:

Maintenance Tel: e-mail:

Safety Tel: e-mail:

Job Description: Job Location:

Job-Site, Hazard Risk Assessment:

Specify:

Job Site Review:

Expendables:

Safety equipment and procedures:

Developed by: Authorized by:

Date: Date: WORKSHEET- ENGINEERING - FIELD-TECH

Individual and/or specific application requirements justifying the development of a new ‘‘Gear-list Authorization’’ must confer with the business system 1,000 psi to 55,000 psi maintaining software-manuals integrity (Administration) (Figs. 1.221– 1.226).

228

1 Succeed in Residential, Commercial and Industrial Environments ”GEAR - LIST AUTHORIZATION”

Date:

Customer & Company:

Job Nr.:

Address: Web site: e-mail:

Purchasing Tel: e-mail

City: State:

Engineering Tel: e-mail

P.O. Box: Zip Code:

Maintenance Tel: e-mail

Safety Tel: e-mail

Job Description: Job Location:

Job-Site, Hazard Risk Assessment:

Specify:

©

Job Review Performed by:

Expendables: Other:

Product Encountered: Hazardous Material:

Developed by: Authorized by:

MSDS

Specify:

Date: Date: MANAGEMENT

1.30

Compile Application Register Catalog

229

”GEAR - LIST AUTHORIZATION” - amendment

Job Nr.:

Date:

Customer & Company:

Address:

Purchasing Tel: e-mail

P.O. Box: Zip Code:

City: State:

Web site: e-mail:

Engineering Tel: e-mail

Maintenance Tel: e-mail

Safety Tel: e-mail

Job Description: Job Location:

Job-Site, Hazard Risk Assessment:

Specify:

©

Job Review Performed by:

Expendables: Other:

Product Encountered: Hazardous Material:

Developed by: Authorized by:

MSDS

Specify:

Date: Date: MANAGEMENT

230

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GEAR - LIST

Nr.

Date: Address:

Customer & Company:

City: State:

Web site: e-mail:

Purchasing Tel: e-mail

Engineering Tel: e-mail

Job Nr.: P.O. Box: Zip Code:

Maintenance Tel: e-mail

Safety Tel: e-mail

Job Description: Job Location:

Job-Site, Hazard Risk Assessment:

Specify:

©

Job Review Performed by: Plant hardware, equipment, surface area:

Hydro-blast equipment:

Plant location:

Expendables: Other:

Product Encountered: Hazardous Material:

Developed by: Authorized by:

MSDS:

Specify:

Date: Date: GEAR - LIST- SHOP-YARD

Chapter 2

Application Register

Abstract The reader can identify a known and unknown job criterion including the possible undisclosed precise particulars to facilitate the creation of an explicit job gear-list. Corresponding to over 450 specific job entities, more than 25 primary applications are described within the commercial, marine, and industrial environment. When an necessary application curriculum is recognized, the revealing ‘‘register’’ numbers are branded by business and industry identification, manufacturing hardware or process, service industries identity or its practice, type of product to be removed, the area identification, or environmental and disaster terminology. The application ‘‘register’’ is also expanded or fine-tuned with successfully completed and not yet registered job performances. Based on an existing job report and its application gear-list, a correlating ‘‘register’’ number is established to identify the primary and secondary application identities in chapter application core.

2.1 Example: Identify a Job Criterion and Create its Job Specific Gear-List Example: How to service a Condenser or small tube heat exchanger 1. Lookup the primary and secondary application register number (s) in this Chapter, ‘‘Application Register’’, page 235 Condenser or small tube heat exchanger . . . . . . . . . . . . . . . . . . 14.19. 4 The correlating core number 4 (bold) identifies in Chap. 3, ‘‘Application Core’’, section 4.203 the service application supported by its gear-up list and safety requirement.

W. Maasberg, Commercial-Industrial Cleaning, by Pressure-Washing, Hydro-Blasting and UHP-Jetting, DOI: 10.1007/978-0-85729-835-5_2,  Springer-Verlag London Limited 2012

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2. The Secondary ‘‘register’’ number (s), .19. applies either to application similarities or an application criterion necessary within the primary job description, offering the required gear-up list, facilitating the conception of an advanced and specific tool requirement. Section .19, ‘‘Application Core’’, section 19, explains the industrial pipe, pipeline and sewer lateral cleaning-service method (s) often necessary or similar within a condenser cleaning procedure, presenting its technical safety and gear-list requirement. Section .14, ’’Application Core’’, section .14 explains possibly necessary hydrostatic test procedures for boilers and condensers offering the technical requirement, safety curriculum and its specific gear-list. 3. The application ‘‘Register’’ is expanded or fine-tuned with successfully completed job reports and not yet registered job performances. Based on an existing job report and its application gear-list, a correlating ‘‘Register’’ number is established to recognize the primary and secondary application identities in Chap. 3, ‘‘Application Core’’.

2.1 Example: Identify a Job Criterion and Create its Job Specific Gear-List

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Pressure-washing, hydro-blasting, UHP applications and environments 1,000255,000 psi A Acid tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19 Acidize aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.24 Absorbers (spray-wet absorbers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Absorption filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Abrasives-sand-sponge blasting and refuse recovery . . . . . . . . . . . . . . . . . . . 7.24 Acid plant precipitators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20.22 Acrylic removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . After coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aircraft hangar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19.24 Aircraft-carrier fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.13 Aircraft, coating removal, cleaning (private-commercial-industrial) . . . . . . 13.21.24 Air conditioner-chillers, commercial-industrial . . . . . . . . . . . . . . . . . . . . . . . . 11 Air conditioning systems commercial-industrial . . . . . . . . . . . . . . . . . . . . . . 11.19 Air-cooled finned tube heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Air preheater units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Algae removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Amusement parks-theme parks . . . . . . . . . . . . . . . . . . 1.2.5.6.7.12.19.22.23.24.25 Anchor-chain, locker compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 Anchor chain compartment, lateral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Animal grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.19.24 Animal shelters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.7.19.24 Aquatic pools-tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.5.7.10.12.19.22.23.24 Arm and tray elevators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.22.24 Asbestos removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.24 Asphalt removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16.21.24 Asphalt breaking equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.22.24 Asphalt mixing and paving equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.22.24 Assembly lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.24 Atomizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Autoclaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automobile repair shops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.21.24 Awning and sign cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.24 B Backwashing tunnels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 Bag-house cleaning and refuse removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 Balanced tray thickener-cone scraper, feed well, overflow box and pipe, blades….2.7.22.23 Ballast tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Barge service (fuel tanks, containers, holds) . . . . . . . . . . . . . . . . . . . 2.7.13.23.24 Barnacle growth (oil rigs, piers, ships) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.24 Barrel cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Bagging bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Batch crystallizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 Batch reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Barrel, solid rocket fuel, demilitarizing warheads-bombs . . . . . . 2.4.5.7.11.13.19.24

22 2 11 11 23 11 5 4 12 22 5 4 4 4 11 23 17 22 22 21 12 17 21 13 12 21 21 21 22 22 12 2 19 22 22 22 22 23 22 22 4 22 22

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(continued) Bayonet-tube exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Benson sulfur recovery systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.11 Blast-furnace pipe precipitators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19 Bilge cleaning and preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 Bitumen removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.22.16 Black liquor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.16.19 Blast furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.11.16.19 Boiler cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.7.14.19 Boiler hydrostatic testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Boiler-slagging-slurry pipe lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22 Box driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.21 Bridge concrete reclamation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.23 Bridge cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.10.19.23.24 Bridge decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.6.10 Bridge decks expansion joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.23 Bridge pylon cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23 Bridge deck concrete rehabilitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.23.24 Bridge (industrial structures) lead coating deleading-removal . . . . 2.6.7.12.13.23.24 Brick walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brick (used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.23 Bubble cap cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 Bubble gum removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Building washing, repair, restoration . . . . . . . . . . . . . . . 1.2.5.8.12.15.17.19.24.25 Bunker seed product removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16.12.24 Bulk storage tanks for finished products . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.11.24 Boats-pleasure craft services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.7.23.24 Bottling equipment-facilities . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.11.12.21.19.24 C Caked sludge removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.22.24 Calcium carbonate removal (boiler tubes) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.22 Carbon removal (engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18 Carbon deposits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.19.24 Castings, filaments cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 Catch basins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Canners-canning equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.12.22.24 Candy and confectionery manufacturers . . . . . . . . . . . . . . . . . . . . . . 2.7.12.22.24 Caustic tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 Cedar roof shingles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 Cement dust removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.24 Cement slurry removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.12.24 Cement truck cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12.24 Chemical storage tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 Centrifugal separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.22 Chemical metering-foaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chemical rinse aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 11 22 22 22 12 22 22 4 14 19 22 6 12 12 10 6 6 5 1 1 22 12 12 22 22 12 22 7 4 21 13 18 19 21 21 22 25 7 6 21 22 21 2 24

(continued)

2.1 Example: Identify a Job Criterion and Create its Job Specific Gear-List

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(continued) Chemigum removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.19 Center dividers (roadside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 City fountains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.5.12.23.24 Chewing gum removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chicken crates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.12.24 Chlorine cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Chutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19 Clarifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.6.10.19.23 Clay pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cinder-block cleaning, coating removal, CMU units . . . . . . . . . . . . . . . . 2.5.15.12 Clinker removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 Closed belt conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20.22 Coating removal on steel and concrete surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . Coal blow tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19.24 Coal-rock crusher-grinder-pulverizing hardware . . . . . . . . . . . . . . . . . . . . . 7.19.24 Coal sludge, settling ponds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coal storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 Concrete truck cleaning, cured concrete removal on vehicle components 2.5.3.22.24 Coke discharge headers, coke compressors . . . . . . . . . . . . . . . . . . . . . . . . . 18.19 Coke handling hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21.22 Coke heater barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Coke production (refinery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.19.20.21 Coke removal after refinery fire . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.19.12.20.22 Cokers (refinery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.3.19.20.22 Cold storage buildings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.7.24 Cooling towers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19.24.22 Compressor service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Concrete cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Concrete demolition-scarifying-rehabilitation . . . . . . . . . . . . . . . . . . . . . . . 5.7.24 Concrete construction forms and accessories . . . . . . . . . . . . . . . . . . . . . 2.12.21.24 Concrete form boards, molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21.12 Concrete production machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 Concrete sealer and necessary prep-work . . . . . . . . . . . . . . . . . . . . . 2.7.12.23.24 Crime scene cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.15.24 Condenser hot well decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13.14.22 Condenser or small tube heat exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19 Condenser tube sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Construction site, cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.19.24 Container cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Continues vacuum crystallizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Continuous horizontal-vertical vacuum filters . . . . . . . . . . . . . . . . . . . . . . . . . 22 Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 Conveyor belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12 Crank case (machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.18 Crankshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Continues-flow conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13.19

22 5 17 12 21 22 20 22 19 1 3 19 5 20 21 7 7 21 3 3 3 22 3 21 12 11 16 6 6 6 6 6 6 13 4 4 4 12 22 4 11 22 21 21 21 21

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(continued) Conveyor elevator shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.22.24 Corrosion control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12.23 Covering the angles of eaves (attic, roof space) . . . . . . . . . . . . . . . . . . . . . . . . 25 Crude oil removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.13.19 Culverts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cylindrical clarifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylindrical, coal bunker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 D Dairy-barns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.8.9.10.11.15.19.22.24 De-burring, (burr-metal flash removal, course edge polishing, surface modulation)…………….23 Decontamination of holding tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.13 Degassing (sewers, pipes, tanks, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 Decks-porch-landing preservation-restoration (wood) . . . . . . . . . . . . . . . . . . . 2.15 Digester (paper, pulp, sewage, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19 Disaster cleanup-odor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.12.13.19 Disc and plate clarifier, filter assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 Dispense bactericides-disinfectant and/or sanitizing products . . . . . . . . . . . . . . . . . Direct heat rotary dryers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Dredging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.22 Demilitarizing warheads-bombs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drill pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.22 Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Drive-thru and sidewalks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Driveway cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 Drum filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 Drying beds-evaporation ponds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.24 Dust suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12.24 Double-Pipe exchanger with longitudinal fins . . . . . . . . . . . . . . . . . . . . . . . . 2.11 Double-shell indirect-direct rotary dryers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Dough removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 Dust-impingement separators of various designs . . . . . . . . . . . . . . . . . . . . . . 2.22 Dust hoppers of various designs for solids separation (cyclonic-bag-house-gravity) 7.22 E Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Etching (glass, wood, and steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Electrostatic spray cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Emulsifying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.16 Environmentally correct pressure washing, hydro-lasting and UHP services . . 2.7.13 Epoxy removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Evaporator (forced circulation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 Evaporators, short or long tube-vertical or horizontal . . . . . . . . . . . . . . . . . . . . 22 Excavation (hydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Exhaust fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Expansion joint cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exposing concrete slabs-aggregate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

20 2 1 22 19 22 22 12 8 22 19 25 22 15 11 2 3 7 13 19 9 12 12 11 7 2 4 3 22 11 11 22 18 5 7 24 5 22 4 7 8 10 6

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(continued) Exposing dried concrete surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.12 Explosive-volatile, environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.13 External piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.22 F Facades, general buildings, etc . . . . . . . . . . . . . . . . . . . . . . . 2.12.19.15.23.24.25 Feed-water heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fermentation residue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.12.22 Felt, filter medium, including bag-house interior . . . . . . . . . . . . . . . . . . . . . . . 22 Feed silos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.10.15.19.20.24 Feed equipment, troughs, mix-feed grinders . . . . . . . . . . . . . . . . . . . . . . . 2.11.22 Fermentation towers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 Feed water tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Freeze driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Fence restoring (wood) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 Fire restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 7.10.15.19.24.25 Fiberglass lined tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Filter presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire-tube salt-bath heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.22 Fire-tube boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.22 Fin-fan cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22 Flash rust removal-suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12 Flight decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 Floating pontoons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Floors-cleaning, product-refuse removal . . . . . . . . . . . . . . . . . . . . . . . 2.5.7.15.24 Floors, concrete cutting, scarifying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.23 Floors refinishing and resurfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.24 Flues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8.19.22.24 Fluidized feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 Fluidized-bed and cyclone arrangements, including tanks . . . . . . . . . . . . . . 7.11.19 Fly-ash removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19.20 Forms and molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 Fog tunnel (steel plant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16 Fouling film evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Foils, 3M, removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Foundation cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9.22.24 Fountains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Footer base (concrete) Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24 Food service areas, food residue . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 8.15.19.24 Fountains-water sport facilities-gardens, municipal pools, aquatic exhibition tanks…2. 5.7.24 Friction rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fuel tanks, decontamination (nuclear) . . . . . . . . . . . . . . . . . . . . . . . 2.5.12.13.19 Fuel tanks, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.12.13.19 Furnaces (revolving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22

6 22 19 1 4 11 11 22 12 22 22 22 25 12 22 11 11 4 4 4 2 5 12 6 12 20 19 22 22 21 7 4 12 6 17 6 12 12 21 22 22 3

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(continued) G Garbage shafts, chutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15.19.24 Gas line-pipe cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Gas pipeline hydrostatic testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 Gasket surface cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.22 Gas stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.13.19.22.24 Gas distributors for gases containing solids (fluidized bed operations catalyticcracking)22 Garbage-refuse areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.15.19.24 Generating tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glass-lined equipment, autoclaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 Glass flake-vinyl ester coating removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.23 Graffiti removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Graphite removal, uranium bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 Gravel cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grease traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.13 Grease and oil pits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.19 Grid iron-cat walk cleaning, scale removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Grinders-mineral crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.16.24 Grocery carts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 Gum removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gypsum removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24 H Hatching trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.11 Hazardous industrial waste recovery . . . . . . . . . . . . . . . . . . . . . 2.5.7.11.15.19.24 Heat exchanger cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat exchangers, shell side cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Heater tube sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Heater tubes cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy equipment cleaning services . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22.23.24 High-rise buildings, cleaning, restoration (above four floors) 1.2.5.6.7.9.13.15.17.20.25.23.24 Historic structures, statues, art-deco façades . . . . . . . . . . . . . . . . . . 1.2. 5.15.23.24 Hop grain mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.12.15.21 Hop grain storage units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.15.21.12 Hop strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11.12.21 Hopper rail cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13.21.24 Horizontal fire tube boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 Hotel pools and general services . . . . . . . . . . . . . . . . . . . . 1.2.7.12.15.19.23.24 25 Hot scale removal (steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal-flow plate precipitators (cement plant) . . . . . . . . . . . . . . . . . . . 4.12.19 Horizontal and vertical mist eliminators, vessels, tanks . . . . . . . . . . . . . . . . . . . 2 House siding cleaning (dirt, atmospheric film, mildew, fungus, oxidation removal)1.2.15.7.24 Hydraulic-oil tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16 Hydro-excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19 Hydrofluoric acid-alkylation plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.19.20

20 19 15 12 12 11 12 4 22 5 5 13 7 19 13 12 21 21 12 12 21 13 4 4 4 4 21 12 12 22 22 22 22 4 17 3 22 22 12 22 7 22

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(continued) Hydrostatic testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22.16 Hydro-vac-systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazardous materials cleanup technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I Incinerators, commercial-industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20.22.24 Incubating trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12.21.24 Industrial structures, coating removal-deleading . . . . . . . . . . . . . . . . . . . . 1.2.23.24 Industrial elevator shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.24 Insect-pest suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Injection molding machinery (plastics) . . . . . . . . . . . . . . . . . . . . . 2.4.11.19.24.22 J Jacketed exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Juice deposits removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11.21.19.12 K Kettles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10.21 Kiln deposits (rotary kiln) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Kneaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 L Large tube heat transfer units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Latex (sealing water dams) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.12.23.24 Latex buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.12.21 Laundry shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Lime silos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 Lime removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.21.22 Lint deposits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8.11.24 Livestock containers, holding areas, barns . . . . . . . . . . . . . . . . . . . . . . . 2.7.19.22 Locomotives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.12.24 Louver dryers, product feed assembly, hot air chambers and exhaust stack . . 7.12.20 Lube oil towers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.16 M Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.11.7.12.24 Magnesium salts removal (boiler tubes) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19.22 Marine growth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17.19.24 Mash vats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19.12 Mastic removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.10.24 Masonry cleaning-restoration-preservation . . . . . . . . . . . . . . . . . . 2.5.6.7.15.23.24 Material recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12.24 Meat packing equipment, processing . . . . . . . . . . . . . . . . . . . . . . . . 2.7.19.22.24 Mechanical parts cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.24 Metal oxidation removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.23.24 Metal, polishing-cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Military-naval environment . . . . . . . . 1. 2.3.5.4.6. 7.10. 13.14.15.16.21.19.22.23.24 Mill scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mist eliminators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.20.12.22 Mixers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.21

14 7 24 3 2 5 20 21 15 22 4 22 22 3 22 4 10 22 20 22 1 12 12 21 22 22 21 4 23 22 12 1 13 21 21 21 18 12 3 11 22

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240

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(continued) Molds (construction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.12.24 Mold-fungal contamination, removal-remediation, odor control . . . . . . 2.7.12.13.24 Monuments-ornamental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Multi-element cartridge clarifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19.22.24 Municipal pools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.5.12.2.3.24 N Natural gas lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.22 Natural latex tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 Neutralizing basins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.22.23.24 Nuclear reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.5.7.11.12.19.14.16.22.24 O Odor-stench, removal-control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.12.24 Oil lube coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.11 Oil lube systems, cleaning, scale removal, preservation . . . . . . . . . . . . . . 2.7.11.22 Oil-petroleum product storage tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 Oil tanks (crude-bunker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.16 Oil well equipment cleaning services . . . . . . . . . . . . . . . . . . . . . . . . 2.7.19.22.24 Oil spill-cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.22.24 Oil traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19.22.24 Ornamental statues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.5.12.15.23 Outside-packed head condenser with vapor liquid separation . . . . . . . . . . . . . . . . Ovens-industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 P Packed column-towers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19.12 Packed-lantern-ring exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 Packing and labeling machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 Paint booth, paint overspray removal . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.20.24 Paint facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.11.12.19.20.22.24 Paint heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.11.12 Paint pipe cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.20 Paint stripping-removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.24 Paper manufacturers . . . . . . . . . . . . . . . . . . . . . 1.2.3.4.5.7.8.11.12.14.16.19.20.24 Paraffin removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.7.19 Parking areas and garages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.7.10.19.24 Parking garage, pavement cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.19.24 Parking garage, expansion-split and joints . . . . . . . . . . . . . . . . . . . . 2.7.12.19.24 Pasting walls, floors open gondolas-dust suppression . . . . . . . . . . . . . . . . . . . . . 7 Picnic tables-grills, highway-park services . . . . . . . . . . . . . . . . . . 1.2.7.5.12.23.24 Pile driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24 Pipeline protective coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.19 Pipeline hydrostatic testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Piping-internal, decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.19.24 Pipe and sewer cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20 Plate and frame type exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.19 Pools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Polishing, metal bur-removal, honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Polymer jetting-blasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 15 17 12 17 19 22 7 13 15 16 16 22 22 21 13 4 17 4 3 11 4 21 5 5 22 19 12 22 22 12 12 10 2 25 9 22 15 13 19 4 17 18 2

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2.1 Example: Identify a Job Criterion and Create its Job Specific Gear-List

241

(continued) Polymerization reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19.24 Pond bottom cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19 Pools-residential-public, ornamental fountains, exhibition pools-tanks 2.5.7.19.22.23.24 Portable water tank cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Preheater columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11.19 Preserving steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.23.24 Pressure leak testing-hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16 Precipitators-scrubbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.19 Process equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.11.13.14.16.22.24 Public telephone-rail-bus booth surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.24 Q Quench-boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.22 R Radioactive trace element remediation . . . . . . . . . . . . . . . . . . . . . . . 2.4.5.7.11.24 Radiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 Railcar tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Railroad cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.13.22.24 Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.7.11.19.22.24 Recovery systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19.21 Refractory buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Refrigeration systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19.22 Resealing-water proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.7.10.23.24 Resin, solidified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7.19.22 Restoration-construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.5.6.25.13.24.25 Road maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.7.10.19.23.24 Road-marking removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rocket, missile motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13.19.24 Roller-flight, conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.19.22 Roller-chain, conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.19.22 Rotary sieves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Rubber removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.21.22 Runway rubber removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 Rust removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.12.23.24 Rust proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.12.23.24 Raw material bucket elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19.22 Rotary kilns, air-tempering chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Rotary calciner-cooler and feeder assembly, stack, furnace lining . . . . . . . . 7.20.22 Railcar washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 Roof shingle cleaning (wood, composite, plastic) . . . . . . . . . . . . . . . . . . . . . 2.24 Roof safety procedures while cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Restrooms-locker rooms, showers, highway, stadiums, industrial manufacturing…2.7.19.24 Radiators-fin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roasters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rock base cleaning (construction, mining) . . . . . . . . . . . . . . . . . . . . . . . 7.9.10.24

22 23 17 22 22 2 14 22 21 12 4 13 11 22 21 13 4 3 4 12 4 12 12 12 22 21 21 11 12 12 5 5 21 3 3 21 25 25 12 11 21 5

(continued)

242

2 Application Register

(continued) S Salts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sandstone-limestone cleaning, mold remediation . . . . . . . Sandblast-abrasive blast methods . . . . . . . . . . . . . . . . . . Sanitize, food service-livestock-farm-veterinarian vehicles Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scaffold cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scarifying surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scrap processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scrubbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second stage area decomposer tubes . . . . . . . . . . . . . . . Sedimentation tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . Settling ponds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sewage treatment plants . . . . . . . . . . . . . . . . . . . . . . . . Sewer, man-hole-culvert cleaning . . . . . . . . . . . . . . . . . Sewer-pipe cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . Shingle (wood-composite-plastic) . . . . . . . . . . . . . . . . . Shellfish breeding containers, tanks, areas . . . . . . . . . . . . Ship-boat dock-piers . . . . . . . . . . . . . . . . . . . . . . . . . . Ship deck cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ship hulls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shopping carts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shredder systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sidewalks and drive-thru’s . . . . . . . . . . . . . . . . . . . . . . Sieves-filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . Sieve-tray tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Silos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Skirt cleaning, airports . . . . . . . . . . . . . . . . . . . . . . . . . Sludge removal in settling ponds . . . . . . . . . . . . . . . . . . Sludge-refuse removal-disaster cleanup . . . . . . . . . . . . . Slurrifying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smoke chambers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smokestacks-flues . . . . . . . . . . . . . . . . . . . . . . . . . . . . Soil treatment, remediation . . . . . . . . . . . . . . . . . . . . . . Solid waste removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Soybean processing plants . . . . . . . . . . . . . . . . . . . . . . Spiral-plate exchanger . . . . . . . . . . . . . . . . . . . . . . . . . Spill removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spill cleanup services . . . . . . . . . . . . . . . . . . . . . . . . . . Spiral wheel and roller conveyor . . . . . . . . . . . . . . . . . . Stadium cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stacks and Chimneys . . . . . . . . . . . . . . . . . . . . . . . . . . Steam-vapor-gas exhaust stacks . . . . . . . . . . . . . . . . . . . Spray-drying towers . . . . . . . . . . . . . . . . . . . . . . . . . . . Steam boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steam engine-turbine . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . 1.2.5 . . . . . . 2.15.24 ........... . . . . . . 2.12.24 ........... . . . . . . . 2.5.12 . . . . . . 2.23.24 7.11.13.19.22.24 . . . . . . . 7.11.19 . . . . . . . . 4.7.22 . . . . . . . . . 7.19 . . . . . . . . . . 19 . . 2.6.5.19.23.24 . . . . . . . . 10.24 . . . . . . . . . 7.24 . . . . . . . . 2.5.24 . . . . . 2.19.21.24 . . 2.5.7.12.24.25 . . . . . . . . 2.5.21 . . . . . . . 5.12.24 . . . . . . . . . 2.24 . . . 2.19.13.22.24 . . . . . . . . . 2.24 ............ . . . . . . . . 19.11 . . . . . . . . . 2.21 . . . . . . . . . 2.24 . . . . . . . 9.19.22 ........... 7 . . . . . . . . . 9.12 . . . . . . . 2.12.24 ........... 9 . . . . . . 2.7.11.24 . . . . . . 12.13.24 . 2.4.11.12.19.21 ............ . . . . . . 2.7.12.24 . . . 2.7.12.19.24 . . . . . . . . . 2.12 . . . 2.8.10.19.24 . . . . . . . . . 7.19 ............ . . . . . 7.11.19.24 . . . . . . . . 2.3.14 ............

12 1 23 21 2 21 6 21 22 19 22 7 22 19 12 25 7 23 12 23 21 21 12 11 22 22 12 7 15 7 22 20 13 7 22 4 13 13 21 12 20 20 22 4 23

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243

(continued) Steam-plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.7.11.12.14.16.19.20.22 Steam generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.19 Steam generator, hydrostatic testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Steel cutting-demolition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steam generator channel head decontamination . . . . . . . . . . . . . . . . . . . . . 2.14.24 Steam-tube rotary dryer, dust drum, steam manifold-tubes . . . . . . . . . . . . . . . 4.19 Steel mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.4.7.11.12.14.19.20 Stone-brickwork cleaning, sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15.24 Stone cleaning (monuments) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15. 17.24 Storage silo with life storage shelf and reserve storage arrangement . . . . . 2.7.19.24 Store fronts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 Storage tanks, drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Submersible abrasive blasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sulfur condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Super-heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.11 Surface hardened exterior finish removal . . . . . . . . . . . . . . . . . . . . . 2.3.11.23.24 Suspension coal bunker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12.19 Swimming pool cleaning services . . . . . . . . . . . . . . . . . . . . . . . . 1.2.5.7.19.23.24 T Tank lining-coating removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 Tank-cleaning, product recovery applications . . . . . . . . . . . . . . . . . . . . . 2.7.13.24 Talcum powder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12.19.20.24 suction heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tank trucks-urea deposits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.22.24 Tanker truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Tanks, hydrostatic testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.24 Tar cookers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.12. 19 Tar products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16.22.23.24 Tennis courts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.24 Theme-amusement parks . . . . . . . . . . . . . . . . . . . . . . 1.2.5.6.7.12.19.21.23.24.25 Three drum water tube boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.14.20 Towers (trays-refineries) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.19.22 Towers (refinery), hydrostatic testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tractor-trailer fleet washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13.22.24 Tube bundle cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 13.22 Tunnel cleaning, restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.5.6.7.24 U Underwater anchoring-pylons-piers-lock gate structures . . . . . . . . . . . . . . . . . . 24 Underwater dredging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Underwater hydro-blasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Underwater abrasive blasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uniflux trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.22

4 4 15 23 13 22 22 1 17 22 12 22 23 11 4 19 4 5 22 12 5 22 22 22 21 22 22 14 12 12 12 12 17 4 11 14 21 4 12 23 23 23 23 11

(continued)

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(continued) Utility water tanks.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 U -tube heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Urea deposit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.21.23.24 V Vacuum-rotary dryer, steam jacket, vapor discharge pipes, spiral agitator . . . . 3.6.19 Vacuum dehydrators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Vacuum drum filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vapor dispersion trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vaporizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19 Vent condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum-ducts and piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19 Vacuum-filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum towers (refinery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.14.19 Vacuum vessel, hydrostatic testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Vapor line scale removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Vitrification furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 23.24 Vertical-flow plate precipitators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Vehicle service areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.21.24 Vehicular accident cleanup-remediation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.24 Vessels-autoclaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Veterinarian hospitals and animal sanctuaries . . . . . . . . . . . . . . . . . . . . . 2.7.19.24 Volatile substance removal and effluent separation . . . . . . . . . . . . . . . . . . . 2.7.23 W Wash water control, recovery, filtration, recycling . . . . . . . . . . . . . . . . . . . . . . . . Wash water evaporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water abrasive blasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water damage-remediation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Water gardens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.5.12.15.19.23.24 Water-film pipe precipitators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12.19 Water-tube boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14.19 Water tube package boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14.19 Water well cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Weld seam polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.23 Weld slag removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wastewater reclamation technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wood pulp removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19.21.22 Wet or dry air-filter bank installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Wood pre-staining preparations-color restoration . . . . . . . . . . . . . . . . . . . . . . . . . Wood cleaning, restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 Water proofing interior–exterior surfaces . . . . . . . . . . . . . . . . . . . . . . . . 2.5.23.24 Walk-in coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.24 Water tank cleaning, dehumidification, coating rehabilitation procedures . . 2.7.13.24 Warehouse loading docks, storage surfaces . . . . . . . . . . . . . . . . . . . . . . . . 2.19.24 Wineries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.21.22.24 X–Y–Z Zoos . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.4.5.6.7.8.10.11.12.15.19.21.22.23.24.25

22 4 22 22 22 11 11 22 4 8 11 22 14 19 3 11 12 13 22 12 22 24 24 23 15 17 22 4 4 9 18 18 24 11 11 25 25 12 12 12 12 12 17

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Chapter 3

Application Core Curriculum 1,000–55,000 psi

Abstract In detail reviewed are more then 25 major marine, industrial, and commercial complexes, explaining emerging and existing application techniques. When possible, the pros and cons of prior cleaning or product removal methods, rehabilitation, restoration and demolition practices are compared and referenced. All chapters feature an extensive application ‘‘gear-list authorization’’ which identify and outlines most necessary gear and tooling, including support equipment to manage purchasing, sales forces, and operators in their attempt to create a functional ‘‘gear-up list’’. When cross referencing between chapters ‘‘Introduction’’, application ‘‘register’’ and the ‘‘Application’’ core curriculum, everyone involved is equipped to interrelate independently with detailed business procedures. The book industry and job specific will introduce the all-important paper trail which begins with a job hazardous risk analysis, always followed by a trade ‘‘application review’’, and equipment ‘‘gear-list’’, guiding to a procurement-bid procedure to initiate a work order.

Pump horsepower, PSI 3 GPM: 1714 5 HP For intermittent duty, a gas engine must produce at minimum double the pump horsepower requirement For continues duty, diesel engines torque-power curve at its given rpm identifies the horsepower requirement Brick–block–stone–stucco and masonry façade cleaning, structuring, general surface preparation and restoration, hot and/or cold water, detergents 1,500–5,000 psi, at 2.5–5 gpm Surface pasting, airborne dust suppression, applying extended service, non-film forming seal applications, biosecurity, sanitizing, deodorizing, low or high pressure, down-stream W. Maasberg, Commercial-Industrial Cleaning, by Pressure-Washing, Hydro-Blasting and UHP-Jetting, DOI: 10.1007/978-0-85729-835-5_3,  Springer-Verlag London Limited 2012

Fig. 3a

Fig. 3b 247

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3 Application Core Curriculum

injectors (Fig. 3a), metering equipment 150–3,000 psi, at 0.005– 0.010 gpm plus Clinker–slag–coke removal (Fig. 3b), kiln–boiler–furnace cleaning, thermal-hot scale removal, cracking 5,000–55,000 psi, at 2.5–22 gpm plus Condensers or small tube heat exchangers (Fig. 3c), large tube heat-transfer units, after coolers, steam generators, three drum water tube boilers, ring exchangers, plate and frame type exchangers 7,000–36,000 psi plus, at 22 gpm plus, hand-held or automated tools, equipment Coating–paint–graffiti removal techniques on surfaces such as asphalt, concrete, masonry, structural steel (Fig. 3d) and aluminum, high-temp industrial coating-insulation deletion method, 2,500–55,000 psi, at 2.25–25 gpm, hand-held or automated tools and equipment Concrete-aggregate, cleaning–cutting–scarifying (Fig. 3e), heavy demolition, restoration and finishing, concrete removal-cleaning procedures on industrial equipment and vehicles with UHP equipment 10,000–45,000 psi, at 2.25– 60 gpm plus Dry–wet vacuum applications (Fig. 3f), dredging, emulsifying sludge, hydro-excavation, gravel cleaning, pumping fluids, dust-refuse or bio-product loading, transfer or removal of industrial product 3,000–7,500 psi, at 5–45 gpm plus Duct-work, canopy hood installation cleaning (Fig. 3g), acid and sanitary treatment, pipe cleaning prior to installation of liner systems and the coating of interior steel-iron pipes ([) 2,500–10,000 psi, at 5–45 gpm plus Directional–horizontal underground pipe installations (Fig. 3h), water well cleaning, water jet-grouting, pile driving 3,000–8,000 psi, at 10–45 gpm plus Expansion-control joint cleaning on rigid pavement, sidewalks, decking, tank and pool construction, grout–membrane– plastic–rubber–elastic removal (new product installation) 3,000–14,000 psi, at 5–22 gpm Filters, screens, felts, bag-house units, trays for catalyticcracking, vacuum suction rolls radiators-fin-fan (exterior), airpreheater baskets, staggered channel, wire mesh-plate-vane mist eliminators 2,500–10,000 psi, at 5–45 gpm, hand-held or automated tools and equipment Flatwork-surface cleaning (Fig. 3i), gas stations, banks, restaurants drive-thru, machine shops, warehouse structures, parking garage areas, and hangar facilities, vehicular–pedestrian tunnel

Fig. 3c

Fig. 3d

Fig. 3e

Fig. 3f

Fig. 3g

Fig. 3h

Fig. 3i

3 Application Core Curriculum

surfaces, etc. 2,500–7,500 psi, at 5–45 gpm plus, hand-held or semi-automated tools and equipment Hazardous industrial waste recovery and soil treatment, asbestos, radioactive trace element remediation (Fig. 3j), vehicular accidents and cleanup of crime scenes 1,500– 14,000 psi, at 2.5–45 gpm, including UHP services, hydro-vac and HAZMAT operations Hydrostatic testing of boilers-steam generators (Fig. 3k), gas and vacuum vessels, towers, tanks and nondestructive leak testing hydraulic systems 500–45,000 psi, hot or cold charge water volume delivered by plant supply or centrifugal pump Mold remediation, disaster cleanup, water damage-sludge removal, insect–pest suppression, odor–stench control 500– 7,500 psi, 2.5–45 gpm plus, hydro-vac systems, rotary surface cleaner, turbo nozzles, abrasive injectors, etc. Oil lube systems (industrial), tanks, oil compressors, hydraulic equipment services, light oil jetting, 1,500–4,000 psi; the gpm performance may vary as to nozzle configurations applied befitting the unit’s size and type. Ornamental–monuments, city fountains, theme-amusement parks (Fig. 3l) hotel and municipal pools, aquatic–marine pools and tanks 500–5,000 psi, at 2.5–10 gpm according to tool and application Polishing, etching, metal burr-flash removal (Fig. 3m), weld seam polishing, surface modulation 3,000–45,000 psi, at 2.5–22 gpm, utilizing UHP technology and hydro-abrasive blast equipment Sewers, laterals (Fig. 3n), culverts, sumps, industrial pipe cleaning, pipeline cleaning and high-Pressure-water abrasive cutting applications 3,000–45,000 psi, at 2.580 gpm plus. Steam–vapor–gas–flue stacks, industrial elevator shafts, laundry, garbage chute cleaning and sanitizing 3, 000–7,500 psi, at 5–60 gpm, various rotating and centered 2D–3D tank cleaning equipment Stationary—portable, industrial–commercial equipment, vehicle fleets, rail–car (Fig. 3o), truck–trailer–tanker trucks, hot and cold water, detergents, manual—automated equipment 2,500–7,000 psi, at 5–45 gpm, Tanks, vessels–autoclave (Fig. 3p) container cleaning, volatile substance removal and effluent separation 2,500–22,000 psi, at 5–95 gpm, hot and cold water, detergents, manual–automated equipment

249

Fig. 3j

Fig. 3k

Fig. 3l

Fig. 3m

Fig. 3n

Fig. 3o

Fig. 3p

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3 Application Core Curriculum

Hydro-abrasive blasting 3,000–6,500 psi (Fig. 3q), steel cutting-demolition applications, underwater hydro-blasting and dredging 3,000–45,000 psi, at 2.5–45 gpm Wash water control, recovery, filtration, recycling, wastewater reclamation technology, evaporation, hazardous materials cleanup, chemical rinse aids 2,500–7,500 psi, at 5–22 gpm Wood structures–roofs–decks–landings–fencing (Fig. 3r), wallboard cleaning, facilitating coating painting-preservation procedures, vinyl and aluminum siding cleaning, tile-asphalt roof cleaning 500–5,000 psi, at 2.5–5 gpm

Fig. 3q

Fig. 3r

3.1 Brick–Block–Stone–Stucco and Masonry Façade Cleaning, General Surface Preparation–Restoration On restoration or construction sites, most of us have witnessed brick cleaning efforts displaying a great dust cloud generated by dry abrasive blast operations. These clouds prove the shortcomings of an abrasive blast material which is either too fine, coarse or too sharp, hence possibly destroying brick glaze, mortar and masonry surfaces. The reuse of abrasive materials, a not so uncommon practice among contractors also furthers an uneven porous surface appearance and aided dust development. In addition, the developed dust clouds present a tremendous health hazard to all involved, including pedestrians in the immediate and distant vicinity. Wet abrasive blast methods, utilizing an air blast procedure employing a water mist to control dust expansion can discolor brick surfaces, thus requiring a secondary wash-down via high-pressure water resulting in mud accumulations unsuitable for delivery to a storm drain system. For cleaning purposes and in spite of its shaky validity, the abrasive soda-blast technique in operation is also identifiable by a possibly enormous white dust cloud spewing baking soda, unidentified coatings and the removed brick–concrete surface film (glaze) into the atmosphere creating its own specific hazardous environment is quite often applied for graffiti removal applications. Regardless of the so-called abrasive or micro abrasive cleaning method employed, it is a fact that adding a profile by disturbing the underlying surface being cleaned is not an acceptable criterion and can be catastrophic when applied to historic structures, stone and aged masonry within a cleaning or rehabilitation procedure. One will only hasten the attrition to surfaces substrate produced by soot, salts, acids, weather cycling, water, moss and/or possible mold recurrences. Sealing these failed and most likely contaminated surfaces with liquid sealers or epoxies only delays the deteriorating process and does not represent a restoration or cure-all for past environmental impacts. The last 40 years, unrivaled national and international restoration and/or cleaning successes stand in opposition to overzealous sales efforts by service

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Fig. 3.1 a Drywall before, b drywall after

providers, architects and restoration–preservation–rehabilitation officers. Some will offer chemical and abrasive cleaning solutions by overstating their novice opinion in suggesting that competitor’s high-pressure water cleaning operations are damaging to honed, textured or polished finishes on brick, block, exterior dimension stone, friezes, stucco, architectural masonry, composites and grout surfaces. Microscopic test procedures before and after jetting processes on these various surfaces have proven this opinion not only wrong, but also misleading. Opponents are still not aware that for instance, 3,000 psi at 5 gpm can be utilized to remove failing coatings from wide-ranging drywall surfaces with minimal surface wetting, avoiding the puncture and peeling of underlying drywall paper and gypsum (Fig. 3.1a, b). Also within this performance level a 45 fan nozzle at a 20 standoff distance is deemed perfect to gently remove residue from this operator’s fingernails. Further, microscopic tests have also revealed the importance of exploiting a technically matured fan nozzle design with a gpm–psi configuration specifically addressing the individual surface criterion encountered. A one size fits all nozzle application does not exist. Adhesion–bond–absorption–adsorption and the possible static attachment ability between a surface–substrate, deep-set stain or soot on encountered surfaces and architectural features under examination must first be determined (mildew, patina, dirt, soot, coatings, graffiti, chemical haze, oils, urea, salts, efflorescence-calcium carbonate, etc.). Once an optimal technical removal criterion is established a gentle environmentally correct and superior job completion is the positive aspect of any high-pressure water cleaning or restoration effort. This is especially a time-saving method when deep seated stains are removed following high-pressure water cleaning procedures utilizing poultice techniques under standard guide ASTM C-1515, and/or possible chemical and bacterial concentrate or liquid seal applications. To perform standard chemical application methods the economical exploitation of various metering devices is also of essence. Combining today’s high-pressure water variables and cleaning solutions with a refuse pickup, filtration and recycling capability most often renders past methods and preservation technologies too expensive or obsolete. Today, contractors cleaning exterior building façades and architectural surfaces for aesthetic reasons (Fig. 3.2a, b) speak to and offer application expertise to achieve the first line of defense against potential negative environmental, traffic, human and

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3 Application Core Curriculum

Fig. 3.2 a Masonry cleaning in progress

possible vandalism impacts which can include offering a regular maintenance program for normal care to control surface staining events. This required expertise differs substantially between new and historic structures. The façade inspection consists of a general inspection and detailed inspection in areas where the greatest exposure, surface contamination and possible damage exists. As part of a façade inspection, ASTM E2270-03 for unsafe conditions requires the review of an existing service history. Evaluating the masonry epoch (Fig. 3.3), type and prior applied cleaning techniques, their successes, or appearing damage which sometimes support accelerated deterioration of soiled surface substrate will subsequently guide every future cleaning or rehabilitation procedure. Besides environmental influences damage can be visibly identifiable by recognizing loss of surface stability and glaze, architectural detail due to prior aggressive chemical or abrasive cleaning techniques which also result in advanced surface friability, reduced adhesion and tensile strength of mortar and grout or a advanced interior degradation of brick, terra-cotta, masonry and block structure due to the remaining active chemicals, biological and/ or acid contaminations. When these types of failing conditions are encountered the chemical cleaning and physical scrubbing technique is deemed obsolete avoiding further surface deterioration. Surfaces susceptible to physical–mechanical chemical or forces are cleaned with neutralizing pressurized water only. When determining the PSI requirement to break adhesion or produce solubility of a specific product and surface soiling, the protection of the fragile surface is achieved by reducing the fan jet’s water volume (mass) to the point where a substrate surface modulation or abrasion by water velocity is null and void. The square footage cleaning performance is determined by fan jet coverage and standoff distance. Pressure washing equipment operating at 5 gpm, can also apply dual 2.5 gpm fan jets either individually or overlapping attached to a nozzle carrier (Fig. 3.4). Operating industrial equipment will permit the utilization of (Fig. 3.5a, b) multiple gun operators, accelerating job completion.

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Fig. 3.3 Brick variations

Fig. 3.4 Dual 2.5 gpm fan jets

Fig. 3.5 a, b Duel gun cleaning operations

The variables of a customers intent to clean or restore, and/or his comprehension of the naturally present patina (Fig. 3.6) including architectural character of his building components must be understood by contractor and architects alike. They must make sure that all cleaning and restoration efforts are performed to the mutually derived and agreed final visual appearance and necessary technical aspect. A customer’s possibly varying opinion or his second-guessing the effects within a jobs progression and subsequent appearing visual results while cleaning operations are still performed must not ever undermine the contractual status. Therefore, this situation demands a prior correct assessing of surface dilapidation, contamination and discoloration encountered.

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3 Application Core Curriculum

Fig. 3.6 Brick patina

Fig. 3.7 Water-abrasive cleaning

Various possible brick–block and stone surface manifestations can sometimes be suggestive and incorrectly preconceived by prospective customers when relating to a final surface appearance found sometimes unattainable by solely utilizing high-pressure water. Often customers’ visual guidelines or expectations are derived from past witnessed favorable surface appearances produced by abrasive and over aggressive chemical cleaning operations. A practical ‘‘demonstration’’ creating various test patches is highly recommended satisfying all involved by projecting an overall final appearance which permits also a closer understanding to required tool selections, time necessities or constraints and application processes. Contractor’s expertise will include the recording of the visual results and presentation of long term effects by extended weathering and aging of these test patches. Extensive rehabilitation procedures will almost always allow for test periods between 6 and 12 months, generally the longer the better. Coated, discolored or aged deteriorated brick, block, concrete and masonry surfaces often identify their environmental and structural circumstances related to their decaying or unsightly appearance on specific building areas (Fig. 3.7). These areas must be identified and, after repair–restoration procedures, also tested to adjust cleaning procedures to achieve surface appearance similar, or at best like the

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Fig. 3.8 Calcium efflorescence

predominant surfaces on the building treated. This also includes the identification of possible hidden metal and copper anchorage responsible for rust-copper staining events, or masonry blistering within or above the substrate. Rust stains or sheen developing during a cleaning procedure are often the result of an excessive iron content reacting with minerals delivered by blast-water to the substrate. It is imperative to check pH-values and trace metal content of the water supply especially when cleaning a light-colored porous stone and/or architectural features preventing a possible permanent discoloration as it is important to confirm the effective neutralization of all surfaces by rinse water with pH 6.6–7 paper (runoff). Also, besides controlling water runoff on façades, one must control wind swept acidic–alkaline misting to vulnerable and sensitive metal–aluminum frames, glass, various architectural components such as marble and limestone surfaces, wooden structures, cars, neighboring facilities and foliage within the work area. These applications and technical controls will often vary or be fluid according to weather and seasonal circumstances. In the course of unintentional chemical misting and favorable circumstances a prior incomplete chemical neutralization endeavor can also produce a mild etching effect on various surfaces. Also excessive evaporation and absorption of chemicals and/or blast-water refuse must be addressed immediately and monitored to avoid contamination and future surface soiling brought on by water hydraulics and evaporating contaminants (Fig. 3.8) to the masonry surface (aggravated by unknown chemicals, mineral efflorescence such as soluble salts, etc.) Conservation and restoring structures is of a specific nature where specialization justifies the addition of equipment for application processes such as for instance brick reversal or turning outside damaged surfaces to inner wall (Fig. 3.9), which includes the utilization of brick–block–concrete cutting equipment, abrasive blast applications and water-filtration–recycling equipment. Contractors involved must research structures diligently to general establish the following to parameters; tensile strength of brick and masonry (Figs. 3.10, 3.11) surfaces depth of 00 , this always varies substantially (friability) between job assignments due to environmental impact and past brick firing processes, which

256 Fig. 3.9 Brick inside out option

Fig. 3.10 Cementitious stucco

Fig. 3.11 Stucco after cleaning

Fig. 3.12 Pressure-washing procedure on swing-stage

3 Application Core Curriculum

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Fig. 3.13 a Efflorescence, b removed

are today much higher, leaving a historic brick (Fig. 3.12) highly susceptible to wrongful cleaning applications and chemical influences to their softer porous inner core (muriatic–hydrochloric acid); mortar grout strength to the depth of ‘00 , considering all general and hard to reach) or obvious specific problem areas. Establish necessary fan nozzle coverage (15 to 65) for problematic surfaces such as cornices and eaves, and/or test satisfactory pressure-water volume ranges for turbo nozzles and hand operated recycling-vacuum supported spin-jets to guarantee a gentle surface wash down while preventing ghosting, streaking, surface modulation or grout damage. Turbo nozzles must be managed with respect. This type of nozzle rotates with ultra-high rpm a angulated straight hard-hitting jet, producing not only cleaning but also a pulsating jet impact to the surface and can be especially damaging to low tensile strength masonry composites, wood, friable brick, sandstone and/or terra-cotta. This damage may occur starting at 1,000 psi plus to 2.5 gpm plus. Often the source of staining is an unknown. After removal of all surface contamination with a 15 to 65 fan nozzle design, the appearance of metallic stains may require a chemical reduction treatment which dissolves the metallic salts when rinsed away. Removing these reddish-brown stains (rust) probably of ferrous or ferric origination by embedded iron or steel fixtures located somewhere within the structure being cleaned can be problematic. Before attempting the stain removal application, the source must be identified. Rebar structures and metal fixtures buried within must be laid open to undergo isolation by applying coatings or plastic spray-on systems to all metal surfaces treated by hp-water, water abrasive-blast or UHP method. In this process, the removal of the moisture source to the metals must also be performed preventing future oxidation. Copper and bronze stains often found on roof and ornamental structures mostly identified by green or muddy brown surface discoloration are also caused by oxidation, moisture and/or excessive humidity. If stains are produced while generating a desired patina the source cannot be controlled. This leaves only the adequate surface cleaning and stain removal application combined with a possible clear coat or deep absorbing liquid seal system to the areas in question.

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Fig. 3.14 a Façade before, b façade after

Removing efflorescence (Fig. 3.13a, b) protruding from mortar on bricks, aggregate blocks, concrete walls and/or delaminating acrylic stucco and coatings from masonry surfaces including various stages of mildew development, ivy-vine surface penetration, rust-copper stains and/or heavy smoke stains from fire are all specifically identifiable applications well-suited for the pressure washing specialist. Most of these applications can be performed between 1,000 and 7,000 psi water only, especially when combined with a water pickup and recycling capacity. Although continuous hp hot-water above 212F can positively shorten removal times of various coatings on masonry surfaces and/or accelerate successful deepstain removal applications. After a disaster cleanup, remaining fire and smoke stains caused by wood or paper can best be treated with a solution of caustic soda (lye: sodium hydroxide), applied with either abrasive injector, chemical pump, metering equipment or downstream injector and/or by roller. Caustic soda is corrosive requiring adequate safety gear avoiding skin contact and tarpaulin procedures to protect all surroundings and/or sensitive areas from possible wind swept misting. Cleaning natural stone brick–block and aggregate façades and/or construction cleanup procedures on brick (Fig. 3.14a, b) and stucco walls can by considered the most simplest application requirement within this commercial or industrial facet but require attention in that soiled new surfaces can not be adulterated within the cleaning process. Nor can possible water damage occur to new products like window seals, glass, aluminum, wood and drywall. Many brick cleaners contain a small percentage of fluoride necessary to clean silicon oxide found in brick, granite and masonry surfaces. Precautions must be undertaken before a cleaning procedure by high-pressure water is initiated, since the possibility of etching glass and/or sensitive surfaces exists (particularly soft plate). It is recommended that glass windows, doors and anodized aluminum frames be masked with polyethylene sheeting. Sandstone, Brick, and granite cleaners should not be sprayed on windy days as they could be deposited on unmasked surfaces.

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Fig. 3.15 a Brick before, b after

Fig. 3.16 Brick cleaning before casement installation

When performing services on high-rise buildings, brick and masonry cleaning methods (Fig. 3.15) remain mostly equivalent to the application criteria developed for commercial buildings (two to eight floors, Fig. 3.16). Generally, brick surfaces are cleaned from top to bottom and versus chemical cleaning procedures which most often start sectionalized from the bottom up. This is to avoid a chemical attack on unclean surfaces which can result in permanent etching and discoloration of underlying surfaces. The practical application approach and variety of high-pressure water cleaning techniques is sometimes combined with a desired chemical cleaning process which varies drastically according to the range of building designs, their height, vehicle and pedestrian traffic, erection and obstruction by sidewalk canopies, seasonal weather-temperature, protection of

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Fig. 3.17 a Brick before, b after

surrounding foliage and environmental concerns regarding possible hazardous discharge to sewer systems, etc. Specific application directives are straightforwardly obtained by correctly evaluating the practical access and unobstructed tool utilization to surfaces in question. This includes the vertical–horizontal manual maneuver of spin-jet equipment supported by vacuum refuse equipment, generally exploited utilizing the existing scaffolding (pipe) in use by other trades. The lightweight, vertical 400 to 500 industrial vacuum hose assembly, tied to scaffolding in isolated hundred feet increments secured every 25 ft with tie-downs, is sufficient to deliver low volume water refuse to the filtration–recycling unit advantageously situated on the bottom of any building. Swing stage platforms in size of 8–50 ft as well as operations from boom or man lifts on building surfaces less than eight stories high are alternative access solutions. The ability to employ various masking methods (Fig. 3.17) to sensitive structural components with plastic sheeting, tape or liquid strippable masking products for windows and window frames, are some of the obvious identifying job criteria which furthermore permit the application of high-pressure water cleaning techniques on buildings overall surfaces. True is, that the introduction of high-pressure water applications has substantially abridged chemical cleaning methods by providing environmentally correct and superior time-saving cleaning solutions. It is untrue that high-pressure jets drive chemical solutions into a masonry substrate regardless of prior wetting with clean water to avoid excessive and uneven chemical absorption into a masonry substrate. This is not to say, that on ultra sensitive, damaged or decayed surfaces a two-step chemical cleaning process before or during pressure washing operations would not be beneficial to some specific job assignments (deep-set stains, surface crust-deposits). A correct chemical application is designed to neutralize itself within the reaction process, but its success also depends on a thorough rinse procedure. Acid with a 1.5 pH, applied to surfaces in question and upon satisfactory dwell time treated with a 12.5 pH alkali further emulsifying contaminants suppose to render the chemical runoff to a pH 7 solution. Chemicals are best

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applied by a separate low pressure pump facilitating ease of application, fluid volume control, unnecessary misting and a controlled dwell time procedure. This also means starting the rinse application from bottom up and then down ensuring that the runoff water and surface–substrate produce a neutral pH 7. Avoiding the two-step chemical cleaning method in a surface restoration procedure, pressure washing techniques can be enhanced today by utilizing organic chemicals (acids) designed with a buffer component, neutralizing the acid within the emulsifying process of identifiable stains and surface contaminants. These types of restoration chemical are also best applied by a designated secondary pump and can mitigate the brick saturation process with water. Rinsing all surfaces with pressures ranging from 500 to 3,000 psi, applying cold-water will neutralize surface–substrate and run-off water to a pH of 7. Operational variables such as chemical strength, volume, evaporation and saturation or the important chemical dwell time differ drastically within ambient temperatures encountered on a jobsite. The blanket statements that historic brick buildings are highly susceptible to damage from muriatic acid (hydrochloric) can be considered quite outdated since the application of raw undiluted acid does not exist within a restoration chemistry. Hydrofluoric (acid) restoration chemistry holds a far greater potential for damage to surfaces and substrates (if not precisely administered) than correctly diluted hydrochloric acid. The decision to apply either the scraping method versus high-pressure-water to remove mortar residue on new brick surfaces is only undertaken due to varying adhesion and mortars’ possible chemical surface interaction, which may result in visual ghosting situations due to the permanent damage or etching–softening– discoloration by mortars saturation and dwell time. After the scraping procedure, the use of acid is often unknowingly–knowingly applied to achieve a visual blending effect between disturbed and undisturbed surface appearances. New brick can be very hard on its exterior and will without doubt tolerate the direct removal of most construction residual within a construction site cleanup procedure. In this case, the weakest and most sensitive areas are utilized to identify the important psi–gpm baseline configuration which can vary drastically between various tool configurations (nozzles). Most likely determined and adjusted to concrete–grout surface strength and brick edge–corner tensile strength, avoiding all possible scenarios of high-pressure water damage determines this gpm–psi configuration which must then also permit the total removal of all mortar spatter and various construction residuals. On new construction sites, indifferent pressure-washing operations responsible for the removal of excess mortar, efflorescence and general construction contaminants sometimes bear the blame for bricks’ excessive whitening, metallic and/or brownish staining. Most often this occurs when a specified proprietary chemical and its intended accredited cleaning procedure by a site architect and/or brick manufacturer is inaccurately applied. Under these circumstances the liability of a pressure-washing contractor is immediately thought of or at best made suspect to the appearing visual faults. This inquiry will point to possibly none or inadequate surface wetting procedures, excessive atmospheric cycling, humidity–heat,

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Fig. 3.18 Brick staining

excessive chemical dwell time, and/or inadequate rinsing-neutralization procedures or the commencing of pressure-washing applications before the curing of concrete–masonry–grout is complete (30 days plus if at all possible). It is always of benefit to a pressure washing contractor to be aware of an applied grout–mortar product, which varies dramatically between brick and stone installation requirements. The mix proportions can sometimes be analyzed or revised to resist a possible leaching scenario from its color, lime or Portland-cement constituents. Architects and construction site managers should not forget that the culprit may also be the metallic elements in clay responsible for creating various visual effects. These metals being soluble by acid may also result in the spread of tarnish-staining across brick surfaces more often visually stronger on brick face top and bottom joints. Neutralizing the acid with an alkaline liquid–hydroxide solution is successful, but it will not remove the created stains. Rather, in the drying-evaporation process it develops a salty white residue across a brick surface, which is removed with pH neutral high-pressure-water, after a chemical is applied to re-dissolve the existing metallic stains. Excessive metallic activity on various brick surfaces can also originate from incompatible mortar–masonry applications, unprotected brick transportation and unidentifiable storage environments subject to various harmful environmental conditions. Brick staining on new construction is most often reversible but best avoided first of all (Fig. 3.18). The preeminent protection guarding against the unknown is education and research prior or alongside a jobs procurement procedure. This starts with identifying the brick and its manufacturer to possibly retrieve their cleaning recommendations, which most always recommends not using any type of acid. Nevertheless, when researching their product recommendations, most often their label and MSDS information will refer to some sort of acid (probably thinned-buffered). As a result leaving the unsuspecting speechless reminding us that the specialist is always the pressure-washing contractor. Also, regardless of cleaning techniques applied the contractor must avoid all technical application circumstances which can be made responsible for inconsistent surface appearances and ghosting possibilities. One will at a distance first survey all surfaces in question to identify any adhering organic debris, mortar smears, paint-coating spatter, adhesive contamination, cement dust accumulations and specific concentrations of concrete–grout construction spatter. These mortar concentrations are more likely noticeable in the spatter area of the masons’ scaffold-plank board which during the building process moves

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horizontally upward in 4–6 ft increments. A scrape crew must systematically remove all spatter; protruding mortar smears and, in short, all materials which may seal a brick surface possibly promoting an uneven absorption–adsorption rate and/ or fan-jets surface dispersion other than the rest of the unimpeded brick fascia. The crew will mainly utilize wooden spatulas–paddles–scrapers and hard organic– plastic brushes, removing all surface contaminants as uniformly as possible, including the areas of soffit, eaves, gables and possible exterior insulation and finishing systems which often require their own specific cleaning procedures. Again, stepping away from the cleaned–scraped surfaces will help to more effectively identify irregular uneven surface appearances before the actual washdown commences. Also this cleaning process should include scaffold boards prohibiting repetitive spatter during the final rinse process. It is important to pre-wet or better saturate all brick surfaces equally avoiding a disproportionate sponge like chemical absorption. This also insures that the applied chemical remains on the brick surface to be cleaned negating discoloration by bricks soluble trace elements and/or excessive chemical absorption (squander). The best chemical reaction results are achieved when the product contains a strong surfactant permitting the chemical to adhere to surfaces for an extended dwell time by controlling its runoff. Surface damage and discoloration are the result when permitting solutions to dry. Particularly on hot days, dwell times should not exceed 2 min. Pressure-washing brick surfaces in increments from the bottom up, applying a 25 to 65 fan nozzles with an approximately 20 ft stand off distance to surfaces utilizing 2.5–5 gpm per wand at pressures adjusted to the necessary stain removal threshold at the recommended stand off distances will permit a very speedy and gentle job conclusion. Stain removal and brick cleaning operations are concluded when buildings top row is reached and the rinse cycle with pH neutral fresh water begins from top down utilizing an appropriate nozzle standoff distance. Also the controlled sectionalized rinse off cycle now includes all surfaces from eaves, cornices, window frames, etc., and requires periodic testing of surface and its runoff water to its neutral pH 6.6–7 balance (paper). After verifying the sufficient and important surface–substrate drying time and result by considering also the possible entrapment of water vapor in specific or prone areas within the substrate structure, concrete–masonry, terra-cotta and brick surfaces are treated with either breathable barrier and/or breathable water repellent deep penetrating clear (Fig. 3.19) or pigmented non-film forming coatings. According to exterior exposure, climate and architectural desires, applied coatings are solvent or waterborne and can be applied, by airless paint applicator systems and/or water injector method. Cleaning procedures on high-rise buildings require sometimes extensive highpressure hose assemblies. Identifying the psi losses within a high-pressure hose assembly recognized as pressure drop or friction loss can simply be done by removing the nozzle from its gun barrel retainer and actively operating the hp-gun, avoiding nozzle restriction. The necessary psi-energy is correctly identified by equipment pressure gauge when the direct displacement pumps max operating rpm is maintained. A pressure gauge with a sufficient incremental readout incorporating

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Fig. 3.19 Brick before and after sealing

Fig. 3.20 Limestone before– after

a male/female quick-coupler armature attached between a pump heads discharge fitting and the first hose assembly is an alternative evaluation procedure identifying the psi requirement when pushing a water column throughout an open hose-tool assembly. Adding the indicated psi necessity to the equipments standard max operating pressure will permit the evaluation for added horse power input prerequisites. Piston–plunger pumps by force deliver high-pressure water equally throughout any system. The only question is the horsepower essentials, identifiable by an engine and pump overload scenario when internal friction becomes excessive. This technique is most practical for all pressure drop evaluations concerning a hose-tool assembly, since it includes the hp-hose length and restricting hose fittings, friction losses by internal gun or tool designs and distant job locations, and is inherently far more precise than a mathematical explanation often presented by various application enthusiasts. It will not identify nozzle design efficiency or required standoff distances to surfaces cleaned. Before a cleaning solution by high-pressure water for natural stone and its substrate in question can be offered the requirement exists to correctly identify the stone’s architectural intended purpose and possible origination. Marble, granite, limestone (Fig. 3.20) or slate in their widely varying commercial applications, such as interior and exterior wall cladding, interior or exterior paving, curbing, pool and

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Fig. 3.21 Chemical application

Fig. 3.22 Cleaning and rinse cycle

statuary applications must be correctly identified as to their original architectural surface structure and present soiling and/or aggressive surface contaminants. Siliceous stones–rock are quartz based stones such as granite, serpentine, slate and soap stone, and, under normal conditions are easy to clean. Calcareous stones are travertine, onyx, marble and limestone which are susceptible to liquid— chemical detergents at levels other than pH 6.6–7. Therefore, high-pressure water cleaning and rinsing of these stones is the preferred cleaning method. Stains in stones are likely of organic and metallic materials or of an oil–grease saturation nature. Most deep-set organic stains will require an oxidizing agent such as peroxide or commercial–household chlorine bleach in various solution ratios to water. Again, deep-set stain removal processes on marble and limestone substrate are similar and often only vary in the chemical being applied (non-acidic). Limestone–marble contain calcium carbonate and are very sensitive to chemicals, especially to acidic cleaners. Chemical application specifications (Fig. 3.21) are established only following high-pressure water removal of all surface contaminants and upon a dry and/or wet substrate ensuring that any products used are specifically formulated for the limestone and marble deep-set stain removal application (ph-neutral non-ionic detergent, light bleach or ammonia water solution). At the completion of the cleaning process the stone is properly rinsed (Fig. 3.22) and left free of any residual alkalinity or acidity. Limestone and marble can be pre-cleaned using high-pressure water at 500–3,000 psi with a 25 to 65 fan nozzle at 2.5–5 gpm. After the adequate drying, stone cleaning applications are often finished by applying water repellent, penetrating but air permeable sealer.

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Fig. 3.23 Dry and stabilized art deco

Cleaning outdoor pool, hot tub and patio areas (moss and algae), with pressures from 2 to 5,000 psi up to 5 gpm hot or cold water utilizing a turbo nozzle or fan-jet assembly can be supported by suppressing future growth in applying a mild household bleach treatment after the moss, fungus and algae are removed. At times, where a stone is blackened it may be necessary to pre-clean with an alkaline product starting from the bottom of the building or structure working upward. The product can be applied by brush, spray applicator, roller or pressurewashing gun, moving from natural break to natural break. Following a 3-min dwell time, the alkaline solution can be rinsed using the above mentioned pump performances. It is recommended that a mild acidized cleaner be utilized after the alkaline cleaner has been thoroughly rinsed. This acidized cleaner and subsequent rinsing will remove any inorganic residual contaminants and ensures that remaining alkalinity is neutralized. Under certain conditions, such as extreme friability of a monument (Fig. 3.23) stone surface as often found in cemeteries, rinse pressure can be reduced to equal a kind of rubbing–brush–bristle stroke category. Also excessively weakened, decaying brick or porous configuration specifically stone can be treated with an stone strengthening and water repellent air permeable solution, which when absorbed does not equal a coating rather will slowly cure within the stone structure providing enhanced physical stability when dried. Lightly soiled limestone seldom requires the alkaline pre-cleaning process. Remember, limestone and marble substrates are semi-self-cleaning stones and are most often best maintained by high-pressure water cleaning operations with varying pressure and water volume adjusted to surfaces encountered requiring no further chemical treatment. Many areas of a building are never exposed to water. Nonetheless, over a period of years, encrusted black substances, chemically identified as calcium sulfate, will form under eaves, cornices and belt courses. Unfortunately, the few chemical cleaners that attack these encrusted areas also attack the surrounding calcium carbonate. Therefore again high-pressure water equipment can be applied to

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Fig. 3.24 Pores limestone, clean and dry

Fig. 3.25 Soiled limestone

dissolve the calcium sulfate by a prolonged and repetitive soaking with plain water (atomized). Final removal is achieved by applying a pressure-washing gun at 500–3,000 psi at 2.5–5 gpm with fan nozzles at 25 to 65. Prior to commencing a soaking operation, a building must be inspected for areas most susceptible to inner water seepage. All areas where water could penetrate are caulked and covered by plastic. City or well water should be tested to determine their mineral content and pH value. Cascading water with a high mineral content may cause stone to discolor. In-line water treatment and filters are available to remove excessive amounts of minerals. Water utilized for cleaning should always have a neutral pH value of 6.6–7. Excess acidity or alkalinity will also affect the minerals in the stone and can later be possibly responsible for surface discoloration appearing at some stage within the water evaporation and surface drying time-frame. The use of nonferrous tooling is recommended within this type of cleaning–restoration application. The position of nozzle carriers will guarantee even coverage over all calcium sulfate areas and, if the timeframe demands, securely fastened to scaffolding. The prior wetting, soaking, intermittent jetting or continuous mist (atomized) spraying process always commences at the top of a structure. Never forget, that in soaking operations, foundations must be protected to prevent leakage into basement areas. Also masonry cleaning can be quite seasonal. Porous substrate (Fig. 3.24) is vulnerable to freezing and thawing (cycling) as is the repair or repointing procedure of mortar joints which commonly will not commence with temperatures below 40F and above 90F. More often than not are the aggressive air pollutants (Fig. 3.25) not the only contributors to surface soiling and structural deterioration

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on restoration and/or preservation sites demanding a variety of trades working alongside in harmony. Treatment of contaminants such as iron oxides (rust), copper stains, urea, or removal of coating–paint and sealants are identified by historical architects as they also identify the method of removal and utilization of specific chemicals and their application. Historical commissions providing a funding grant may maintain a direct review involvement to guarantee projects scope, which includes verifying the performance criteria by all trades involved within a restoration procedure. Architects employed by a historical commission will work closely with construction site architects to guarantee strict adherence to agreed plans and specifications identified at the pre-bid conference, combined with contractors insurance-bonding and can do qualification statements, guaranteeing work methods and results. Generally the project philosophy to clean a historic masonry, brick, marble or limestone structure is to remove and/or neutralize the visually changing and possibly destructive contaminants such as carbon-soot, acidity, algae, fungus, molds, paint and coatings, etc. while not damaging or altering any of the original masonry design, stone tooling details, texture and adjacent joint’s grout surface integrity. The contractor should always exact precise application procedures determined by architects as to the practical validity, and desired tool applications. This includes reviewing carefully the chemical manufacturer’s literature, or best, consult with a representative as to their opinions and product warranties. Application variations must always be discussed in the mandatory pre-bid conference to their validity avoiding discrepancies brought to the architects’ attention after work has begun. Often an opinion may develop during the inspection of an existing condition on a historic building site which may speak to or dispute one or various proposed application techniques. This can include a hidden performance problematic when working in unison with other trades. The scope of work and specifications for masonry cleaning and historical brick restoration may include, besides cleaning and a sealing performance, a limited mortar joint repair–installation and/or replacement of pigeon control systems, etc. Added trade involvements require attention. Specifications will be identified such as masonry restoration and cleaning; and under the division; special conditions; required miscellaneous services which call for reasonable customary conformity inherent to restoration requirements involving all trades including that of a pressure-washing contractor. Coordination of work with other trades, and the continuous protection of the portion of work performed during a cleaning and restoration procedure must therefore always be addressed and can result in a fluid, quite varying application criteria. The pressure washing contractor must also be careful to address the final construction site cleanup. Various trades produce various waste materials, stains and possible surface contamination. In addition to his operational cleanup provisions he can consider and possibly include his required time and expertise to wash and polish glass inside out, remove foreign matter, marks, stains, foreign paint, caulking, fingerprints, soil and dirt from painted and/or decorated stained work, or on hardware fixtures and equipment surfaces found on exterior or in interior areas. This cleanup provisions are very important and can be quite substantial demanding

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Fig. 3.26 a CMU block before, b CMU block coating removal, c CMU block after

time and equipment necessities best identified within the contracts general conditions. New or old buildings regardless of stone or masonry structure are most often designed to consider basic airflow–heat loss and water vapor migration through the buildings envelope, consequently protecting structural components as well as guarding against damage produced by mildew and/or mold growth. The contractor is well advised to study typical insulation, vapor and air barrier designs including façades brick–stone iron (beams) straps, anchors and/or wall retainer systems and their possible locations. Often when deviating from an original building design, the subsequent changes to the air to air transmission coefficient resulting from restoration procedures and/or erection of structural additions, obscures or mistakenly encloses critical areas. This can perhaps produce an unforeseen mitigating path for mildew–mold development as it may also divert water or vapor penetration to unexpected building areas. There are distinct differences between vapor and air barrier systems which vary regionally in their design criteria. Various flashings, cavity flashings and present weep-holes, their locations including drainage configurations for buildings inner to outer envelope which include the identification of interior to exterior gravity drainage locations into the public main sewer installation are all factors to be considered in a well developed job description. Information on air–vapor barrier design technology can further be researched on the Internet, http://www.airbarrrier.org When the need arises to clean concrete masonry units which are smooth or split-faced (CMU) block walls (Fig. 3.26) high-pressure water is always superior to any other cleaning method including the application of all chemical techniques. Most often these structures require services not due to weathering or general soiling but more often due to the removal necessities of graffiti-tagging, surface preparation for coating or masonry work and/or an existing coating–paint delaminating problem. The latter, most likely due to substandard adhesion created by environments within the block wall cavity, responsible for producing an elevated moisture vapor transmission through the wall. Chronic increases in moisture vapor pressure carrying calcium salts to the outside surface of the wall forming a visually visible efflorescence is typically accompanied by coating cracking and peeling along block joints and block surfaces which include accelerated coating damage on the building side more susceptible to thermal cycling (south side versus north side). The nature of concrete block’s porous surfaces is ideal for the utilization of a

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Turbo nozzle operated between 2,500 and 5,000 psi at 2.5–5 gpm hot and/or cold water. Turbo nozzles inherent variable angle intensity permit the cleaning and removal of coatings in deep crevices, concrete voids and pores and will always outperform the abrasive blast technique. Manually operated, vacuum supported spin Jets are also ideal due to the added potential of refuse separation, water filtration and recycling capacity. When aged and deteriorated coatings are to be removed, the reasoning might not only be to provide a sound substrate for a new coating application. Aesthetic reasons can be the motivator to leave a substrate uncoated and exposed or else an existing coating contains hazardous materials as lead and heavy metals preventing remodeling or demolition procedures and/or sometimes existing coatings are damaging to a substrate by limiting adequate moisture release (non-breathable) accelerating structural decay. The selection of required tooling and job essentials depend on the condition of the substrate, the type of coating encountered, adhesion to and penetration into the substrate, number of paint layers and elasticity–tensile strength factors. In general, applying high-pressure hot-water above 200F utilizing a 15 to 25 fan jet or Turbo nozzle is the preferred tool combination effectively outperforming coldwater combinations at 3–7,000 psi. If it is found to be lead paint, which is becoming one of the most recognized generally hazardous materials one will find, that a comparatively low-cost coating removal application is disproportionately obscured by necessary product-refuse handling and deletion costs due to enforced local and federal lead abatement–disposal regulations. There are several methods to determine whether paint contains a toxic level of lead. Savvy contractors will always carry a household swab test kit to possibly justify a further refined test procedure. Testing can be done with a portable X-ray fluorescent analyzer or a sodium sulfite solution. The most reliable testing is achieved by utilizing an atomic absorption spectrophotometer. Samples of paint are analyzed by state-commissioned laboratories. Separating refuse from blast-water and recycling the blastwater through a phosphoric filter assembly permits a concentration and volume reduction of the lead (heavy metals) containing refuse. Contaminated paint forces contractors to identify, contain and package the compressed refuse according to the law before a transport to a hazardous waste incineration or deposit site is possible. For exterior lead abatement, the high-pressure, low-volume water removal method sometimes combined with a periodic chemical initiation process offers several advantages over expensive snail’s pace chemical removal operations. Lead-free paint can be removed without the involvement of a hazardous material handling regulation in particular when water recycling and refuse filtration–separation equipment is utilized. Nevertheless the accumulation of a refuse volume must be understood as to its potency and possible health risk. Although graffiti removal is included in the coating removal chapter, it is impossible to determine an adequate cleaning procedure without on-site testing, for the artist vents his creativity on the most unimaginable surfaces. Difficulties arise due to the virtually unknown paint medium, often a solvent based product penetrating into substrates porous surfaces or various coloring products adhering to a vast variety of painted surfaces, which must first be tested as to its structure and

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GEAR - LIST AUTHORIZATION Brick - stone - stucco - masonry cleaning, structuring, restoration Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Fig. 3.27 abrasive-blast equipment

Purchasing:

Engineering:

Maintenance:

Safety:

Tel:

Tel:

Tel:

Tel:

e-mail:

e-mail:

e-mail:

e-mail:

Job Description: Job Location: Job Review Performed by:

Job Site Risk Assessment:

Specify:

Base structure: Granite:

Marble:

Sandstone:

Limestone:

CMU block w. Slate: Brick pavers:

Exposed aggregate: Exposed concrete slab: Travertine:

Sand surfaced brick: Concrete: Brick:

Stucco-synthetic: Steel-iron: Other:

Scale - stain - coating - paint type : Efflorescence: Graffiti: Lead paint: Mortar: Epoxies: Oxidation: Lead: Toxic contamination: Environment:

Test:

Urea, organic-growth: Mildew: Iron oxide (rust-copper): Fungus-mold: Grease-oil: Other: X-Ray fluorescent analyzer: Sodium sulfite solution:

Industrial:

Existing structural damages: Patch testing: Methods:

Commercial:

Residential:

Explanation:

Chemicals: Cold high-pressure water: Hot high-pressure water º F:? Water abrasive blasting: Steam cleaning:

Products: psi: psi: psi: Temp:

gpm: gpm: gpm: gpm:

Nozzles: Nozzles: Nozzles: psi:

Total sq footage below 10 ft.: (ground up) Total sq footage above 10 ft.: (platform?) Scaffolding: Structural circumstances: Vegetation: Steel-copper fixtures: Drains, drainage:

Boom lift: (bucket)

Tarpaulin procedures:

Traffic-pedestrian control: Other:

Aluminum fixtures: Overhead power-lines: Vehicle traffic-pedestrian:

Describe application and work procedure: Wand extensions, water filtration recycling, vacuum supported spin-jets, turbo nozzles, etc.: Itemize equipment: safety gear, expendables, labor time, equipment times, etc.

possible friability. There are some surfaces which permit the utilization of a crystalline (Fig. 3.27), inert, odorless and water soluble abrasive product, calcium carbonate powder (baking soda) or a minuscule amount of Portland cement powder and possibly nutshell grain products providing a buffing, slightly abrasive surface treatment when combined with high-pressure water (abrasive injector).

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The chemical industry provides many useful cleaning solvents. Applied are only the ones which provide maximum paint removal capability while discouraging ghosting (the faint outline of graffiti in pores). Should ghosting appear the aforementioned cleaning techniques are effective. Used brick suppliers may view the hydro-blast method as the most innovative cleaning procedure available today. Bricks are laid in tight formation and blasted between 2,000 and 7,000 psi at 2.5 to 5 gpm with a 20 to 65 fan or turbo nozzle. Tight brick formation is essential to the preservation of edges. The industry has developed a variety of tools that apply high-pressure water at lower volumes, achieving a much higher square footage performance rate than previously possible with spray bars. The industry refers to these units as whirl disc, rotary jet carrier, spin-jets, rotating ramp carrier, surface jet mill and turbo nozzles. Their designs are intended to be mobile or in a hand-held configuration either air, hydraulic or self-propelled. Some will feature a vacuum capability combined with a refuse collection, and water-recycling filtration unit. Such state-of-the-art tools are vital to any successful surface cleaning process and often will totally eliminate the need for chemicals. Brick restructuring or antiquing is achieved by conventional water abrasiveblast methods. Brick glazing is removed by exposing porous, sometimes, colorful, uneven structures. The coarseness of the blast medium applied at pressures ranging from 3,000 to 7,000 psi is the determining factor for the final surface structure. For brick hardness, surface strength and information on composition; Information on the Internet; Water proofing-repellent, non-film forming silicone and epoxy compositions for concrete, exterior brick, stone and masonry surfaces. The Brick Industry Association, http://www.gobrick.com, EIFS-synthetic stucco, http://www.exterior-design-inst.com, The Stucco Manufacturers Association, http://www.stuccomfgassoc.com, The Portland Cement Association, http: //www.cement.org, National Concrete Masonry Association, http://www.ncma.org

3.2 Surface Pasting, Airborne Dust Suppression, Liquid Non-film Forming Seal Applications, Biosecurity, Sanitizing, Decontamination, Foaming–Soaps–Detergents–Acids Cleaning and/or restoration complexities or lack of necessary psi–gpm performances may require a chemical metering process supporting pressure-washing or water-jetting endeavors. Furthermore, there are various mitigating factors justifying the tool expenditure and subsequent specialization in application technology. Injector proficiency can support a coating and paint removal task, deodorizing and/or solid odor counteracting technique and the application of breathable liquid penetrating sealers to concrete–masonry–brick–block and wood surfaces. In the transportation and agricultural environment chemical injectors and foam generating equipment may be of importance to apply insecticides and herbicides, alkaline and/or acids to various surfaces. Commercial and industrial environments may be in need of bulk oil–grease and/or deep set stain removal applications of the

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same, or the utilization of flash rust-corrosion inhibitors, phosphatizing iron-steel surfaces to enhance paint bonding criteria and/or providing biosecurity-sanitation as well as fungus-mold inhibitors. Incorporating the equipment for polymer jetting procedures or various decontamination practices in commercial, industrial and nuclear industries (power plants) requires extensive technical and fluid-dynamic knowledge facilitating the correct usage of this equipment. In discovering today’s viable pressure-washing and hydro-blast cleaning characteristics, the major chemical manufacturing industries have as yet to set and create adequate practical application guidelines for customers favoring highpressure water tool technologies. Therefore the application technician must hone his chemical application curriculum by recording all past job experiences and results creating his or her practical information base. In-depth knowledge and characteristics of contractors’ equipment and tool performances (gpm–psi) in relevance to a variety of successfully completed application histories which also takes into account all encountered surfaces–substrates, their uniqueness and job specific application circumstances such as chemical dwell times and rinse procedures, weather, temperature and humidity, etc. The first upstream–downstream injectors were utilized by Leonardo da Vinci for delivering paint to his canvases. Today there are five mechanical methods to introduce various liquids to a pressurewasher or hydro-blast water stream. Upstream injectors introduce liquid chemicals to the water suction side of a unit either directly into the water supply hose before the introduction to the float tanks ball or water metering assembly or between the float tank and the pump water intake. Both methods will permit only the additions of liquids negating coagulation, depositing chemical constituents, generate abrasiveness and/or foaming characteristics. Adding a liquid polymer to the blast-water reducing water turbulence created by inferior nozzle designs in focusing its water jet is an example as is the adding of sodium nitrate for flash rust suppression. Also in upstream metering processes, utilizing excessive chemical acidity must be guarded against. Keep a light chemical viscosity to avoid coagulation by insuring proper mixing with water. If the upstream metering method must be used, consider purchasing and installing a metering pump operating at approximately 125–150 psi with flow adjustability from 0 to 1 gpm. These chemical pumps are electrically actuated via a float mechanism, pressure switch, or series flow switch sensitized by the trigger-gun operation. Metering pumps operating at 24–115 V or air-hydraulic driven are readily available. The discharge line of a metering pump may be installed directly into the in-line suction orifice of a hydro or pressurewashing pump. Recently, most pressure-washing and hydro-blast systems feature a trigger-gun operation allowing the operator to commence water jetting at will. In the off position, an automatic pressure regulator will bypass and return the produced water volume to the suction side of a hydro-blast or pressure-washer unit, either into its water storage tank (float tank), or directly into the pump head suction orifice. This operational method creates a basic problem for most upstream metering functions installed between float tank and pump head. The necessary vacuum is created by a pressure reduction in the water supply line restricting the

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free flow of water to the pump head. A flow restrictor is strategically installed into the suction orifice at the bottom of the water storage or float tank. The volume of chemicals allowed entering the suction side of a pump head is regulated by a needle valve. Preset, adjustable, or solenoid-operated valves are available with a performance range of ten parts water to one part chemical up to 240 parts water to one part chemical. The applicable ratio also depends on viscosity and various specific fluid characteristics. A one size fits all chemical application setup does not exist due to technical and application varieties. Contractors wishing to utilize such a chemical injector method must be aware of the following; any water flow restriction to the suction side of a pump is disturbing. It is a known fact that such restrictions enhance cavitational effects. In time, accelerated cavitation will damage pressure regulators, valves, pistons and their packing and include the gear-end when a gaseous-compressible water medium is encountered (pressure-stroke). Dubious also is when the trigger-gun in off position signals to the pressure regulator or pressure relief valve to return chemically-admixed water to the storage or float tank. This facilitates foaming and/or air saturation added to the already chemically admixed by-pass water (internal water velocity). Avoiding further introduction of chemicals to the by-pass water within the closed trigger-gun position, some manufacturers return this by-pass water directly to the suction orifice of the pump head, equalizing the vacuum otherwise maintained between restrictor and pump head suction orifice, thus stopping chemical draw from the chemical valve. Manufacturers in their efforts to prolong pump life discovered that saturated bypass water returned directly to pump heads suction orifice can cause, besides cavitational damages to valves, pressure regulators and packing, a thermal shock to ceramic plunger sleeves. Evident especially when prolonged jetting intervals occur and jetting operations are continued introducing cold water to excessively heated packing-sleeve surfaces. Due to their elevated rpm configuration piston pumps are not suited to build a vacuum on their suction side, nor are they generally matched to pump viscous chemicals exceeding jetting waters specific weight and friction characteristics. Overall, the upstream chemical metering method is at best limited therefore contractors are destined to compromise. Regardless, gravity feed procedures are more common than one admits, although continuously adding chemicals to the storage or float tank causes eventual damage to equipment. Job variety can result in chemical variety only accelerating such damage possibilities. Downstream injectors (Fig. 3.28) situated on the pressure side beyond the pressure regulator, burner assembly and thermostat on hydro-blast or pressure-washer units have the operational advantage that chemical, detergents and acid contact with equipment internals is avoided. The disadvantage is that most downstream injectors are operational only by reducing the hydraulic pressure within the highpressure hose. This is performed by adjustment of a dual wand assembly shifting from jetting nozzle to an oversized nozzle reducing systems operating pressure, or by utilizing a variable pressure single wand nozzle affixed to the trigger-gun assembly. Most often an injector adjustment must also be performed with every hp-hose addition compensating for the Hp. Water in added fluid friction-drag and

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Chemical-detergent Tubing-barb Chemical flow adjustment

Check valve-ball Vacuum chamber Spring Bernoulli, reversed nozzle-

Hp.Water in

Nozzle

Fig. 3.28 Downstream injector

mass. Depending on the injector’s design, Chemical volume control is recognized to be quite inconsistent or at best difficult due to variable chemical viscosity; and chem.-hose length. Injector performance can possibly be rendered altogether inoperable when the hp-hose and gun assembly requires more then 220 psi water transfer pressure impeding the necessary vacuum development of 35% plus reduction of systems operating pressure. Only when recognizing the actual gpm jetting performance is a precise metering function possible. A variable dual or single lance-wand extension permits a low-velocity, low-pressure application for the all important chemical dwell time. Most injectors are adjustable, dispensing one part chemical to four parts water (up to 1 part chemical to 240 parts water). There are operational disadvantages to downstream injectors. Less sophisticated injectors do not dispense chemicals beyond 150 ft of hp-water hose length. Accumulated friction losses and flow restrictions in hp-hose assemblies will not permit the necessary pressure drop of 35% plus actuating the injector. On hot water machines an erratic injector operation can be caused when lowering the waters boiling temperature under reduced pressure. Chemical injectors’ functionality will also be compromised when installed in opposition to intended waterjet flow. Injectors are sensitive to chemical caking, fluid impurities and have a marginal acid resistance. Chemical applications and operation of chemical injectors is best guaranteed by an experienced operator. Excessive hp-hose runs or pressures above 200 psi require an in-line high-pressure chemical inject or (Fig. 3.29), which can be installed to the first or any hp-hose assembly including the last nearest to the jobsite and trigger-gun operator. This psi performance combined with the injectors’ precise metering function supports most all application varieties.

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Fig. 3.29 In-line highpressure chemical injector

High-pressure water Vacuum chamber

Chemical tubing-barb

Fig. 3.30 Abrasive injector, pressure-washer

Unnecessary chemical usage and accidental misting is always of great concern. To create and achieve a celled foam matrix to support various dwell-resident times of a desired chemical or detergent upon a surface–substrate the industry developed a foam nozzle technology utilized most often within the food industry, or for biosecurity applications in agricultural environments and automated vehicle–truck and/or rail–car wash operations. The various available foam nozzle designs prove quite insufficient within the pressure-washing and hydro-blast application palette. Pressure-washing and hydro-blast applications in commercial and industrial environments often require a far greater nozzle standoff distance to surfaces facilitating a quick and practical chemical application not achievable with dual wand or foam nozzle technology. Converting water abrasive injectors (Fig. 3.30) and concrete cutting heads to chemical injection-foaming devices has proven quite successful in providing a superb nozzle stand off distance. Displacement pumps at their given operating rpm permit a precise chemical metering function. Due to ultra-high nozzle velocities (Fig. 3.31) within the vacuum chamber, a super tight foam matrix is produced, while misting of surroundings is Chemical tubing-barb dramatically mitigated contributing to a far greater nozzle stand off distance and area coverage otherwise not obtainable (300% plus). Because of increased chemical resident-dwell times, the ease of visual surface coverage-assessments, the achieved greater nozzle stand off distance between operators and surfaces in question, or the desired advanced product foaming parameter and/or superior water jet rinse impact renders this injector type quite indispensable. Tool or equipment application simplicity can be specific within

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Fig. 3.31 Converted cutting head

High-pressure water

Vacuum chamber

Chemical tubing-barb

Detergent Chemical tubing-barb Chem.-nozzle Vacuum-diffuser chamber High-pressure water

Fig. 3.32 High-capacity injector to 7500 psi

certain industries, as for instance, decontamination in nuclear power plants, where vacuum generating high-pressure water will carry one part chemical which is combined with a chemical introduced on the vacuum or discharge side of an injector. In contrast to chemical injectors, they create a much higher vacuum and airflow ratio. These commercial and/or industrial water abrasive blast units function more like a jet pump to convey the otherwise necessary abrasive supply. The possible chemical fluid draw can also be 2–8 times higher in fluid volume than the necessary amount of water to operate an abrasive-blast (Fig. 3.32) or concrete cutting as is the vacuum development between 2200 and 3100 of mercury (In HG.). Controlling the chemical volume is achieved by a simply predetermined and sized chem.-nozzle or in operating a needle valve assembly to adjust the chemical supply by volume or flow. Mix ratio is determined by calculating pressure– washers or hydro-blast units’ gpm performance and actual desired chemical volume added per minute or hour. In general, jet-injectors are the extension of a trigger gun wand-barrel assembly isolating chemical contact to the injector assembly. Therefore, material compatibility, acidity, flammability, abrasiveness and viscosity are of secondary concerns. Injectors offering a superior chemical compatibility are readily available. The inherent advantage of this injector type is that the chemical fluids accelerating into the injector’s vacuum-mix chamber greatly diffuse the actual jetting

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Fig. 3.33 Gas station area

Fig. 3.34 Waste stream recovery

impact. Injector design permitting, jetting impact can also be manipulated by a steady measured air flow to the chemical suction hose or vacuum chamber. Exterior–interior area decontamination by sequestering radioactive metallic ions and suspending these particles in a two-step procedure permitting a flushing– pumping–rinsing and wiping application, or cleaning–removing and suppressing mildew and algae contamination by utilizing a sodium-hypochlorite treatment, and for grease or tar deletion by applying caustics such as sodium or potassium hydroxide can be considered the industrial application utilization of this type of injector. Performing flat work (foaming), such as on gas station areas (Fig. 3.33), drive-thru’s and in large parking facilities or for dispensing bactericides, disinfectants and sanitizing products in agricultural environments, and/or pasting walls, dust suppression on floors and open gondolas (trucks–trailers, railcars) including performing disaster cleanup procedures and fire restoration applications can be considered the commercial utilization. When applying high quality, penetrating and high foaming biodegradable chemical concentrates, designed to react with greases, fats, wax and carbonized materials to either dissolve or emulsify them, water–chemical ratio and predetermined dwell times must be precise. Their general mix ratio to water for a light soiled condition is approximate 80:1, a moderate to heavy condition diluted 50:1, and where heavy wax, grease and carbon deposits are present diluted 20:1. It is important to realize that a high-pressure water cleaning application performed with fan jet, turbo nozzles or spin jets will remove 98% of all surface contaminants. The resulting waste stream (Fig. 3.34) derived from cleaning gas stations, fast food and bank drive-thru surfaces, parking facilities and pedestrian traffic areas,

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etc. will most likely result in a hazardous waste stream classification, especially when an emulsifying agent has been applied. This will require the utilization of a mobile water filtration and recycling unit. Controlling and preventing all created discharge to enter adjacent sewer systems or open grounds is imperative. Metals such as cadmium, lead, and copper can interfere with reproductive cycles of fish, invertebrates and other aquatic life, as does turbid water affect the growth of aquatic plants by reducing available sunlight and the smothering of bottom dwelling aquatic organisms. The generating source of pollutants by motor vehicles is transferred, and therefore includes the accumulated refuse discharge from parking lots, gas stations and drive-thru areas. Hydrofluoric, phosphoric and Nitrilotriacetic acid, sodium–potassium hydroxide, are ingredients found in various concrete cleaning products and includes Meta, Para, and Ortho-Xylenes compounds found in various biodegradable concentrates. These trace elements must always be removed from all surfaces within a high-pressure water cleaning application. Most of today’s water repellent silicone based technologies, providing non film forming; deep penetrating product applications (breathable sealers) for stucco– masonry, concrete, brick and stone surfaces are manufactured as either water or solvent borne identities. Preferred for their environmentally correct and safety advantages, water borne products are most often applied utilizing the water injector method due to minimal volatile organic compound emissions (VOC). This application is most often intended to protect and enhance the look of exposed concrete, stucco–masonry, brick and stone surfaces. Solvent borne products are most often applied with manual pump-up sprayer units or paint-coating equipment. In transport to and from a jobsite all solvent and water-born products, including chemicals in liquid or dry form must always be identified and accompanied by a material safety data sheet, utilizing OSHA’s hazardous communications standard 29 CFR 1910.1200, recognizing the chemical manufacturer’s name, hazardous ingredients-identity, physical and chemical characteristics, fire and explosion hazard data, reactivity data and conditions to avoid, health hazard data, precautions for safe handling and use, which does include product control measures. When acting in response to operational mishaps or accidental releases, the liquid product jetting and vac-jet recovery is an excellent application technique when dry, viscous or liquid bulk materials–products are returned to their manufacturing process or containment. Providing this cost effective and measurable product recovery solution by circumventing further contamination of products in question is quite alluring to maintenance personnel as is the equipment utilization when flammable or volatile substances are present and they must be removed or transferred. Final cleanup endeavors after a bulk removal on remaining surfaces are also most often subject to decontamination and/or sanitation procedures by any one of these five chemical injector methods. Equipment effectiveness relates directly to pump horsepower-input, requiring a minimum of 20 horsepower to enter this application field. General commercial and industrial product transfer applications demand a 45–150 hp plus jet-pump drive.

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The removal of contaminants, corrosion and condensation and/or water entrapped within a hydraulic-oil or lube-oil system is a variance of this application curriculum. When an appropriate scale removal and corrosion neutralizing application is performed utilizing possibly pre-heated turbine light oils or applying heating oils, diesel fuel and liquid chemicals, which include jetting with soda-ash brine or if slurry-emulsifying techniques are applied, fluid knowledge and fluids structural behavior patterns expressed in abrasiveness, viscosity, specific weight, flammability, compressibility, foam-ability and acidity must be fully understood. When using liquids other than water, extreme caution must be taken to protect the pressure-washer and hydro-blast unit’s gear-ends. Fluid handling should best be supervised by a chemical fluid engineer. The fluid-end (pump head), packing, o-rings, hoses and trigger-guns must be compatible with desired blast media. Piston pumps, the heart of a pressure-washer or hydro-blast unit, utilize high-grade materials resistant to most common fluids within this application. Incompatibility of packing structures will result in brittle or softening of packing materials. This should not create a problem as compatible packing is available through packing or equipment manufacturers. Products passing through the packing structure (packing glands) are best collected in buckets or returned to unit’s suction tank via a small portable air, hydraulic or electrically-driven pump. Electrically-driven pumps can be used only in the absence of volatility and fire or explosion hazards. First and always disconnect the ignition system by removing the power cable or belt drive from the generator when pumping flammable products through a pressure-washer and its hot water burner assembly. Due to ignition source and heat generation, gas engine pump-drives are incompatible with most applications. Flammability and compressibility (psi) must always be a known parameter. Anything above the specific weight and viscosity of water will force a reduction in pump-engine rpm. Most applications do not require more than 1,800 psi operating pressures. The rpm reduction will keep velocity and valve timing under control. At all times, the operation must be within the frame of the gear-end and motor’s rpm-horsepower performance curve specified by its manufacturer. A secondary pressure regulation and fluid oriented adjustable safety valve combination must also be included with most every application encountered. Polymer jetting methods are regarded by most operators as mystical. Mechanically-charged polymer water reduces the ongoing cavitational process by providing a fluid drag reduction to valve and pressure regulator surfaces, pistons, ceramic sleeves, packing and nozzles. Scientists have developed liquid additives capable of reducing up to 50% of the liquid drag found in these high velocity areas. This is especially noticeable in units operating above 3,000 psi. Operators recognizing a dramatic improvement in nozzle standoff distance especially when inexpensive cylindrical nozzles are utilized, which are generally designed for approximately 3,500 psi operating pressure and are quite common to the pressurewashing and hydro-blast industries. A 200% increase in jet nozzles standoff distance can be expected. High quality cylindrical nozzles with operating pressures up to 36,000 psi will achieve up to a 35% improvement in standoff distance. The nozzle manufacturer’s all-around knowledge in physical fluid technology

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(Bernoulli’s theory) and his mechanical production capabilities are most often responsible for vastly varying differences in nozzle-jet performances. Regardless, high-pressure water containing a 0.3% polymer additive enhances the nozzle standoff distance improving its water-jet structure. When in the market for a polymer metering device, it is important to recognize their operating precision. A polymer imbalance, whether positive or negative of a 0.3% solution, diminishes all advantages gained. Employing a trigger dump-gun design is not advisable; polymer costs are too high. To avoid a breakdown of the emulsion, storage and operating temperatures must be kept at 40–90 F. During operation, polymer hydration time following continuous injection to the system’s suction tank must never be less than 2.5 min before actual use. Polymerization of pressure-washing or jetting water is highly debatable. Operating costs compared to the contractor’s chargeable hourly rate are generally not profitable. It is also quite difficult to convince operators that adding polymers will accelerate a job completion. Consider a test with polymer-charged water when an extremely hard scale removal application must be performed and necessary tooling and psi–gpm performances are not available. Generally a fluid drag reduction is not of an advantage when high velocity water is responsible for removing coatings, corrosion, concrete and resilient industrial products etc. By industrial standards, hydro-blast equipment produces an comparatively low fluid volume within its high pressure water application. Therefore, in the mid 1950s, the conversion to function as a hydraulic power source for the general mining industry developed into a feasible market identity (oil emulsions). Operating hydraulic systems, hydraulic cylinders and self-adjusting shields (longwall) in the performance of tunneling procedures was the first application criteria within the mining environment. Today, most hydro-blast equipment is simply converted to permit the pressurized transfer and circulation of oil emulsions, or on the jobsite facilitating the service requirement to operate a trigger-gun and variety of nozzlelance and flex-lance assembly’s. The utilization of oil-based pressurized fluids is of importance when tankcleaning applications or slurrification-agitating procedures are performed gaining necessary liquid–viscous product transfer characteristics to exploit the hydro-vac transfer, pumping and product separation method, or providing product feed to various industrial pump equipment and tank car–truck identities. This important application capability is especially helpful when oil-based products such as hardened bunker-seed and tar pitch require agitation to gain a semi liquid consistency dramatically enhancing removal times, or utilizing pressurized heated turbine oil for cleaning and removal of metal remnants in failed oil compressor gear-box equipment and their bearing lube oil supply and discharge pipe systems, including contaminated oil storage facilities. These application entities can be found in power plants, refineries, chemical industries, or on marine vessels and barges, in ship-holds and product storage facilities throughout the commercial and industrial complex. Generally pressures between 800 and 1,800 psi at 5–20 gpm tempered or heated oil is sufficient. Speciality nozzles, controlling oil vapor–mist effects are of necessity in confined areas or spaces.

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GEAR - LIST AUTHORIZATION Biosecurity, sanitizing, decontamination, chem. - concentrate applications Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location: Job Review Performed by: Downstream chemical injector:

Job Site Risk Assessment:

Specify:

©

Dual wand injection: Single wand-adjustable nozzle:

Through abrasive injector: Foam nozzle: Upstream injection: Pump-up sprayer: Chemical metering: Chemical metering pump: Admix to suction tank: Through flow restrictor suction side: Other: Other: Biosecurity Decontamination Neutralize Acidize Sanitize Polymer jetting: Polymer metering pump: Polymer quantity: Polymer hydration time: Chemical classification: MSDS: Explain dwell-resident time : Viscosity: Specific weight: Flame-ability: Compressibility: Foam-ability: Acidity: Water borne non-film forming, breathable silicone sealer: Solvent borne sealer: Identify surface structure-friability and nature of substrate: Rinse procedure: Water-waste stream, filtration-recycling equipment: Verify essential tooling: Safety procedure: PPE-safety gear: Water-ricochet arrester device Itemize equipment: expendables, labor time, equipment times, etc.

‘‘Pasting’’ is described as a process which suppresses, fuses and seals or confines industrial dust and powder-like products in any given area. Hydro-blast applications in coal transporting tunnels and storage units, various product transporting systems, dust suppression in manufacturing environments, foundation cutting applications, etc. are in need of this pasting process. Wind whipped dust may impede a manufacturing environment and is unanimously considered a breathing-health hazard, which may also in accumulation form a highly-unstable flammable or explosive environment (substance). When working in such an environment, most often dust suppression is deemed necessary. The service provider–contractor should employ the formula of lowest fluid volume times its highest pressure; this produces a mist–fog matrix, applied either individually with a trigger gun and fog–mist nozzle assembly or with fog–mist nozzles affixed in a series to a rigid lance. Railroad cars transporting mine tailings or coal dust pass

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Fig. 3.35 Water arrester, components-tooling

Fig. 3.36 Water-ricochet arrester device

through a stationary pasting unit to mist the open loads and fuse the outer dust– product skin; when desiccated protection against product loss by whipping-air velocity and subsequent unnecessary dust development is achieved. The hydrounit’s suction tank or an upstream injector is utilized when a dust-suppressing solvent or paste such as calcium-chloride is chosen (with a specific weight of 1.23 kg dm3). When deciding on a dust suppressant chemical it is important to verify the liquid product’s, low viscosity (water like), foam-ability and lack of abrasiveness to protect the pump’s fluid-end (valves, etc.). The constant water-dusting procedure is also applied in the suppression of airborne asbestos while performing dismantling, removal or packaging procedures achieving a low waste product wetting factor. A continuos air monitoring and sampling device must be worn to record and prove adequate air purity while performing this application. A simple water-ricochet arrester affixed to operators shoulder in close vicinity of nose–mouth-respiratory protection (Figs. 3.35, 3.36) will protect filter test paper from water-ricochet. When sealing earthen walls-cavities to prevent water seepage into the adjacent ground or structure by providing and constructing a confined blast-water and refuse pick-up basin, airless coating spray systems, available most anywhere are perfectly suited to apply viscous sealing compounds which prove especially handy in small, confined areas when foundation cutting applications are practiced (rubber, plastic, foam).

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GEAR - LIST AUTHORIZATION Surface pasting-fortification, airborne dust suppression Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location: Job Review Performed by:

Job Site Risk Assessment:

©

Tank cleaning: Dust suppression: Bag-house areas: Silos: Food processing vessels: Foundation cutting: (pump cavity) Mine tailings: Asbestos removal: Storage unit: Rail cars: Other:

Industrial area: Mining industry:

Refinery:

Chemical industry: Other: Equipment: Upstream injector: Downstream injector: Spray-bars: Nozzles: Specify: Other:

Specify:

Orifice size: gpm/psi.

Hydro-blast unit: Pressure washer: Airless paint sprayer: Water-ricochet arrester device Other:

Method: Slurrifying:

Bunker-seed removal: Pasting process: Dust suppression:

Agitating: Transfer oil emulsions: Oil -temperature-viscosity:

Other:

Viscous sealing compound:

Specify: rubber, plastic, foam, etc.

MSDS:

Dust suppressing solvents:

Specify:

MSDS:

Chemicals:

Specify:

MSDS:

Abrasiveness: Viscosity: Foam -ability: Combustible: Describe application and work procedure: Itemize further equipment, PPE-safety gear, expendables, labor time, equipment times, etc.

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3.3 Clinker–Slag–Coke Removal, Kiln–Boiler–Furnace Cleaning, Thermal-Hot Scale Removal (Cracking) When producing cement, etc. the continuously operating rotary kilns and mini kilns may sooner or later develop a product ring adhering to brick refractory reducing kiln’s internal diameter, resulting in an accelerated product movement throughout a unit’s interior. Due to this, internal temperatures will also raise disturbing kiln’s temperature profile to undesirable levels during the manufacturing process. Extreme material accumulations may completely block the internal diameter in radial direction, forcing a production shutdown. The 1950s method, to precisely aim a Remington cannon toward the clinker obstruction in a cement kiln (Fig. 3.37a, b) is not only outdated, but also very costly due to production time loss, shell and labor costs. The hydro-blast cleaning method embodies the thermal shock principle. High-velocity, cold-water jets fired in short bursts (water bullets) from a heavy lance (schedule 120 plus) in appropriate length, usually 150 –600 or up to 900 causes a thermal shock, cracking and breaking the cement clinker while the kiln slowly rotates in its production cycle. In this process, relatively small water volumes are applied conveying no appreciable cooling effects to the refractory and kilns internal operating temperature. The nozzle carrier (hard-hitter) pointed at a 5 to 10 angle produced by a curved 20 lance tip extension will strike the clinker obstruction directly avoiding all water jet contact to refractory. As the kiln rotates, the lance will position itself enabling tool operators to precisely manipulate the nozzle with a minor rotation of the trigger gun-lance assembly (outer perimeter to the center of the kiln). A minimum of 10,000 psi and no more than 19 gpm are the input requirements. Cracking rock-like formations while in a jetting operation, the general kiln clinker movement can momentarily bury parts of a rigid lance, which is considered an operational prerequisite. Clinker impacts to the lance assembly can be quite violent and will, do to kilns rotation, loosen right-handed straight or tapered thread assemblies (NPT); therefore, all lance couplers are machined and feature a counter thread (straight, preferred metric non-tapered left) to prevent possible loosening, water leakage and/or loss of lance. The kiln in rotation will naturally remove material from the obstructed lance permitting the constant movement necessary to pinpoint, within a jetting procedure, clinker formations adhered to the refractory structure maintaining a 600 to 1200 nozzle standoff distance to brick formation. To protect the lance from melting or deforming a constant pulse cleaning method is adapted to guarantee adequate cooling by blast-water passing through. Undesirable deposits also appear in the kiln’s suspension and grit pre-heaters which may further prohibit the uniform production distribution throughout the chute and grit cooler. To accommodate structural exterior and kiln’s interior circumstances within the removal of various clinker formations, the correct sizing of a hydro-lance and trigger gun assembly must be performed. This is facilitated by an array of high-pressure lance accessories in increments of 50 , 100 , and 300 , befitting the strategically placed service ports permitting adequate access to all

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3 Application Core Curriculum

Fig. 3.37 a, b Cement kiln

important areas. Regardless of application, an aircraft grade steel-alloy lance material enhances tensile strength (up to 50%) and is superior in flexibility factors (bend and kink) in comparison to all other useful materials. Seamless, stainless steel tubes may outperform carbon steel by 25%. It is not unusual that red-hot clinker fragments are hurled with great explosive velocity into the operator’s area. Operators involved are to dress in fire-retardant, or best, in full fireproof safety gear featuring integrated heat and shock resistant eye protection (filter strength similar to a medium–heavy welding glass). Due to extreme heat, never allow a non-operating lance to remain in the fired kiln. It will result in irreversible lance damage. Fossil fuel utility boiler: Clinker–slag development on the fireside of a fossil fuel utility boiler (steam generator) can be dramatic when the coals defined purity, firing, airflow and burner tip conditions, excessive service requirements or power utilization drops below the generator’s operating specifications. The time frame for a clinker mass development is quite circumstantial and may develop over 12 months or possibly within a 24–48 h time frame. While in operation the early detection and clinker poking phase by maintenance personnel maintaining the fire room’s process, maintenance engineers will in an emergency situation consider the simultaneous clinker–slag removal by hydro-blast thermal shock method. Protecting suspended boiler tubes and the slag-ash grinder assembly from catastrophic clinker collapse possibly damaging the vital interior which includes the throat area of bottom ash hoppers or hoppers inner area depending on size of the firebox is their intent. Power plant personnel involved with furnace slag removal which is also referred to as clinker poking are almost always aware of the critical areas and considered next to maintenance engineering department the best info source for a contractor. The hydro-blast removal method is also superior to the explosive blasting method in that the thermal shock application permits the adequate sizing of clinker debris in a controlled effort not to overpower the tube and grinder assembly. This stands also true when a clinker removal application is performed

3.3 Clinker–Slag–Coke Removal, Kiln–Boiler–Furnace (Cracking)

287

under a general plant shutdown situation (off-line) and various hydro-blast technologies including a rotary nozzle design criteria is exploited. A clinker formation may develop from the bottom near the grinder assembly upwards or be suspended within the tube structure which can include the area of the burner assemblies. Inspection, service and overhaul access on boiler and steam-generators are situated upward of grinder assembly to the burner assembly area and are utilized to orient the lance-base armature to the required internal clinker areas. A counterweight located below the catwalk balances the jet’s recoil forces, thus enhancing the operator’s overall lance control. This permits lance operators to reach all developing clinker formations, including all of the lower temperature areas which are visually recognizable by a dull reddish pipe–clinker–slag tone (especially found in the unit’s corners and bottom sections of the fire room). Approximately 10,000 psi, 30 gpm satisfies most circumstances encountered. 8,000 psi, 30 gpm have proven adequate in 80% of removal procedures, but is unsatisfactory when hardened clinker bulk disrupts its own flow to the grinder section of the unit. When hardened clinker bulk is encountered efficient cleaning time is of utmost importance. Apply the thermal shock method to all flowing and rigid materials, avoiding excessive interior cooling. A quick, operating response is essential and supported by a predetermined sizing and exterior placement of necessary high heat lance extensions fitted with quick couplers (trigger gun assembly) and situated near service ports as are all necessary high-pressure hose armatures are pre-installed. To offset the constant temperature loss within a continuous and sporadic jetting procedure is it important to establish a periodic, possibly ‘ hourly time cycle to regain max operating temperature to then again remove clinker–slag flow restrictions and buildup starting at the cooler-cold side of a formation. It is essential to maintain the highest possible operating temperature to effectively clean and extract the available coal dust energy. Providing services to utility companies may require the utilization of 75–250 hp pump capacities, operating an array of industrial hydro-blast tool selections which can include dredging tools, sludge and dry product vacuum recovery equipment and supporting tanker–trucks. Waste-oil, waste-product incineration utilities: Icicle-shaped ring deposits and incrustations appear every 60 –100 in oil sludge burning systems where temperatures may reach 2400 to 3000F. Furnace lengths range between 250 and 350 and depending on the make and type, measure 60 –80 in their internal diameter. Incrustations are more likely to be found on the fireside of the units. A 200 highpressure rigid lance (schedule 80) and a unit at 7,000 psi and not more than 16 gpm are sufficient when removing these incrustations at full operating temperature. The thermal-shock clinker-ash removal method is also offered to the commercial–industrial waste and BIO fuel incineration–heat producing industry. Refinery coke drums and headers; in short, all coke-handling equipment, including their chromium pipes (800 plus circumference) can present a problem when contractors are not aware of the job location. The operator’s free movement may be restricted by physical heights, restrictive locations and encountered horizontal and vertical distances between hydro-blast unit and actual job site and last,

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but most important, the extremely hard and more often glazed adhered product found throughout a system’s interior. Coke shakers and their screens are comparatively simple to clean; 8,000 psi, 16 gpm is adequate and best applied with a 25 fan nozzle. To bridge horizontal shaker distances which are possibly up to 250 , a 00 rigid lance (schedule 80) with T-form dual orifices neutralizing the nozzle’s recoil forces enhance the operator’s control and work procedure. When cleaning refineries chromium pipes the following aspects are considered: vertical heights, pipe diameter and overall length, coke products tensile strength and adhesion, and to prevent scale streaking appearances or events the correct nozzle and jet’s standoff distance from the product-pipe wall. The contractor applying 20 two 36,000 psi at 9–15 gpm are the fortunate ones, especially when rotary-nozzle carriers reduce water jet standoff distances from the pipe work. Manually-operated block and tackle (’00 ), such as those utilized offshore, permit an endless rope-feed and present a comparatively inexpensive application method. Block and tackle are simply installed to the center of pipe structure to lift and transport nozzle carriers and/or ultra-high-pressure hose assemblies to any desired height or distance, eliminating the physically strenuous and otherwise possibly dangerous pulling techniques. Furthermore, this method permits the contractor to correctly accomplish the cleaning procedure by pulling, in controlled increments, the ultra-high-pressure hose assemblies, including the sometimes rotating nozzle carrier assembly slowly upward throughout the pipe system from the bottom of any given unit and in its wake producing a perfectly clean interior pipe surface. There are companies specializing in providing rigging assemblies of interest when repetitive work can be guaranteed or intended which in design is similar to smoke stack cleaning fixtures–apparatuses. When coke drums, headers, flanges, etc. cannot be cleaned with ultra highpressure water or a minimum of 14,000 psi, abrasive injectors such as concrete or steel cutting heads can provide effective removal of coke from steel surfaces when utilizing fine-structured or non-grit soft blast materials (soluble abrasive). This method also effectively polishes steel surfaces within the cleaning procedure. It is often found that interior pipe surfaces exhibit previously inflicted damage, therefore presenting a higher adhesion factor which escalates the material buildup when transfer processes are in action. A rigid lance fitted with two steel–concrete cutting heads in T-form (neutralizing the recoil forces), equaling approximately 500 ‘00 width, will allow material removal practices wherever rotating nozzle carriers may not be applied. The hose delivering soluble abrasives is affixed to the high-pressure water hose assembly. Mill scale removal: Metal industries engineering groups are constantly striving to optimize the surface quality in their production of products in hot-rolling mills. The hydro-mechanical mill slag-scale removal method is not considered a contractor’s cleaning application rather an equipment manufacturer’s specialty. Steel industry product and process varieties also constitute within their mill slagscale removal practice high-pressure water quench procedures to remove the excess mill slag-scale by thermal shock. Red-hot iron leaving the rolling mill is

3.3 Clinker–Slag–Coke Removal, Kiln–Boiler–Furnace (Cracking)

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GEAR - LIST AUTHORIZATION Clinker-slag-coke removal, kiln-boiler-furnace cleaning, thermal-hot scale removal (cracking) Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail Job Description: Job Location: Job Review Performed by:

Tel: e-mail

Tel: e-mail

Tel: e-mail

Job Site Risk Assessment:

Rotary kilns: Grit pre-heater: Suspension pre-heater: Grit cooler: Chute: Steam generator: Boiler: Grinder assembly: Equipment: Hydro-blast unit: Schedule 120 lance sections: 5 -10 lance radius: Specify: Hydro-trigger gun: Lance extensions: Specify 5’, 10’, 30’, (ft): Fire retardant-proof safety gear: Heat-impact-proof filtered eye protection:

Oil sludge burning furnaces: Garbage incineration: Coke drums: Chromium pipes: Coke-shaker screens: Flanges: Hot rolling mill: Others:

Lance-recoil eliminator: T-lance: Nozzle carriers: Roto-spin jets: Specify: Rope-block and tackle: Abrasive injectors: Other:

Product encountered: Hazardous material: Describe application and work procedure: Itemize equipment, safety gear, expendables, etc.

Specify:

Specify:

Length: Specify:

Nozzle centralizer:

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3 Application Core Curriculum

introduced to a water fan-jet treatment under various water pressures. This starts with a stationary placed hydro-unit, producing from 300 to 14,000 psi and stock width depending 10–200 gpm. The forced rolling mills high-speed red-hot stock is introduced to a water fan-jet configuration mounted in an overlapping nozzlejet pattern to a stationary spray-bar armature creating the quench process by thermal shock. Water volume is kept to a minimum avoiding or better controlling the cooling and/or production chill factors which are possibly a manipulative capacity as their production process may call for. Some companies prefer to install pressure accumulators throughout their system to arrest the flow characteristics customary to piston pumps. The hydro-power is delivered by spray-bars mounted across the rolling stock’s face. The nozzle standoff distance determines the location of the nozzle spray-bar from the rolling stock and is selected and tested in the production process before the final nozzle fixation is completed. The applied fan nozzle degree, orifice size and horsepower–psi configurations are the determining factors. To ensure the water’s pinpoint and thermal shock capability, the fan nozzles must be of the highest possible quality supported by very clean water. Mill scale, a thin layer of brittle iron oxide can be removed with high-pressure water (35–55,000 psi) but this is not a function of a thermal shock to its surface, rather, it is a function of erosion produced by high velocity water jet. Combining this with unmanageable cavitational influences involving imploding gaseous water molecules upon the mill scale surface results in a irregular product removal function and pitted surface appearance. The removal rate with highpressure water of tightly adhered mill scale is commercially ineffective compared to available alternative means such as for instance by water abrasive blasting. Where mill scale adhesion or its interface appears in areas sporadic, lifted or eroded by corrosion and/or demonstrates a rust development within its formation, high-pressure water is very effective and of interest especially when surface tolerant coatings are to be applied.

3.4 Condenser or Small Tube Heat Exchangers, Large Tube Heat Transfer Units, After Coolers, Steam Generators, Three Drum Water Tube Boilers, Package Boiler Services Condensers, boilers, heat and small tube exchangers (Fig. 3.38) are found in all major industries. Refineries achieved a certain independence acquiring contractor services by developing and installing stationary semi or fully automated tube bundle cleaning systems (Fig. 3.39) which service 1–6 units at a time. Nevertheless, major plant shutdowns produce a large exchanger variety in numerous service locations providing job opportunities to contractors well versed and tested in this industrial environment. Service providers utilizing high-pressure water as a tool also transferred their manual operating experience to semi or fully automated and mobile equipment available in various configurations. This type of equipment

3.4 Condenser or Small Tube Heat Exchangers

291

Fig. 3.38 Various boiler and condenser designs

potential can only be manipulated to its fullest capacity when manual cleaning methods and their criteria concerning condensers and heat exchangers is fully understood. The procedure of tube cleaning is categorized into 4 steps starting with scale removal of the outer circumference (shell-side), including all tube surfaces into the center of unit, and is completed by cleaning the tube sheet of all products and gasket materials. Shell-side cleaning is also the least strenuous and time-consuming procedure. Product consistency and adhesion factor, the volume of product and physical tube design encountered will determine the technical form by which the external tube cleaning method is performed. Service location, bundle rotation and general accessibility, bundle exterior tube circumference, quantity of tubes and their formation, existing damage such as deformed tubes or sagging bundles and the actual width between tubes is a consideration. U-tube or straight tube design, products chemical category, as well as product hardness, adhesion, viscosity and hazardous categorization, the outer circumference fouling and characteristics toward the center of the tube bundle and finally necessary safety procedures are all determining factors which must be thought of in order to optimize the bid procedure, tool selection and work method. Manually cleaning condensers or heat exchangers outer tube circumference is considered tedious work (into the center of the unit); however, in most cases it is quite simple. The water-jet penetrating adhering debris or product structure tends to ricochet materials and deflected water into the direction of the trigger-gun operator, diminishing visual control, forcing him to rely on imaginative and systematic body mechanics. It is also imperative that all tube surfaces come in direct contact with the water jet operation. This again is achieved by a four-step jetting procedure and the controlled rotation of the tube

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bundle being serviced. It is also helpful to identify and visually mark the cleaned tube area to ensure operators effectiveness; waterproof coloring pens or soft wires are good marking utensils. Refrain from utilizing heavy marking objects such as bolts due to the fact that the jets water velocity might accelerate them into a dangerous projectile. Most hydro or water-blast tool manufacturers supply short 10 –60 ft, 00 in diameter ([) trigger-gun extensions which incorporate a nozzle (round jet, hard-hitter) in such a way that permits the lance and nozzle retainer to fit between bundle tube structures. This achieves a shorter nozzle standoff distance from the product and results in a higher jet impact, especially helpful when large and compact tube bundles are serviced or exceptionally adhering and/or hard resilient materials are encountered. In order to prevent renewed material adhesion to a cleaned surface, tar or sticky viscous materials must be suspended. Soapy or thinning additives are metered into the blast water. The common practice to heat blast water by introducing steam to a water supply or suction tank of a hydro-blast unit to mitigate tar-like products further adhesion possibilities will with certainty accelerate pump damage not only to the fluid-end, but also to pump’s gear-end structure. Operating pressures generally vary between 2,000 and 22,000 psi, 5–19 gpm per flex-rigid lance assembly. An ample amount of face shields or tear-off visors, rain gear (PPE) and duct tape are absolutely essential. For various reasons, next consider the cleaning of both tube sheets and their specific areas (bolt holes, threads, gasket areas, and tube overlap). Because a visual identification of possibly plugged tubes is impossible when servicing U-tube condensers, a simultaneous identification and marking of plugged (clogged) tubes on the tube sheets face is necessary during cleaning procedures. The verification promotes adequate safety precautions through the correct use of hydro-tools and further supports a better estimate for a job completion. Contractors working in plant are sometimes inclined to further accept tube bundles to the existing workload voiding the prior bidding process. A quick verification of tube soiling will prevent the embarrassment of presenting incorrect time estimates and overall cost fluctuations. To verify the location of blocked tubes, install a high water volume round jet nozzle to the high-pressure trigger-gun operating quickly and precisely at medium pressures over all tube rows throughout the bundle face (4,000 psi). A suddenly developing water column will characteristically back-flush toward the trigger-gun operator, identifying a possible plugged tube. Intensifying jets velocity by pointing the nozzle directly into the tube orifice will often raise water pressure sufficiently to rupture the fouling point, eliminating the need for added attention. Mark plugged tubes with a cork slightly larger than the tubes interior diameter ([) or mark the location on tube sheets face with a waterproof pen (Fig. 3.40). If there is adequate tube sheet drying time the cleaned but still plugged tubes will release products or seeping water, revealing their location. However, this method should not be fully trusted. Bent tubes creating water pocket-condensation can slowly release water which will mark the tube sheet, resulting in possibly incorrect plugged tube identification. To leave a favorable impression with customers, the

3.4 Condenser or Small Tube Heat Exchangers

293

Fig. 3.39 Automated system mock-ups

Fig. 3.40 Marker tool characteristic

tube sheet’s face should be cleaned with a short-barreled gun, with a 15 fan nozzle at approximately 8,000 psi. To further enhance the appearance an abrasive injector with a fine-light media (soluble abrasives 0.02 [ or less) at 4,000 psi can be applied. When operating a flex lance system in the attempt to clean heat-exchangers or condensers there are 12 rules which must become second-nature to all operators involved: 1. Never start job-rigging and cleaning operations before a prior adequate safety meeting informing labor force of corporate safety procedures (contractor) incorporating and providing a step in–out area for operators and their gear. Conduct in-plant safety meetings and familiarize the work force with the customers plant emergency procedures, which includes identifying in-plant shower and eyewash facilities. 2. Never come in physical contact with tube bundles waste product before a product classification has been established and safety gear is selected accordingly. 3. Never allow the operators to work over the threshold limit of their concentration and endurance. Injury is otherwise imminent!

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4. Never allow the operation of hydro-rigid-flex lances unless the knowledge of stop–go–shutdown commands communication is firmly embedded into the operator’s subconscious. 5. Never commence operation without gaining secure footing, sometimes difficult when viscous, oily products are removed. 6. Never operate without first properly securing the condensers lance-nozzle discharge side with tarps, restricting general surroundings with safety barricade tape, identifying hydro-blast operations and being aware and in control of water-debris flow, therefore avoiding the customer’s anger unnecessary secondary cleaning procedures. 7. Never permit a rigid or flex-lance operation without a safety back-up man who controls either an emergency shut-of switch or a secondary in-line shut-off valve (foot valve). At all times the safety man must also be in constant and non obscured visual contact with lance operators, tube orifice, and hydro-lance equipment. 8. Never permit the handling or operation of flex-lances without adequate hand protection provided by industrial-grade chemical resistant rubber gloves. Cuts are inflicted by defective, contaminated metal spears protruding from covered hose braiding which may result in blood poisoning and infections. The rule applies, regardless of whether the lance is pressurized or not. 9. Never allow free lance travel into or throughout a tube avoiding the otherwise explosive return possibility of the lance nozzle assembly and simultaneous excessive hose kinking, which may result in a catastrophic lance failure and grave injuries to the operators (bursting or the development of nozzle-like orifices). 10. Never position the operator directly in front of the tube being serviced. 11. Never operate without gauging and limiting flex lance travel within ‘00 beyond the tube exit orifice, thus permitting the cleaning of the total tube length and providing an acoustic sound identification of nozzle’s location. It also protects the lance liner from otherwise premature damage inflicted by the tube edge to hose and nozzle armature. 12. Never after a job completion and after dismantling contractors equipment leave the job site avoiding the corporate tailgate meeting recording all jobrelated problems, successes, possible injuries if any and future possible job improvements. Following are three similar procedures described involving a 250 condenser containing 400, ‘00 tubes which are mud soiled, but open. 1. Mud scale is removed throughout the unit by simultaneously operating three flex lances, mounted to a three-pronged manifold which is an integrated part affixed to a primary foot valve assembly ahead of secondary safety valve assembly. The operating pressure is set at approximately 4,000 psi. The nozzle configuration is 6 orifices 9 45 flat work, is best divided into 9 gpm performance of the available hydro-blast unit. Verify the desired water volume configuration to ensure adequate passage throughout the entire tool assembly

3.4 Condenser or Small Tube Heat Exchangers

295

Fig. 3.41 Flex lance rotation

(horsepower requirement), including the high-pressure water hose, trigger guns or foot valves and flex lances. 6–9 tubes are serviceable per minute. 2. Hard scale throughout a condenser is removed by simultaneously operating two -inch flex lance affixed to a two-pronged manifold which is also affixed to a primary foot valve assembly ahead of secondary foot valve-control. This permits the cleaning of 3–4 tubes per minute. The nozzle configuration is 6 orifices 9 30 or 45 9 gpm–psi (depending on the hydro-blast unit’s performance). 8,000–14,000 psi is necessary in most applications of this sort. 3. Very hard scale is removed with a single flex-lance directly affixed to a foot valve ahead of secondary foot valve assembly. Depending on the hydro-blast unit, the nozzle in this case, provides 6 orifices 9 30 9 22 gpm 20,000 psi (differs with nozzle manufacturers). The cleaning rate is reduced to approximately one tube per minute. Less cumbersome, but a gray area exists when a flex lance performs a job technically better-suited for a rigid lance procedure. When tubes are partially-fully plugged, the nozzle in use must feature an added jetting orifice (other than existing self-propelling jet orifices). This orifice is located forward, toward the center of the tube, removing all products encountered. An explosive hydraulic piston force toward the operator will occur when debris is permitted to form a tight seal between tube wall and nozzle (Fig. 4.5) assembly forcing the assembly ‘‘lightning fast’’ out of the tube. This condition is prevented when a correct flex-rigid lance application procedure is introduced which includes the systematical rotation (Fig. 3.41) of the nozzle assembly in its forward and retracting cleaning procedure (35 to 60) (Fig. 3.42). Permitting adequate spacing between nozzle-hose circumference and tube wall (Fig. 3.43) and/or encountered inner debris clearance must also be of first concern. Always secure a minimum of ten times the water volume produced by the forward orifice to pass between a nozzle-hose assembly and tube wall or its hardened debris scale. Most important restrict the free travel of the lance assembly. Incrementally and systematically clean tube walls completely in 40 –80 sections by

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Fig. 3.42 Possible tight seal between nozzle-hose circumference and tube wall

Fig. 3.43 Adequate spacing between nozzle-hose circumference and tube wall

Fig. 3.44 Possible tight seal between nozzle-lance circumference and tube wall

removing all adhering debris before advancing the nozzle assembly further down the tube. This is especially of importance when paints, epoxy resins, synthetic latex, vinyl emulsions, etc. in solid and semi solid or various grades of viscoussticky nature must be removed from plugged tubes. The same symptoms can be experienced when the nozzle tolerances itself to tube walls are critical, and the operator allows the uncontrolled propulsion of the nozzle-hose assembly into the tube structure. Manually cleaning solidly plugged tubes is considered strenuous and time consuming, especially when rigid-lance procedures are required. Nevertheless it is the most effective cleaning method. Utilize the rigid-lance when extremely hard products, resilient or utterly viscous sticky materials are encountered. Cleaning results are achieved by directing the combined jetting force in various degrees toward the product and tube wall, releasing numerous jet-recoil forces upon the operator (Fig. 3.44), resulting in nightmarish operating conditions. Furthermore, the operators endure a constant bombardment of somewhat diffused, high-velocity refuse and water. If you must manually operate the rigidlance, never operate a lance below a 3/800 tube wall and more than 100 in length alone; someone may risk wearing the lance around his extremities. As a 100 rigid lance requires one operator, a 300 rigid lance must always be manipulated by three operators; One to guide and pilot at the tube’s orifice, one situated at approximately center of the lance pushing and guiding, and one to push and control the hydro-blast trigger gun (Fig. 3.45). Be sure of your verbal STOP–GO command system, because everybody’s safety depends on it. Rotate the positions of the personnel as they tire.

3.4 Condenser or Small Tube Heat Exchangers

297

Fig. 3.45 Numerous and sometimes erratic jet-recoil forces Fig. 3.46 a Various UHP hose interior [, b nozzles

Due to various undisclosed high-pressure hose/lance and available armature varieties [ (Fig. 3.46a), and/or hose run distance to a job site, combined with manually drilled soft metal nozzles (Fig. 3.46b) and their unidentified gpm performance is a scenario most often responsible for inadequate and/or a slow cleaning procedures. Completed hose-tool assemblies are best tested as to their pressure loss by removing all nozzles, securing hose-ends within a fixture open to atmosphere avoiding whipping while testing. Performing readout at systems pressure gauge operating at pumps predetermined rpm requirement will quickly identify the psi necessity to force set gpm performance throughout a tool assembly. Identifying and adding the subsequent necessary horsepower capacity to pump drives (motor-engine) overall performance capability within the designated power curve reveals systems true power input requirement and will possibly reveal an overload scenario most often responsible for pump gear-end and/or engine failure. Shell-side cleaning is a simple application with various tool possibilities and it nearly completes a condenser–heat exchanger service cycle. Exterior bundle cleaning and when operators enter a shell directly to water or abrasive blast the units surfaces clean of debris is it required that an unaware by-passer’s safety is guaranteed. Cordoning off the immediate work vicinity, restricting traffic with barricade tape, and post warning signs in visually-strategic areas is a must. To verify operator’s safety always double-check the plant maintenance department’s previous lockout procedures (locks) concerning all flanges, valves and any pipes which enter the vessel, preferably adding your own locks. A vessel entry permit must be obtained and the recommended safety standards according to plant and OSHA laws must be followed. If shell-side cleaning becomes a daily routine, build a few simple tools to eliminate the shell entrance; for instance,

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Fig. 3.47 Soiled condenser tube sheet

Fig. 3.48 Cleaned condenser

install a mobile tripod arrangement with an adjustable diameter to support T-lance configurations, dual abrasive cleaning heads, turbo nozzles, etc. Requirements of surface cleanliness vary depending on the visual, X-Ray or hydrostatic follow-up test procedures. The interior shell-side cleaning method more or less is similar to tank-sewer or surface cleaning procedures (confined space). The condenser cleaning process is generally applicable when servicing large tube heat transfer units (Fig. 3.47) which physically may only vary in tube [ (mainly larger and tube length considered longer). A difference also appears due to the fact that tube bundles may not be extracted from their shell structure. The similarity between after-coolers and large tube heat-transfer units is obvious. However, here you will find that tubes in their numbers range from few to literally hundreds and tube size will not exceed ‘00 [ (Fig. 3.48). A hydro-static test, also belonging to the contractors application variety is possibly required after units assembly in its location or while still in its service bay. A service provider should always remind the customer of this possibility. Nowadays highly mobile and automated rigid power-lance equipment (Fig. 3.49) and multiple or individual flex-lance cleaning systems are available and can compete various areas where the manual tube in cleaning procedure is deemed to cumbersome or time-consuming. Three drum water tube boilers, usually categorized from 600 psi main propulsion aggregates to CK 60 commercial–naval units operating in their respective vessels from 1,200 psi, containing approximately 1300 tubes plus, which includes general industrial auxiliary boilers (manufactured by Foster Wheeler, Apco, etc.) are found everywhere in the industrial environment. In the past, circulating a 10% hydrochloric acid solution followed by a pacifying, neutralizing procedure was the

3.4 Condenser or Small Tube Heat Exchangers

299

Fig. 3.49 Power-lance equipment

general internal tube cleaning method. In their physical structure there is no resemblance to condensers or after-coolers. However, the high-pressure water cleaning method for scale removal on or in boiler tubes is still considered a tubecleaning application. Chemical cleaning, called for a final water flush of the unit, which is intended to remove all loosened scale. Once applied, the hydro-jetting technique (1958) immediately proved superior and environmentally friendly displacing the chemical procedure. However, this excludes the pacifying–neutralizing flash-rust protection process of raw carbon steel tube surfaces. In the tube cleaning process service providers apply 1 lb. sodium nitrate per 100 gallons blast water, avoiding aggressive oxidation and rustdeveloping factors. To provide complete rust protection during the units drying time it is wise to lightly douse the complete tube and mud drum surfaces. Mud drums (bottom of unit) tend to be inaccessible or impractical to enter; the cleaning is therefore performed from the top down by entering the steam drum above the fire room. Tubes in older units (20 plus years) are up to 400 [; generally expect 100 [ to 300 [ tube sizes. Tube quantities vary from hundreds to thousands, according to boiler’s size-power, age, manufacturer and industrial use. Likewise for the length of the tubes; pressure-fired generating tubes are 140 –260 long and their inside [ ranges from approximately 0.800 to 1.6700 [. In a steam drum the longest tubes are found at the top of the unit. Tubes from the top to the center range from 470 plus to 300 plus and from center down to the floor pattern of the drum 300 plus to 200 plus. The tubes of a 40 year old Foster Wheeler unit (containing 600 tubes at 3‘00 [) are 360 to the center of the steam drum and then decrease down to 250 in length. At the time of tool selection it is important to recognize any changes in tube size, common in most units. These units can also be found in the food processing industry. Scales appear soft, hard, resilient or brittle and require an experienced operator to make an adequate tool selection. When the hydro-unit’s water performance is limited, streak appearances in jet impact areas are likely, especially when large tubes bear hard, brittle and adhering scale (300 plus). A 200 whirl-jet (ultra high rpm) may compensate for this shortcoming with its jetting characteristics. To avoid the tangling of safety lines, high-pressure water hoses and electric cables, start the cleaning procedure on the far side of your entry, regardless of which side you initially entered the steam drum.

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3 Application Core Curriculum

As the work proceeds a safety-man visually situated (confined space entry qualified) on the exterior of manhole which was entered by the operator will pull the slack of the high-pressure hose, electrical cable and safety line, providing unimpeded movement for operator in this cramped and confined environment. Knee protection is a must; the stubby tube ends will otherwise hinder the operator. The operation, of a one or two flex lance assembly or a ‘00 [, high-pressure hose is standard; however, selection may vary depending on equipment water volume psi performance and pipe [. Pressures of 7,000–14,000 psi are essential (product adhesion depending). Lighting is best supplied by a 12-V explosion-waterproof fixture. By installing fans or air-injection blowers to the manhole opposite the steam drum’s entry, fresh air for cooling and breathing purposes is supplied. Important, ‘‘don’t obstruct dedicated emergency exit’’. Again, never enter any vessel without having received all permits from plant maintenance department. Make sure that all boiler drains located at the bottom of the mud drum are opened and locked out. Furthermore, supply an emergency egress system which is fastened to the belt of the operator and an air back-up unit situated outside the steam drum in immediate reach of designated safety man. Manholes come in all sizes; to prevent a possibly deadly surprise ensure that the air back-up unit (Scott Air Pack, etc.) will fit unobstructed through manholes entry. The safety line may also serve as a means of communication; for example, one tug means feed high-pressure hose, two tugs means retrieve high-pressure hose, three tugs means activate high-pressure safety valve (safety backup), and constant tugging signals an emergency. In your safety efforts remember not only to concern yourself with your immediate work location, but also keep a keen eye on your surroundings, especially when a major plant maintenance procedure is in progress and various trades perform independently a multitude of maintenance operations. Utility steam generators utilizing excessively contaminated fossil fuels, or operating with inconsistent oil temperatures which may result in a varying and/or faulty combustion, etc., can develop hard incrustations consisting of calcium, glass, copper, vanadium and so on which may adhere to super-heaters or generator tube surfaces. Deposits are removed on incline generating tubes by jetting them from three sides, hitting all tube surfaces including surfaces in depth of the tube structure. Super-heaters most often develop a clinker-glass like scale only within the first, second and third tube structure. By fitting a short-barreled gun with a 20 , 5/800 in [, schedule 80 rigid lance, and incorporating the nozzle in such a way that the nozzle fixture does not exceed 5/800 in [, the free movement between the tubes is possible, providing a greater water-jetting effectiveness. Secure necessary scaffolding, provide ample lighting, heavy-duty raingear, gloves, double face protection (face shield, eyeglasses) and top entry safety harnesses or, if suitable, safety belts and lines. Consider these items job essentials. Operating pressure may range from 8,000 to 22,000 psi, 19 to 10 gpm. To prevent soiling of previously cleaned surfaces, water-jetting procedures start at the highest interior point of tube structure. Various effective tools are available applying high-pressure water semi automatically.

3.4 Condenser or Small Tube Heat Exchangers

301

GEAR - LIST AUTHORIZATION Condensers, small tube heat exchangers, large tube heat transfer units, water tube boilers Customer & Company:

Date: Address:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Job Nr.:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Review Performed by: Plant hardware: Heat exchanger: Condenser: Boiler: 3-Drum water tube boiler: Mud drums: Steam drums: I.D. of tubes: Small tube exchanger: Tube-sheet: Shell side cleaning: Steam generator:

Equipment: Waterproof coloring pen: Chemicals: Specify: MSDS: Hot water: High-pressure trigger-gun: Flex-lances: Rigid-lances: 3-Pronged lance manifold: 2-Pronged lance manifold: Rigid lance cleaning system: Foot valve:

Tube type:

Nr.: O.D. of tubes: Bundle rotation: Deformed-damage tubes: Sagging bundles: U -Tube design: Straight tube design: Super heaters: Gasket area: Fire room: Other:

Plant location: Vessel entry permit: Nozzles: Remote-automated jetting equipment: Lance tripods: T-dual abrasive cleaning head: Turbo nozzle heads: Rotary jet: 12-Volt or air-drive explosion-proof lighting: Rust-inhibitors, metering equipment: Knee protection: Other:

Other: Product hardness, adhesion, viscosity: Specify: Fouling characteristics: Specify: Physical surroundings, safety procedures: Specify: Describe application and work procedure: Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

Others:

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Nr.

Customer & Company:

Date: Address:

Web site: e-mail:

City: State:

Job Nr.: P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Plant hardware:

Hydro-blast equipment:

Plant location:

Equipment:

Product Encountered: Hazardous Material:

MSDS:

Specify:

Describe application and work procedure:

Describe safety procedure: Itemize equipment, safety gear, expendables, etc.:

Maintenance work on steam generators, as found in fossil fuel power plants, require the use of hydro-blast power in three categories; clinker removal, spot or total outer surface and internal [ tube cleaning of incline wall tubes and often followed by hydrostatic test procedures to visually identify tube leaks. Identified leaking tubes are replaced and/or welded, automatically requiring a follow-up hydrostatic test validation. Test pressures applied will vary with the manufacturer’s specs and are usually 1.5–4 times the operating pressure of a steam

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generating unit. When cleaning boilers or steam generators, especially when high water pressures are necessary, always be aware of the brick structure (fire-side); brick should neither be unnecessarily saturated by water (eliminating extensive drying times) nor damaged by high-velocity water jets.

3.5 Coating–Paint–Graffiti Removal on Surfaces such as Asphalt Concrete and Clay Masonry, Cementitious Wall Board, Structural Steel, Aluminum Surfaces, Wood Facades, Surface Flash-Rust, Corrosion-Oxidation Control Electrostatic paint shop facilities are traditional to automotive assembly lines. They where first to exploit high-pressure water (1963) to remove cured thin-film and/or heavy paint accumulations by paint-misting from cabin floors and walls, grid-iron catwalks, air filtration equipment exhaust-ducts and hoods, flue stacks, sedimentation in water channel-systems and on chassis transport equipment, etc. Today’s facilities are generally cleaned within the progression of a plant maintenance procedure. The high-pressure water coating removal technology, operating at up to 45,000 psi applying comparatively low water volumes does permit a protracted UHP trigger-gun operation incorporating a spin jet assembly. Elevated water volumes may be necessary for bridging voids or deep surface recesses facilitating penetration for a coating or substrate removal application and can require the utilization of a jet cart (rotating), eliminating all recoil forces upon operators. These applications are quite self-explanatory and mainly vary due to safety procedures enforced by individual maintenance departments or industries when considering the physical cabin size and various chassis transport equipment, product characteristics and volume, adhesion, elasticity, tensile strength and structural circumstances regarding underlying steel surfaces. The blanket statement that 20,000 psi plus water pressure will effectively remove a cured coating or paint covering from various substrate is generally misleading. Psi–gpm configuration and the subsequent specific tool selection will significantly vary with every individual job description and might start in successfully utilizing 3,000 psi at 5 gpm with cold or hot water or manually operating two Spin-Jets at 40,000 psi and 6 gpm at a 250 ft2 (plus) per hour coating removal rate. Throughout industrial and commercial environments, a successfully performed coating–paint removal application depends solely on the correct assessment of a substrate’s identity, characteristic of its possibly present anchor profile or the identifiable surface roughness, identification of structural–surface integrity (corrosion, oxidation, friability), and consideration of potential variances in coating adhesion and interface makeup to substrate or the interface adhesion factors between coating layers if so desired. Further, the encountered multitude of preservation, restoration and/or cleaning requirements does include possible identification of prior coating–paint failures. This is most often identifiable by

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coating delaminating, blistering, cracking, flaking, oxidation or corrosion resulting from previous inadequate substrate preparation or a past coating selection (system) impervious to the specific substrate and environment. The substrates rehabilitation and technical prerequisite in question must also include the consideration of its future repair, coating or seal performance criterion, which is an important identifying characteristic influencing the determination of a correct hydro-tool selection, subsequent psi–gpm–horsepower requirements, overall work procedure and surface preservation, between removal and installation of any new coating system. The available tool potential and its application flexibility, variety and safety requirements concerning the contractors’ equipment ought to be fully understood by all involved. Therefore prior to a job commencement it can be necessary to include a application specific lecture as to the service provider’s trade criteria involving customers maintenance superintendents, project engineer’s and restoration architects, etc. Equipment-tool performances above 10,500 psi require an advanced tool design and application specialization regarding all applicable safety standards and/or necessary desired tool combinations. Equipment performance and its design criteria may vary substantially between equipment manufacturers and industries tool suppliers. Testing a substrate to warrant a correct and practical removal assessment may also require scaffolding and containment procedures not yet erected or operational. Under these circumstances care must be taken to identify problem areas in obstructed, concealed, out of sight or physically hard to reach coated surfaces. 1. Traffic-line markings on asphalt–concrete substrate in pedestrian zoning, aviation and vehicular traffic areas (traffic/line foils-coating markings), or as found on interior and exterior parking facilities and/or game lines in amusement parks such as go-cart facilities, etc. are most often subject to erosion by surface abrasion to markings resulting in loss of glass beads or otherwise visual retro-reflectivity. Traffic marking paints–coatings are classified as standard meaning non-durable or durable. Standard markings include solvent or water-borne coatings with fast drying characteristics. These coatings range in volume solids from 58 to 68% and their applied film thickness ranges 12–18 mills, dry. Durable traffic markings might also be a thin film water-borne paint incorporating fast drying latex binders. Often, a longer life traffic marking consists of a two component epoxy, polyester or two component polyurea and can include thermoplastics and/or preformed tapes. These durable coatings are of 100% solid materials. Their applied film thickness can range from as low as 12 mill to a high build of 40–120 mill (1–3 mm). Due to their VOC content applications are today limited. Regardless of coating type utilized (except foils) numerous recoating necessities can lead to peeling or flaking of coating layers. In most instances a prior and proper surface treatment is foregone since purpose is usually served with a minimal clean-up endeavor (often air blast only). This aloof coating practice does contrast to most construction sites where new road surfaces or frequently changing traffic patterns require imminent and sometimes simultaneous line removal-recoating procedures. Manually operating a trigger-gun assembly featuring a 15 fan nozzle or single orifice spin-jet unit (Fig. 3.50) can in some areas be possibly exchanged for a

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Fig. 3.50 Traffic-line removal

Fig. 3.51 Coating-foil removal

Fig. 3.52 Damaged bituminous product

water soluble and inert abrasive blast application removing the shortest of traffic line coatings. The exploitation of conventional air abrasive blast techniques can be viewed as marginally applicable due to health and environmental impact. Also equipment layout necessities in often restrictive areas, and a likelihood of possible wind swept abrasive-dust contamination prohibitive in aviation and/or sensitive manufacturing environments, etc. are occurring difficulties. A variety of hydro-blast tooling can be manually operated (Fig. 3.51) or is found affixed to a mobile platform. These mobile units also incorporate a vacuum reclaim source (wastewater, coating debris). The mobile water source, hydro-blast unit, and spin jet assembly which, besides its narrow set or adjustability in removal width, can remind in functionality of a runway rubber deletion unit. On surfaces of an asphalt-aggregate basis, water pressures of 7,500 psi up to 12,000 psi are utilized, on concrete surfaces up to 36,000 psi. The gpm performance will vary regarding to traffic line width, coating depth and interface adhesion to substrate, substrate condition and original intent of the available tool design. The UHP jetting method and specifically designed equipment encompassing this application can also be mobilized for removing coatings in a measured procedure, avoiding damage to the substrate and edge structures such as those found on runway drainage grooves. 2. Bituminous product installs (Fig. 3.52), which insulate surfaces such as on pipes, trusses, siding and flashings, etc. are, due to their metal substrate, simply

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Fig. 3.53 Concrete interface restored

Fig. 3.54 Coating liner removal

removed utilizing fan or spin jets (Fig. 3.53) with pressures generally ranging from 5 to 14,000 psi). The location of these surfaces may require extensive tarp procedures and water discharge control measures. 3. Surfaces requiring the removal of deteriorated or failed elastomeric proofing products or the removal of bituminous deteriorated game surfaces on water-residential–commercial tennis courts are also applications largely overlooked. Jet carts work well in this general product removal application. When properly adjusted the soft underlying bituminous or rubber-like court structure can be maintained while removing or cleaning the on-court painted markings only. The qualified contractor will manipulate nozzle size, determining necessary psi–gpm performance, the necessary rpm by nozzle degree (adjustable) to surface stand-off distance by judging desired penetration parameters within the paint structure and adhesion interface to the substrate (Fig. 3.54). Adjustability of cart’s rotating nozzle carrier relating to the nozzle standoff distance is critical and must be precise in its function. Depending on tennis court’s substrate condition, operating pressures range generally between 7,000 and 10,000 psi. Applying hot pressurized water may also be of an advantage when temperatures can be maintained above 200F. The total removal of a tennis court base is a standard procedure and can be supported by a vacuum-truck operation, which requires only a few tools to rake up and collect shredded base material which generally maintains a low water wettingsaturation. A hazardous waste removal procedure is most often incorporated. A strong concrete substrate may destruct at approximately 8,000 psi plus, when nozzle standoff distances, water jet size or degree, and gpm performances are incorrectly manipulated or a prolonged stationary nozzle impact time to surface is permitted. 4. Laitance, sealers, brittle encrustations or resilient thick coating removal applications (40-mil plus) on horizontal, vertical and overhead concrete surfaces as found on decks and stair cases, parking areas, drive-thru or driveways, deteriorated primary containment (tanks) or lining–coatings for secondary containment, and/or

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Fig. 3.55 Intact interface

coating systems on warehouse flooring, etc. are often found within the commercial environment. As in the industrial criterion the correct identification of a substrates condition and coating interface characteristic must be achieved and understood (Fig. 3.55). This is especially important when comparisons to conventional thin or thick film coating and/or concrete paste removal methods, including surface profiling–roughening, require creating an anchor pattern, producing maximum adhesion are considered within a bid procedure. These conventional methods may include the dry abrasive blast application utilizing an air driven vacuum collection system or operating a centrifugal wheel shot blast unit, steel shot blasting, wet abrasive blast techniques, impact and rotary impact tools, which include needlescaling tools and large mechanical scarifying equipment. Today’s advanced vacuum assist high-pressure water tools manipulated by trained personnel prove superior in most areas to the conventional tool utilization especially when the water filtration, recycling and refuse separation capacity is added. The environmentally friendly, and in its process super clean remaining surfaces will standout especially when creating surface roughness or various profiles-heights into the corner structure of a prospective surface substrate. The physical and chemical properties and possible variations of concrete surface (Fig. 3.56) appearances seldom compromises removal applications between (penetrated sealer) -0 to 4 mils (-0 to 100 lm), or the removal of thin film to high build coatings between 4 and 40 mils plus (100 to 1,000 lm plus). Also these application and tool developments accelerated the design characteristics of emerging electronic-digital scale and roughness gauging equipment and includes the destructive coating thickness gauging criteria, which is often the only guaranteed method to test certain coating-substrate and interface combinations applied to concrete, wood, plaster, etc. permitting the identification of individual layer thicknesses of a multilayer coating system. Also pictorial concrete surface standards are established and produced by various industrial identities including the WJTA, SSPC and NACE associations. To their membership they provide a knowledge base concerning advanced test procedures for surface cleanliness (salt, chlorides etc.), coating adhesion verification, substrate pull-off testing and moisture gauging fundamentals under various climatic conditions which include steel surface preservation techniques for various job descriptions and coating varieties.

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Fig. 3.56 Simultaneous waste stream recovery

Regardless of any coating deletion which suggests either a mechanical or hydro-tool selection, one must exercise an in-depth substrate research procedure to achieve and verify the possibility of a visually smooth, or undisturbed, and if, desired roughened and/or coarse but overall uniform surface appearance. The determined results can dramatically enhance, or for that matter, guide to a correct tool application in particular when the opportunity exists to obtain the original records of the prior surface condition to the first and now deteriorated coating installation. Deteriorating coatings and possibly the concrete paste structure or its interface might conceal possible problems which may arise due to structural damage, rebar-metallic corrosion (rust-copper stains), concrete paste flaking or cracking caused by settlement or delaminating paste due to abrasion repairs and physical damage, prior oil–chemical-acid saturation, resulting carbonation or due to coating damage from earlier freeze–thaw cycling to cement paste or substrate by moisture–water seepage and/or concrete surface variations due to unnoticeable and/or faulty concealed repairs. Further more, there is a concrete failure possibility introduced by a potential chemical reaction (internal attack). This can be noticed when an inconsistent surface paste strength or aggregate surface weakness is present. The bond and interface strength to concrete is specified in psi (300–450 lbs.) or as is stated ‘‘concrete fails before the loss of bond’’. The experienced contractor will employ this information to avoid presumption when choosing the set-up of his tooling. When applying pressures above 6,000 psi a light weight steel sheet strong enough to withstand approaching water turbulence situated beneath the jet-car at its operating starting, finishing or turnaround point prevents ghosting or damage to the concrete surface (Fig. 3.57a, b). The labor force may move this sheet, utilizing the masking effect when operations are started or ended. Black rubber high-pressure hose assemblies tend to leave streak-marks when pulled over hard porous concrete surfaces; to prevent this keep hose slack on the surface being cleaned. 5. Removal applications of nonskid coatings installed to resist harsh chemicals and heavy steel or rubber-wheeled loads which are found in chemical processing and storage areas, health care, institutional or educational facilities, food processing or meat cutting areas, automotive manufacturers and dealers, aircraft

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Fig. 3.57 a, b Jet-carts offering simultaneous waste stream recovery

hangars, equipment assembly lines or product sumps-trenches and secondary containment areas. These older advanced floor systems are often comprised of 2–4 layers, starting with an optional elastomeric membrane, followed by an epoxy prime coat. The third layer is a matrix of grated, at times colored, abrasives (quartz) and 100% solid epoxy to provide the necessary strength and chemical resistance. The final coat, also an option, consists of a clear epoxy finish which adds extra protection and an attractive gloss. When removing such coatings the following aspects must be established: Identify the makeup of the sub-floor (brick pavers, butt metal, quarry tile, concrete, or wood), its condition and in particular, its condition prior to the original floor installment. Restorations are performed to accommodate a new process–product or equipment expansion, etc. Often industrial coatings are applied to damaged, badly eroded, poorly cleaned and prepped floors. Aged floors are possibly uneven or pitched therefore a cured deteriorated epoxy coating (self leveling) may also vary in thickness in surface areas not easily identified (described in mil.) If it all possible, retain floor manufacturers physical property sheet, and coating identity generally specifying hardness in shore (70–85), compressive strength which is commonly between 17,000 and 19,000 psi and tensile strength between 12,000 and 13,000 psi. 6. A coating, adhered to a floor substrate constructed of tile allows a similar removal practice. Industrial tile grouts are generally super hard preventing damage by high-pressure water and therefore do not require specific attention. The individual deletion of coating layers may prove difficult due to the floor’s irregularities. When coatings are removed from a brick substrate, the possible interface malleability does demand close attention. The spin-jet’s adequate rpm adjustment, removal transfer tempo, gpm–psi and nozzle configuration (including nozzle standoff distance) must be thoroughly tested to avoid brick-grout and/or brick surface damage on soft-core bricks. 7. Concrete coatings–sedimentation–spatter deletion on job related equipment and tooling can sometimes be expressed within a coating removal classification. Cleaning concrete form-boards (Fig. 3.58), which are normally coated with a bond breaker for easy removal after curing, can be considered an equipment maintenance function as is the cleaning of scaffolding, exterior and interior concrete truck surfaces, cementing vehicles and all concrete-related tooling. Applying a highpressure trigger gun, fitted with various lance extensions and equipped with a hardhitting round jet nozzle, and/or single orifice turbo-nozzle and sometimes simply

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Fig. 3.58 Dismantled form boards

Fig. 3.59 Fan-jet ghosting

utilizing a 158 fan jet at pressures from 3,000 to 14,000 psi at 3–22 gpm can be considered customary to the industry. Ultra high-pressure water applied with specialty tooling in areas or spaces (concrete-drums) to remove hardened-cured product. When applying lower water pressures at insufficient gpm performances a product or product film destabilization may be necessary. Muriatic acid can in some instances be applied to cement-concrete residuals supporting the desired breakup. Most store-bought muriatic acids are measured in 20 Baume at 31% by weight. Cement-concrete film or film like residue may be treated with 1–5 parts acid admixed to ten parts water supporting product film separation from its surface by cold or best hot high-pressure water. When objectives are accomplished the area of application and surroundings are best neutralized by a low-pressure water-wash similar to the acid neutralization performed after a conventional acid profiling endeavor with water acid ratios equaling more likely 1 to 1. Always verify the surface neutrality by means of a simple pH paper. Trigger-gun lance-barrels featuring an adjustable blast screen will aid operators in visual control while adding extra protection from flying debris. Under these circumstances an uncontrolled wastewater runoff to a storm sewer system is illegal. Form-board bond breakers are

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Fig. 3.60 Jet-car ghosting

generally formulated from oils, greases, silicones, waxes and/or cured polyurethanes (form-release agents) and are the culprits in leaving residual material upon newly poured surfaces, which must under most circumstances be removed to permit a satisfactory bonding of coatings. After a 6 week curing time surfaces to be coated must be handled with care avoiding concrete paste damage, visually identifiable if a thin film coating is installed. Contaminated paste can be cleaned free of residue by various standard methods. Cleaning with hard-hitting round jets is not advisable due to subsequent surface ghosting. Much of the available equipment can be altered by a fan jet curriculum, supporting psi and gpm performances suitable for nozzles capable of a 25 to 65 spread. Pressure and water volume configurations are set to cancel out all ghosting (Fig. 3.59) possibilities on newly poured and cured concrete surfaces (Fig. 3.60). A secondary option exists within this application to provide a surface or roughening procedure (anchor profile) at various degrees supporting a superior thick-film adhesion factor most often suggested by coating manufacturers. The notion or opinion that cold highpressure water will force surface oils or greases deeper into a concrete substrate is untrue and misleading. Today’s vacuum assist spin-jet technology outperforms any other solution, especially the steam cleaning application when combined with various emulsifiers, solvents or detergents. Heating a concrete substrate with steam will only enhance a deeper concrete contamination. 8. Commercial aviation’s taxi, parking and jet-bridge areas are also outlined with paint indicator lines-stripes and are in need of periodic restoration when they appear visually faded or require a removal application due to constructional and/or operational traffic changes. Sometimes a dual surface application can be encountered due to adjacent concrete–asphalt tarmacs. Self-propelled or hydraulically-driven spin-jets are most suited for this application. They offer a physical and technical water jetting adjustability while performing a simultaneous vacuum assist refuse removal capacity forgoing area contamination and cleanup procedures. Care must be taken to avoid ghosting characteristics or damage when in the vicinity of asphalt surfaces bordering a concrete tarmac. Pressure and gpm

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adjustments must be performed before any operation can be introduced to a softer asphalt–concrete blacktop. Also, spin jets self-propelled and/or mechanically rotating nozzle carrier extensions must safely clear all recessed and lightly protruding runway markings or light fixtures. Manually operated spin-jet carts are ideal when working in obstructed jet bridge boundaries visually identifying equipment complexities. Jet cars designed to remove highway road markings feature two orifices within the width of a standard road coating line-marking. The versatility of these units is ideal. Contractors can apply them to spot clean surfaces or to remove rubber-paint-coatings including 3 M foils. When spot resurfacing practices are performed by utilizing higher pressures they can also be applied to scarify concrete or asphalt substrate, especially in physically confined or hard to reach areas. Operating pressures and gpm performances vary substantially between available tool designs and application fundamentals ranging from 7,000 to 36.000 psi producing up to 36 gpm. A single or multi-gun operation is possible (fan nozzle or spin-jet fitted), and sometimes necessary within this application environment. Under these circumstances airports’ safety requirements concerning the labor force and equipment placement are somewhat more elaborate and include fastening safety barricade tapes securely in most likely a wind-swept and high traffic area, strategically placing weatherproof warning signs-cones restricting access to trigger-gun operator’s work area, and while in operation eliminating water-misting conditions often introduced by inexperienced operators. Equipment and accessories must be located so as not to interfere with the movement of planes, jet bridge tires and their mobile structure, fueling, and baggage operations in case of an unforeseen operational emergency, general maintenance endeavors and airfield vehicles. An environmentally sound water soluble abrasive material which leaves no trace can sometimes be applied. A multitude of grains are available to polish, edge, hone and/or remove materials. Nevertheless a vacuum assist wastewater and refuse removal capacity is most often mandatory. 9. Deteriorating coatings and their substrates such as clay masonry units or pressed extruded brick surfaces and concrete masonry CMU’s (Fig. 3.61) as found on block or brick structures and include stucco walls and soffit elements can be either solid or hollow core. Their manufacturing processes are extrusions or form pressing operations. Today’s block densities are much lower than older units (Fig. 3.62). Due to highly developed high strength cementing materials and the substitution of sand or gravel with low density aggregate such as clinker residual admixed as fillers, industrial or various pumice byproducts, etc. which can lead to a greater substrate moisture penetration and often advanced by deteriorated coatings-sealers and/or environmental influences. The moisture can leach soluble calcium compounds from mortar joints, and/or develop mildew growth accelerated by coating flaking; peeling, cracking and blistered surfaces with visual symptoms appearing as white chalk like powder or calcifications known as efflorescence are also identifiable in areas of coating failure to the substrate. The available selection of water soluble abrasive blast-media enhanced application varieties greatly within

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Fig. 3.61 CMU coating removal

Fig. 3.62 Cleaned CMU block surfaces

industrial and commercial environments. Possible substrate diversity does not permit a one size fits all coating removal solution. Extreme substrate friability may require prior chemical treatment to compromise a coatings adhesion to its interface, and then supported by a gentle water-wash (45 to 65 fan jet) utilizing equipment starting at 500–3,000 psi with hot or cold water, eliminating damage so often produced by spatula. Water volume and a specific tool design for each application which can include making use of the scouring effects produced by water soluble abrasives with a grain size specifically chosen for its desired surface manipulation does reduce common labor intensive job descriptions. 10. Deteriorated paint or coating removal applications producing lead residual often found on dilapidated commercial and wooden structures most always require an industrial cleaning and waste-removal approach. This will trigger automatically all applicable OSHA standards for worker protection, including a constant air monitoring process, and prior blood testing of the labor force establishing the allowable baseline or evidence of pre-existing unacceptable blood contamination. State and federal laws concerning the hazard classification, transportation, storage, and waste removal techniques when controlling–eliminating a possible airborne lead dust activity while in a removal process is of quintessence. High-pressure water as the primary tool is especially effective when blast-water is recycled within the water cleanup procedure utilizing a final phosphoric filter component

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Fig. 3.63 a, b, c Wood restoration

removing lead trace elements from the recovered water. Before removing lead containing paint from exterior wood, stone or brick surfaces, several protective measures must be undertaken. Exposed soil surrounding a dwelling must be covered with a 6 mill plastic that should be attached to the bottom of the building with duct tape or other fastening methods. The 6 mill plastic must extend a minimum of 140 away from the dwelling. If the pavement surrounds a dwelling, a plastic covering may not be necessary except to envelop drains in the area. Once the water jetting process has begun, the lead paint will drop off onto the plastic or pavement. The hydro-vac method is ideal to separate blast water and simultaneously fill 55 gallon drums with the semi dry coating waste. Regardless of correctly packaged semi dry refuse a Hazardous Liquid–Solid Waste Permit is required to transport drums to a licensed hazardous material dump site. It is essential that operators wear gloves, facial protection, respirator and full rain gear. Under no circumstance can digestion by skin, mouth or air be tolerated. Moderate or severely deteriorated paint-coatings such as those possibly exhibited on exposed laminated beams and columns, dimensional lumber, wood panels-façades (Fig. 3.63a, b, c), decks, staircase-steps, shingles and/or shakes which will most often also reveal a variety of wood substrate damages to be first classified cleaned and/or repaired before an adequate coating or staining solution can be determined. Numerous coating layers may also hide hazardous materials such as asbestos and lead often found on older building structures and public

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works projects requiring containment and disposal procedures. With regard to those the high-pressure water cleaning–recycling technique is superior to conventional abatement methods when quickly removing all loose and delaminating, cracked flaked-peeling paint-coatings, which includes paint-coatings with an inferior interface makeup (bubbled). Within the removal process, mildew, oil and grease stains will also become obvious and visually enhanced by the subsequent drying process. Low volume–high pressure water administered with a correct fan nozzle and jetting degree will not over saturate wood surfaces. The operator must identify existing damage to the substrate, eliminating in his application procedure the raising of wood grain and ghosting appearances. Exclusively and not subsequent to an incorrect water jetting procedure, the drying process can be distorted by remaining coating remnants developing the tendency of edge curling and wood grain splintering also due to the raised grain drying process. After surface drying this occurrence is simply manipulated with a mechanical belt sander, plastic spatula, brush etc. Avoid the use of steel or copper wool when cleaning or removing such surface adulterations. For a long time to come, caught wool fragments in the protruding grain will produce discolorations in newly applied stains-paints and coatings. Regarding various wood restoration requirements and/or techniques, a coating mitigation and the following combination of chemical cleaning and neutralization procedures of wooden façade components is always best supported by a gentle and neutralizing water wash. A variety of paste and poultice concentrates for coating removal applications and neutralizing–cleaning products are specifically designed for this job criterion. Best results are achieved in testing products as to their coating deterioration characteristics enhancing the following water jetting and neutralizing procedures. Specific chemicals support a super gentle coating removal technique requiring a diluted ratio of up to 4 to 1 parts of water. The only practical way to determine the best mixture is to conduct tests on the substrate in question. After testing procedures are completed rinse patches thoroughly and allow them to dry. Once dried the cleanliness of the patch is obvious and any discoloration, ghosting or whitening of wooden substrate must be further cleaned and/or neutralized. Chemicals are applied by injector utilizing volume control by its metering device, brush-roller and/or airless pump systems. Often restoration projects will not allow scraping by wooden, plastic or steel spatulas. A trigger-gun with a refined fan-jet assembly and the appropriate gpm–psi configuration is far gentler within a compromised coating removal procedure. As to the initial process of a coating removal endeavor, this decision varies with every job description. Starting at the bottom of a structure and applying the solution evenly upwards is often considered the standard but can result in substrate surface discoloration and water saturation if not correctly addressed. Sometimes, a failing or deteriorated coating may protect the substrate sufficiently when starting on top of the structure. Regardless, after a dwell time of 15 min (or as specified), rinse the surface free of product and residue by applying 500–2,500 psi at 2.5–5 gpm. In some instance, rinse pressure must be reduced to levels prohibiting further interface modulation to extremely damaged or friable surfaces. However, it is important that all chemicals

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Fig. 3.64 Interior–exterior structural geometries

be thoroughly removed, leaving substrate and surface interface with a neutral of pH 6.5–7. Wood variety, remaining original tool markings, environmental conditions or exposure, chemical influences, façade neglect and age and/past restoration and/or structural repairs almost always result in an slightly irregular surface appearance which must be carefully evaluated. Only when secondary cleaning-neutralization procedures are completed and surfaces are completely dry can a correct assessment as to the surface preparation and final coating installation be performed. Also within a job bidding process, consider the wildly varying containment cost protecting human life, structures and environment. Fluctuating within every job description or application, pricing can vary from $0.10 to $0.80 ft2 and does not include the hazardous waste removal, storage or treatment–placement cost. 11. Paint, coating and rust removal applications on structural steel and metal surfaces such as on columns, beams, joists, etc. flues, stacks, pipes, tanks and so forth are nowadays quite one-dimensional. The application problem only arises due to encountered structural circumstances. Job specifications and, also customary to available air abrasive blast equipment, the physical hydro-tool limitations can be challenging. A limited nozzle access to interior or exterior structural geometries is supported by a hand power tool application. Bridge structure, interior ship-hull, and tank configurations may require a 1–5% surface treatment by alternative tooling. Industry tool dimensions and development for or within a specific job criterion may vary substantially due to available manufacturing and engineering means. Besides service providers competing, partially responsible for this tool dilemma is the resulting product liability, engineering and manufacturing capacity–flexibility when tools are developed on a short notice for a not so often recurring job specification. The distinguishing advantage of high-pressure water to resist dispersion and its ricocheting capacity especially when laden with abrasives will outperform air abrasive blast techniques (Fig. 3.64). The tooling required may vary drastically and can be of a permanent or quick exchangeable design. The challenge will always be to effectively reach all hidden and obstructed surface areas within a coating or rust-corrosion deletion procedure. A service provider is best advised to maintain a close relationship with his tool manufacturers engineering department.

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Fig. 3.65 Reference photographs

As to steel surface preservation and drying methods performed simultaneously, immediately after and/or as a periodical endeavor in a coating-rust-corrosion removal application to control flash rusting events are a technically developed criterion. Flash rust expansion intensifies especially when metals are newly active due to a hydro-blast coating removal or hydro-abrasive blast performance exposing the surface–substrate. Environmental circumstances such as location, humidity, cool damp days, inadequate tarpaulin procedures, time frame between cleaning and coating application, etc. are only a few factors which may accelerate a potential surface problem. Paint-coating applicators work systematically and often in tandem with the coating removal crew in that; coatings are removed for 4 h and then followed by the coating procedure. Applying and utilizing the SSPC and NACE international guide and reference photographs for steel surfaces (Fig. 3.65) prepared by the hydro-blast and UHP jetting methods are of great guidance toward a superior coating deletion procedure and the selection of a new coating system. Latest coating developments also result in industrial product lines stable under a certain degree of permissible flash rust development with not so circumstantial improved coating adhesion parameters. The visual coating and rust removal reference performed on various steel surfaces is identified as water jetting, WJ-1, clean to bare substrate, WJ-2, very thorough or substantially clean, WJ-3 thorough clean, WJ-4, light clean. Surfaces can show variation in texture, shading or color tone resulting from environmental influences, changes in metal pitting, mill scale, type of steel and probably its original surface condition, differences caused by the initial abrasive blast technique creating an anchor profile, abrasive size, sharpness and prior blast patterns. Flash rust comparisons are identified as no flash rust, light moderate or heavy. The direct removal of wastewater and coating refuse by jetting equipment

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Fig. 3.66 Simultaneous refuse removal

(Fig. 3.66) incorporating a vacuum function will reduce the severity and extend the time frame of flash rust expansion as will the elevated temperatures to steel surfaces resulting from the release of kinetic jet energy and friction (surface-heat). Removing the soluble contaminant and sodium chloride or salt from steel substrates within a coating removal process is a superior high-pressure water application advantage unattainable by other means. A corrosion inhibiting procedure must not negate this advantage. Since the mid 1960s, thousands of industrial steel-base units were hydro-abrasive blasted, primed and coated prior to their equipment assembly. In all imaginable industrial environments the delivered final equipment product in either mobile or stationary form has never exhibited a recordable coating weakness or failure due to a high-pressure water abrasive blast procedure or its technical uniqueness. Chemical corrosion inhibitors should only be applied when a coating manufacturer can assure that their product is compatible to a flash rust inhibitor in question. Liquid or soluble inhibitors can be sodium nitrites, phosphates and benzoates or amino materials such as amino methyl propanol, etc. Precise metering procedures of such chemical inhibitors regarding to level of concentration in blast water as a direct application or by roller and/or airless system is imperative. Controlled are also surface drying times and avoidance of wind swept dust situations, inhibitor pooling possibilities on cleaned surfaces where evaporation may result in concentrations limiting a coating adhesion or promote future coating blistering and delaminating. Coating applicators will follow coating manufacturer’s corrosion control guidelines to guarantee adhesion specifications. A loss of coating adhesion and/or osmotic blistering is likely when manufacturers’ specifications are disregarded. When large areas or areas of difficult access must be inspected, flash rusting events may occur before a visual and physical inspection can be performed. Under these circumstances and before jobs initiation, the creation of various test patches, offering the required surface cleanliness and recording the drying times, ambient conditions and subsequent possible flash rust development or its severity can establish an overall guideline as to the total expected substrate cleanliness.

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On interior steel tank flooring, besides trigger-gun operations, spin-jets or jetcars are the preferred tool identity for exerting pressures between 10,000 and 45,000 psi; removing all coating or elastomeric layers to expose an even gray steel structure. Coating removal rates range from 50 to 250 ft2 per hour. The vacuum recycling ability will eliminate nozzle misting and fogging due to ambient temperature variances, as well as those circumstances which are controlled when utilizing manually operated vacuum assist equipment for corner and vertical work. This does not mean that a continuous process of moving air throughout the confined space in question facilitating dehumidification and evaporation is foregone. Often a coating application includes air heating-filtration within the interior confirming an adequate ventilation procedure. The balance between the return air flow, dehumidification, temperature and relative humidity must constantly be monitored controlling a possible flash rust scenario. A stable sub-floor also permits the removal of individual layers, in particular when a base elastomeric membrane is present. This may add to dehumidification time due to water trace saturation within the remaining coating. Precise jetting parameters are achieved by the manipulation of jet-cars correct forward speed, rpm and gpm–psi configuration combined with the available nozzle variety and adjustable nozzle stand off distance to the elastomeric membrane. Aircraft-carrier flight decks may also be an example of when nonskid runway coatings must be removed or serviced within this application standard. The tarmac sub-structure, built of steel, will constitute no applicable pressure limitations for the contractor, other than naval job specifications. These specifications are identified as to; total base removal, base spot removal practices and rubber or paint stripe removal. Tooling consists of a skid or mobile dual axle-mounted hydro-blast unit with an automated traversing single or multi-head spin-jet assembly, waterrefuse filtration and tank either located on the plane elevator nearest to the work site or in the flight decks’ bay area, low and high pressure-hose runs are kept to a minimum. The actual psi requirements are often comparable to coating removal applications on oil–gas pipelines or fuel tanks with stringent safety regulations; however most ships are serviced on pier-dock site therefore do not require an operational flight deck. Besides naval specifications contractors’ safety requirements are geared to the marine industry criteria. Steel surface preservation is a naval standard introduced to the contractor and must be followed explicitly. Water pressures range between 14,000 and 40,000 psi, gpm performances according to applied coating removal-width and subsequent hp availability. At times it is necessary to upgrade and install a secondary water filtration element to avoid contaminated water from pier or vessels potable water supply. All operational, coating removal, hazardous waste-refuse handling and safety procedures are specified by naval yard operations or their sub-contractor and include all asbestos coating or insulation removal deletion applications. 12. Even though the removal of graffiti (tagging) on various substrates is included in this chapter (Figs. 3.67 a, b, c), it is impossible to determine an adequate solution when lacking the on-site investigation identifying the appropriate cleaning

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Fig. 3.67 a, b, c Varies graffiti events

Fig. 3.68 Vacuum-UHP jetting

or removal method. Most often vandals vent their creativity by utilizing a location advantageous to their message criterion. Therefore all conceivable areas or surfaces are subject and include residential–commercial–industrial structures, public buildings and restrooms, mass transit vehicles, stationary or rolling industrial equipment, etc. (Fig. 3.68). Acrylic latex paints, enamel spray paints, chalk and the ever evolving coloring variety delivered by highly durable aerosol cans, and/or crayons, ink, dyes, lipstick and powerfully formulated marking instruments are the stain producing paraphernalia. The vandals prefer presentation sites, where achievements stay on display for an extended period of time. For any contractor, difficulties arise due to the mostly unknown colorant adhering to a vast variety of painted or coated concrete compounds and/or stucco concrete paste and exposed aggregate surfaces including synthetic brick and fired brick, their mortar joints, tile, CMU block (Fig. 3.69), concrete surfaces poured in place, tilt-up or cast-in place (Fig. 3.70), wood, vinyl or various natural stone substrate, etc. This is exaggerated by varying surface porosity, possible substrate damage and unknown interface adhesion factors, discoloration of the interface makeup by unidentifiable pigment and environmental influences resulting in that no single removal technique by highpressure water and/or chemical method exists.

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Fig. 3.69 Masking graffiti

Fig. 3.70 Cast concrete panel

Fig. 3.71 Visually blending into cover graffiti

Indecision by affected property owners as to the deletion of the visual expression will only attract further or repetitive tagging activity. Visually blending in by painting over affected areas (Fig. 3.71) will result in an unattractive substrate and possible future building damage due to air flow restriction, moisture and/or mold development. A new, smooth appearing paint-coating (improved canvas) will also invite further tagging activity. The temptation to employ a novice professing professionalism within this application criterion is risky business. Needless surface ghosting manifestations or irreparable surface–interface and substrate damage might occur when an untaught utilization of water jet energy via equipment producing modest 1,500 psi-plus and a rotary spin jet or 15 fan nozzle at 5 gpm is allowed.

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Fig. 3.72 Damaged CMUblock and concrete surface interface

As this example illustrates not only was a sacrificial coating removed, the contractor also created permanent ghosting effects by damaging CMU block and concrete interface (Fig. 3.72) structure into substrate depth. Providing pictorial proof as to prior successful job completions on similar substrate accompanied by detailed job report and customer information is always of a great advantage for an aspiring service provider as it can also be an educational tool for prospective customers’ job reality. Next to an arrest, a customers’ perseverance in maintaining a graffiti-free structure is the only real deterrent. Responding to vandals’ endeavors within 8–36 h (max), exhibiting qualified cleaning procedures and the installation of either sacrificial or better permanent anti-graffiti coatings is paramount. This action is the preeminent deterrent especially when a substrate appears miraculously untouched or the new endeavors will not adhere and/or shrivel in the drying process. Ideally, the previous performed removal application will require property owners only to utilize a light high-pressure water wash supported by an environmentally friendly detergent when recurring tagging events appear. Nevertheless blues and greens are generally more difficult to remove then reds and blacks. A gentle or delicate graffiti removal process on porous substrates such as concrete or its surface paste, masonry aggregate, brick, sand and limestone, etc., is performed in correctly identifying and chemically destabilizing the graffiti accumulation from its surface. After an adequate dwell time (chemical) and before light buffering abrasives are utilized is it important to follow the graffiti outline by applying a 15 fan nozzle to remove all loose or soluble coating residue to avoid all damage to the substrate. Hot pressurized water is almost always of an advantage on porous substrate. Ghosting or removing the faint outline of a coating can be problematic if a minuscule layer of substrate is not to be manipulated (interface). Spray paints composed of solvents which evaporate depositing pigments and their adhesive require a straightforward removal technique of the appearing central

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Fig. 3.73 a, b Abrasive blasting

pigment concentrations (poultice-solvents), and is followed by the neutralizing pressure-washing application and barrier coating installation. Pigment originating from metallic oxide or a synthetic compound adhering to a surface can require the chemical breakdown of the ionic force (static). Chemically introducing an extremely high level of hydrogen activity is specifically helpful when supporting a high-pressure water ghost removal application which proves successful time and again. The industry also developed penetrating chemistry directly applicable by metering device and trigger-gun application supporting pressure-washing endeavors on various metal, vinyl, wood, and painted–coated surfaces. And then there are phantom graffiti remnants that can chemically simply not be removed requiring the versatile water-jet abrasive technology (Fig. 3.73). Alternative blast media such as cement powder (Portland), nutshell, sodium bicarbonate or a fine soluble buffering abrasive with a relative soft, 2–3 on Mohs hardness (scale) will achieve a superior interface cleaning procedure visually avoiding interface manipulations or interface and substrate damage. These products are especially successful for or within minor job descriptions. Comparative inexpensive abrasive injectors, trigger-gun mounted, fitted with a fan jet-barrel permit the introduction of a controllable scouring effect. The utilization of solvent based products such as lacquer thinners, acetones and chemical paint removers of unidentified origin must never be introduced to a surface. They may not only discolor adjacent substrate but will leave a pigment laden discoloration within the interface area of a coating removal procedure. It must also be assumed that unidentifiable chemicals are of hazardous origin thus requiring product identification. If identified, the MSDS information will almost always require adherence to an assortment of local and federal recovery laws and safety requirements. Anti-graffiti products should be non-toxic, containing no ethylene chlorides, chlorinated solvents, methanol–methyl chloride, toluene, or acetone. The recommendation of a chemical product for various coating destabilization procedures should always be supported by its manufacturer. The necessary

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information retrieved includes the identification of preferred brush, roller or spray equipment, necessary environmental conditions while the work is performed (temperature–humidity), chemical adhesion characteristics and required dwell time, coverage rate on various substrates considering applicators tool requirement (brush-roller application requires more product), competitive pricing per square foot, applicable safety procedures and product identification (MSDS). Most chemical manufacturers have established methods or recommendation for a cold or hot low or high-pressure water rinse technique and if necessary specific neutralizing procedures of a substrate in question. A service provider performing various job descriptions within this coating removal procedure is well advised to consider vacuum–recovery and water filtration–recycling equipment, as it is important to understand necessary and always changing tarpaulin procedures. Selecting a breathable, non-visible sacrificial or non-sacrificial graffiti barrier is a question most often confusing to a customer. The coatings work on the same principle in that cleaned porous masonry surfaces are protected against paint soaking into the pores, subsequently adhering or producing a discolored interface structure. The choice between none or a sacrificial treatment depends on the frequency of attack, substrate type, location, visual nuisance factor, human or vehicular traffic conditions, climate and various unlawful or depraved messages, eat. A variety of water soluble, water-based and breathable (wax type) sacrificial graffiti barrier coatings are available. They must be reapplied to a surface after a graffiti project and barrier coating are removed simultaneously. Some sacrificial, semi and permanent coatings require a specialized base coat installation. There are a few non-visible or non-sheen producing coatings available supporting a repetitive graffiti removal practice (5–7 times). Substrates introduced to this type of barrier coating must be approached with suspicion. This does include prior treated surfaces such as historic limestone and sandstone façades, structures or areas and their design variants. These coatings can also be dramatic if imminent or future repair and/or tuck-point endeavors are desired on brick walls repelling the necessary grout adhesion. Most often it is quite impossible to verify past cleaning intervals and graffiti removal methods. High-pressure hot-water removal temperatures should not exceed 200F to avoid possible stain-pigment setting of unidentifiable coating remnants in the interface structure. A contractor unaware of substrates service history and products utilized in the past should be cautious as not to create irregular surface appearances due to variances in a barrier coating adsorption. Within the coating application one must also be vigilant to avoid barrier runs which are often rolled or smeared out by a novice applicator creating discoloration or darkening effects when remaining wet film thickness, absorption and drying times are dissimilar to the primary coated surfaces. Varying a barrier coating identity, property owners ought to be made aware of, or find it acceptable that a minor darkening or gloss enhancement to the substrate appearance might be possible. A uniform coating application exhibits an equal surface wetting appearance within an application process. Wind disturbance of the spray pattern is more often than not the culprit in an uneven surface application procedure.

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Inspecting and testing a substrate as to a future visual quality and achievable adherence-penetration of the desired coating and its performance and/or equally the proposed graffiti cleaning–removal technique, operators–applicators test substrate–surface absorption parameters randomly and then the desired cleaning method on small and visually out of the way, least noticeable and/or arbitrary areas before an overall cleaning and re-establishment of a barrier coating is performed. A visual variation can be produced within the absorption coefficient of a substrate and must sometimes be addressed within a dissimilar cleaning method. Also the possibility to feather in visual surface irregularity or appearances by a pressure-washing effort can be greatly influenced as to its success by varying substrate absorption or adsorption parameter and/or positive charged pigments (ionic charge). The application of water based coatings (wax type) are performed in mild temperatures above 40 to 50F facilitating an adequate product mixing and emulsification avoiding otherwise a possible visual surface remnant (gray sheen). Generally, barricade coatings require 3–6 h drying time, temperature and humidity pending, as they also may require a second coat expanding drying times up to 72 h. To estimate the coverage of a barrier coating per gallon applied for metal is approximate 600 ft2 per gallon requiring one application, on sealed and painted–coated wood or concrete surfaces also one application at approximately 450 ft2 per gallon, on painted concrete block (CMU) with two applications, proximately 400 ft2 per gallon, on stucco, brick, fired brick, concrete block or cast in place, also with two applications, approximately 300 ft2 per gallon. A cleaned surface dry and prepared requires approximately one labor hour to install 2,000 ft2 of barrier coating. These estimating values are approximate and vary dramatically between job applications due to new or historic substrate, unreliable adsorption or absorption, varying surface porosity, substrate hydraulic conditions, temperature and humidity and/or applied product characteristics and applicable environmental standards. Non-sacrificial breathable barrier coatings can be silicone based products, or coatings based on several major resin chemistries with silicone and polyurethane based materials providing a long-term service life, despite repeated graffiti removal applications by high-pressure water. These coatings enhance bonding to the substrate, resisting water, oils, and paints ore marking materials. Penetrating treatments of this type will provide anti-graffiti properties but will not alter the look of the substrate. Various coatings are available, and can be chosen to harmonize with the existing overall installation utilizing a universal tint machine. Coatings range from relatively low-cost acrylics, to better performing polyurethanes and epoxies, some of which can be applied to metal surfaces. Penetrating silicone based treatments are generally not suited for metal, various smooth stone, and to some degree even hard glazed brick surfaces, nevertheless they are most effective in warding off ghosting effects. As to an overall general and detached judgment, one can only say that a hard, non-porous impermeable and relatively smooth surface is inherently much easier to clean and protect than a permeable porous (soft or hard), or very rough and/or heavily textured substrate.

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GEAR - LIST AUTHORIZATION Coating - paint - graffiti removal on steel, concrete, stone, brick, and wood substrate Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Job Review Performed by: Structural circumstances: Horizontal: Overhead: Vertical: Confined space: Vessel entry permit: Hazard classification: identify: Access procedure: Scaffolding: Tarpaulin procedure: Vegetation: Aquatic environment: Traffic control: vehicular, pedestrian: Effluent control measures: Coating waste control measures: Test Equipment: Soluble salt meter: Thickness gauge: Pull-off adhesion test: Surface profile gage: Surface moisture meter:

Specify:

©

Coating deletion: Friable: yes: no: Lightly: serious: Limestone: Sandstone: Stone: Brick: Mortar: classify Concrete: Wood: Aluminum: Steel: Coated steel: Other:

psi?

Alternative abrasive: Chemicals: dwell time: Detergent: dwell time: Specify: MSDS: Cold water: gpm: psi: Hot water: gpm: psi: Soluble paint-coating: yes: no: Rinse method: Barrier coating: Sacrificial -permanent One code: Two codes: Flash rust inhibitor: Other: Coating installation specifications: Airless paint sprayer: Chemical metering equipment: Ventilation equipment-procedure: Dehumidification equipment:

Nozzles: Hydrovac-system and Vacuum-box: Water filtration and recycling: Abrasive injector: Other: Other:

Patch testing method:

Coating, tensile strength and adhesion:

Specify:

Physical surroundings, safety procedures: Specify: Describe the work procedure: Itemize equipment, safety gear, expendables, labor time, equipment times, etc.

Areas:

Other:

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Fig. 3.74 A preventable ghosting event

In today’s restoration and/or construction domain, preventive technologies are available for new or restored concrete surfaces, providing both the structural and aesthetic requirement. The two-in-one concrete curing and graffiti control product which also protects the structural substrate from expansion, contraction, and temperature extremes is quite versatile. Protecting against graffiti, these coatings are impervious to ultraviolet rays, ozone, salt water spray, and acid rain. These coatings contain fluorinated high slip anti-stick additives, which when vandalized prevent adhesives from adhering to coated services (stickers) and will while applying graffiti shrivel the colorants while inducing product slippage down wall surfaces. Possible minor remaining trace elements, will wear off with normal weathering. Paint ghosting scenarios (Fig. 3.74) are simply removed with a low pressure washing application. Because this coating is applied to new concrete the product bonds with the substrate aggregate. After adequate concrete curing (28 days plus) and coordinated with the following form board removal endeavor coatings are simultaneously–immediately applied producing an approximate 2–2.5 mil wet film thickness.

3.6 Concrete-Aggregate Cutting, Scarifying, Surface Preparation, Demolition and Restoration During the Roman Empire, buildings, bridges and water pipelines were constructed using a building material known as opus cementitious, a mixture of burnt limestone, loosely added rock, and water. The technology used then was lost, only to be rediscovered 200 years ago with the use of a product known as Portland cement. In 1867, the Frenchman Monier added steel reinforcement, enhancing the strength of the product we know as reinforced concrete. The high alkalinity pH value of approximately 12–13 prevented the corrosion of concealed steel, making this a highly successful process. Concrete is a product containing limestone, clay, and various aggregates, is sensitive to acids, salts, carbonation and concentrations of sulfur dioxide (SO). Hardened, it is susceptible to micro fractures, often a result of structural tensions, mechanical or hydraulic-driven impact tools, and erosion by mechanical abrasion. Edge spalling of joints, spalling by impact and environmental

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Fig. 3.75 Concrete deterioration

Fig. 3.76 Light aggregate removal

shock resulting from sudden climatic change and/or freeze cycling (Fig. 3.75), etc. are added circumstances a concrete structure endures. Under favorable atmospheric and internal conditions, a general deterioration of exposed rebar (steel) expanding up to six times its original volume can accelerate surface discoloration and damage in depth any susceptible structure. However, a prematurely deteriorating concrete substrate may also be the result of an incorrect specification, or construction process. A repair or rehabilitation project requires the removal of deteriorated and damaged concrete aggregate (Fig. 3.76). The removal performance by high-pressure water is adjusted (gpm–psi) to the damaged concrete interface zone avoiding all further negative influences to the remaining intact concrete matrix. Compared to all mechanical removal methods the unproblematic determination and recommendation as to the necessary area of attention (removal depth) of an affected concrete substrate will prove vital to a job estimation criteria. Subcontractors also should be aware of concrete repair strategies proposed or introduced to a restoration–rehabilitation endeavor in question. To circumvent performance challenges, the service provider best understands all possible causes including wear and tear criteria to the structure in question.

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Fig. 3.77 Repaired damage

Fig. 3.78 Deep UHP aggregate removal

As much as he should understand the following repair methods which hopefully address the root cause of the concrete’s deterioration-symptoms (Fig. 3.77) facilitating an estimation process requires close cooperation of its property management. All physical access constraints and environmental obligations must be considered as does the structural safety during the test procedures. The presence of a structural engineer is always advisable, identifying all added load classifications by equipment and reduction through removal of concrete mass in the tested areas (Fig. 3.78). If reinforcing bars (rebar) are exposed during a demonstration or test procedure, the steel structure should be treated with a corrosion inhibitor. Extended time periods between an investigative process, bidding and the final job initiation also requires the protection of exposed rebar structures. Assorted coatings and/or a suitable primer and/or zinc-rich paint cover can be applied. Removing deteriorated or damaged concrete in inaccessible areas to or below the rebar structures can best be achieved by using a trigger-gun starting at approximately 14,000–43,000 psi. A variety of straight and rotating nozzle configurations are available. To ensure visual control and operator safety, an adjustable splash guard is affixed to the gun barrel. At these pressures, the recoil energy developed by a jet must be controlled or offset to a physically manageable force. Do not reduce pressure; reduce equipment water volume performance instead. Cleaning and slightly enlarging stress fractures and cracks to accommodate polymer modified concrete grouts or chemical grouts reacting to form a gel or

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Fig. 3.79 Concrete slab, before–after

Fig. 3.80 Concrete aggregate cleaning

solid are applications often encountered within structural restoration projects. Appearing cracks and/or fissures have many causes and can be the result of weathering, mechanical or thermal stress, settlement and shrinkage or faulty construction process and design. Regardless of cause, a high-pressure water jet is most suitable for cleaning and preparing cracks vertical and horizontal surfaces gaining the desired adhesion factors. The contractor must choose tool criteria by correctly identifying the desired application, which can affect the appearance only or be structurally significant. This can only be achieved once the extent and reason for the cracking-fissure developments have been established and successfully managed by either preventive maintenance or justified reasoning. Exposing aggregate gravel on concrete slabs (Fig. 3.79), traditionally performed by rotary steel brush systems on production sites, sometimes in combination with acids or multiple acid applications, is being successfully displaced by today’s high-speed spin-jets rotating a single jet about its axis (Fig. 3.80). The nozzle standoff distance will be approximately 1–1‘0 above the concrete surface. Required pressures range from 3,000 to 5,000 psi. Manually-operated spin-jets can produce cleaned areas of approximately 45 square yards per hour, thus utilized in large area applications representing triple the production capacity of a single trigger-gun fan jet assembly. These values are based upon a 6–8 h aggregate drying time. Hardened surfaces (Fig. 3.81) demand the use of spin-jets at 6,000–10,000 psi, producing a cleaned area of 25–35 square yards per head per hour. Nozzle standoff distance will again depend on nozzle size

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Fig. 3.81 Before–after, aggregate cleaning

and rotating speed, effective nozzle spray pattern, available horsepower input and tensile strength of concrete adhering to aggregate (gpm performance). A single fan jet operation is often impractical when cleaning large soiled vertical concrete slabs, building facades or ornamental surfaces. The spin-jet assembly is capable of cleaning up to 90 square yards per hour, effectively avoiding surface ghosting appearances. This is achieved due to the enhanced nozzle standoff distance, subsequently resulting in greater area coverage. Alternatives to this application are based on chemical power. A concrete cleaner (acid) is applied to slab surface by an injector or roller, etching the slab surface structure to the point where 2,000 to 3,000 psi at 4–5 gpm and a 45 fan jet is adequate to clean and neutralize the substrate. Due to the restoration and preservation varieties on buildings of all ages, materials and there designs, hydro-blast and/or UHP tool requirements will differ drastically as does the support equipment which must facilitate those varying operations. Gaining jobsite access, protecting the construction site from falling debris, controlling water accumulations, water-misting as well as performing adequate tarpaulin procedures are variations, dictating the choice of specialized tooling. Removing concrete-mortar in a controlled manner is often supported by precutting (diamond blade) and establishing area identification (Fig. 3.82a, b), subsequently providing a smooth edge configuration. After concrete-mortar removal this also supports an aesthetic least visible to repair fill application. Care must be taken as not to cut into to the rebar structure. The blade angulations’ pointing to healthy or hale substrate supports and enhances adhesion capacity of various repair material. The blade degree is also determined by mortar’s aggregate size to protect edge structure within the removal process. Controlling the aboveground construction site while performing a cutting, demolition or scarifying application differs substantially in its technical requirement

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Fig. 3.82 a, b Concrete edge precutting

to underground operations. This includes the area of foundation-footer cutting (Fig. 3.83) or structural concrete removal techniques (Fig. 3.84) in high-rise basements’, subterranean construction sites such as pedestrian, vehicular, rail and subway tunnels, and in the interior of water dam or mining facilities, etc. Within an application procedure these areas can or will be classified as a confined space. Most often a subcontractor status exists to a general contractor which requires a combination of, traffic, general construction safety, additional trade logistic controls and advanced environmental application technologies such as for instance water filtration and recycling procedures. Hydro-cutting, scarifying–roughening or demolition applications may depend on specific structural circumstances requiring an impact-vibration less, atmospheric non volatile, heat-less and explosion proof procedure avoiding all water pooling, saturation and rubble or waste accumulation possibilities. Concrete cutting or removal applications will test a subcontractor and contractor’s ingenuity with every assignment involving multiple trades. Backhoes and bobcats are employed to excavate exterior foundation of soil, creating a cavity large enough to facilitate the necessary movement for operator and high-pressure water tooling. This includes creating a designated area for accumulating debrisrubble and a 17 amps or equivalent submersible float-actuated trash pump with a capability of transferring four times per minute the water generated within an application criteria. It is prudent to include a backup source proficient to function independently and under any mitigating-unforeseen circumstance. The hydro-vac

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Fig. 3.83 Foundationcutting

Fig. 3.84 Structural concrete cutting

vacuum system accomplishes with various hose diameter’s (200 to 1000 ) the flexibility to retrieve or keep free of water accumulations, small and difficult to reach interior locations, areas and cavities. The precise determination of vacuum hose size, hydro-blast and UHP equipment and/or tool necessities can only be established when the structures aggregate size (rock and rubble) and the physical volume in their location are determined. A contractor wishing to operate in an excavated, more than 40 deep interior– exterior trench must also provide a qualified competent person continuously enforcing the OSHA regulation 29 CFR 1926 which monitors and correctly secures the trench location eliminating trench destabilization by heavy load, vibration, water saturation, faulty equipment, etc. Under no circumstance can water be allowed to seep into adjacent grounds. A multitude of secure trench stabilizing equipment and pasting techniques (tar, foam, rubber liners) are applied, supporting and covering the total interior cavity before a submersible pump is placed below the application area. The pump’s discharge hose is connected to a

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storage tank (roll-off box) which separates heavy debris and simultaneously discharges water to a water filtration and recycling unit. When concrete cutting applications are underway, tarpaulin procedures and a heavy steel plate will protect the surroundings from jet’s directional impact and diffuse the high velocity water or water-abrasive jet to the bottom of the cavity. Whenever possible, direct abrasive jets velocity to the building’s exterior and do not load abrasive garnet within the exterior cavity area. There is a variety of equipment available to affix concrete cutting gear to footers, and walls, as there is a variety of successful application criteria, where the shovel of a backhoe or bobcat is applied to securely mount and stabilize equipment. Most importantly, the nozzle standoff distance to a concrete surface should not exceed ‘00 . A standard cutting operation on a foundation reinforced with rebar measuring 20 in width should produce a minimum cut of 60 –80 linear feet per hour. Hydro-cutting precise squares into reinforced concrete slab-flooring can be achieved using a four-wheel cart mounted with jets angled at 15. Jets are guided by a form or straight-edge in smooth repetitious movements. The depth of the cut should not exceed 00 below the rebar structure. Once the cut has been achieved, the process is finalized by impact hammer. Use caution, the jet must not break through the concrete base as this will result in subsoil tunneling. Ground-flooring and hydro-cutting procedures can be cumbersome (tunneling effects) when compared to diamond blade cutting methods. Some manufacturers claim superiority in this specific application. Physical circumstances surrounding water jet technology simply do not yet support such claims. In spite of existing controversies, hydro-cutting plays an invaluable role when working within volatile environments such as refineries, explosives and weapons industries, mining, marine industries, or flour and coffee mills, etc. where development of heat, gases and sparks could be truly problematic. By nature, debris accumulations consist of water, abrasive garnet and fine structural material (hydroabrasive cutting), generally resulting in a simple refuse recovery process versus the hydro-blast or UHP concrete demolition applications where aggregate rubble of various size demands an exacting removal criteria. Starting in early 1970 the need to repair structural concrete facilitated the development of heavy concrete demolition, then identified as hydro-demolition. This in turn provided the technical parameters, psi–gpm requirements and calculations for various substrate removal and roughening procedures. In considering most technical variances for a nozzle configurations utilizing up to 600 hp pumpdrive capacity; nozzle design, gpm–psi performance with varying stand-of distances to the rebar enforcements and beyond was established. The steel cutting method is derived from earlier design technologies for bridge pylon cutting applications (1967) incorporating the ability to perform the cuts through their existing rebar structure simultaneously utilizing abrasive concrete cutting heads. This capability was introduced to construction sites where bridge expansions were deemed necessary and later on bridge piling where a base deterioration required repair. Today, available hydro-tools enable us to cut concrete and rebar structures, or if desired, remove concrete only, exposing the cleaned rebar in a fully-anchored

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position, creating no micro fractures within in the substrate’s anchorage. Pylon cutting is achieved through the use of a concrete-cutting head, utilizing a water abrasive mixture at 10,000–36,000 psi, 8–38 gpm. Cutting head design and performance capabilities vary as to manufacturer’s experience-ability and pump drives power range. Depending on an encountered application the necessary garnet volume can range from 50 to 200 lb per hour. A copper slag grit of 1 mm works well. Colorado or California silica is usable and less expensive, but the actual cutting time could increase up to 30%. When utilizing ideal technical conditions, a heavilyreinforced 60 Ø bridge-piling is cut within 2.5 h. The industry supplies hydraulic or air-driven running gear featuring a metering device to control the forward drive similar to cutting tools applied in pipeline cutting or welding operations. Equipment manufacturer pending, the adjustable cutting speed can range 10 –200 per hour. When choosing a unit, one must pay close attention to its attach-ability. Such units feature combinations of vacuum, chains and other mechanical devices to accommodate various application and fastening criteria. A well-designed abrasive water-jet will maintain its tight formation while cutting through reinforced concrete. Experienced operators adjust the forward cutting motion by recognizing the appearance of jet parting the channel. A diffused or partially diffused jet indicates the drive speed is too high and should be slowed to the point where diffusion appears minimal. If logistically possible, install the unit above the cut to be performed, thus minimizing soiling of unit’s hydraulic-air drive-chains, sprockets and general running gear, etc. Concrete removal applications are not so similar. The major difference being the absence of abrasive material and the accumulation of waste aggregate which requires effective removal, storage and transportation solutions. Aggregate size differs as to the specific concrete function–application resulting in variable technical application solutions encountered with every jobsite. Adding various physical surface variations, job location and ever-changing environmental prerequisites which include blast water recovery, filtration and recycling methods, the highpressure water concrete demolition–rehabilitation criteria differs in: • • • • •

No deformation or damage to rebar structure or its anchorage (Fig. 3.85a, b) Rebar corrosion removal to desired standards achieved within the aggregate No structural vibration, impact or abrasion damages Total avoidance of developing micro fractures and fissures in substrate More clear-cut measurable-estimating decree for load classification within the demolition–restoration • No dust development, correct application indifferent to aquatic environment • Superior production times and gentler removal in comparison to all other methods. Hydro-trigger gun operations are equally common for various concrete removal applications and are enhanced in today’s utilization of UHP tooling and subsequent specific application techniques. When refurbishment is deemed necessary,

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Fig. 3.85 a, b Corrosion free rebars

steel railings and failing railing fixtures buried in possibly stress-damaged concrete must be removed without further disturbing the surrounding aggregate. This is manually performed with a high-pressure trigger gun at 10,000 psi and no more than 8 gpm or a UHP trigger-gun applying 36,000 psi generating 3 gpm. This effortless type of spot maintenance is of an advantage to general contractors when considering that concrete tear resistance is improved up to 80%, making this application ideal in difficult areas or on intricate concrete structures (Fig. 3.86). An adequate horsepower requirement, combined with sufficient accessories and tools will provide a dual gun capability found always advantageous when high volume workloads are anticipated. Effectively splash guarding the procedures, controlling various traffic situations, removal of aggregate and fixtures from the jobsite, operating blast water recovery, filtration and recycling equipment can be a complex mission and must be in detail calculated and added to overall time and cost estimates, which are most always competitive and more importantly less costly to the contractor than previous job solutions and their methods. The industrial environment also requires mobile and stationary guidance systems effectively offsetting nozzle or nozzle carriers recoil forces with standard operating pressures ranging between 8,000 and 45,000 psi, and can vary from 55 to 1,200 horsepower configurations. Overall, the in depth desired demolition capacity depends on adequate horsepower-input enabling a nozzle standoff distance to the concrete structure. In opposition the ultra-high-pressure (UHP) water-jet or turbo nozzle facilitates a controlled and quantifiable concrete removal application, working at comparatively

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Fig. 3.86 Damage-corrosion free

Fig. 3.87 Concrete jet mill

minimal water volumes, equaling a limiting but precise standoff distance with substantial lesser horsepower inputs and trigger-gun recoil forces. Apart from water volume applied, in required space (nozzle standoff distance); a repetitive nozzle fixation to surface–substrate-interface is of utmost importance. This is true for manual (body mechanics), automated and fixed mobile equipment operations, guaranteeing a precise and repetitive concrete milling procedure and, for this matter including constant and if necessary gentle surface cleaning methods will always establish their business superiority and application competitiveness (Fig. 3.87). This is especially obvious when competing for road, tunnel, and bridge maintenance contracts, where it is an indispensable application facet. In the last decade, surface cleaning, restoration and rehabilitation techniques developed and found to be superior, financially most competitive and outperforming prior parallel services and technologies in most areas. Mobile equipment or better mobile and affixed nozzle carriers are the epitome of precise and repetitive performances, guaranteeing set nozzle standoff distances applying various horsepower inputs with varying forward, sideways and elevated– vertical–overhead milling capacities. Some of the available equipment is designed for multipurpose application varieties, including surface cleaning, coating removal, concrete surface roughening–profiling and demolition, or the cleaning, coating and corrosion removal on steel surfaces. The construction industry is finally applying jet mills, which were designed decades ago and successfully tested in the field. General contractors found the hydro-method enhanced adhesion 70–80% while out-performing all other concrete removal techniques up to 70%. The process is dust-free and most importantly differentiates between deteriorating and damaged concrete, eliminating further operational mechanical influence, especially significant when concretes

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Fig. 3.88 a, b, c, d Scarifying concrete

compressive strength and integrity falls below 5,000 psi. Loosened material is swept up and removed by a standard street cleaning machine (vacuum-rotary brush). Finer particles are then flushed by fire-hose and introduced to a water recycling and filtration unit, resulting in ideal resurfacing conditions. Bridge deck restorations require resurfacing of worn, deteriorated or cracked and/or blistered decks, and can include preparing the structures sidewalks, railings and buried fixtures. Generally the removal depth of such deteriorated surfaces is between 00 and ‘00 but can vary to a 1‘00 layer on older structures due to many past repair procedures. The required specification and at will manipulated surface roughness varies between job site and is subject to product specifications in the resurfacing phase. This is today considered a straightforward application criterion and is most often performed with a mobile self contained unit. Operating pressure on a truck or tractor mounted traversing jet mill is between 10,000 and 43,000 psi at gpm performance required by traversing nozzle carrier design (Fig. 3.88a–d scarifying concrete). Equipment square footage performance varies by design and horsepower input, and can be between 400 and 950 ft2 per hour depending upon cover deterioration and depth performance requirements. Sidewalks and other confined, narrow or inaccessible areas are scarified using a manually operated jet mill in combination with hydro-blast or UHP trigger-gun operations. These units have the capability of scarifying or product removal within 200 of the curb, preventing damage to insulation and maintaining the curb profile in its entirety. Manually operated units feature large pneumatic tires, allowing for a smooth roll-off performance and, in doing so, achieving a controlled nozzle standoff distance. This operation requires protective skirting procedures (mobile) within jet mill’s and trigger-gun vicinity, keeping barricade costs to a minimum. The preparation of new concrete road decks (Fig. 3.86) by profiling a semi cured concrete substrate to a desired product

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specification can require a close or sometimes stepped procedure between surface prep crew and company installing the required system. Often concrete’s internal specified humidity must be maintained requiring moisture barrier procedures while in the profiling process. Temperature, curing, shrinkage and drying times of various product systems within a new installation procedure must be controlled. Maintaining a concrete’s correct moisture content can also be of importance when repair or structural expansion procedures are undertaken. To update or increase bridge load qualifications, contractors may be required to remove concrete aggregate below the second rebar structure on all load essential areas such as bridge decks and bridge heads. Once this is completed, rebar matting is added, gaining required tonnage. When the original pre-stress qualifications of a bridge are in jeopardy, mechanical removal methods (impact-hammer) have proven to be inadequate. Vibration deformation and expansion of rebar metal cannot be permitted. Light weight tractor-mounted deep scarifying units are readily available, operating at 20,000 psi, to 45 gpm, cutting to a depth of 400 per passage, producing approximately 14 square yards per hour removal rate and cleaning simultaneously the rebar structure to S.A. 2.5, and in most instances eliminating final sandblast procedures. Most importantly, before, and while in a structural rehabilitation, expansion, or load increase process, a consistent assessment and fluid analysis, determining the repairs influences on the structural integrity within the demolition, repair and the final new product installation process must be at all times guaranteed. To do this it always includes the control and precise estimate of the additional weight introduced by the hydro-blast equipment and support equipment, shifting weight classification by tractor trailers loading concrete refuse, and considering the vacuum-trucks utilized to perform the final cleanup which are always exceedingly heavy due to concrete-water weight, possibly one-sided general traffic loads, and the loss of unforeseen or miscalculated weight-bearing integrity due to concrete removal, especially during times of possible seasonal frost, etc. This safety criterion demands a very close and effective relationship between subcontractors, contractors, engineering and department of transportation. Overall, when removing failed concrete by the hydro-demolition method (Fig. 3.88) an up to 75% savings in time, labor and equipment expenditures can be realized. Adhering to all OSHA safety regulations, stressing adequate scaffolding, tarp procedures effectively controlling water, concrete refuse flow, including barricades and traffic controls are all areas where added efficiency is realized. When scarifying bridge heads and bridge side walls the various tractor-mounted units are equipped with an overhanging robotic and adjustable fixture accommodating a vertically-positioned jet mill. Utilizing this method eliminates the erection of scaffolding, but requires tarpaulin procedures to protect traffic and the employment of water recovery and recycling-filtration procedures. A removal performance criterion requires approximately 14,000 psi at 34 gpm producing a scarified area of 1700 -linear 1700 -width 1000 -depth and is accomplished within three 8 h shifts. Within this application field, cement wash, bituminous products, general paints and epoxies are often removed in specific areas with a, 15–20 fan nozzle at

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approximately 11,000 psi, at 6 gpm. Concrete will destruct at about 12,500 psi; 11,000 psi is the recommended applicable pressure. At this given psi–gpm performance, an area of approximately 300 ft2 can be cleaned per hour. Suggested tool choices for this application are hydro trigger-guns, turbo or spin jets and jet cars. With these available tool configurations, applied wet and dry abrasive blast methods removing contaminants-products or to prep a concrete surface (profiling) becomes obsolete. The low-fluid volume, high pressure system configuration delivering its velocity by means of a qualified fan jet will not attack a concrete substrate surface but allows an absolute cleaning method in porous depth. Hardened epoxy coatings often lack strong adhesion to a concrete base. Spin jets, jet cars and turbo jets are the ideal equipment for this job. With older structures, the possibility exists that concrete surfaces cannot withstand volume–pressure requirements to penetrate and remove acrylic products. In such circumstances, try a lower volume nozzle at 3 gpm and 11,000 psi. Again, to clean surface areas, spin jets and turbo nozzles at lower volume configurations are the most effective. If paint adhesion cannot be broken below the compressive tensile strength of a concrete–coating interface, the hydro-abrasive method may be a gentler procedure. Protecting interior and exterior concrete surfaces in various industrial environments is a common prerequisite. When applying today’s modern coating systems it requires a proper surface preparation, providing proper coating adhesion. Up to 80% of all coating failures are due to inadequate surface preparation and cleanliness. A service provider specializing in and delivering an ideal surface condition is well advised to be aware of customers future intentions for the surfaces he treats. When a following coating procedure is concluded and premature coating failure occurs his past services will be the first to be investigated. Appropriately recording the applied job specifications and results are important, as is maintaining the results in an orderly fashion to be recalled at any time. The best defense is to educate a customer as to the merits of a correct coating application. Work should not be performed on rainy or foggy days and temperatures below 50F if not otherwise specified. Concrete structure has cured at least 30 days at material temperatures of 75F plus, and a surface pH value should be between six and eight. Concrete must be free of moisture, meaning that concrete seldom drops below 15% in its structure. Past concrete enhancement or treatment such as hardeners, sealers, form-release agents, curing compounds must be compatible with coatings or removed. This removal process is a hydro-blast job description. Identify and provide coating manufacturer’s surface profile requirement for best results. Apply various test patches and perform pull-off tests. Given the nature of widely differing concrete surface appearances and unknown conditions such as deep-seated contamination, chemical imbalance, friability, roughness, porosity and unidentified permeability can be principally limiting to coating performances in adverse conditions, as well concrete surface applications and high-pressure-water tooling will vary substantially. Competitors within the field will utilize milling equipment (cutting teeth on rotating drum), flame blasting, needle gun equipment, scarifying with rotating disc, shot-blasting and vacuum recovery, acid etching and steam cleaning, or wet and dry abrasive blasting also with vacuum recovery.

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GEAR - LIST AUTHORIZATION Concrete cutting, scarifying, surface preparation, demolition and restoration Customer & Company:

Date: Address:

Web site: e-mail:

Job Nr.:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location: Job Site Risk Assessment: Specify: © Job Review Performed by: Blistered bridge decks: Parking lots: Bridge heads: Intersections: Bridge pylons: Sidewalks: Foundation-footer: Steel railings: Stress damaged building: Railing fixtures: Brick building: Concrete slabs: Concrete flooring: Building facades: Cured epoxy: Other: Other: Overall cutting depth and width: Overall square footage to be serviced: Overall material volume to be removed: Other: Existing structural damages: (explain) Safety procedures: (explain) Spot demolition: Acid treatment: MSDS: Spot scarifying: Acid neutralization: Spot cleaning: Confined space: Blast water available: Surface pH: Blast water dischargeable: Other: Equipment: Jet car, spin jets, turbo nozzle, jet mills, deep scarifying unit, whirl disk: Roll Off-Box: (Water tight) Ultra high-pressure pump: psi-gpm Roll Off-Box: (Vacuum) Hydro-demolition equipment: psi-gpm Water filtration and recycling: Concrete cutting head: Vacuum truck: (CFM? Mercury?) Abrasive cutting head: Steel plate: (Specify Size) UHP, trigger-gun-nozzle: Abrasives: (lbs) Specify grid size: ? Hydraulic air gear assembly: Barricades: Magnet-vacuum base assembly: Protective skirting: Vacuum-jet-recovery: Surface profile-roughness gauge Flash rust inhibitor: Rust converter:

Describe application and work procedure: Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.: Environment: Industrial Commercial

Residential

Today each and every one method has disadvantages to a high-pressure water application, especially in the area of cleanliness, treating fungus, molds and dissolving or removal in depth of soluble contaminants. Environmentally producing the smallest footprint with least of all possible air contamination, safest application performance in most volatile industrial and marine environments, no impact, spark-flame-heat or mechanical shock

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development, and most often a surface friendlier product removal procedure within a tremendous time savings criterion are hydro-blast application advantages. The fundamentals of surface preparation, cleaning and coating-concrete are well explained in publications offered and provided by SSPC the society for protective coatings.

3.7 Wet–Dry Vacuum Applications, Dredging, Emulsifying Sludge, Gravel Cleaning, Dust-Refuse or Bio-product Loading, Transfer or Removal of Industrial Product, Hydro-excavation, Pumping Fluids Waste product disposal and/or product–material recovery by utilizing the nondestructive, cold and spark free vacuum technology which includes transferring volatile-flammable products in unpredictable areas and confined spaces is an expertise developed for sewer cleaning and sewer waste recovery by WOMA corp. 1958 (Fig. 3.89). The equipment is powered by a straight-thru or ring-jet vacuum pump producing commercial and/or industrial performance, operating between 18 and 600 hp. This robust application variety, ease of vacuum hose manipulation, diversity of accessories and jobsite accessibility is this equipment’s obvious advantage. Superior material transfer capability in height and distance, equipment limited volume and weight, providing an unmatched disaster clean-up potential due to power and water source indifference especially when combined with a water filtration–recycling capability and the constant transfer of static electricity, which is so menacing to the industrial vacuum truck industry, etc. are further motivating facts to utilize a hydro-vac wet–dry mod system. Comparable in operational intent and basic technical function to the common shop-vac or, if so desired, to the high-capacity industrial vacuum truck (Fig. 3.90). Their major difference lies in a lesser application versatility and subsequent variety.

Fig. 3.89 Ring-jet vacuum pump

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Fig. 3.90 Industrial product transfer system

The Hydro-trenching, excavation of buried infrastructure, pot-holing for fence and utility poles and the directional drilling of test holes etc. has found its market by utilizing industrial vacuum trucks hydraulically manipulated hose-pipe boom assembly which incorporates the high-pressure water nozzle fixture, enhancing soil breakup and flow characteristics as previously performed with various sewer cleaning equipment. The absence of static electricity and physical damage by excavating equipment to concealed gas, water, fiber optic, electrical general utility infrastructures, vulnerable especially when space, size and ground restrictions are present is circumvented (Fig. 3.91). Hydro-trenching is safer and more cost effective than operating mechanical excavation machinery or manual digging procedures. Trenching can be dramatically enhanced when supported by 3=800 hydro-lance assembly utilizing round jet or turbo nozzle equipment up to 2,500 psi 2.5 to 5 gpm. Various hydro-tools can greatly support a controlled soil removal capacity when trenching.

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Fig. 3.91 a, b Hydrotrenching vacu-crown

Fig. 3.92 Jet-pump, product separator-tooling

A site related qualified pre-job meeting considering possible site restrictions and permits, pedestrian and vehicle safety, possible overhead–underground danger (electricity-buildings, etc.), qualified shoring of trenched structure, soil conditions, dewatered soil dump site and procedures, adequate water management, recording of soil removal productivity and the signing of the pre-job meeting as well as the signing of the tailgate meeting paperwork are all basic job necessities. Jet-pumps are utilized as high velocity liquid transfer pumps, high volume solids-product transfer-loading equipment, and as a vacuum compressor energizing a vacuum roll-off box container providing wet or dry mode functions incorporating product separation and air filtration for the pump air intake. All three methods differ only in placement of jet-pump job location, horsepower input, vacuum performance and subsequent creation of airflow-volume throughout a rigid-mobile pipe or hose assembly. The shop-vac utilizes an electric energized fan-impeller to create its vacuum, the power for commercial–industrial vacuum trucks is derived from an engine driven gear or fan blower, whereas the hydro-vac wet–dry system develops its power via the jet vacuum-pump. Product separation, filtration in removing materials or products from the transporting airflow is described at best as similar. For instance, an 18 hp pressure washer will power its vacuum-pump, which in turn utilizes created air-vacuum energy to shop-vac like accessories (Fig. 3.92) and debris collection in a container. The 18 hp vacuum-jet systems differ only in physical size, being larger and sturdier. The main difference between them lies in application versatility, due to creation of max-vacuum and higher-airflow performances.

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Fig. 3.93 a, b Tractor, vacuroll-off box

The jet pumps ability to create near absolute vacuum independent of altitude (29 mercury or 10 m water column) subsequent high velocity air movement in hose assemblies, pipes and vacuum tanks prompted hydro-manufacturers and contractors to develop an array of material handling applications. Some of the more common applications are sludge removal in digesters, dredging of settling ponds, fly-ash, talcum, refractory and coal dust removal in refineries, power plants, bunker-seed removal in ship and barge product holds. The vast application variety requires differentiating and recognition of three applicable hydro-vac systems, including the performance capabilities of pressure washers at 18 hp and hydro-blast units from 25 to 600 hp. Hydro-vac dry mode operations above 100 hp generally feature a cylindrical or square vacuum roll-off box (Fig. 3.93) situated stationary on-site (10–60 yard) or truck trailer mounted (roll off box) with a hydraulically operated dump-gate, liquid discharge valve and interior primary and secondary water-misting system controlling volatile atmospheres and can feature a simple secured explosion relief venting system. Cyclone and configurations are found between the vacuum box and vacu-jets suction orifice, separating remaining airborne particles. When volatile products, areas and confined spaces are encountered the filtration unit can be placed and employed offsite or outside in safe distance connected to vacuum box by pipe-hose assembly only. The contamination by airborne particles of the vacu-jets drive water can further be prevented by utilizing a mobile air scrubber unit which in turn permits the reuse of water by the hydro-pump system. This added mechanical air scrubbing is crucial, especially when powder-like or flammable gaseous products are transferred. Caution. Be aware of suspended dust-like products and/or their environment which may be highly flammable or explosive not only under normal operating conditions but especially as a secondary combustible dust emission source due to a primary minor explosion, earthquake, wind swept situation and/or manufacturingequipment failure, producing a series of deflagrations or shock waves resulting in fugitive suspended dust fuels. Besides being accidental, these situations are more often found in industrial facilities which do not maintain a housekeeping program,

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addressing periodically the cleaning of vertical and horizontal areas, such as on top of pipes, beams, ledges, production facilities, etc. OSHA identifies the potential of six major combustible dust sources: Agricultural product as egg white, milk powder, soy–wheat–wood flour, various starch and sugar powders. Agricultural dust as in coffee, corn, cotton, potato, rice, grass dust, etc. Carbonaceous dust as in charcoal, coal, coke, cellulose, soot, etc. Chemical dust as in sulfur, sodium stearate-ascorbate, ascorbic acid, calcium stearate, etc. Metal dust as in, aluminum, bronze, iron carbonyl, magnesium, zinc, etc. Plastic dust as in, poly-ethylene, acryl-amide, epoxy resin, phenolic resin, urea– formaldehyde, etc. In operation hydro-vac systems do not develop a volatile heat source and by nature continuously discharge static electricity generated while transporting products-dust throughout a vacuum system (friction). This does not mean that equipment must not be connected to an OSHA approved ground point guaranteeing a continuous grounding path on-site or in every unit identified by customer. Continuously misting dust suspension and concentrations is achieved with low volume nozzle elements, strategically placed within a vacuum hose assembly, vacuum pickup tools, vacuum box-container and cyclone filtration unit. Employing this high velocity air moving vacuum equipment is especially effective in industries where the potential for combustible dust explosions and fires exist. This includes industrial bag-house interiors, coal storage facilities and their conveyor tunnels, fossil fuel power plant equipment and storage, sawmill environment and storage, bakeries equipment and storage, grain handling equipment and silos, milk evaporation towers to mention a few, all belong to the hydrodry-vac application palette. Application techniques, as always, will vary with adequate product specification, consistency and their location. When extensive horizontal and vertical vacuum hose distances are required, vacuum hose suction orifices are fitted with high-velocity air nozzles to accelerate the movement of the material and provide adequate air-product ratio. Always consider the necessity of respiratory devices. When an acceleration of product removal time is possible (materials permitting) a vacuum hose manifold is installed, adding yet another operator. An 800 vacuum hose is then reduced to two 400 hose ends, bearing their required accessories. Wet mode applications represent pulling gravel, liquid, or moisture-saturated products through a vacuum hose into a vacuum box. Product introduced to the low-velocity area of a vacuum box forces adequate product separation from high velocity air, permitting the bypassing of cyclones, and more importantly, the baghouse assembly. This eliminates possible friction losses due to vapor saturation of filter cloth coverings. Most hydro-vac systems feature a manually-operated slide for both dry and wet mode operations. If adding 3–15% drive water to materials being removed does not constitute a problem or challenges the job objective, the direct application of

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the vacu-jet can be highly successful. The vacu-jets nozzle velocity is utilized to slurry product, in turn, producing an adequate product viscosity, enabling the operation of trash or transfer pumps and therefore increasing the possible product transfer distance. Such product transfer processes are quite common, as are degassing sewers, tanks, and vessels. Gaseous air is water-doused and then transported through hoses and pipes to be released into a designated area or atmosphere. Vacuuming flammable liquids and powders is safely performed due to the constant dissipating of developing and potentially dangerous static electricity (friction). Not only has the vacu-jet added application multitude to the power washing industry, it has also further enhanced existing applications. All jobs present their unique particulars. In operation, product behavior varies greatly throughout a vacuum hose, filtration and hauling system. To implement an equipment layout procedure maximizing and establishing the conveying rate (tons/h), precise material information must be obtained from potential customers to identify following: Material: Aerated: Sieve-granular analysis: (specify size and specific weight) Does material easily absorb moisture from air: Does material easily absorb moisture from water: Is material aggressive in regard to: Iron, steel, aluminum, natural rubber, other: Must special provisions be considered for toxicity, volatile or explosive atmosphere: Does material present any hazards to personnel: Is material free flowing:

Bulk density: Viscosity: (lb/ft3) Settled: Caked: Maximum moisture content: % Does material cause abrasion: Temperature of material:F

Filtering and collection of dust:

The vacu-jets commercial usefulness starts with a minimum 18 hp pump drive. Necessary hp range is determined by job description, classifying product consistency (mass, dry or wet, viscosity, specific weight), vertical and horizontal distances the product must travel between pickup and discharge point. The integrated number of elbows, 45 and 90, determining the transfer vessels feed by gravity or suction, and type of transfer vessel as tanker truck, railcar, vacuum roll-off box and location, considering indoor or outdoor application or both etc. Reviewing a hydro-vac operation one can refer to the interior vacuum hose diameter ([) as the approximate reference point of pressure washer’s hp range: 200 [ is approx. 18 hp, 2.500 [ approx. 35 hp, 400 [ approx. 100 hp, 600 [ approx. 180 hp, or 800 [ approx. 300 hp.

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Within any transfer process of sewage from a city digester it is important to realize that slow-moving sewage water tends to separate from its bulk material (snails-organics). If allowed, snails and other bulk materials cake or settle in areas where physical friction or static pressures reduce the materials velocity. To avoid caking or settling, bulk materials are constantly agitated by a low-volume, highvelocity rotary nozzle situated close to discharge cone of the digester. If a rotary nozzle cannot be adequately buried, or if free nozzle rotation cannot be guaranteed, a sewer cleaning nozzle (1 9 4, at 45 to 90) affixed to a rigid lance can be forced down through the top entrance of the vessel, enhancing the product movement in the critical cone area. When movement toward the hydro suction orifice affixed to tanks discharge cone has stopped, a rigid lance operation may becomes necessary to achieve a slurry process converting sewage to flow. Pump stations delivering digester sewage into drying beds sometimes fail, calling for a dual hydro-vac-trash pump operation. An in-line hydro-vac injector adequately destructs and accelerates sewage slurry to a degree that 600 to 800 [, high-volume trash pumps affixed in series to a drag line can deliver products up to 3,0000 away; this eliminates trucking and other expensive work modes. Product knowledge and product behavior in transfer processes must be understood and properly recorded. Anyone involved in this industry will testify that job circumstances and product parameters are so diversified that generalization as to a job bidding procedure is impossible. Prior to bidding, a physical inspection must be made possibly requiring a tank or confined space entry permit. Correctly identifying the product to be removed, its volume, adhesion and/or flow consistency, as well as considering the vessels structure will enable the contractor to submit a qualified bid. It is sound practice to add ones own locks and markers to the customers valves and flanges situated on the vessels supply and discharge lines, in doing so, avoiding unauthorized operational changes. If hot work (welding) is performed in the vicinity, make sure all pipes leading to and from the vessel are adequately vented and free of gases. Flash explosions have been numerous and are most commonly caused by people not connected with the contractors’ staff. Spark-resistant pressure washers or hydro-blast units are required and force the use of diesel fuel driven units. Most hydro-manufacturers do not spark-proof their electrical systems, which is required when operating in flammable and volatile areas (refineries, chemical plants, etc.). Applying acid-proof mastics (silicone) to battery poles (+ -) and all other open electrical connections is a must. Hydro-blast units or pressure washers operating in volatile areas are grounded to protect against the possible development of static electricity. A copper cable with a spike and clamp properly situated will provide ground conductivity. The grounding of machinery must be extended to hydro-vac pumps, hoses, venturi blowers and air compressors, in short, all machinery in use. While in operation, a fire/safety watch must be posted on tank entries or vessel manholes. To reduce contamination possibilities by traffic relating to a vessel especially following a crew’s shift change, create a step in–out area for all involved. In the bidding process, consider the added cost of safety procedures and

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necessary safety gear. Air monitoring devices such as draggers, gas meters, venturi air blowers and fans are important assets, as are air gear, face masks and standby emergency air units (egress systems). Top-entry harnesses, belts, ropes, lowvoltage explosion-proof lighting, lots of fire extinguishers (situated by machinery and manholes), steel-toed boots, extra rain gear, duct tape, rubber gloves, and ear protection are major expenditures. Further costs can be accrued in the categorization and hazardous recognition of a product. The distances to hazardous dump sites, transportation permits, adequate quantity of licensed dump trucks, dump site fees, and taxes should not be overlooked. Consider the hydro dry-vac method a natural. Under load, gear blower-operated trucks can and will create tremendous heat on gear surface area and muffler exhaust systems (units built prior to 1990), creating a fire hazard when oil products or flammable vapors are present in the vacuum box. Furthermore, heavy, gooey products tend to cake in vacuum hoses creating a slowdown of the necessary airflow, subsequently reducing product movement. This effect, combined with a 60% maximum vacuum performance on gear blower-operated vacuum trucks, causes a slowdown in product movement (prior to 1990). In comparison, the vacujet pump operates under load at a 95% constant vacuum (close to the theoretical limit), therefore developing a much higher air velocity in vacuum hoses when products cake or present a high-viscosity factor. Oil and fuel tanks, 1500 –3000 in diameter (Ø) may feature steam coils affixed to the floorboard or ceiling float mechanisms, hampering the operators free movement and as such, complicate cleaning efforts. Squeegees are practical tools in efforts to move the product to the vacuum hose orifice, which preferably is situated at the lowest area of the vessel. Caked, sticky products that adhere to tank bottoms and walls may be jetted off and slurred. Most flammable vapors are rendered harmless when doused and cooled while passing through the jet pumps water cylinder. When applying light oils or diesel fuel as a blast medium, oil, tar and bunker seed products are returned to the production process. Hydro trigger-guns with a lance extension incorporating fan nozzles at a maximum of 1500 psi operating pressure are sufficient to remove and slurry the most stubborn petroleum bulk materials. If diesel fuel is used, try to keep the nozzles submerged in the product, limiting fuel atomization. Generally, pump packing will soften with the extended use of diesel fuel and should be exchanged before a high-pressure water cleaning application is performed. Converting piston pumps to this type of operation requires technical safety procedures, which includes installing adequate pressure regulators and safety valves, engine rpm control to guard against over pressurization, etc. To avoid unnecessary friction loss in vacuum hoses, the truck vacuum box should be as close to the work area as possible. A low-volume nozzle attached to a vacuum hose orifice, which in operation meters minute amounts of fuel to waste-airflow, lessens friction between the product and the vacuum hose liner. Corrugated low-cost vacuum hoses, most commonly applied by contractors, have their advantages in that they offer higher flexibility, lighter weight, and lower cost; however, their inherent and excessive friction losses render them useless in this application.

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The mere presence of a vacu-jet pump on the job site will promote a subconscious effort by the labor force to apply the unit whenever possible, stimulating the further development of applications. When hydro-blasting, water and scaled materials can accumulate in the bottom of industrial vessels in particular when outgoing or incoming lines are situated below the water runoff point when, as for instance, the accumulated scaled materials in refinery tower tray cleaning applications are performed which can hamper the final cleanup procedure. Under these circumstances, employ a 200 or 300 vacuum hose, incorporating a vacu-jet within the available Hp range. The discharge hose is situated at an area where the accumulated blast water may freely separate from the scaled materials. Very often, materials are so minute or physically diminished that the vacu-jets discharge medium is directly delivered by sewer system to the sewage treatment plant. The hydro-vac pump also provides enough velocity to create a fluid drag sufficient to transport suspended materials through a sewer system. As cooling towers accumulate vast amounts of lime and silt sedimentation in their low-velocity areas, a 38 gpm vacu-jet can directly slurry and move the product into the operating high-velocity channel (6,500 psi at 98% vacuumefficiency). In this case, disconnect discharge hose from the hydro-vac pump and submerge the pump directly into the main water channel (fasten). This will result in the acceleration of the channels overall water velocity, enhancing further movement. A 400 [ 1500 smooth suction hose will reach all low-velocity sections of a cooling tower. The cooling towers water velocity will transport most of the bulk materials to settling ponds, thus eliminating the excessive cleaning cost when general plant-tower shutdowns are imminent. Always start cleaning procedures on the towers’ water discharge side; this eliminates the possible slowdown of loosened materials by existing product obstructions, therefore keeping the overall water velocity at its highest possible level. Safety procedures should be concentrated to the adequate use of protective clothing. Excessive contact to lime will result in skin irritation (diluted lime as well). The vacuum hose operator should never enter the unit without a safety harness and secured lanyard. He must be physically and optically controlled by a safety man situated in the towers entrance, who is, at all times, in visual contact with the hydro-units operator. The tower’s water velocity is regulated and therefore, provides manageable working conditions. To harness recoil forces always fasten the vacu-jet securely. If company safety procedures permit, emergency communication can be established via an air horn (overpowering sound levels of air props and hydro-blast units). Cleaning scrubber tanks, autoclaves and grinders, large rocklike formations must be broken down. A hydro-blast trigger-gun with a 50 rigid seamless stainless steel extension lance, bearing a straight jetting nozzle is utilized to effectively break refuse accommodating interior diameter of a vacuum hose in use, thus allowing the material to pass to an open dump box (8,000 psi +). By adding a velocity diffuser box to the vacu-jet pumps discharge barrel the delivered material is further demolished by the subsequent impact on the diffuser

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plate (up to 300 ft/s). This practice permits the loading of open watertight dump trucks fitted with a water overflow valve. After loading is completed the remaining excess water is pulled to the material surface, avoiding sloshing due to truck operation. Specific weights of the materials being transferred must be heavier than water and preferably non-solidifying, keeping discharged water contamination to a minimum. When standard vacuum trucks are not available, the diffuser box most definitely enhances contractors application capabilities. When sewer–pipe cleaning applications are performed, culverts, sumps, catch basins are designed and intended to become sewage traps (Fig. 3.94). To remove trapped sewage debris the preferred equipment includes a waterproof dump truck incorporating a vacu-jet pump (optional diffuser-box), and baffled discharge pipevalve assembly for the removal of excess water and a hydro-blast unit in tandem responsible for the actual sewer cleaning process. Industrial contractors with equipment can enter the pipe and sewer cleaning business utilizing the reduced operating cost especially when the materials collected are generally minute in volume. To accommodate movement of large debris it is important to apply a 290 lift capacity operating a vacu-jet pump and a 60 vacuum hose assembly. Contractors performing this application repetitively may also consider purchase of a vacuum roll-off box designed to incorporate the dry–wet mode hydro-vac method, further enlarging their application capability. This should especially be of interest when adequate hydro-blast units are already in service. Industrial service companies, their owners and managers must come to the realization that the hydro-vac systems capability will soon or later generate enough capital to permit a purchase of the most advanced industrial vacuum truck equipment; expanding the application variety. Dredging accumulated sedimentation from ponds, settling ponds and neutralizing basins (Fig. 3.95), an application found in fossil fuel power plants, coalwashing units, cement plants, railroad yards, fish hatcheries, etc., can enlarge a contractors palette while avoiding financial expenditures. The necessary mechanical gear in question is either a hydro-vac dump truck wet mode system or a vacu-jet pump, which can also be affixed to a nearby slurry-collection tank or pump station. The slurry-collection tank may be incorporated with a hydraulic or air-driven submersible sludge pump, which further transports sedimentation to any given disposal site or necessary drying bed. The work method to be employed depends on the vertical and horizontal conveying distances, where the vertical distance is measured from the water-sludge surface level to the top inlet of dump truck or vacuum roll off box and/or a pump station transfer vessel-tank. All horizontal vacuum hose layout distances are measured from the suction orifice of the vacuum hose-dragline, including the vertical rise from the pond base to the water-sludge surface, where a flotation unit with an elbow from vertical to the horizontal is located. Product viscosity, specific weight, purity, product adhesion and bulk density factors will more or less determine the necessary removal and transfer time.

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3 Application Core Curriculum

Fig. 3.94 Truck mounted Hydro-vac system

Bulk fly-ash and suspended lime products located below the water in visual distance (up to 500 ) can quickly be removed by operating a manually-controlled flotation device. The control of suction hose depth adjusted, ropes are utilized to move systematically and in grid fashion the flotation assembly over the pond base. The buoyancy of the flotation unit must be above 900 lb when operating a 40 [ plus suction hose preventing excessive bobbing motion. A constant product movement and greater product flow is achieved by adding a circular plate to the suction orifice, beneficial when the product appears to be thin-layered or tends to adhere to the pond base. Suction plate adhesion to the pond base is avoided by adding high-velocity water channels, intended to attack harder mud formations within the center of the suction orifice. Clogging induced by debris such as sagebrush, rags, tin cans, wood, etc., is avoided by screening. The screen must be, at minimum, four times larger in surface area than that of the hose diameter; the screen mesh, however, must be slightly smaller. For instance, a 40 [ suction hose orifice must be fitted with a 160 screen and a 3 ‘0 mesh. When blockage occurs, switch the injector to the off position, permitting the existing water-material column in the vacuum hose to back-flush, thus forcing the debris off the filter screen. In general, sediments are somewhat suspended due to specific weight and water saturation factor, prompting the start of a dredging operation at the deepest point of the pond. An avalanche-like product motion, enhanced by the negative water pressure developing around the suction orifice, is a dredging characteristic. At this point of operation, the suction hose affixed to a flotation unit is moved, as required, in the direction of flowing material. Common industrial pond sizes allow a simple

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Fig. 3.95 Job-report, fossil fueled power plant

three-man operation. The major importance lies in the systematic movement of the suction hose throughout the pond area. A one-man vessel-flotation device following a grid outline, established by ropes, enhances control in murky waters. On a further note, this method of dredging outperforms other practices in price, time and labor intensity. Ponds or settling basins often feature thin-layered liners constructed of asphalt, clay, concrete, or rubber. Products turned solid, due to operational oversight, evaporation or chemical reaction cannot be removed by the conventional method which employs bag-hose, caterpillars or the like. Damage to the liner is avoided by the use of the high-velocity, low-volume slurry method. Slurry nozzles come in many variations and operate between 500 and 5,000 psi at 4–40 gpm. The slurry product is best removed with a ring-vacuum injector, either operating a vacuum box, wet or dry mode (Fig. 3.96), or placed on an open dump truck. To avoid the possibility of caking, product and physical behavior patterns, especially when products are transported by a vessel, must be tested for viscosity and setup times before (Fig. 3.97) high volume removal calculations are performed.

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3 Application Core Curriculum

Fig. 3.96 Lime pond, job-report

When cleaning, scaling, and preserving oil lube systems utilized for the operation of H2O compressors, main turbine bearings and blowers in refineries, power and steel plants, the vacu-jet method is incorporated; however, under a different applicable pretense. It has been found that the usual hot oil circulation and flushing

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method applied by maintenance departments to rid oil lube systems of fine contamination, scale and debris is inadequate, in particular after system repairs are exercised (exchanging damaged bearings, pistons, sleeves, and filters). In applying light oil as blast medium (heated turbine oil), the oil-jet impact and high-velocity maintained throughout the cleaning procedure by the oil jetting technique guarantees that the present scale and debris will not settle or remain in the system’s low-velocity cavities. Available flex lances will accommodate most pipe radiuses. Older oil lube systems may require minor modifications to fully provide access to the pipe system. The vacu-jet pump can be located at a distance providing vacuum power. The flex lance vacuum feed unit is bolted or clamped to all strategically located pipe flanges. Oil heating and vacuum container units including the oil filter component are kept in the immediate vicinity to access of the oil lube system, preventing unnecessary friction or temperature loss throughout. Necessary blast oils are generally supplied by the customer’s maintenance department. The lighter the weight classification of the blast oil (turbine oil), the higher the possible operating pressure (up to 3,000 psi). When flushing and cleaning open compressor gear-ends, lube oil storage tanks, filters, and containers, maintenance departments must research system failure, which is substantiated in collecting mechanical debris. It is a nice gesture to collect and identify materials and, if possible, identify their locations. One will find bearing parts, aluminum, brass, and metal shavings, gaskets, and filter materials. With these efforts, maintenance engineers will be able to conclude their findings more precisely. When cleaning, some materials will fully suspend, especially when high-viscous turbine oil grades are employed. Positions and general locations of cavities, gears, sumps, bearing housings, and oil discharge-intake orifices must be located and cleaned. The 00 flex lance with a 6 9 .039 9 45 nozzle guided and secured in its travel by a ’00 , 6-ft schedule 80 aluminum tube, incorporated with a radius sufficient to fully reach (in its flex lance extension) the total cavity area will do the job. Maintain a handful of flex lance tubes with a variety of radiuses and a selection of 00 straight jetting lances (30 –60 ) with quick couplers accommodating a selection of T-pipe fittings with adequate nozzles as they will be necessary to reach all areas. Always start from the top of a unit proceeding downward, including the final wipe-down. The standard spraying characteristic of a water-jet fan nozzle is lost and appears defective when pumping light oil through them; however, they still provide better area coverage than roundjets (hard-hitters). While working above large compressors, tanks, or pipe assemblies, oil overspray is probable. To avoid injury by falling or slipping, concentrate on good footing procedures. When reusing blast oils, hydro-blast units produced low fluid volume is of an advantage to the high volume hot oil flushing procedure as a much smaller oil filter capacity is required. Filter surface area and size (generally 3–5 lm) solely depends on required volume per minute, oil viscosity, weight, debris concentrations and temperature. Customer maintenance department or operations handbook will provide oil fluid specifications standard to the cleaning procedure. Pricing in this application may be determined by

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3 Application Core Curriculum

competitor’s high-volume flushing operations, translating to approximately three times the hourly hydro-blast rate, which includes two operators. Higher corrosion factors, synonymous with steel piping, require water, preferably demineralized, as a blast medium. Working pressures up to 10,000 psi may be necessary. After the scaling procedure has been completed, the vacu-jet system is applied to rid the system of all water pockets and vapor. Once this is complete, the pipe interior is preserved with an oil film applied by the flex lance, eliminating further corrosion possibilities until the unit resumes its’ services. Bacteria removal and general cleaning of rock and gravel formation in commercial fish and spawning waters is generally considered a dredging application. Water jets at ultra-high speeds form a constantly-moving semi-stationary liquid piston in barrel, creating in its motion density the necessary vacuum (air velocity) to transfer any conceivable substance at high speeds through its liquid formation, resulting in a tremendous cleaning effect by the jet impact, velocity, and turbulence. This application is at its best when a correct rock and gravel separation from the contaminated and silted vacu-jet water is accomplished. This is achieved by creating an adequate water runoff situation to physically retain the cleaned rock material containing silt and turbid water. Lake beds, rivers and container locations will determine the sites of the runoff areas which are situated so as to permit the easy return of the cleaned rock material to the original pickup site. The incorporated vacu-jet pump (minimum 400 [) with a buffer box to protect the rocks from damage and permits a controlled gravel and rock relocation, preventing excessive water turbidity. Recoil forces are largely diminished by buffer box and therefore allow the semi-automated operation of a rope-controlled flotation vessel, thus placing the gravel and rock materials in the desired areas. Faced with accumulated hot ashes in clinker grinder areas (found in fossil fueled boilers or hot furnace products), as well as industrial spills where hot burning ashes or liquids are in dire need of removal, the hydro vacu-jet pump is converted to a ‘‘killer’’ fire-fighter that in its path extinguishes, cools and douses products while relocating them to a secondary location. Hydro-vac injectors are only to be employed when hot or burning product is water compatible in its dry, wet or flame-combustible state. Any vacu-jet design is employable; however, all must feature heat-resistant corrugated flexible metal hose technology on their suction and discharge ports. Knowing that generalizations concerning this application may result in a volatile or explosive situation, is it suggested that questions are directed to qualified personal in specific field of product specialization. Cold storage facilities and refrigerated work areas, found in food industries, may utilize a vacu-jet system that permits high-pressure water cleaning methods, yet contains and removes all waters and debris in its working path. A manuallyoperated vacu-brush retaining a 15 to 90 fan nozzle in its belly is applied in hard-to-reach areas. The mobile units are designed with the same principle in mind; they hermetically contain nozzle overspray and return debris to a sewer or hydro-vac container, thus challenging large floor plans with reasonably smooth

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Fig. 3.97 a, b, c Job, evaporation pond, labor time sheet

surface construction. Manufacturers offer various new designs and applicable units starting at 18 hp and can be gas or propane operated. All should feature a dependable chemical injection system which applies soaps, detergents, light acids and liquid disinfectants. Resources. The primary national fire protection association (NFPA) regarding standards related to the hazard of fire and dust explosions, NFPA 654, from the manufacturing, processing and handling of combustible particulate solids, NFPA

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3 Application Core Curriculum

Fig. 3.98 Vortex formation in pump’s water supply tank

61, prevention of fire and dust explosions in agricultural and food processing facilities, NFPA 484, standard for combustible metals, NFPA 664, standard for the prevention of fires and explosions in wood processing and woodworking facilities, NFPA 655, standard for the prevention of sulfur fires and explosions, http://www.nfpa.org See the safety health information bulletin SHIB 07-31-2005, combustible dust in industry: preventing and mitigating the effects of fires and explosions, http://www.osha.gov When designing a water and/or vacuum tank for a multi use application is it important to incorporate a possibility for various fluid draw capacities. Application or pumps varying performances pending, the interior design criterion is often insufficient, creating a possible vortex formation. This vortex formation (Figs. 3.97, 3.98) can be especially responsible for confusion when trying to solve or determine why high-pressure water hose assemblies excessively pulsate or can be responsible for either a slow and/or sometimes explosive piston pump failure. Havoc may also arise when product volume-flow estimates are inconsistent.

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GEAR - LIST AUTHORIZATION Dry-wet vacu applications, dredging and emulsifying sludge, gravel cleaning, product transfer Customer & Company:

Date: Address:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Job Nr.:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Job Review Performed by: Digesters: (city management) Digesters: Settling ponds: Tanks, vessels: (industrial) Tanks, vessels:(ships, barges) Bag-house: (industrial) Sewers: Drying beds: cooling towers: (industrial) Scrubber tanks: Autoclaves: Other: Product: Sludge: Fly-ash: Talcum: Coal dust: Cement dust: Others: Tools: In-line air, water: Hydro-blast hose: (∅ and feet) Vacuum hose: (∅ and feet) Elbows: Vacu-Jet: (∅ 2, 4, 6, 8 inches) Hydro-unit: (horsepower?) High velocity spin-jet: (slurry) Sewer Cleaning Nozzle: (slurry-specify) Rigid lance: Vacuum brush: Vacuum truck: Describe application and work procedure:

Specify:

Culverts: Sumps: Catch basins: Ponds, lakes: Neutralizing basins: Conveyer tunnels: Grain silos: Milk evaporating towers: Spawning tanks: Boilers: Cold storage facilities: Other: MSDS: Bunker-seed: Gravel: Liquids: Organic snails: Flammable vapors:

45°

90°

Non-flammable vapors: Sticky products: Viscosity: Lime: Silt: Sewage: Others: Flotation device: Vacuum box: (yards?) Dry-wet mode: Specialized fire suppression system: Spark/ember detection for suppression activation: Open dump-box: Diffuser box: Stationary, in-line pump, tank: High volume trash pump: Tank entry permit: Air monitoring device: Others:

Safety procedures: Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

©

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3 Application Core Curriculum GEAR - LIST

Customer & Company:

Date: Address:

Web site: e-mail:

Nr.

Job Nr.:

City: State:

P.O. Box: Zip Code:

Purchasing

Engineering

Maintenance

Safety

Tel: e-mail

Tel: e-mail

Tel: e-mail

Tel: e-mail

Job Description: Job Location:

Job Site Risk Assessment:

Job Review Performed by: Plant hardware:

Hydro-blast equipment:

Equipment:

Plant location: Expendables: Product Encountered: Hazardous Material:

MSDS:

Specify:

Describe application and work procedure:

Describe safety procedure: Itemize equipment, safety gear, expendables, etc.:

Specify:

©

3.8 Duct-Work, Canopy-Hood Installation Cleaning, Acid-Sanitary Treatment

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Fig. 3.99 1963 a, b, c US 1960 patent draft

3.8 Duct-Work, Canopy-Hood Installation Cleaning, Acid-Sanitary Treatment, Cleaning-Chemically Treating Pipe for Liner System Installation, Coating Interior ([) Steel-Iron Pipe The process of cleaning, chemically treating, or painting internal pipe surfaces [ (Fig. 3.99a–c), which include the interior duct surfaces of air conditioning systems, kitchen exhaust units, and general steel pipe-ducts, is an age-old application made possible with the development of pipe and sewer cleaning nozzles powered by water and/or compressed air. This application criterion eluded coating manufacturer and hydro-blast contractors alike (Fig. 3.100). Today the necessary tool varieties such as tube–pipe–duct nozzle centralizers (Fig. 3.101) supporting interior cleaning, sanitary surface treatments or interior coating–painting applications after an acid and neutralizing procedure are readily available from various sources and manufacturers enhancing application capabilities. Remotely operated cameras and robotic transporters can be utilized in various support functions and are available on purchase or rental basis. In the past, contractors, with a little self-help and ingenuity were able to utilize this application criterion successfully providing specific and specialized services. Nevertheless most interior pipe rehabilitation–restoration procedures are nowadays performed with vertical and lateral lining systems, which after installation may initially cure in place when forced onto the pipe wall by air pressure (6–12 psi). The creation of a verifiable leak-free, in place, cured lateral pipe lining, especially within the mainline junction portion depends on factors that include the identification of pipe material, pipe wall contaminants and interior damage permitting possible groundwater infiltration, necessary access and interior pipe surface preparation techniques.

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Fig. 3.100 1958 nozzle patent draft, Germany

Fig. 3.101 Nozzle with tool centralizer

The performance or adhesive quality of resins applied to an interior pipe surface within a CIPP lining procedure depends on the correct identification of pipe substrate, cleanliness and surface roughness-anchor profile. This is quite simply achieved when clay, concrete or steel pipes are restored. The hot or cold hydroblast or industrial pipe jetting application supported by various detergents necessary for typical grease and refuse accumulation removal and/or the utilization of various specialty sewer cleaning nozzles, including employing centered rotary nozzle carriers (Fig. 3.102) will quickly perform this requirement. Today PVC drain and sewer pipe systems feature various polyethylene-polyurethane film surfaces requiring a specific resin, which can be ISO polyester, vinyl-ester, silicate and epoxy to warrant adequate adhesion. In any case, the industrial pipe and sewer cleaning technique by hydro-blasting (hot–cold water) combined with today’s available hydro-vac application diversity is the predominant tool combination for prepping duct, pipe and utility drain lines before a coating or lining-sleeve product can be installed. To understand this new application identity is it probably best to study similar application criteria and its performance technology. Location:

Boeing Aircraft Company Building 4-01 Wing Heating Area Washington, USA

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Fig. 3.102 3D Nozzle-tool centralizer

Job Description: (Fig. 3.103) Clean, remove rust scale, neutralize and paint concrete-lined sub-floor, steel duct system (400 to 3200 [), a horizontal system with lateral side arms (app. 3000 ) supplying heated air throughout the aircraft wing paint shop. The overall condition of the duct system had been such that during operation, rust and accumulated debris contaminated the general building environment to the extent that the installation of a new system seemed imminent. The present corrosion, in multiple layers, led to this opinion and therefore triggered a contractor’s involvement. The contractor offered to remove rust buildup, acid treatment and neutralization of concrete and iron pipe, clean area, and paint coating procedures, plus guaranteeing a long-term solution with a written 12-month warranty (accepted). Material and Equipment Requirements. 2000 , 1‘00 fire hose, 150 hp hydroblast unit, 4000 , ‘00 hydro-blast hose, 6 9 1.5 mm [ pipe cleaning nozzle with cable ear, 30-yard vacuum tank truck with 400 [ hydro-vac wet-mode system, 3000 –40 [ vacuum hose, airless paint spray unit (2,000 psi), 1000 airless paint hose, 180 airless paint nozzle, mobile paint nozzle carrier (centralizer), respirators, gloves, boots, rain gear, duct tape, four 1/800 steel cables (1000 each), two cable ratchets, oxalic acid, sodium nitrate (rust inhibitor, neutralizer), tile-clad paint and primer. Procedures. The steel duct installed within the concrete sub-flooring appeared very soiled and corroded. To remove all rust formations and debris throughout the system and to provide an ideal penetration dwell time for the oxalic acid (applied after cleaning), a pipe cleaning procedure utilizing the hydro-blast unit at 6,000 psi, 35 gpm combined with a 6 9 1.5 mm, 45 pipe cleaning nozzle was engaged. Simultaneously, the hydro-vac unit in play with a 400 vacuum hose was placed in the duct system’s lowest area to remove all arriving debris and water; in doing so back flushing into the system was prevented. Once rust formations were successfully removed, the duct system was completely saturated with oxalic acid over a 15-h period to provide ample dwell time. By adding oxalic acid to the hydro-blast unit suction tank, the 3,000 psi, 35 gpm nozzle velocities provided a great mechanical jetting impulse which reached all corners and cavities of the system. The following day, the employed hydro-vac unit removed the somewhat diluted acid within minutes, followed by a thorough pipe cleaning procedure

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3 Application Core Curriculum

Fig. 3.103 Boeing aircraft, job description

removing all remaining acidity. At this point, steel cables were attached to the nozzle assembly and strategically placed to accommodate the upcoming paint procedure. Utilizing the self-propelling forces the nozzle and high-pressure hose assembly carried the steel cables throughout the pipe system which were detached in 850 sections at every exhaust floor opening. Before retracting the jetting hose-nozzle assembly, the cable ends were secured to a steel bar and suspended above to prevent their disappearance into the pipe system. To prevent rust film development during the drying process the jetting water carried a 3% sodium nitrate consistency. Overnight, the available air-heating unit transferred vast amounts of air (at 140F.) throughout the duct assembly,

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Fig. 3.104 a, b, c Evaporative

dissipating the remaining moisture content; the pipe system was left in a warm, ready-to-paint state. The paint procedure was started by applying primer throughout pipe system. The cable attached to the centered paint nozzle carrier enabled a smooth two-man operation. One operator was situated at the farthest floor opening pulling the paint nozzle carrier, affixed to the cable, towards his location. This facilitated the starting position of the paint procedure. The operator in control of the airless paint sprayer and its respective high-pressure paint hose then pulled the operating paint nozzle carrier toward his location. By passing three times, section by section, the primer application was completed. Important. Before the drying process sets in, suspend cables in mid-air of duct systems [ by affixing a cable ratchet to a steel pipe centered across the opening of the floor surface tightening the cable to a point that contact to pipe wall is eliminated, avoiding adherence to drying paint surfaces. As a result of operating the wing heating system at 120F, the adequate drying of the primer was guaranteed. Finally, three layers of paint were applied utilizing this technique. This elaborate pipe–duct system forced painting all lateral side arms first with a smaller threepronged centered nozzle carrier before concentrating on the main air supply line. Nevertheless, this is a simple application and should therefore be vigorously considered by hydro or coating contractors, especially nowadays with ready available tooling. Cleaning equipment applied, and various cleaning techniques for HVAC systems are a knockoff technology derived from the hydro-vac, and pipe sewer cleaning criteria. The technical components differ only in that the nozzle-hose propulsion and cleaning medium are compressed air combined with the utilization of high-capacity negative air machine systems producing various high velocity air capacities incorporating a high efficiency particulate separation (0.03 lm) and HEPA filtration technology with 99.97% efficiency. Nevertheless the necessity to clean air duct systems differs substantially in that generally bulk material or waste products are not the and fin-fan cooler removal criteria. There are exceptions to the rule. Duct cleaning and mold remediation entails cleaning of various heating–cooling components of forced air systems. These components include the supply and return air ducts and registers, grills and diffusers. In commercial–industrial HVAC systems, boilers, heat-exchangers and chillers, heating and cooling coils, condensate drain pipes and drip pans, fan housing and evaporative coolers–cooling towers, etc. (Fig. 3.104) are applications of industrial nature.

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3 Application Core Curriculum

Fig. 3.105 a, b, c HVAC duct cleaning

Applications differ substantially in identification and classification as to the need of a remediation-cleaning procedure (Fig. 3.105). Most often the indoor air quality, high air humidity, mold, dust accumulation and pest infestation or a fire hazard are the common denominator, especially when air intake filtration requirements are not adequate. Also various environmental disasters, fire, storms and flooding or manufacturing processes can have accelerated adverse effects on air duct systems, requiring periodic cleaning intervals. In office or commercial buildings such as airports, remediation is most often performed at night to minimize occupational disruption of tenants and customers, and minimizing potential contact to contaminants disturbed during an application processes. Also, before a mold remediation occurs the course of growth must be corrected before the cleaning or removal applications are initiated. Mold requires moisture for growth, which is introduced most often by excessive humidity, damage to the system itself and/or poor construction and can also be transferred from interior surroundings such as infected carpets, drywall, wood, dripping– leaking pipes, condensation, etc. Residential and commercial contractor qualifications differ substantially as to training, licensing and utilization of equipment. Professionals can be categorized into four classifications: 1. Certified air system technician (ASCS) specialized in cleaning and restoration of commercial and industrial HVAC systems which includes servicing process exhaust and dust collectors systems. 2. Commercial and industrial ventilation system-mold remediation specialist (VSMR) offering certified hydro-mechanical, filtration and microbial remediation (CMRS) developed by the American indoor air quality council. 3. The industrial service provider for cleaning boilers, heat exchangers, condensers, chillers, cooling towers, bag-house units and various filtration equipment for modern industrial processes, where large quantities of airborne

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Fig. 3.106 Roof exhaust fan and duct structure

pollutants in various forms of particulate, gases, vapors, fumes, and mists are to be removed. Air streams can be toxic and in concentrations often exceeding safe level of exposure and can include the cleaning of plant production hardware in commercial–industrial HVAC environments. These air filtration systems most often operate above 25,000 acfm and will be designed to a staggering air volume requirement for specific manufacturing processes, as in cement plant, fossil fueled power plants, steel mills, waste incineration, bio-fuel plans, coal mills, ferroalloy production, etc. 4. Restaurant kitchen and cookery operations require a certified fire prevention hood and exhaust duct cleaning process which is a periodic undertaking especially where insurance, fire marshal-departments and law require quarterly or biannual cleaning intervals. Times are determined by high-volume cooking operations such as 24-h restaurant operations, charbroiling or chinese wok cooking where stubborn peanut oil residual presents the most difficult removal criteria, or a moderate volume cooking operation where duct system inspection requires a semi annual cleaning procedures. Smoke or grease laden vapors deposit their residue throughout hood and duct systems interior, including on the lateral duct roof structure (Fig. 3.106), where fans, draft diverters, and oil– grease collection systems must be cleaned to bare metal (NFPA 96, standard) and may include the cleaning of possible leak and runoff areas on roof surfaces. This also requires roof access and safety according to OSHA fall protection and safety procedures. Accessing a duct system can only be considered when a confined space entry procedure and its regulations are introduced. Safety concerns must be rigorous especially in regards to faulty electrical wiring, electrical lock-out procedures and identifying open drip-proof equipment not adequately sealed for steam or water jet contact. This does initiate a correct coverage-sealing procedure of all fixtures susceptible to moisture or water intrusion guided by international fire, mechanical code and OSHA regulation (electric socket, levers–switches–light fixtures, fan-motors, etc.). Preparation of interior kitchen services is critical as is the job walk to identify possible additional work, which can include grease traps and drains, floors, walls, ceilings, cold and refrigerated storage areas and production equipment. Equipment includes ovens, fryers, grills and storage racks, floor mats, etc. Identifying a possible added workload can drastically alter preparations and essential plastic covering (Fig. 3.107b) procedures.

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3 Application Core Curriculum

Fig. 3.107 a, b, c Essential plastic covering

A generalization for required tools are; FDA, EPA approved chemistry with MSDS sheet always posted on customer’s premises, live microorganisms for grease traps, cardboard wedges, spatulas, continuous plastic sheeting 12.50 by 2000 by 1.5–3 mil (rolls), duct tape, metal or plastic clamps, suction cups, short barrel trigger-gun, acid-alkaline foam nozzles, various extra short wand extensions offering quick couplers to trigger-gun and nozzle with a choice of 35 to 90 radiuses facilitating jet coverage on grease track channels and plenum areas, chemical resistant non-marking high temperature–pressure hose (3/8), centered high temperature Spin-Jets, and turbo-nozzles, various wastewater recovery and filtration equipment including the necessary vacuum hose and shoe fixture, roof access equipment and fall protection, warning signage as to cleaning activity, waterproof electric lighting, flashlight and personal protective gear. Adjustable pressures may range from 500 to 4,000 psi at 2.5–5 gpm hot 200F and cold water. Developing a quick effective and straightforward strategy to capture created wash water within the cleaning process of filters, hoods and duct system is a contractor prerequisite. The goal is to avoid all contamination of surroundings. Applying water recycling-filtration and disposing of grease–waste products correctly will always be the dominating qualifying criteria. The installed plastic

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Fig. 3.108 Hoods filter component’s

Fig. 3.109 Ducts 3D centralizer

protection sheeting must be able to withstand splash and water jet ricocheted and simultaneously funnel all wash water to a collection barrel, possibly outfitted with a sump–pump (10 gpm) permitting the direct disposal of wash water to an oil– grease separation unit or filtration system which can be of an advantage especially in remote or sensitive areas. Kitchen oil–grease waste is not of petroleum origination therefore requires more often only the capability and consideration of customers adequate and legal waste water discharge curriculum. The front or visible side of filter component’s (Fig. 3.108) and canopy surfaces requires obvious and simple cleaning endeavors. The invisible hidden areas of a duct system which are most likely also the low air velocity areas such as those found especially behind filters, in grease filter track channels, the build up behind plenum cavities or horizontal-lateral ductwork runs, in particular on multiple floors will require a contractors full attention and capability. On multiple floors exhaust systems laterals require access panels, every 100 –150 , which can be an added business opportunity when offering the installation of NFPA approved panels. When cleaning the main hood structure a direct contact to the fire suppression system, its cables, linkages and fuses by caustic chemicals, high-pressure cold–hot water jet or nozzle-wand is uncalled-for. A contact with this sensitive equipment can possibly activate the fire suppression system. After job completion a final wipe-down and cleaning of fire suppression nozzles and fixtures, including red caps (nozzle covers) is permissible as is the reinstallation of caps by pressing them gently on to the nozzle orifice. Cleaning, vertical–horizontal ductwork (Fig. 3.109) also requires the removal of the roofs exhaust fan motor and hood structure. When lifting the fan motor off its frame a physical restriction by the electric wiring must be guarded against to avoid possible damage. Providing and installing a hinge kit for the fan assembly circumvents a risky and cumbersome removal practice. When first inspecting an exhaust fan as to its operational function and possible imbalance

370

3 Application Core Curriculum GEAR - LIST AUTHORIZATION

Corrosion, fat-grease removal, chemically treating and painting (∅) of pipes, ducts and tubes Customer & Company:

Date: Address:

Web site e-mail

City: State:

P.O. Box: Zip Code:

Job Nr:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail

Tel: e-mail

Tel: e-mail

Tel: e-mail

Job Description: Job Location: Job Review Performed by:

Job Site Risk Assessment:

Specify:

Others:

Mud: Corrosion-rust: Mold: test: Specify: Bacteria contamination: Pests: Specify: Fats: Petroleum based: Grease: “ “ Oil: “ “ Carbon: Others:

Pressure washer: hot-cold Hydro-blast unit: hot-cold Pipe cleaning nozzle with cable ear: Vacuum truck: Hydro-vac system: Vacu-box: Airless paint spray unit: Paint hoses: Paint nozzle centralizer: Nozzle centralizer: Cables: Other:

FDA, EPA approved chemistry: MSDS: Acid: Rust inhibitors: Caustic: Detergent: Foam nozzle: Wand extensions: 35° to 90° Cardboard wedges: Spatula: Plastic sheeting: (visqueen) Other chemicals or live micro-organisms: Rags: Other: Specify:

Sewers: Pipes: Air conditioning-heating system: Kitchen exhaust units: Duct work: Roof unit Evaporative cooler-cooling tower:

Describe application and work procedure:

Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

©

yes

no

3.9 Directional–Horizontal Underground Pipe Installations

371

which is in itself not necessarily a result of a grease accumulation, a contractor is best advised to inform customer of this situation, which may reveal after cleaning prior damage to the impeller fan assembly. A smooth or adverse wobbly rotation to an intact, undamaged fan can only occur if an inadequate cleaning procedure was performed leaving residual which produce imbalance to a lightweight air impeller assembly. Roof surfaces can also be heavily saturated with fats and grease, probably a result of leakage from fan housing construction breaks or spillage by inadequate collection of grease passing through fans grease spout. Various grease collection systems are available, requiring a simple installation procedure. Cleaning roof surfaces also requires the collection of wash water and its subsequent grease content. The rain gutter can be considered a water conveyance system, but can often and only when isolated be utilized to transfer wash water to the filtration grease–oil water separation unit. The gutters are last in line to be cleaned and neutralized of any fat or grease content. After the cleaning procedure the entire exhaust system is inspected by a properly trained and certified competent person acceptable to the authority having jurisdiction in accordance with Table 3-8.1. The job walk will quickly identify access inadequacies when determining fat–grease–oil accumulations throughout the system. Inspection access to all areas of duct vent system is of utmost importance to verify that all surfaces are cleaned to bare metal. The entrepreneur is best advised to contact the IKEKA International Kitchen Exhaust Cleaning Association for training, licensing and possible equipment choices, http://www.ikeka.com, National Air Duct Cleaners Association, http://www.nadca.com, Indoor Air Quality Association, http://www.iaqa.org. Additional duct cleaning services can include servicing dust collection systems, stack cleaning, industrial ovens, lab hood exhaust systems, laundry exhaust systems, paint spray booth and stacks, etc.

3.9 Directional–Horizontal Underground Pipe Installations, Water Well Cleaning, Water Jet-Grouting, Pile Driving Today, various methods are employed to install lateral horizontal-pipes or conduit below asphalted or concrete road surfaces replacing expensive trenching applications. Developed in the early 1970s, varies hydraulic pipe thrust machines incorporating a 400 vacuum hose sleeve and a high-pressure water access fitting to the ram-block retainer situated between hydraulic cylinder and pipe assembly facilitating the removal of soil through the center of an advancing pipe assembly (pipe-jacking). This directional horizontal pipe installation technique under asphalt and concrete surfaces such as runways, highways, sidewalks etc., is supported by a sewer–pipe cleaning technique combined with a simultaneous hydro-vac procedure while removing soil and water from the advancing pipe interior. The water jet’s excavating force greatly reduces pipe-conduit installation times by reducing

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3 Application Core Curriculum

friction upon pipe assembly supporting the hydraulic cylinder force through varying subsoil conditions. A protected, centered pipe cleaning nozzle affixed to the cone assembly is situated guaranteeing that water jet impact is slightly behind and within the penetrating cone edge. The pipes’ lateral thrust advancing and delivering soil formation into the jetting cone, excavating soil into the vacuum supported pipe interior, reduces pipe friction and subsoil densities. The cone assembly, protecting pipe edge and nozzle may vary in size and nozzle jetting degree-angle accommodating pipe-cone assemblies interior [. To prevent collapse or hydraulic fracturing of subsoil areas or for that matter infrastructure is it imperative to keep the jet’s final impact contained within the interior of the cone-pipe wall protecting soil, clay, silt and sand formations. The jet’s velocity does only enhance the overall soil movement throughout the advancing pipe assembly. Water jetting procedures must always be simultaneously activated when an hydraulic pipe advancement is initiated. Vacuum operations, are only introduced to maintain soil flow and continuous removal to refuse collection facility. Soil conditions below parking areas, roadways, runways, etc., are generally known and do not pose an operational hazard. Depending on the pipe diameter to-be-installed, units with the capacity of 5–35 gpm, 3,000–6,000 psi (Fig. 3.111) are applicable. This excavating method must not be confused with a core rock drilling procedure which starts at a much higher pressure and low water volumes (app. 45,000–65,000 ? psi-and possibly produced by and referred to as intensifiers). When utilizing horizontal drill equipment (Figs. 3.110, 3.111, 3.112) for small and medium underground pipe installations a pilot hole on the surface on one side of obstacle to be crossed must be established before operations can begin. The drilling follows to the designated profile below and beyond the obstacle to exit at the surface on other side. The second phase entails a correct setback and creation of a cavity sufficient to accept pipeline-conduit, utilizing hydro-vac equipment. Pulling conduit or pipeline through the enlarged hole presents the third phase. The established key parameters ensuing from a geotechnical investigation must be followed closely which include identifying the practical pressure of drill fluid applied, pilot hole setback distances and depth of cover, which will depend on soil properties and geotechnical data gathered during preconstruction analysis. Applying adequate drill fluid pressures (Bentonite-mud) while in the directional– horizontal drilling process is a balancing act to maintain borehole stability, and sufficient pressure but avoiding the possibility or minimizing the potential to initiate excess plastic yield losing drilling mud to pilot hole or surface. These are only a few technical aspects which must be considered and can be complicated when drill speeds and drill fluid pressures are inconsistent resulting from varying soil conditions, depth and cover, utilities, various infrastructure, groundwater and space restrictions, etc. Hydro-technologies applied to regenerate water well systems (Fig. 3.113), and perforated drainage pipes set up in gravel substrate (pack) surrounded by sand and soil designed to enhance water flow characteristics are applications made possible due to nozzle criterion similar in appearance to equipment utilized for pipe

3.9 Directional–Horizontal Underground Pipe Installations

373

Fig. 3.110 Horizontal drill equipment

Fig. 3.111 Pump-head (slurry)

Fig. 3.112 Drill-bit and nozzles

cleaning, hydro-vac and pile driving applications. This application differs in that a two-step cleaning process is required and begins with the verification of an adequate groundwater table involving well systems design criteria. Necessary tool requirements will change with every man-made water well design and drainage pipe configuration, which includes altering or inconsistent soil and gravel pack conditions, well depth and well’s spire drainage configuration. Sooner or later all wells will lose their water volume performance due to restrictive sedimentations such as iron oxide, magnesium, calcium and other compounds responsible for various water flow limiting crust developments which may include

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3 Application Core Curriculum

adverse influences by chemical elements. Bacteria and biological effects can also be responsible for flow restrictions in perforated filter tubes. The draining area of the tubes, the water-carrying earth, gravel pack and sand (loam) will become less permeable restricting the overall water flow, including the permeability of the water-carrying substances and therefore may reduce efficiency up to 90% of the original well performance. Under most circumstances, interior drainage tubes are submerged and feature longitudinal slits or similar perforations. Steel brushes applied to clean these perforations are, at best inadequate. The sewer pipe cleaning technique is far superior due to the fact that pipe perforations are totally cleared of blockages due to the repetitive pipe jetting procedure and subsequent agitation of adjoining drainage areas, releasing sedimentation further enhancing the water flow ratio of a well. The secret reveals itself in the high-volume, low-pressure nozzle configuration; 2,000 psi, 60 gpm jet-penetrating power which will remove restrictive sustenance and agitate all exterior perforated pipe areas and adjoining well soils. This jet-penetrating performance is an industrial equipment standard and can also be produced with most of today’s sewer cleaning trucks (units) ideal for this application. Well basins are kept clear of water by operating a submersible pump powerful enough to maintain low water levels in the well casing. The well casing is serviced first utilizing the cleaning power of a 3D tank-cleaning nozzle. Most filter tubes are fitted with check valves, keeping water accumulation to a minimum. To protect the operator during the pipe cleaning process a high-pressure hose guide assembly (Fig. 3.114) incorporating a retainer for the nozzle hose armature and a simple slight gate is affixed to the valve flange joint. Adequate cleaning of perforation is best achieved by slowly and repetitively cleaning the pipe lateral, permitting an extended but constantly slow-moving water jet dwell time. A selfpropelling and centered 3D nozzle is the ideal tool for this application. Allocating an adequate cleaning time and agitation through pipe perforations of the surrounding soil-gravel pack formations guarantees in turn long-term water productivity. All OSHA’s confined space entry regulations must be introduced including fall protection, top entrance harness, plumbing take-out an lock-out procedures, and electrical lock-out, etc. (pumps etc.) Establish water-explosion proof lighting, sufficient communication between equipment operator, confined space safety man and labor force. It is the secondary process that constitutes a complete restoration of up to near 100% well production. Lance sections of 250 in length (schedule 100, ‘00 [) are vertically forced into the perimeter of the well ground and sand-gravel packed perforated spear boundary. The nozzle’s high velocity water (1.5 [ 9 5 9 1.5 [) will clear and assist the movement downward up to 1000 with little effort. Lance couplings are small-shouldered and can be drilled, creating two 1/6400 nozzle orifices, therefore minimizing friction in these areas. To guarantee top psi and gpm performances check the water volume capacity of available unit before drilling procedures are undertaken. When nozzle assemblies are forced within 30 of the well depth (spear or corrugated pipe), permit an agitating 10 s dwell time to

3.9 Directional–Horizontal Underground Pipe Installations

375

Fig. 3.113 Well casing, pipe Jeter, well spears

Fig. 3.114 Hp-hose guide assembly

surrounding gravel-soil filtrate before the lance pulling is initiated (section by section). A small caterpillar or front loader (Fig. 3.115a, b) can be engaged for the installation of a multiple lance fixture (3–4) as similar in its process then a soil remediation–grouting–stabilization procedure. When utilizing a high-powered hydro-blast unit, of 150 hp plus, the operating pressure can be raised achieving nozzle recoil forces supporting the retracting of lance equipment by small and cost effective construction equipment, which must provide a 250 lift capacity. Working from the near center of the well, covering all essential filter spear areas, will upon completion finish the regeneration process. It is prudent to clean the inside ([) of filter spear tubes once again applying this time a disinfectant to the water suction side of unit such as sodium-hypochlorite NaOC1 (metered). The water–chemical mix ratio is prescribed by either the chemical manufacturer or the water plant engineer. Applying both cleaning processes in a mid-size well can take up to 4 days.

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3 Application Core Curriculum

Fig. 3.115 a, b Lance assembly

The high-pressure water technology has also found its way into the jetting assisted sheet pile driving method which includes river dike shoring procedures, manufacturing underwater concrete casings, bridge and subway structures, and so forth. Tens of thousands of tons of piles have been driven with the assistance of hydro-jetting technology. Hydraulic operated equipment and cranes fitted with mechanical-hydraulically energized rams sometimes incorporating vibrator-assist equipment to enhance dynamic drive are most commonly used for this procedure. Adding high-pressure water jets to the exposed sheet pile edge reduces sheets skin friction to interlocking grooves and soils with added result of substantially diminishing ground vibration velocities, important in areas where dike stability or sensitive buildings are present. High-velocity water jets will dramatically decrease the overall sheet point friction, producing in various soils a 50–70% production increase while maintaining a 35–45% material and labor saving factor. The pile sections width and soil conditions will determine the need of one, two or four symmetrically arranged small diameter hydro-lance assemblies; one or two per sheet is generally sufficient. Preventing nozzle damage, and contamination (plugging) or undue stress by soil compression and created impact-friction the jetting procedure simultaneously commences with every pile driving operation. A simple steel retaining cap providing nozzle protection is firmly welded approximately 200 above the sheet pile edge. The ‘00 schedule 80 steel lance is secured by clamping devices or a rectangular 00 metal strip to the sheet in approximately 60 intervals, permitting a minimum gap of 1/800 between the lance and the nearest point of the metal strip. When in a high pressure low water volume application (high density clay), lance deformations possibly produced in a recovery lancepulling operation are averted. To avoid vertical slippage, a 00 retainer hub is welded above the high-pressure water manifold situated on the top side of the sheet pile. Prior lance assemblies retraction, this hub must be removed. Direct weld tagging every 80 to sheet can be employed for low-pressure high water volume applications (compact gravel-soil) where lance material recovery due to low cost of schedule 40 pipe materials justifies the loss. This also is a

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GEAR - LIST AUTHORIZATION Excavating, drilling, sheet pile driving and water well cleaning Job Nr.:

Customer & Company:

Date: Address:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Water well:

Specify:

Water well systems:

Equipment: Submersible pump:

Specify gpm:

Hydro-blast equipment:

Perforated drainage pipes:

Specify:

Hp hose guide assembly:

Filter tubes:

Specify:

Lance sections:

Tube drainage accessibility: Well basin ∅

and depth:

Well casing walls:

3-D self-centered tank cleaning nozzle: Specify:

Filter-spear depth, length, ∅ : Sheet pile:

Length:

Lance assembly unit:

Specify amount: Disinfectants:

Water treatment:

Pile dynamic analyzer: Design-width:

Other:

Caterpillar:

Pile echo tester:

Front loader:

Specify:

Other:

Describe pile driving method and location: rail, foundation, barge or marine environments: Describe application, tool utilization and work procedure: Describe soil remediation and grouting procedure: Describe geotechnical data and soil profiles: bedrock, glacial soils, marine soils, organic-inorganic soils, fill soils, etc. Describe pile type and load classifications:

Itemize further equipment, safety gear, expendables, labor time, equipment times, etc:

criterion in specific areas where geological circumstances (sandy-mud soil, etc.) within a sheet pile driving operation call for a ground stabilization procedure. In this case utilizing lance equipment to inject cement grouts or Bentonite slurry to improve toe strengths and overall structural soil integrity and/or water tightness is the application. It must be noted that this hydro-support method has yet to confirm geological changes within high consistency soil condition as first feared by

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3 Application Core Curriculum

Fig. 3.116 a, b, c, d, e Various concrete surfaces

engineers. Water jets psi and gpm performance are adjusted to operate within the plastic yield level of various soils encountered. Compact gravel, sand and clay formations have all proven the possible reduction of rams from 3,000 to 1,300 (at equal soil conditions) to the depth of 500 with a high-pressure water application.

3.10 Expansion-Control Joint Cleaning on Rigid Pavement, Sidewalks, Decking, Tank and Pool Construction Expansion-control joints mainly embody the need to eliminate possible stress damage due to load, environmental and thermal influences on concrete surfaces and structures (Fig. 3.116). Stress damage is generally a result of poorly distributed or excessive loads, inadequate subsoil conditions, and water damage to soil, organic growth and excessive temperatures, such as freeze–thaw cycling. Expansion joints may also be created or added where hairline fractures are present or likely to worsen and/or when structural changes are needed. The contractor must be careful in choosing the right application criteria. Joint technology can be confusing which can include a specific joint design for a contraction, construction, expansion and isolation criteria. The contraction joint, is a formed and/or tooled or can also be a sawed groove (Fig. 3.117) creating a weakened plane regulating the location of cracking by thermal-dimensional changes of different parts within. An expansion joint is a separation provided between adjoining components permitting movement, where expansion is likely exceeding possible contraction of a structural component or a separation between pavement slabs filled with a compressive joint sealer and/or manufactured components sealing and providing a compressive joint placed between prefab concrete slabs.

3.10

Expansion-Control Joint Cleaning on Rigid Pavement, Sidewalks, Decking

379

Fig. 3.117 a, b, c Sawed groove and its equipment

Construction joints are made in concrete before and after interruptions of concrete placement (pouring), or positioning of precast concrete units by installing strips of wood, rubber and foam, plastic or metal components. Isolation joints are defined as a separation between adjoining components of a concrete structure generally on a vertical plane at a designated designed location to interfere least with performance of the structure, yet to tolerate relative movement in three directions avoiding formation of cracks elsewhere. The pre-job classification should identify past project management stipulations categorizing design and type of joint, its width, depth, product, mastic-polymer, its trade name or manufacturer, design purpose and then necessary installation necessities. This greatly assists hydro-blast technicians to decide upon a correct tool selection and adjustments for the given circumstance encountered. Subject to confusion are most often contraction and construction joints. When removing product from a construction-control joint system is it important to require detailed knowledge concerning possible design variances within structural locations. Reinstallation and/or re-sealing of construction control or expansion joints require most often a dissimilar hydro-blast application criterion within a deteriorated product removal process. Application technology may also vary due to necessary installation, compression, sealing or adhesion parameters required by a specific joint product to be installed. The major application parameters are following below. Is a contractor obligated to remove backer rod or blocking media, waterproof membrane material, and is the installation of a bond breaker or separating tape necessary or a refacing or widening of joints required? A close working relationship is essential with any contractor responsible for new installations verifying necessities of product characteristics especially when establishing backer road width in a refaced joint and its required width–depth according to proposed

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3 Application Core Curriculum

Fig. 3.118 Cutting by highpressure water

identity of the sealant-polymer material installation. Traffic and weather can play a major role within a job’s progression and is critical when the cleaning and joint drying time or curing of an elastomeric is considered. The expansion joint’s width, structural integrity and desired mastic-polymer removal depth, deteriorated mastic-polymer elasticity and adhesion factors which are widely-variable parameters including the identification of its hazardous component, and disposal requirement are particulars also to be considered. Sometimes, the remaining indentation hardness of an elastomeric-polymer can be a guideline as to the removal time requirements but again can be varying due to weather cycling and products overall integrity. 3/800 joints and greater permit the utilization of a mobile oscillating nozzle carrier adequately weighted (50%+) to overcome and control the nozzle’s recoil forces, assuring the operator’s safety. A plastic curtain affixed alongside the unit’s exterior prevents excessive water overspray and allows a better visual control while the unit is within the advancement (Fig. 3.118). The nozzles are adjustable and their jets are set between 1 and 5, depending on joints cleaning width and depth. The jet’s overlapping point is responsible for the cleaning depth. The nozzle angulations are set so that water jets impact is guaranteed to affect all expansion joint surfaces within a cleaning path. Nozzles located near the unit’s pivot center provide the correct jet standoff distance from the joint edge and the mastic material, thus delivering the maximum water velocity to the adhesion areas. Oscillating speeds range from 60 to 360 per minute depending on the mastic’s resiliency. 600 –5000 per hour are standard cleaning performances and are proven to be very successful on concrete runways, jet-bridge and aircraft parking areas, bridge decks, coal storage facilities, etc. Pressure-gpm

3.10

Expansion-Control Joint Cleaning on Rigid Pavement, Sidewalks, Decking

381

Fig. 3.119 Cutting by highpressure water

performances of the oscillating units range from approximately 7,000–10,000 psi, 20 gpm. Expansion joints below the width of 3/800 create a problem due to the fact that the jet’s velocity and power cannot directly or effectively attack the mastic adhesion areas, realistic jet impact angulations are therefore impossible within the straight down joint surface areas. In this case, preferably apply a high-pressure, low-volume concrete or steel cutting head in conjunction with a minimum amount of soluble abrasive medium (not exceeding 50 lbs hourly). These small joints will channel the high-velocity abrasive water mixture, removing mastics and creating an adequate porous surface. Gun barrel steel guide (Fig. 3.119) affixed to the nozzle fixture can greatly enhance jet guidance and spalling of edges. Before new mastics are installed, a thorough cleanup and drying process in the immediate joint area is essential (hydro-vac system). If required due to excessive footage, a dual or triple gun operation is advisable. Trigger-guns with water deflector shields allow a safe, more controlled work method in areas where movement is restricted enhancing the overall production rate. Approximately 5 gpm, 10,000 psi per gun is a common operating standard. The concrete–steel cutting heads are also applicable when repairing and sealing pools, fish tanks, digesters, dams, and so forth. Cracks, blisters, and fractures are exposed and then water-abrasive blasted (soluble) to gain adequate material porosity (starting with pressures at 3,000 psi and no less than 5 gpm). If abrasive materials are not desired in the vicinity a concrete scarifying unit at 12,000–22,000 psi may be the alternative or the UHP method utilizing turbo-nozzle, etc. A side note: Emerging weeds, grass, and their roots are removed in the same fashion, except a weed-killing chemical is metered to the blast water or directly applied into the joint before resealing processes are conducted. Reappearances of weed growth are highly unlikely. High-pressure water jets are extremely root-damaging and enhance the chemical action, providing a long-term weeding solution.

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GEAR-LIST AUTHORIZATION Expansion control joint cleaning, sidewalks, tank and pool construction Date: Address:

Customer & Company:

Job. Nr.:

City: State:

P.O. Box: Zip Code:

Purchasing

Engineering

Maintenance

Safety

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Review Performed by: Concrete flooring: Concrete runway: Expansion joints: Hairline fractures: Jet bridge areas: Aircraft parking areas: Aircraft hangars: Bridge structures: Ponds: Fish tanks: Water dams: Digesters: Cool storage facilities: Others:

Equipment: Hydro-vac system: High pressure trigger gun w-deflector: Oscillating cleaning unit: Concrete-cutting head: Chemicals (weed killer): Chemical metering procedure: Turbo nozzle:

Other:

Describe application and work procedure:

Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

©

3.10

Expansion-Control Joint Cleaning on Rigid Pavement, Sidewalks, Decking

GEAR - LIST

383

Nr.

Job Nr.:

Date: Address:

Customer & Company: Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Building type:

Pressure washing - hydro-blast equipment:

Non-expendable equipment:

Expendables:

Product Encountered: Hazardous Material:

MSDS:

Specify:

Safety procedure:

Work procedure:

Developed by: Authorized by:

Date: Date:

384

3 Application Core Curriculum

3.11 Filters, Screens, Felts, Bag-House Units, Trays-Catalytic-Cracking, Vacuum Suction Rolls, Radiators-Fin-Fan, Air Preheater Baskets, Staggered Channel, Wire Mesh-Plate-Vane Mist Eliminators Dismantling fouled air pre-heater baskets facilitating a cleaning procedure is a practice of the past. In fossil fueled power plants there are two cleaning alternatives available reducing the related maintenance and cleaning costs. First, the installation of a permanent and automated system, which is located on air preheater units’ low-pressure side, can specifically reduce maintenance scheduling problems by eliminating a vessel entrance procedure. A mobile or stationary hydro-blast unit, generating a minimum of 50 gpm at 10,000 psi, will supply the hydro-power to a rotary spin-jet nozzle carrier installed to a traversing unit which moves repeatedly from the center to the outside perimeter of the basket assembly while the basket disk is in a slow rotation. The jets will penetrate upward through hardened and crusted materials throughout a 12-ft basket structure. Early tool designs successfully applied nozzle carriers utilizing three jets incorporated to the traversing unit. Operating at approximately 60–80 gpm at 10,000 psi a lesser vulnerability as to failure was the major advantage especially when applied to the vacuum side of a basket structure. In any event, the nozzle design and standoff distance will be selected in accordance with various basket depths and fouling characteristics. The physical design of a standard jetting nozzle does not permit a tight jet configuration throughout excessive and obstructed blast distances especially when utilized by a spin-jet. To compensate for inadequate nozzle design criteria the experienced technician will make up for resulting energy loss by enlarging nozzle orifices [, accommodating water mass (volume) to the necessary psi performance, which is a prerequisite and only possible when adding the horsepower requirement. A tight water jet configuration resulting from an advanced design criteria will deliver far superior jet standoff distances dramatically reducing horsepower necessities. Cleaning baskets from top side of a rotary assembly utilizing the same stationary or mobile traversing technology highly automates this otherwise rigorous manual procedure. The second option requires the manual operation of hydro-blast trigger-guns requiring confined space entry procedures. Operators experienced with these units will not be able to outperform a mechanical system. However, where material deposits and density drastically varies, the manual and systematic basket area-toarea performance criterion is more effective, avoiding the repetitive and timeconsuming mechanical method when isolating and cleaning the problem areas. Extensively-soiled units throw loosened products above the basket surface while in the cleaning process. To allow oversized materials to pass through the basket grid, either the manual shredding (hydro-trigger gun) or the simultaneous use of the hydro-vac unit is suggested, avoiding the shredding procedure. Sufficient lighting,

3.11

Filters, Screens, Felts, Bag-House Units

385

Fig. 3.120 Air preheater basket

Fig. 3.121 Fouled basket

in area being cleaned is of utmost importance; verify lockout–takeout procedures on vessels plumbing and electrical circuits. Scrubbers and mist eliminators (Fig. 3.120), distillation columns and acid mist scrubbers applied in reclamation processes may also remove mist droplets of sulfuric and phosphoric acids from stack gases, such as those found in chemical processing systems. These systems incorporate a wire mesh, zigzag or wing-baffled structure in wood, metallic, plastic or fibrous design to separate mist droplets of 35 lm plus from massive air flows, also common in vent stack mist eliminators, which are found in paper-pulp mills. They are applied especially when product carryovers are constant or a given possibility (Fig. 3.121). Fiber bed mist eliminators in cylindrical or panel construction are installed to prevent a visible stack plume. Special attention is required when choosing a specific tool selection and subsequent psi and gpm configuration. A cleaning process must prevent damage to the fiber-plastic materials, possible when gpm performances and nozzle stand-off distances are incorrect. Misuse of turbo nozzles can create substantial damage to a fiber-plastic structure. The highest-quality fan nozzles (15 to 20) will prove effective at 5,000–10,000 psi. Nozzle orifice [ (gpm) is selected by recognizing penetration requirements concerning the mist eliminator’s structure and product accumulation, density-tensile strength. One must be careful to protect fiber-plastic materials which are sensitive to direct jet impact and more so to high water volume velocities possibly required when removing stubborn crusted materials. Sufficient lighting in units confined space, adequate and safe footing protecting the fiber-plastic bed structure and understanding the unit’s design criteria is of utmost importance to correctly identify fall protection. In most industrial plant situations fin-fan air cooled or heat exchanger cleaning is nowadays semi or automatically performed. For emergency repair situations a manual cleaning application or the utilization of a portable service unit is practical. The manual exterior cleaning of fin fan structures must be undertaken with care.

386

3 Application Core Curriculum

Fig. 3.122 Fin-fan exchanger (a, b, c, d, e)

Obviously sensitive metal-aluminum fins (Fig. 3.122) cannot be introduced to physical contact by a trigger-gun barrel’s nozzle assembly, nor can pressure or water volume configurations exceed fin strength, resulting in deformation. The criterion is only the depth of fin fan tube structure reaching all surfaces by manipulating the gpm–psi configuration (Fig. 3.123). Single, dual or triple round jet nozzle assemblies are most effective and deep penetrating with least of lateral force development to fin-fan structure, especially on horizontal units. Most damage to fin structure occurs through operator slippagecontact. Space restrictions are often encountered when servicing commercial units on roofs or in confined equipment space which requires flexibility in tool design and their application. At some stage during a plant service cycle the necessity to overhaul a selfcleaning baghouse unit (Fig. 3.124) is sometimes complicated considering the existing combustible explosion threat (dust). Adding to the fire triangle of oxygen, heat and fuel, the deflagration of dust particles in sufficient quantity and concentration can cause a rapid combustion especially in a confined space or enclosure such as buildings, vessel or equipment. The utilization of industrial vacuum trucks can be relatively risky due to development of static electricity, and heat generated by necessary tight gearblower tolerances (mashing) and the high temperature transference to the muffler assembly possibly causing equipment fires and/or explosion when a filtration breakdown, overload scenario or grounding interruption occurs (debris-box).

3.11

Filters, Screens, Felts, Bag-House Units

387

Fig. 3.123 Powerine proposal

The removal of accumulated dust and bag house fines in volatile agricultural, wood, chemical, metals, plastic and carbonic dust environments can safely be performed utilizing various hydro-vac methods. A possible electric static charge created through friction within a vacuum hose assembly does not occur due to the constant equipment grounding-conductivity by water jet transference. The vacu-jet pump does not retain mechanical parts to develop heat or any other ignition source. Practical application variations are categorized into three methods; either directly pulling dust accumulations and debris through a vacuum injector assembly, utilizing 400 –600 [ vacuum hose runs, avoiding all contact or filtration problems by liquefying bulk dust to be deposited in tanker–trucks, evaporation, settling

388

3 Application Core Curriculum

Fig. 3.124 Baghouse unit

ponds, or landfill. This situation also permits the placement of power-pack, pump stations and vacuum injector off-site when services are performed in or near volatile vessels, equipment and areas. The second alternative permits conveying product over excessive elevations and distances by establishing an off-site pump station continuously loading and pumping by incorporating sludge-mud transfer equipment. The third possibility and often applied is the dry product removal method utilizing mobile vacuum containers (roll-off box) energized by highpowered hydro-vac pump equipment to permit the possible product return to process or dry storage requirements. When cleaning interior surfaces of centrifugal separators, rotary sieves, drum or disk filters, one will find a similar tool selection when powdered or dust accumulations must be removed. The application and safety variances lie within the industrial environment encountered and their products manufactured. The air pollution control systems filter bags (fabric) draped over cages are most often cleaned off-site. Pulled over a cage the interior surfaces are cleaned by a centered dual 45 fan jet T-assembly at 200–800 psi. Necessary cleaning pressures do vary according to fiber type of bags encountered. Processes, pending their structure can be of cotton, nylon, glass, polyester, etc. Interior shell surfaces are subjected to a 3D tank-cleaning nozzle for the washdown application. Interior cleaning applications range widely from 1,000 to 8,000 psi, 2.5–22 gpm; utilizing trigger-gun with affixed turbo nozzles, fan jets from 15 to 45, depending on encountered substrate and material or the adhesion of sedimentation. Once again, the final tool selection is chosen when understanding the manufacturing process, type of sedimentation or calcification involved and the overall design integrity of a unit specified. This includes being aware of varying safety equipment and its application. So-called suction rolls in paper mills (Fig. 3.125), belong to the filter element cleaning category. In operation, or on arranged maintenance intervals, process operators either utilize a trigger-gun fitted with a 20 fan nozzle (no more than 6,000 psi) or a timing device activating a repetitious cleaning system incorporated

3.11

Filters, Screens, Felts, Bag-House Units

389

Fig. 3.125 Suction role

Fig. 3.126 Filter plates

to the felt roll-off point, enhancing the paper product’s quality and felt production lifespan. The interior diameter ([) of a dismantled suction roll is cleaned at approximately 6,000–8,000 psi, bringing a T-lance fitted with two 20 fan jet nozzles to action or utilizing a centered 2D nozzle carrier. Frequently, their coneshaped orifices best release adhered scale accumulations when the nozzle velocity is first applied onto the narrow side of the cone. Cleaning the outer perimeter of the suction roll is therefore of an advantage. Important: Be aware of the direction of production process-flow throughout a suction roll and all other air or fluid filtration systems. Material adhesion is best broken down by applying the jet’s velocity against the units production flow, characteristically providing a better or rougher surface structure, permitting a greater jet-penetration factor, therefore, when technically possible, cleaning procedures must start at the gravity vacuum or discharge side of any given unit. When repetitious work becomes necessary, stubborn, adhered products have most likely been neglected in previous cleaning procedures and may escalate the prior estimated cleaning time. Above all, it is important to clean all areas in depth. This drive for excellence is also important when cleaning filter press systems hydrating industrial sludge. Their filter plates retain fine, horizontal or vertical channels (Fig. 3.126). The filtrate emerging from the filter cloth is drained throughout these cavities. Developing crust and obstructions result in production time losses. Deposits are removed by mechanically-driven fine-toothed steel brush possibly adding a surface profile. Medium pressures of 3,000–6,000 psi, at 4–9 gpm and trigger gun-operated 15 to 20 fan nozzle will solve this application much quicker and without the possible damaging effect of harshly-employed steel brush applications. For standards related to fire and dust explosions, http://www.nfpa.org, NFPA, 654, 61, 484, 664, 655, and for

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combustible dust national emphasis program, safety and health information bulletin (SHIB) (07-31-2005), combustible dust in industry, http://www.osha.gov. GEAR-LIST AUTHORIZATION Filters, screens, felts, bag-house units, trays for catalytic-cracking, air-preheater baskets, etc. Customer & Company:

Date: Address:

Job Nr.:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Review Performed by: Fin fan air-cooled or condenser: Centrifugal separators: Specify: height, , access: Rotary sieves: Drum filters: Disk filters: Suction rolls: Filter presses:

Air pre-heater baskets: Scrubber, mist eliminator: Distillation columns: Acid mist scrubbers: Wire mesh (zigzag): Wing structure (wood, metal, plastic): Vent stack mist eliminators: Fiber bed mist eliminators: (cylindrical, panel, specify Ø):

Equipment: Hydro-blast unit: Round jet (hard-hitter): High pressure trigger-gun: Lance extensions-T-lance: Flex lances: Fan jet : 15°, 20°, 45°

psi:

gpm:

psi:

gpm:

Other: 3 D nozzle: 2 D nozzle: Nozzle centralizer: Vacuum hose :∅ Hydro-vac equipment: Vacuum roll-of box: Other:

Specify: psi: gpm: Specify: psi: gpm: Specify: Vacuum-hose: length Specify: tooling

Product Encountered: Chemical: hazard: describe:

Yes

No

Specify:

Describe application and work procedure: Mud pumps: Pump station: based on-site, of-site:

Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

Specify:

©

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3.12 Cleaning of Gas Stations, Bank and Restaurant Drive-Thru’s, Machine Shops, Warehousing and Parking Garage Areas, Airport Runways, Jet-Bridge and Hangar Facilities, Vehicular-Pedestrian Tunnel Surfaces Surface cleaning or so-called flat work, is best divided into three basic application identities; 1. High-pressure water washing or cleaning of residential and commercial properties, creating in its function no ground water contamination nor utilizing the storm water conveyance system. This is a prerequisite which mandates that no surface water is discharged to storm sewers, but also includes doing away with a non-hazardous wastewater discharge from house washing operations, resulting in carrying sediment and turbid water on to sidewalks, road surfaces, street gutters or any other conveyance method (ditch) with direct access to aquifers, rivers, lakes and/or sea. 2. High-pressure water washing or cleaning of residential and commercial impermeable surfaces, protecting at all times the storm water conveyance system while creating a non-hazardous effluent resulting from hot high-pressure water cleaning techniques, supported by a range of soaps or mild chemicals. The removal of oil, grease, fats, wax and sediment residual results in an admixed wastewater stream identified and recovered for reduction and pertaining to the governing sanitary sewer district regulation (POTW) disposed of as wash water pH neutral. 3. High-pressure water washing or cleaning of residential, commercial and industrial properties where typically a waste stream is created when utilizing hot or cold high-pressure water to remove coatings, various types of industrial waste products, coverings and corrosion often supported by solvents, abrasives and/or chemical surface preservation products. Removed solid waste must be identified and recovered, blast water recycled and filtered, solvents recycled or reduced for correct disposal and/or incinerated. Hospital main and emergency entrances, supermarket loading-receiving docks and customer entrances, hotel arrival portals, atrium display and entertainment areas, pedestrian sidewalks, city park grills, benches and tables, open-air park structures and tourist facilities, city center expositions, fountains and culinary exhibition areas, subway entrances and exit surfaces, pedestrian areas in botanical gardens and zoos, stadiums and their customer and sport facilities. In short, all surfaces where one must not worry about the water runoff created when applying hydro tools utilizing cold water between 3,000 and 6,000 psi at 4–10 gpm. These applications most often belong to the number one category of wastewater management, and most often require water recovery (Fig. 3.127) and vacuum tooling avoiding overspray or possible misting events (Figs. 3.128, 3.129). Surface areas require barricading procedures displaying warning cones, safety tapes, signage and

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Fig. 3.127 Water bladder berm

Fig. 3.128 Vacuum generator

Fig. 3.129 Vacuum berm

Fig. 3.130 Drain cover, water bladder

primary–secondary (Fig. 3.130) protection for accidental wash water release to the storm sewer system (Figs. 3.131, 3.132). Secondary protection requires water barriers and covers for various street gutter designs and the subsequent storm drain access, preferably incorporating at the

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Fig. 3.131 a, b Hotel arrival portal

Fig. 3.132 Oil–grease residual, before–after

lowest area a backup vacuum-shoe which is independently activated in the event of primary wastewater control failure. The simple closed-loop oil/water separation and wastewater neutralization technique should be modified when utilizing hot water 200F, between 2,500 and 6,000 psi emulsifying heavy oil and grease accumulations especially in hot weather. Today available mobile equipment varies dramatically in operational gpm performance to separate emulsified oil/grease from a wastewater stream (2.5–15 gpm) setting in motion the number two wastewater treatment requirement. Gas stations (Fig. 3.133), toll-booth, bank and restaurants drive-thru, in short, all areas accumulating oils, grease and food remnants on stop and go concrete and/or asphalt surfaces are routinely serviced. Cleaning intervals depend on traffic volume, access possibility and climate (temperature). The application criterion for gas stations and restaurants drive thru may differ slightly in support of durability and aesthetic maintenance efforts. Today’s polymer modified concrete surfaces feature a reduced permeability (oil-stain), a improved abrasion and freeze–thaw propensity at tensile strength of 4,800– 6,000 psi supporting a cleaning solution by high-pressure water incorporating only a mild detergent if so desired (Fig. 3.134a) Nevertheless, gas stations and their fuel companies are considered generators of accumulating petroleum waste products. Therefore, all waste streams removed from their facilities must be handled within the hazardous waste removal criteria (cradle-to-grave). The modern gas stationconvenience store may also operate a carwash facility, sometimes contractually utilized to receive their acidic-alkaline wastewater which is neutralized on site to

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Fig. 3.133 a, b, c Gas station oil–grease residual before–after

pH 6.5–7 and disposed of. Job setup procedures must be thought-out regarding populated, traffic oriented and possibly volatile-gaseous environment. Gasoline and diesel fuel powered pressure washing equipment cannot be situated within the vicinity of any fuel system. This is seldom a problem; the area to be cleaned must be free of equipment, tooling and vehicles (Fig. 3.134b). Contractors equipment will feature a spark arrest grounding wire attached to the equipment while in operation maintaining ground to the designated system which is likely to be found within the underground fuel tank area. Eliminating possible sparks by covering battery terminals with semi liquid silicone is also a good idea. Sanitary sewer district regulation and EPA pending, detergents can by admix to the jetting water or applied directly to a soiled area to by toiled in by broom (pump-up sprayer) which is followed by a vacuum retrieval (Fig. 3.134c) application into a designated container. Professionals fine-tuning their cleaning capacity for large surface areas above 10,000 ft2 hourly, are most often also under time constraints. Utilizing a trigger gun mounted injector (abrasive) permits a quick and precise foaming detergent application over extended distances (400 –600 standoff distance). Foaming and dwell-time characteristics are generally far superior to available foam nozzle equipment developed for fleet or house washing operations. Water–chemical ratio is determined by pumps-gpm performance and chemical flow controlled by needle valve adjustment to injectors vacuum hose. The abrasive hose and hose barbs are exchanged for a 00 chemical hose. Ratio tests and verification are best performed when timing the fluid draw (water). Water drenched surfaces may not reveal the development of ghosting while in a jetting procedure (fan-jet). Rotary surface cleaners and spin jets are in their application most effective to curtail ghosting scenarios often encountered with novice operators. Cleaning capacity (carts) should guarantee at all times a minimum effectiveness of 8,000 ft2 regardless of the distinctive surface soiling found on the above mentioned areas. Correctly

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Fig. 3.134 a, b, c Equipment set-up

set-up rotary equipment will ideally produce approximately 9,000–11,000 ft2 at 3,000–6,000 psi, and if necessary operating at 200F plus, at approximately 5.5 plus gpm. Forward cleaning performance is subject to available psi–gpm, nozzle set up and rotor rpm, nozzle standoff distances and adequate unobstructed hp-hose feed. Circular ghosting is a result of excessive forward thrust (Fig. 3.135) or reduction of rpm due to water pressure loss and/or rotary swivel failure. When purchasing rotary equipment to utilize hot or cold water at 4–10 gpm, let supplier assure hp-swivels’ effective stand times. High-pressure swivels drastically vary in their performance criteria which facilitate the nozzle arm rotation (nozzle body). Excessive leakage within a rotating seal is immediately recognizable and visually noticeable by systems pressure gauge indicating a pressure drop. This is only factual when nozzles, pump packing, valves and pressure regulators are in full operating condition and systems pressure side is free of internal–external water leaks. Compensating for a lost gpm output by raising engine rpm is not a solution especially when operating with extensive high-pressure hose assemblies.

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Fig. 3.135 Spin-jet ghosting

Fig. 3.136 Fan-jet ghosting

Due to traffic loads, toll booth, bank and fast-food drive-through surfaces are usually serviced at night. Almost always these areas are designed with a natural runoff capability providing the self-explanatory placement and position of water barriers and vacuum shoe. Contaminated with bubble gum, foodstuffs and grime, sidewalk cleaning for restaurants and shopping areas can be considered a fundamental job classification. Problems arise when time estimates are required for various spot removal procedures on a variety of substrates. Asphalt, concrete, brick pavers, granite, lime and sandstone substrates require specific attention. Their individual surface uniqueness, especially in hot environments sometimes also contaminated with asphalt and/or bituminous products besides bubble gum can be frustrating. Pressure and temperature requirements on various substrates are adjusted to prevent ghosting (Fig. 3.136) and/or damage, especially when pavers are encountered which are installed to a sand filled-base. Adjusting nozzle impact degree on a rotary surface cleaning unit can be required. The utilization of hot water best above 200F plus at 3,500 psi is ideal for most surfaces. Especially for bubble gum residual, temperatures above 200F are necessary. The higher the temperature the easier gum will melt away. Pressures must be reduced for lime and sandstone

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Fig. 3.137 Parking facilities

pavers. Correctly estimating cleaning times on porous and or frail substrate (sandlime stone) is largely based on experience supported by timing the cleaning of 1 yd.2 within the severest and the least contaminated area (demonstration) and comparing the remaining surface appearance to a visual reference identifying the percentage of the overall spot contamination. This visual reference is also applicable for all other surfaces (The Book of Spots by Lydia M. Ph.D. and Charles A Frenzel). Water barriers and covers are arranged avoiding accidental discharge to the storm sewer conveyance system. Barricading and signage for work area is mandatory and includes the area of equipment and hose runs. Daytime work is most often complicated by pedestrian and vehicular traffic. A contractor should not underestimate the problematic of applying chemicals in busy areas, especially on windy days. Besides the human factor, misting adversely affecting vegetation, awnings, windows and possibly parked vehicles can quickly become a gigantic headache, even though the chemical and visual effects are deemed minimal. Floor and surface cleaning applications such as those found in underground or elevated parking facilities (Fig. 3.137), differ substantially to the bank, restaurant and gas station drive-thru criteria. Contracting bidders submitting offers for services to city-owned structures and nowadays most private garage businesses require a DUNS number (Data Universal Numbering System), obtainable by contacting Dun & Bradstreet, http://www.dnb.com/us/and the central contractor registration, CCR at, http://www.ccr.gov. Deteriorating and outdated concrete classification, years of penetrating oil and grease, various repeated cleaning endeavors and accumulations of remaining trace elements, deteriorating coatings, concrete abrasions and environmental damage etc. are typical to most aged garage structures. Older units may also exhibit advanced concrete carbonation and carbon dust contamination, wind swept debris, bird-pigeon droppings and a variety of traffic problems. Most often these typical conditions determine a quarterly or biannual weekend schedule providing necessary cleaning services at night. Before a jetting procedure is implemented, the structure must be studied to identify possible damaged expansion joint systems, concrete micro fractures, or any other possible circumstance permitting water to seep out or through to ceilings and walls of the next level below. Identifying this leakage possibility is best done at the time of a preliminary job walk. When studying prior staining events on ceilings, especially around recessed light fixtures and electric open wiring, light switch

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Fig. 3.138 Parking garage

Fig. 3.139 Grease oil deposit, before

Fig. 3.140 Grease oil deposit, after

fixtures etc. is it important to notify property management of such an alarming circumstance. Garage structures (Fig. 3.138) may also be part of an emergency exit-access by pedestrian and emergency vehicles alike and must be considered when designing the job procedure and equipment distribution throughout the cleaning process (Figs. 3.139, 3.140). The closed loop removal and filtration-recycling of the created waste stream can be controlled when cleaning top down by utilizing the existing drainage system. Most often this requires a prior pipe-cleaning application of the system. Generally, garage structures primary, and secondary drainage lack the necessary water velocity to self-clean. Over time, where extended intervals of sweeping are utilized expect a heavy debris burden within pipe and, if present, clarifier. Once cleaned the waste-water flow can be isolated by various methods. The pipe-systems cleanout flanges are utilized for the installation of pipe and sewer plugs (Fig. 3.143) isolating the down

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Fig. 3.141 Catch basin

Fig. 3.142 Funnel receiver

stream pipe and sewer access from the developed waste-water stream. The plugs are pressurized-operated by either air or water which can be manually performed. A vacuum hose fixture (Fig. 3.142) or collection trough (Fig. 3.141) is installed befitting a range of pipe or cleanout ports within their physical locations (one). Incorporating the bottom vacuum flange connector for remote operation of the water filtration–reclamation and hydro or pressure washing pump closes the wastewater cleaning cycle. Due to time and area constraints, the physical movement of equipment and trailer is quite impractical. Garage design pending highpressure hose runs are guided up through the center of a unit with quick coupler access for each floor, or in approximately 250 –500 increments. Cleaning performance should always be above 10,000 ft2 per hour per 20 hp drive input. The clean-ability of any coating system refers to the removal of dirt, grime and other contaminants resulting from environmental, storage and manufacturing procedures. Various coatings are designed to withstand the rigors of sanitary and decontamination procedures on coated surfaces such as in food, medical, nuclear and military application environments. Contractors often confuse clean-ability to abrasion and erosion resistance. The clean-ability and scrub resistance is mainly a function performed on the topcoat of any coating system, which may include a verifiable resistance to detergents, solvents, fuels and chemicals. Also a high-pressure water cleaning processes for coating systems intended to be maintained one or more times during the coatings lifecycle may only appear as a cleaning function. In reality the job description called for the removal of oxidization of topcoats surface structure facilitating a reinstallation of the same.

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Fig. 3.143 Sewer–pipe plugs

Under these circumstances the necessary water pressures will range from 6 to 12,000 psi depending on the equipment utilized. Nonskid coating surfaces installed to resist harsh chemicals and heavy steel or rubber-wheeled loads are found in chemical processing and storage areas, educational and health care facilities, food processing or meat cutting areas, automotive manufacturers and dealers, aircraft hangar and or general warehousing complexes etc. Typically, these advanced floor systems are comprised of 2–4 layers, starting with an optional elastomeric membrane, followed by an epoxy prime coat. The third layer is a matrix of coarse, at times colored, abrasive (quartz) and 100% solid epoxy to provide the necessary strength and chemical resistance. The final coat, also an option, consists of a clear epoxy finish which adds extra protection and an attractive gloss. When cleaning such coating surfaces with highpressure water the following parameters must be established: Identify the make of the sub-floor (brick pavers, butt metal, quarry tile, concrete, or wood), and its condition for satisfactory coating adhesion. Often industrial coatings can hide damaged, badly eroded, spalling-blistered or irregular pitched floors. Under these circumstances varying coating thickness, strength and subsequent vulnerability throughout can be expected. Manufacturers’ physical property sheet, specifying hardness (shore), generally 70–85, compressive strength generally between 17,000 and 19,000 psi and tensile strength ranking upward from 12,000 to 13,000 psi cannot be trusted when identifying the necessary pressure range for cleaning operations. The cured film thickness, described in mil may vary in reality due to sub-floor’s structure. The bond strength to concrete is specified in psi (300–600 lbs) or as ‘‘concrete fails before loss of bond’’. The experienced contractor will use this information to avoid guesswork in the set up of his tooling. When the sub-flooring consists of steel and concrete spin-jets for corner work and rotary surface cleaners are the ideal tool combinations. Exerting pressures between 3,000 and 6,000 psi utilizing dual 158 or 258 fan nozzles will remove all surface debris and expose a constant color tone. Precise jetting parameters are achieved by the manipulation of jet-carts forward speed, rpm and psi–gpm configuration combined with the available nozzle variety and adjustable nozzle stand off distance to the coating surface. Black cover (rubber) high-pressure hoses tend to leave streak and pulsation marks when situated or pulled over hard porous surfaces. To prevent this, hose slack is maintained on surfaces to be cleaned. Effective and precise high-pressure hose placement, manipulation and its unobstructed feed by a

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Fig. 3.144 Dual spin-jet operation

secondary operator to the rotary jet-carts is of utmost importance when cleaning large hangars or warehousing complexes. The water runoff control by water barrier, squeegees, natural flow and strategically placed vacuum shoes recovering the waste stream can be mandatory especially when buildings are not connected to a private water treatment facility. Square footage performance (Fig. 3.144) utilizing two times, 20 hp = 40 hp drive capacity will clean a minimum of 20,000 ft2 per hour. A coating installation to a tile and or brick floor-substrate tolerates a similar cleaning practice. Tile-brick grouts are generally super hard and do not require further attention. In these areas the water runoff capability is part of the structures design, featuring a floor drain system. The floor drains are generally installed at the lowest surface pitch or ground level and will guide accumulated water to the water barrier and vacuum shoe area (by drain opening). These applications are typically found below product assembly lines, meat processing areas, commercial kitchens, produce production facilities (canneries), stadium seats and walkways, etc. Electrical outlets are generally open drip-proof (exterior design) and situated so as to accommodate the structures industrial purpose. Regardless of the outlets design, apply plastic sheeting in combination with caulking (silicone) to seal them. Do not point a jet or a reflecting water jet in the direction of the electrical outlet. If circumstances permit, disengage and lock-out the circuit breaker, isolating these receptacles. Reengage circuit breaker only after the job is completed and all materials are removed from the receptacles. When rotary jet carts are too bulky and unpractical due to obstructions (concrete or mechanical fixtures), apply a spin jet affixed to a trigger-gun barrel at 2,000–3,000 psi and no more than 5.5 gpm. Fan jets at 25 or 15 are also suitable. Often surface cleaning applications are not pursued primarily due to the notion that reflecting water jets and their subsequent water velocities are not controllable. Guiding the water ricochet-misting and flow in critical areas, a contractor will require tooling specifically designed to the encountered application. Such tooling is inexpensive and can consist of ’00 [ to 1‘00 [ sand filled, soft light weight flexible hose (both ends capped) or various water bladders and plastic coverings. Weighted hose retains and guides cascading waters to the drainage area. Various water barriers of static (bladders) or vacuum design, incorporating a suction shoe is placed on the lowest point (pooling area). When cleaning massive spread-out

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3 Application Core Curriculum

areas can it possibly be necessary to incorporate a secondary vacuum shoe which is alternatively moved to water pooling situations. Powered by hydro-vac and/or water recovery, filtration and recycling equipment, most available gear is capable of removing 10–20 gpm plus. Pedestrian concrete bridge decks and walkways are most often susceptible to ghosting events therefore also best cleaned with a rotary surface cleaner (jet-cart) performing at 8,000 ft2 per hour plus. Depending on bridge size, a tank truck with power washer unit in tandem is of an advantage. Equipment mobility is essential. Safety procedures are subject to pedestrian and vehicle traffic. Wastewater runoff must always be controlled and reclaimed. Necessary pressures range from 3,000 to 6,000 psi at gpm equipment pending. Runway cleaning, or better the removal of residual rubber created by aircraft tire friction has been offered to airport maintenance departments since the mid 1960s with the availability of compact equipment and in doing so applying up to 600 hp. Today, truck mounted and vacuum supported rotary surface cleaners, retrieve created waste stream simultaneously, separating rubber residual while in a continuous cleaning process. This also permits shorten maintenance emergency procedures between runway takeoff and landing frequencies. The actual psi–gpm requirement is quite often overemphasized when equipment necessities are introduced, especially where gpm–psi performance must be kept within the concretes limitation to adsorb the high-pressure water velocity within the concrete–rubber interface. The following application practice is in some locations or jurisdictions outdated but must be understood to correctly identify similar application criterion. Airport maintenance and managers expect a certain performance capability from competing contractors. Technical provisions are provided to the interested parties prior to the bidding procedure and read as follows; The certification of a contractor must include that the contractor’s equipment has been demonstrated or used in the performance of a contract which has taken place at a US air force base or civil airport and this certification must be signed by the base civil engineer or airport manager. Further, this certification must contain statements that the contractor and his equipment have the capability to remove a minimum rate of 10,000 ft2/h, and if necessary 85% removal rate of loose paint on runway markings. Liability insurance of 4–6 million dollar is considered a standard for most commercial airports and can present a problem for smaller contractors. Reliable radio communication equipment is a must and is required when accessing a runway. No personnel or equipment shall be allowed on the runway prior to radio contact (tower) with airport operations obtaining verbal permission. Emergency landings and takeoffs always take precedence over all contractors operations. In the event that the lead man or safety man is notified that an emergency landing or takeoff is imminent, the contractor must stop all operations immediately regardless of the sequence of events in progress and at once evacuate all personnel from the runway. To do so, military-N.A.T.O. airports provide a 2-min time frame and commercial airports up to 4 min. In this time frame it is imperative to doublecheck the runway surface for any forgotten tools, which should not be there in the

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first place. A runway clearance is considered complete when the linear distance of personnel and equipment is moved a minimum distance of 2000 away from the nearest edge of the runway. At the end of a working shift, all equipment must be brought to a location, designated by maintenance or contract officers, that is not less than linear 7500 ft away from the nearest edge of the runway. For payment of rubber and paint removal, the unit of measurement should be the actual number of square feet accepted by the maintenance or contract officer. Payment for downtimes inflicted by airport operational circumstances will be rounded off to the nearest hour (this is of importance to the contractor). It can be expected that a change in air current or unscheduled traffic loads, emergencies, etc., delay cleaning procedures frequently. The contractor will supply all mobilization, labor and equipment when performing the necessary operations to remove rubber deposits and loose paint from the areas designated by a drawing submitted by maintenance. The removal of rubber and paint from asphalt–concrete or concrete runways shall be accomplished exclusively with high-pressure water. The use of chemicals or abrasive materials will not be permitted. The water which is used for any high-pressure water equipment will be available from the sources shown on supplied drawing at no cost to the contractor. The contractor shall furnish all equipment, water trucks and labor to provide the delivery of the water from the water hydrant or dispenser to the job site. The contractor likewise shall furnish all necessary labor, hoses, wrenches and all other tools and equipment for filling tank trucks. Permanent-type installations of overhead piping to fill water tanks, which may preclude the use of the fire hydrant by the fire department in case of emergency, will not be permitted. Equipment, tools and machinery used in the performance of rubber and paint removal shall be at all times safe and in satisfactory working condition. If the highpressure water is delivered from a spray bar, the nozzle’s jets shall be so configured as to provide total coverage of the area being treated. The contractor shall remove 85% of all visible rubber and restore the asphalt–concrete pavement to a natural surface. 80% of loose, flaking paint, as designated, shall be removed. Hard, firm paint with removed chalk may remain. A medium water pressure of 6,000– 8,000 psi shall be used (today, UHP criteria is of advantage). The treatment of the rubber and paint surfaces should not be injurious to the asphalt–concrete surface, expansion joint sealant or runway lights. If it is deemed by the engineering department that damage to the existing pavement was caused by an operational error, such as permitting high-pressure water application to dwell in one location for any extensive period of time, the contractor shall repair the damage without compensation. A runway sweeper and driver will be furnished and operated by the contractor for the cleaning off of paint and rubber debris from the runway when requested to do so by the engineers. This information is standard in the industry and will vary only slightly due to equipment and runway specifications. The major rubber accumulations are found within the first 3,0000 on both sides of the runway heads (Fig. 3.145). The four large paint stripes are generally 1500

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Fig. 3.145 Runway specifications

long and individually 150 –300 wide and the 52 smaller stripes are 1500 9 60 . Runway border marks are continuous and measure 3, in width. Numbers are 600 long and vary in overall width between 5 and 200 . A standard runways length measures approximately 9,0000 –15,0000 . Early surface cleaning units specifically designed and assembled to accommodate this application featured large water supply tanks with two to four hydrounits individually rated at approximately 150 hp, releasing their hydro-energy upon the runway in utilizing an oscillating or stationary spray bar assembly containing fan nozzles. The metered hydraulic drive capacity moves the vehicle down the runway at required speeds. Certain manufacturers did try to introduce abrasive cleaning methods by exerting their energy via a spray bar assembly and releasing oval abrasive jet patterns upon the runway, failing to convince customers of potential advantage. The newly-developed, rotary surface cleaning units, either self-propelled or energized through hydraulic motors are far superior in their cleaning performance and produce a more favorable horsepower–psi–gpm ratio, cleaning precision, surface cleanliness, application variety, and last but not least, a lesser cost factor in maintenance and purchase price. Asphalt runways resist high-pressure water jets up to approximately 6,500 psi; however, this does not mean that asphalt will withstand a constant jet impact at these pressures. The precise operating pressure is determined on the job site. Due to climatic conditions and general asphalt structure, the actual rubber adhesion variables with regard to the runway surface permit, at times, operational pressures of up to 7,000–7,800 psi and then again lowered to 5,500–6,000 psi. (The UHP criterion differs dramatically in psi–gpm configuration.) The rotating arms including nozzles are adjusted to clear all obstacles, such as runway lighting bulbs and center dividers. Manually operating a surface cleaning unit in a single or dual rotor construction with a cleaning width of approximately 30 9 30 9 60 may be the solution to permit a contractor not yet established in this business (application) an opportunity to compete in upcoming bid offers.

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A hydro-blast unit coupled in tandem with a tanker truck establishes the powerpack assembly, maintaining in this form the necessary mobility. When operating, a 200 –300 high-pressure hose with quick couplers permit the prompt water refill mobility and emergency evacuation of the runway and presenting the flexible lifeline to the rotor cleaning unit. Once adequate nozzle-psi configurations are established, operators are able to work quickly, accumulating approximately 3 miles per hour. Jetting operations may be interrupted due to water refilling procedures and the truck’s directional changes. Preferably start jetting operations at the outer perimeter (truck turning radius permitting), then move to the center line of the runway. Ice shaving units perform in this manner (skating stadiums); this permits the best possible turning radius for the truck and the hydro-unit and therefore enables the most uninterrupted jetting procedure. The existing slack of high-pressure hose provides ample lateral movement for the operator, creating a visual seamless surface appearance and minimizing drag forces and possible rubber markings. Whatever operations one performs it must be certain that personnel and equipment can exit the runway within 2 min, leaving no physical trace. A three-man crew is adequate. One will operate the surface cleaning unit. The second, a lead man is responsible to keep in touch with flight operations (tower) and is at all times in communication with them regarding the runways operational status. He also shares the obligation to maintain all prior safety and tailgate meeting criteria. In case of an emergency evacuation the lead men will follow behind the withdrawing equipment to check for forgotten tools and debris and observe all required distances between runway and operators-equipment. And only then, when all safety precautions are met, will he inform the tower-flight control of runway status. The third man is responsible for operating the truck and trailer. A second truck is located in safe, but close proximity to the runway which in an emergency is mobilized to pull stalled vehicles from an imperiled location. Always keep in mind that maintenance chores are never performed within runways vicinity. Airport’s base civil engineer will purposely specify the roads to the water source it is therefore understood that an alternative route is never used without explicit approval. Filling the water truck is done best by utilizing the fire department’s overhead tanks. Because hydrants are comparatively slow in their filling procedure, valuable time can be saved in this manner (designed to fill fire truck tank within 2–3 min). Rubber is generally deposited on approximately 450,000–500,000 ft2 and is removed in two 8-h shifts demanding a minimum cleaning rate 30,000 ft2/h. This is comfortably achieved by operating a dual rotor surface cleaning unit. Some equipment design engineers claim that a surface polishing effect is more likely by applying high-pressure water only. This however is incorrect and most likely thought of to convince customers to use a water abrasive blast method. In actuality the opposite may occur because a highly-angled abrasive jet stream may hone a surface. Concrete runways of a B-400 plus substrate are less sensitive to climatic circumstances therefore simply dealt with by raising operating pressures to overcome the interface adhesion factors of the encountered rubber build-up. Intact concrete may destruct between 11,500 and 13,500 psi. While in the jetting

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3 Application Core Curriculum

Fig. 3.146 Expansion joint

procedure avoiding expansion joints (Fig. 3.146) completely is best or a pressure adjustment is necessary to avoid damage to joint’s structure and bituminous product. Again, it must be emphasized that this application description is geared to industrial contractors utilizing high-pressure water equipment which can be successfully converted to perform this application avoiding purchase of specialized runway cleaning equipment. Flight deck substrate on aircraft carriers is manufactured of steel therefore it will constitute no pressure limitations for the contractor other than the job specification. These specifications are identified as: total base removal, base spot removal practices and rubber or paint stripe removal. Tooling consists of a skid or dual axle-mounted 150 hp hydro-blast unit incorporating the vacuum supported multi-head rotary cleaning or product removal equipment. The water source is either located on the plane elevator nearest to the work site or in bay area of the flight deck. High and low pressure-hose runs can be excessive. The actual operating pressure is similar to the rubber paint removal application on concrete runways (Fig. 3.147b, c); however, since most vessels are serviced dockside they do not maintain an operational flight deck therefore safety procedures are less stringent. Pressures range between 8,000 and 36,000 psi, gpm according to equipments cleaning width, and available horsepower input. At times it is necessary to install a secondary filter cartridge to avoid contaminating water from pier or vessels potable water source. All safety procedures are specified by the naval shipyard or its contractor. Remember. High-pressure hose runs can be extensive and sometimes require, on the farthest end, a pulsation dampener which will harness the pressure peak developed by the moving water mass throughout the hose line when water flow is shut off. Plane taxi, parking and jet bridge areas (Fig. 3.147b) are outlined with paint stripes and are in need of periodic cleaning when oils, rubber and food residues enhance possible tire slippage, when they appear visually faded, or when removed to suit constructional changes, etc. Applying the dry sandblast method, a common practice with paint contractors, is utterly outdated. Self-propelled or manually operated rotary surface cleaners are most suited for this application. Manually operated trigger-gun mounted spin-jets (Fig. 12.22) are ideal for working in obstructed jet bridge areas around the outlined machinery complexes. Jet-carts

3.12

Cleaning of Gas Stations, Bank and Restaurant Drive-Thru’s, Machine Shops

407

Fig. 3.147 a, b, c, Rubber removal on runway (far-right)

ordinarily designed to remove highway road markings feature two nozzles within the width of standard road striping. The versatility of this unit is ideal. Contractors can apply them to spot clean surfaces or to remove rubber paint and 3 M foils. When spot resurfacing practices are performed utilizing higher pressures they can also be applied to scarify concrete or asphalt surfaces. Operating pressures range from 5,000 to 14,500 psi and produce up to 18 gpm. A single or multi-gun operation is possible (fan nozzle or spin-jet fitted) and is sometimes necessary within this surface cleaning application. Under these circumstances safety procedures are somewhat more elaborate. Place traffic cones, and affix barricade tape and warning signs restricting access to trigger-gun operation and general designated work area. Equipment and accessories are located so as not to interfere with the movement of planes, jet bridge tires and structure, fueling, baggage and maintenance vehicles. The operating pressures range between 3,000 and 11,000 psi, 5–22 gpm equipment pending. At this point, let us refer to the water abrasive blast method. Recently, a major hydro-manufacturer successfully developed water soluble abrasive material (patented). By impact dissolving and traceless, environmentally sound resulting in a new application variety which can be explored. A multitude of grains are available to polish, etch, hone and remove materials. Vehicular–pedestrian tunnel surfaces are, due to disproportionate air movement introduced to surface contaminants, susceptible to water jet ghosting events. The application of chemistry is most always of advantage especially when applied with

408

3 Application Core Curriculum GEAR - LIST AUTHORIZATION Cleaning of gas stations, restaurant drive-thru, machine shops and warehousing

Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Fig. 3.148 manually operated rotary surface cleaners

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Job Review Performed by:

Specify:

Explain surface condition:

Bank drive-thru: Restaurant drive-thru: Gas station drive-thru: Parking garage Parking lots: Bridge decks: Sidewalks: Other:

Concrete substrate: Asphalt substrate: Cured epoxy: Contamination: Oil: Bubble gum: Other:

Overall cleaning width and length: Star time:

Grease:

Overall square footage to be serviced: Finish time:

Other:

Existing surface damages: (explain)

Safety procedures: (explain)

Blast water available: Blast water dischargeable:

Acid treatment: Acid neutralization: Detergent: Surface pH: Rust converter: psi

Pressure washing equipment Hydro-blast equipment: Rotary surface cleaner: Abrasive injector-chemical injector: Trigger-gun-fan nozzle: Trigger-gun-spin-jet: Jet cart:

©

15

25

MSDS:

gpm Water recovery, filtration and recycling : Vacuum truck: (CFM? Mercury?)

45

Vacuum-recovery:

Vacuum shoe: Vacuum house: Water barriers: Barricades: Protective skirting: Other:

Feet:

Describe application and work procedure: Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.: Environment

Industrial

Commercial

Residential

a converted abrasive injector. Utilizing rotary surface cleaners of any type and trigger-gun mounted spin-jets is an essential prerequisite. Waste stream recovery is almost always necessary. Tunnels often feature glazed tiled surfaces requiring the utilization of an excellent wastewater recovery, filtration and reclamation capability to avoid a visible residual film buildup.

3.13

Hazardous Industrial Waste Recovery and Soil Treatment

409

3.13 Hazardous Industrial Waste Recovery and Soil Treatment, Asbestos, Radioactive Trace Element Remediation, Vehicular Accidents, Cleanup of Crime Scenes, Demilitarizing Warheads-Bombs Available pressure washing, hydro-blasting and UHP tool accessories offer applicable solutions distinctively suitable for hazardous industrial waste recovery. Organic–inorganic, non- and volatile products can safely be manipulated, dry recovered or pumped, handled by various techniques and packaged for transport or storage. At the same time, hydro-vacuum applications are exceptionally matched for recovery of accidental dry or wet release or spill of chemicals in open or confined space, and/or in volatile explosive, flammable or gaseous environments. Hydro-vac technologies are utilized for three hazardous material cleanup requirements to remove man-made chemical hazards from water, soil and impermeable, confined or open surfaces. The remediation of contaminated soil can be effectively performed by removing and/or reducing contaminants to meet environmental threshold limits (Fig. 3.149). Directly incorporating the hydro-vac application criteria, utilizing cold or hot water for the passing of contaminated soil through the water-jet configuration greatly supports the physical agitation and release of oil, fuel, phenols, pesticides, heavy metals, etc. This dramatically enhances buoyancy when soil saturated water settles. The designated process equipment facilitates the rise of effluent concentrations to the surface for further treatment by filter, centrifugal separation, flocculation and evaporation processes, etc. Organic–inorganic filtration techniques, hydro-centrifugal separation, flocculation or chemical dosing units, stripping towers, aeration or biological soil treatment and/or confined stationary–mobile biological treatment equipment can be employed on or off site. These soil remediation techniques are vital where solutions from ‘‘cradle to grave’’ must facilitate regulatory approval. Contaminated through commercial and industrial activities where chemical-oil spill threatens a water course, or human habitat often found in the vicinity of commercial–industrial accidents, gas stations fuel storage facilities, asphalt and bituminous product manufacturing or in fuel and petrochemical production environments and associated tank farms are all areas of immediate interest for employment of this technology (Fig. 3.150). Applying high pressure water within the asbestos abatement and removal application is sometimes viewed as controversial. Contractors involved in manual asbestos abatement removing ACM products (scrapers) will argue that the use of high pressure water will add to the disposal costs, and create a messy work area, promoting packaging difficulties or can be costly in case of water damage to substrate. In short, not practical. Their opinion is understandable as it would dramatically alter their work practice; downsizing work force, reduce chargeable hours, accelerating containment and material packaging procedures (ACM) and the reduction in chargeable equipment costs. To protect their markets, equipment

410

3 Application Core Curriculum

Fig. 3.149 Soil washing plant

Fig. 3.150 Soil condition after cleaning-remediation process

manufacturers and their engineers will further argue that high velocity water adds to the possible airborne activity; they justify this with the explanation that asbestos materials impacted by a water-jet are not controllable in their removal process. When the hydro-blast or pressure washing industry is confronted with these types of opinions they will simply quote their customers involved in the daily asbestos abatement process, which does little to explain why, how and what type of specialized hydro equipment is available or necessary. Regulatory agencies such as OSHA, EPA, city and state regulating bodies and their inspectors are therefore, at best, confused because they witness both success and failure when jetting techniques are a part of the ACM’s removal process. All of the prior mentioned opinions are inaccurate especially when one considers that high pressure water jets are successfully applied in nuclear power plants for decontamination practices where airborne particle activity must be held to an absolute minimum and the adding of excessive water, then contaminated, is impractical and not acceptable. Asbestos containing materials and products manufactured before 1981 are still present throughout private, commercial and industrial environments. There are basically three varieties of asbestos; chrysotile, amosite and crocidolite. Some ACM products can be brick, pipe or sewer pipes, textured paints and coatings, spray insulation, filter products, vinyl floor tile and adhesives, HVAC duct insulation, ceiling tiles, roofing felt and shingles, etc. One will find the products in boiler rooms or heat producing areas (pipes), on ceilings incorporated to a multitude of structural designs in commercial, industrial and public buildings, on steel

3.13

Hazardous Industrial Waste Recovery and Soil Treatment

411

Fig. 3.151 Components and tooling splash diffuser

Fig. 3.152 Assembled splash-mist guard unit

beam construction, or throughout merchant and naval vessels utilized as a heat-fire retardant, and so on. Asbestos containing materials (ACM) are installed by various methods; they may be fused to products such as in floor tiles, sprayed on, painted or in sheet form, pre-molded or molded on a job site and covered with a retaining fabric material which sometimes is also painted. The physical circumstances encountered within an asbestos abatement procedure can result in a variety of application utilizations requiring a technically versed knowledgeable crew. As job necessities change within various structures and areas a flexible hydro tool variety is important to offset fore mentioned negative opinions. Permissible exposure limits (PELS) to an airborne concentration of fibers, greater than 0.2 lm of air during an 8 h time waited average or a concentration of asbestos in excess of 1.0 lm per cubic centimeter over a sampling period of 30 min fiber per cubic centimeter cannot be permitted. Continuous personal air sampling (Fig. 3.151), most often a requirement while in the asbestos abatement procedure can be achieved, by simply assembling a plastic water bottle with three scouring pads preferably of plastic nature avoiding the wetting of air stream and therefore filter medium by ricochet water spray. The filter assembly is located in the top section of bottle for easy access filter change (Fig. 3.152). This air sampling unit is affixed to operators shoulder pad near full mask or cartridge filtration equipment. OSHA regulations regarding the

412

3 Application Core Curriculum

monitoring of asbestos exposure, use of protective gear, including respirators, establishing a negative work environment by enclosure, ventilation system and filters, resulting in the reduction of exposure to permissible airborne activity are rigorously imposed. OSHA provides regulations on set up of job enclosures including HEPA filtration, and the establishing of negative environments. Similar to lead abatement procedures a clean room for workers must be established (street clothing), a shower room must be provided and a change area for asbestos contaminated clothing separately incorporated. Asbestos workers must undergo a medical examination and are periodically monitored. Work sites are clearly marked and access limited to authorized personnel only. These are only a few regulations in a substantial and forever changing job requirement. All tool varieties are chosen with one theme in mind which is, regardless of tools functionality that they may not contribute to airborne activity. The hydrovac wet mode systems are therefore ideal; not only do they provide packaging, wetting and removal advantages but in their working mode support the immediate product removal in its air negative state superbly controlling airborne activity. Within the continuous cleanup course the contaminated water is recycled for wetting, vacuum creation, negative airflow and jetting procedures. Obviously, the contaminated water volume, especially on larger jobs is therefore held to a minimum. Any utilized hydro-vacuum exhaust box system must feature a high efficiency particulate air filter (HEPA) capable of trapping and retaining 99.97% of mono disbursed airborne particles 0.3 lm or larger in diameter. The regulatory agencies expect contractors to perform a wetting process to bind all particles that are likely to become airborne when the actual product removal process begins. So, one must ask, what does a proper wetting process constitute? ACM products come in a wide variety, they may be brittle, hard and spongy or a friable material, meaning that these friable materials can be crumbled, pulverized or reduced to a powder by hand pressure. Further, they are thick or thin layered, sprayed on or preformed (encapsulated) to fit pipe radiuses or machinery parts, etc. Water absorption factors vary widely with ACMs. Area temperatures, product dismantling time, product location, accessibility, product thickness and permeability are some factors considered. A wetting agent admixed to the spray water mist may enhance the longevity of the moisture content within the product. Pressure washers’ or hydro-blast units’ gpm performances are generally too high, therefore not permitting a metered fluid mist application. Preferably a secondary unit operating at 1 hp delivering 1.5 gpm (adjustable) with an optional fog and fan nozzle is of an advantage. Wetting always precedes the jetting and removal application. To avoid incomplete saturation due to water runoff and evaporation, the wetting procedure is undertaken within 5 min before an actual ACM removal application commences. An EPA recommended wetting surfactant added to jetting water, consists of 50% polyoxyethylene ester and 50% polyoxyethylene ether can be effective on various asbestos containing substrates. Nevertheless soaking or penetration of ACMs does depend on the composition of

3.13

Hazardous Industrial Waste Recovery and Soil Treatment

413

encountered product. Working in tandem with the jetting, dismantling crew (teamwork) is most effective. Adjustable nozzles are mostly ineffective due to their internal surface configuration. They do not permit best possible fogging, chisel, or pin point configurations, subsequently disturbing the all important nozzle stand-off distance and water jet impact capability. This is especially noticeable when operating such nozzles with pressure washers at 3,000 psi. A rule of thumb. When product wetting times cannot be established, operators must physically check the product for sufficient moisture content (necessary water saturation). On the other hand, when a high product volume and the associating square footage requirement constitutes wetting by pressure washer or hydro-blast unit in combination with a fog nozzle, the fog nozzles must accommodate equipment’s gpm–psi performance for maximum effectiveness. Nozzle gpm–psi performances are established by encountered application variety within numerous low-pressure-gpm ranges. Also understanding the risk factor between friable and non friable asbestos products is of utmost importance. A friable asbestos containing material is one that in a dry state can be crumbled by hand pressure. A friable example of an asbestos containing material is the spray-on fluffy fire proofing material. The non-friable asbestos containing materials do not crumble with hand pressure. For instance vinyl floor tiles may contain asbestos fibers, which under normal conditions will not release fibers. The condition of asbestos containing materials is probably the most important factor. Damage to surfaces can dramatically alter and accelerate the release of dangerous fibers otherwise contained within their structure. Under these circumstances utilizing a fog nozzle is recommended and/or imperative. A fan jet for a wetting procedure is insufficient due to waters high velocity-turbulence creating wind swept and water-product ricochet adding unnecessary contaminated water and airborne activity. According to their installation, ACM removal techniques will vary widely. Roof structures can be joist and beam or waffle slab, and/or steel beam construction which will prove difficult for adequate access and requires a flexible tool selection. A tool specifically designed to remove sprayed on products on steel deck, concrete slabs, etc. consists of a vacuum hose connected to a vacuum shoe which is directly affixed to a high-pressure gun barrel to permit the product removal and collection in one procedure. The high velocity air moving the product also decreases airborne activity within the workplace vicinity. When applying the hydro-vac wet mode system three operational steps are performed in one (Fig. 3.153). The vacuum hose is applied to remove detached ACMs to the packaging drum. The drum head will separate the excess water from the material, and then the ACMs are released to the drum floor. The blast water is returned into hydropump’s isolated water supply tank for recycling procedures. The water supply tank must feature a HEPA filter unit accommodating the vacuum jet’s airflow, volume and velocity. Water can be adequately cleaned with charcoal filters, however all collected asbestos waste must be tested and correctly packaged before a release and transportation to an authorized toxic waste site can be performed.

414

3 Application Core Curriculum

Fig. 3.153 Hydro-vac wet mode system

With the wide variety of applications available, further explanation as to ACM removal practices with high-pressure water is secondary because anyone involved must first understand the guidelines and licensing procedures established by OSHA, EPA, city and state regulatory agencies. Great application variances exist between friable vs. non-friable asbestos structures or sources. Tooling and cleaning techniques are absolutely subject to these guidelines. Never consider an asbestos product removal practice or method, including job bidding procedures, before a thorough and licensed educational program has been completed by all persons involved. Once training and all licenses are obtained, a contractor with an understanding of all physical and legal limitations will narrow the tool variety down to the most practical combination. These days licensing procedures will involve literally anyone touching this application. Licensed individuals include: asbestos abatement contractors and their personnel involved with project managers, supervisors, individual consultants and agencies, inspectors and asbestos management planners, air monitoring technicians, training providers, transport and storage facilities management and laboratories. There are registration application forms for workers, physician’s statement and notification forms. Environmental Protection Agency, National Emission Standards for Hazardous Air Pollutants 40 CFR, section 61.141, subpart M (1984), Asbestos containing materials guidance, http://www.epa.gov/asbestos.jsp. A contractor should acquire asbestos health protection rules and the asbestos licensing section provided by the Department of Health. Further, OSHA Department of Labor #29 CFR part 1926.1101 is useful literature necessary to understand the complexity of this application, http://www.osha.gov. All states provide a list of asbestos training providers with conditional approval to train in their respective states. Laws vary in governmental, military, corporate, public and private environments. In the nuclear material-handling industry, such as nuclear power plants, both hazardous and non-hazardous areas are vital and lucrative for industrial service providers. The plant’s safety procedures are tightly controlled constantly monitored and must be studied in depth by all service and hydro-personnel. Applying

3.13

Hazardous Industrial Waste Recovery and Soil Treatment

415

high-pressure water as a tool in nuclear power plants or facilities for decontamination, decommissioning, or plant dismantling practice does not destruct the radioactive material; rather, it is a process of relocating the materials to the smallest available space to allow their regrouping (ALARA). Radiation is released from plutonium and uranium 238. The radiation emission values depend on the size and mass of the particles found. More mass equals more radiation. Radiations of b- and c-rays are biologically highly destructive and a-rays are comparatively safe. These rays are found on production tools, treatment basins, transportation vessels, storage tanks, tubes, drains and walls. A highly-radioactive coarse contamination (mass) presents no problems within a cleaning process. Removing fine contamination, however, represents a more complex situation and is monitored and secured by battery-operated sensors during the work process. Caustic soda, Phosphatized degreasers or biodegradable detergents are added to the demineralized or salt removed jetting water. The concentrations are standardized, generally ranging from 4 to 10% (diluted), and most often provided by plant maintenance department. Chemicals are metered to the suction tank of a pressure-washer or hydro-blast unit via injector or independent metering device. Depending on the applications, pressures may range from 3,000 to 10.000 psi, 5–19 gpm. Atmospheric contamination by vapor release is minimized when applying low-volume, high-pressure water. Steam-cleaners (hot pressure washers) are by nature not suitable. Fire hose applications add too much water volume to the contaminated product and further lack effective velocity. The hydro- and UHP method reduces the contamination significantly below the operational radiation standard (ALARA). When removing graphite deposits in uranium bars, generally located on the interior [ of the bar assembly it is important to recognize the fact that uranium bars are situated 90 –100 below the water line in immersing basins. When cleaning is required the bars are affixed to a vice-like fixture. The internal cleaning procedure is achieved by operating a remote-controlled pneumatic–hydraulic unit. A rigid lance featuring fan nozzles or rotary whirl-jet is moved in and out of the uranium bar while the bar is rotated by pneumatic– hydraulic drive covering all necessary internal surfaces. The results are unmatched by any other cleaning method. The pressure requirements are 8,500 psi at 19 gpm. The rigid lance is 60 in length and has a 00 [. The lance guiding system is developed with the consideration of plant maintenance departments’ specs. Qualified contractors will decontaminate the Rx cavity to 70% from unit’s operating deck. The actual decontamination to ALARA standards, meaning ‘‘as low as reasonably achievable’’, is performed by three operators and a cleaning crew of two. The first operator controls the decontamination unit (recoilless spray assembly), the second controls the overhead service crane, and the third is responsible for controlling the hydro-blast unit. All three operators communicate with each other as well as with the plants safety engineer via a headphone communication set. Upon draining the Rx cavity the Rx head assembly is set to its location and totally protected with a yellow flame-resistant polyolefin shroud which is lowered over the Rx head by the crane in such a fashion as to provide a water mist tight seal. The shrouds design and fastening/sealing components are manufactured in

416

3 Application Core Curriculum

conjunction with the plant maintenance department. Shrouds installation is completed within 3 h. The decontamination fixture is lowered into the cavity by the overhead crane and is situated below the overflow trough. Before the high-velocity jetting water can be applied a repeated low-pressure wash-down at 200 psi (fog nozzle) is necessary to subdue the otherwise airborne activity. This is done section by section to avoid any possible surface drying before the high-pressure water jetting phase can be completed. After sectional surface wetting, the hydro-blast unit is adjusted to 6,000 psi. The pump’s gpm performance is determined by the nozzles spray bar design and will vary with the manufacturer. At any rate, applied water volume-to-surface blast must by effective within the maximum required operational performance. The crane operator is responsible for moving the recoilless unit in a repetitive section-to-section procedure toward the bottom of the cavity. Furthermore, to secure an even wash-down pattern he should always overlap his previous spray pattern. Operations are discontinued when wash-down procedures have reached within 200 of the cavity floor. Smear surveys are conducted throughout the washed area to ALARA standards. Once decontamination standards are met (approximately 15 K ppm) the two-man crew will descend to the upper Rx cavity floor. The crews tooling consists of a hydro-blast gun with a dual fan-jet assembly, scrubbing pads (scotch-bright), a squeegee, and a sufficient supply of biodegradable detergent and towels provided by the plant’s maintenance department. Again, the crew commences with a wet-down phase (at 200 psi), starting 60 up the cavity wall (around the Rx head) downwards into the total floor area before the manual cleaning procedure, at 6,000 psi, is performed. Excess water will at all times be moved with a squeegee to the lower cavity. Once the total area has been subjected to the high-pressure water the biodegradable detergent is applied and vigorously scrubbed into all surfaces (starting 60 up cavity wall) and floor space with the scotch-bright pads. The blasting, wipe down, and scrubbing procedure is performed approx. four times. Nevertheless, after the second procedure the cleaned area is wiped semi-dry to conduct a smear test to gain understanding of the decontamination levels (by ALARA standards). After the third procedure, plant maintenance will conduct smear tests to identify hot spots and will at this point decide if a further total wash-down is necessary or if the isolated areas are to be scrubbed by hand. A step-in-out area is created to the lower cavity once ALARA standards are met and the cleaned area can be entered without respiratory gear. General access (without respiratory gear) to the lower cavity is most likely not required; however if it is desired, the cleaning procedures are equal to the cleaning method employed on the upper level. When the Rx cavity refueling practice commences the Rx head stud-ring (Fig. 3.154) is cleaned by scrubbing and wiping or by utilization of the hydro-vac brush system. The studs are decontaminated by plant maintenance in a Freon HNS-200C tool cleaning system. Prior decontamination-cleaning of studs and stud-ring also

3.13

Hazardous Industrial Waste Recovery and Soil Treatment

417

Fig. 3.154 Rx head studs

permits maintenance crews Rx head reassembly avoiding the wearing of bothersome PPG and respiratory gear. Again, it is imperative to keep airborne activity to a minimum. One should only utilize highest quality industrial fan nozzles which are designed to perform near mist-less at 6,000–10,000 psi and UHP equipment utilizing turbo or rotary nozzles, if possible, utilizing hydro-vac equipment. The standard estimated time to complete a unit of this type is approximately 68 h. Further decontamination procedures can involve the operational deck, machine shops, holding tanks, piping internals and floor drains-sumps. Heat-exchanger, condenser, feed water heater services (Fig. 3.155) utilizing flex lance equipment, removing calcium carbonate from ash water lines, cleaning cooling towers, and dredging water reservoirs are applications also periodically performed. Macabre, but real is the cleanup and decontamination of crime scene, tragedy and trauma resulting from accident, homicide and self-inflicted death. Compliance with OSHA-DOT-EPA and HAZMAT regulation is crucial. The work environment can be industrial, commercial, residential and of agricultural nature and nowadays involves clandestine drug lab decontamination and cleanup (meth-lab), mold remediation and environmental disaster cleanup. The availability of certified crime scene clean-up technicians who are specialized in biological recovery procedures are of importance. Service provider must establish a written blood borne pathogen exposure control plan concerning decontamination–remediation of biological origination (blood, bodily fluids-fragments) or other potentially infectious waste, and/or materials, providing a written respiratory and personal protective equipment program (PPE), and establishing a technical procedure for a hazardous communication system and vaccination program for their technician-labor force. These are only a few standards expected to be maintained by a serious service provider. Pressure washing and/or hydro-blast equipment paired with tooling selected to provide application variety which includes a hydro-vac system, 25–45 hp, vacuum drum, packaging and effluent separation, HEPA filtration, chemical metering device, etc. are basic tool additions complementing this sometimes overlooked profession. A cradle-to-grave hydro-blast application to demilitarize bombs by removing explosive materials from shells interior is nowadays an automated hydro-blast

418

3 Application Core Curriculum

Fig. 3.155 a, b, c Power plant proposal, feed water heater, condenser

function. Most systems consist of a two stage reclamation process. Operating between 12 and 20,000 psi, utilizing comparatively low volume’s at 5–16 gpm, with various automated stationary or rotating lance extensions operating jetting nozzles in repetitious and rotating configuration creating a milling process proved safe and successful. Explosive material is separated and macerated again by applying high-pressure water within a confined space. The water is recycled for further use in the jetting procedure. Filtration systems can be elaborate depending on explosives origination. The explosive constituent is disposed of in open burn or detonated on a firing range. This application does not belong to a contractor’s curriculum but verifies the endless potential of high-pressure water as a tool.

3.13

Hazardous Industrial Waste Recovery and Soil Treatment

419

GEAR - LIST AUTHORIZATION Hazardous waste recovery, soil treatment, radioactive trace element remediation Customer & Company:

Date: Address:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Job Nr.:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Review Performed by: Nuclear power plant: Production tools: Treatment basins: Transportation vessels: Storage tanks: Rx cavity decontamination: Steam generator channel head: Walls: Uranium bars:

Immersing basins: Condenser hot well decontamination: Heat exchangers: Water intake screens: Cooling towers: Turbines: Feed water heater: Other:

Decontamination: Radioactive material: Removing graphite deposits: Scale removal:

Pipe cleaning: Underwater pipe cleaning: Turbine cleaning: Other:

Caustic soda: Aluminum oxide abrasive: Phosphatized degreaser: Demineralized water: Salt free water:

Chemicals:

Other:

In-plant hydro-unit and tools: Rx head shroud: Rigid lance: Pneumatic hydraulic rotating unit: Recoilless decontamination fixture:

Vise fixture: Metering injector: Metering pump: Other:

Abrasives:

Pounds:

Grit size:

Describe application and work procedure: Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

Explain:

©

420

3 Application Core Curriculum

GEAR - LIST

AUTHORIZATION

Hazardous industrial waste, asbestos-ACM product removal Customer & Company:

Date: Address:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Job Nr.:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Review Performed by: Pressure washer: Hydro-blast equipment: Water recovery-recycle unit: Hydro-vac unit: Vacuum drums: Drum handling equipment: Air compressor: Disposable rags: Disposable protective gear: Polyethylene bags: six mil: Dump truck-roll-of box covered: Roll-off box, vacuum container: he Hot water: Cold water:

Enclosure material: Plastic sheet role:

(polyethylene) six mill:

50% polyoxyethylene ester 50% polyoxyethylene ether Specify:

High-pressure trigger-gun: Flex-lances: Rigid-lances: Nozzles: 15° 20° : specify: gpm-psi Fog nozzle: gpm-psi Spatula: Rigid lance cleaning system: Foot valve: Other:

two mill:

Duct tape: 2 by 4 planks: Negative air space construction: Specify: HEPA vacuum filtration: Continues air flow monitoring: Respirator equipment: Specify: hi particulate air HEPA filtration: Personal protection gear: Specify: Step in-out area: Shower area: Clean room: Other: Chemicals: wetting agent:

MSDS:

T-dual cleaning head: Turbo nozzle heads: Rotary jet:

Rust-inhibitors, metering equipment: Other:

Product hardness, adhesion, viscosity: Specify: Fouling characteristics: Specify: Physical surroundings, safety procedures: Specify: Describe application and work procedure: Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

Others:

©

3.14

Hydrostatic Testing of Boilers-Steam Generators, Gas and Vacuum Vessels

421

3.14 Hydrostatic Testing of Boilers-Steam Generators, Gas and Vacuum Vessels, Towers and Tanks, Pressure-Leak Testing Hydraulic Systems This category also includes nondestructive tank testing of various shapes, design and purpose, including testing production systems which operate under pressure throughout the industrial and commercial environment. For example those tested are; high-pressure natural gas systems and tanks, oil–gas pipelines, various boilerssteam generators in power generating environments, towers, condensers, heat exchangers in production facilities such as refineries, chemical manufacturing complexes and their vessels-systems for various experimental, scientific and manufacturing prerequisites, etc. Hydrostatic tests (Fig. 3.156) can either be conducted under the constraints of industry or a customer’s specification. The customer also must specify as to a nondestructive test as well as burst test. An apparatus subject to positive (+) or negative (-) pressures including high temperature cycling or both will sooner or later need service or repair. Consequently a verification of its proper function is necessary activating a hydrostatic test procedure utilizing pressure-washing, hydro-blasting or UHP equipment (500–60,000 psi). The near incompressibility of water (0.05% at 10,000 psi) or oil is the preferred test liquid which is chosen for the detection of leaks or permanent changes in shape (deformation, cracks). Water is commonly used because of minuscule expansion in case of catastrophic failure to equipment being tested (only if unit tested is correctly purged of air-gas pockets). A penetrating wetting and/or preservation agent (polymer) can be metered to the fluid charge medium. Red or fluorescent dyes can also be added to the water-charge assisting in leak detection. For seams and welds a color developer can be sprayed on to suspect areas immediately identifying a leak. A discoloration remains visible, even if the leak dried overnight. Test pressures may range from 125 to 600% of equipments design pressure, and can be of classified nature concerning industry or military requirement. Welding-repair procedures on vacuum, pressurized vessels (boilers-steam generators, condensers) and vessels subject to high heat temperature cycling will almost always present a hydrostatic test requirement scheduled by engineering or maintenance departments while in either progress of repair and/or after all maintenance efforts are completed. To prevent bodily harm due to a catastrophic failure of any vessel tested, the operators location and distance from the vessel must be carefully determined (exceeding 500 gallons at 50 psi). Pressure washers or hydro-units should not be mobilized to fill and top-off industrial vessels. Water charge times exceeding 1 h should prompt the operation of a high volume-low pressure centrifugal pump (demanding an adequate plant water supply) or a hydrant supply if it is possible. In commercial and industrial environments the utilization of fire hydrants is most likely impossible. Water discharge on an automated fire suppression system will

422

3 Application Core Curriculum

Fig. 3.156 Customer’s hydrostatic test specification

immediately activate a fire alarm and emergency procedure with varying intensity and/or no secondary verification. Hydrants may not always identify their water source or purpose in an in-plant situation. Also, charge water temperature and the method of water heating and temperature safety margins, or possible number of temperature cycles varies from job to job. Most contractors require a minimum charge (4-h), within a bid procedure. The nature of hydrostatic testing, especially field testing encourages maintenance departments to control mentioned application variables often with marginal success. When stress and hold times, vessels fatigue criteria, and evaluation times of vessel components are an unknown and include the possible repetitive timing of charge water temperature cycles, pressure drop procedures for total system leakage analysis, and visual inspection between repair cycles, a contractors approximate time requirement must be established. A typical in-plant work order description of a non-destructive test procedure as classified by plant engineer and maintenance department (Fig. 3.157). Maintenance departments appreciate the written verification of test results by circular chart recorder for their keeping. Chart recorder test ports are most always identified by maintenance departments or field engineers. A contractor is wise to independently operate a currently calibrated recorder installed between the last ball valve assembly of the test manifold to vessel tested verifying his correct equipment function. The chart recorder is never applied or utilized to set or control

3.14

Hydrostatic Testing of Boilers-Steam Generators, Gas and Vacuum Vessels

423

Fig. 3.157 In-plant work order

equipment test pressures. Often, on a weekly basis, contractors will lease mechanical or digital stripe-circular chart recorders and confirmable calibrated in line water volume-psi metering-sensor devices, with an accuracy of ±1 psi to eliminate the otherwise on-site problematic verification of equipment calibration. On this note, most contractor services are required because they provide the necessary equipment capability in adequate psi–gpm and if possible water heating performances. They are not hired to take responsibility for varying test procedures or results. Technical aspects are always controlled by hardware owner or their maintenance personnel. Nevertheless it is important to understand the technical aspects encountered facilitating a correct proposal procedure.

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3 Application Core Curriculum

When filling a vessel always use the lowest pipe flange of the unit to connect water supply hoses, which in some instances will avoid air entrapments (not guaranteed). The vessel’s top ventilation must be sufficient and located on the highest point of the internal–external structure to avoid air entrapment. Sometimes the ventilation valve assembly is too narrow to accommodate the air displacement (circumference [) created by the water feed to the vessel, subsequently pressurizing before the test procedure begins. When test water–oil is drained (through the unit’s bottom) adequate ventilation must be guaranteed (air volume) to prevent a catastrophic cave-in event. Top tank ventilation must by open first and locked-out before a fluid draw can begin. Rushing water–oil masses can create near-max vacuum conditions capable of destroying most vessels encountered. To protect against a system failure (overpressurization) a liquid-filled pressure gauge and a RV valve (pressure relief valve) set at 5% above max test pressure, is affixed to vessels bottom and top vent assembly. Vessel damage is also possible if the RV valve value does not accommodate the full flow-volume produced by either the pressure-washer or hydro-blast pump equipment. A multitude of pressurizations are common, especially when testing large units such as steam-generators, tanks or pipeline systems where maintenance problems occur during welding procedures, or sectionalized quality assurance tests are performed. Around-the-clock standby requirements are frequent; therefore a standby fee is negotiated. During pressurization, maintenance personnel should check for existing leaks at predetermined intervals. If no leaks are detected the desired pressure will be maintained according to the hydrostatic schedule. When applying oil as test medium and ambient temperature fluctuations are possible operators must compensate for the typically elevated contraction or expansion of oil (liquid hydrocarbons) otherwise resulting in a psi fluctuation limiting precise test results. As with high-pressure water hose assemblies, significant pressure variations can be encountered due to weather-temperature cycling when in a static pressurized water–oil charge (direct sunlight). This complicates test procedures especially when long-term static pressures must be maintained (adding-bleeding). By activating the dump-meter valve the pressure drop may be stopped as desired and maintained at its present level by closing ball valve #6. Reducing pressures totally by regulating dump-metering valve until the gauge on the vessel and chart recorder measure or indicate the remaining natural static pressure within unit. The minor compressibility of water (0.05% at 10,000 psi) results in a quick depressurization which also indicates that air pockets are not present in the unit’s interior. Once the test procedures are completed, and only static pressure remains, first open top vent and secure valve’s open position before discharging the test water through the unit’s bottom. Again, this is imperative to prevent vessel damage (Fig. 3.158). Also a site-specific NPDES discharge permit is required for hydrostatic test water released to ground or storm water system. Barricade tape must restrict all traffic in essential areas including the predetermined test site of hydroblast equipment operators. Converting a pressure washer or a hydro-blast unit to a full-fledged hydrostatic test apparatus is inexpensive, simple and does not

3.14

Hydrostatic Testing of Boilers-Steam Generators, Gas and Vacuum Vessels

425

Fig. 3.158 Tank-vessel damage by vacuum

Fig. 3.159 Hydrostatic test manifold

constitute a major technical change. However, units with governors controlling the engine’s rpm while pressurizing their system will need a changeover to a manual rpm control, and in some cases a pressure regulator and adjustable safety valve must be added. To correctly analyze gpm performance a digital turbine flow meter can be added to the test manifold. Pipeline operators and plant maintenance engineers, may follow guidelines set by the American petroleum Institute recommended practices, 1110, testing of liquid petroleum pipelines, state code regulations for marine terminal oil-pipelines, department of transportation, DOT 49 CFR part 194, testing of hazardous liquids pipelines, American society of mechanical engineers, B31.4 testing pipeline transportation systems for liquid hydrocarbons and other liquids. There are eight major components allied to a test manifold (Fig. 3.159), which will permit the flexibility necessary for various test environments and enforced regulatory provisions: 1. The pump’s pressure gauge directly verifies the desired test pressure and indicates the actual psi developed when the pressure regulator is adjusted. 2. The pump’s pressure regulator is set to the max hydro-test requirement. The pressure is formed by closing the dump-metering valve # 3 and ball-valve # 5, thus permitting the produced water to bypass the pump regulator. The volume

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Fig. 3.160 a Test vessel, b chart recorder

3.

4.

5.

6.

of the water-feed is determined by the pump’s rpm and is adjusted to the circumstances involving the encountered vessel’s air pockets. There is a design similarity between the operating dump metering valve and the dump gun #3 which permits the utilization of most dump guns, however, the dump metering valve does not feature a pressure-balancing orifice on the dump side of the valve (removed) nor a nozzle component. This valve provides total control when a manual trigger activated pressurization permits a feel for timing and an optical physical volume control when gauging the excess water, leaving the bypass orifice while metering smaller water amounts to the vessel, regardless of engine’s-pump rpm produced. Over or accidental vessel pressurization is therefore impossible. The pressure relief valve (RV valve) is set slightly above test pressure (max +2%). The valve must be sensitive and completely discharge the produced pump water volume (gpm) and when activated under any circumstance eliminate a further vessel charge. The ball valve is activated to maintain the static pressure in the vessel being tested #6. In case a vessel pressure drop occurs it is suggested to close ball valve #5 to double-check valve #6 for leaks, which can be identified by possible difference indicated by vessels’ pressure gauge and test manifolds chart recorder #7. The amount of water added to the vessel while charging can be determined by reading the turbine flow meter. When operating the dump metering valve the

3.14

Hydrostatic Testing of Boilers-Steam Generators, Gas and Vacuum Vessels

427

GEAR - LIST AUTHORIZATION Hydrostatic testing of boilers-steam generators, tanks pipelines, gas and vacuum vessels Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Tanks:

Steam generator-boilers:

Pipelines: Tubing:

Heat exchangers: Gas tanks: (industrial)

Test Vessels:

Oxygen tanks: (industrial)

Steam Generators:

Other:

Pressure washer: Hydro-blast unit:

hot: “

Heated test water: Cold test water:

cold: “

Centrifugal charge pump: Test equipment: (calibrated)

Charge water pressure: Barricade tape:

Turbine flow meter:

Other:

(calibrated)

Specify: F° -° +° Specify:

gpm:

psi:

Chart-recorder-digital: (calibrated) Tracer concentrate: Fluorescent: Surface tension reducer: In-plant testing: Static pressure difference (+,-) from bottom of unit tested: Test equipment distance from tested vessel: Safe test area location:

Specify:

Systems failure protection RV valve: RV valves volume capability:

RV- valve assembly: Specify:

(calibrate) (calibrate)

Describe application and work procedure: Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

3.14.285

water volume loss due to possible system leaks is also projected. The chart writer records the gpm added to the vessel (if so desired). 7. Pressure-sensitive chart recorders (Fig. 3.160b) are vulnerable to shock, vibration and pump cycles. Install a dampener to produce a smooth chart printout. This unit protects the recorder, especially when the operator abruptly controls the dump metering valve.

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GEAR - LIST

Nr.

Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail

Tel: e-mail

Tel: e-mail

Tel: e-mail

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Plant hardware:

Hydro-blast equipment:

Hydrostatic test of Vessel 204

Plant location: Product encountered: Hazardous material: MSDS: Describe application and work procedure:

Specify:

Describe safety procedure:

Itemize equipment, safety gear, expendables, etc.: Fig. 3.161 in-plant work order

8. The ball valve #6 may isolate the test equipment and in doing so, not interrupt the test procedure. This also permits exchange of chart paper, adding or exchanging faulty equipment or resetting RV values as desired. The static pressure difference (±) between the test equipment’s location and the bottom-center to top of vessel most always be included (Fig. 3.161). Customers

3.15

Mold Remediation, Disaster Cleanup, Water Damage-Sludge Removal

429

sometimes require the installation of an in-house tested pressure gauge to the test manifold #4. Contractors interested in this application may also rent this equipment (complete test manifold) in its entirety. Customers require calibration dates and functional guarantees, which most rental companies provide and renew. Financially this application is lucrative and deserves aggressive salesmanship. Pressure washers-hydro-blast, and UHP equipment units from .500 to 55,000 psi are standard.

3.15 Mold Remediation, Disaster Cleanup, Water Damage-Sludge Removal, Insect–Pest Suppressio, Odor-Stench Control Wind, water, fire or the combination of all three provide a business potential for honest and experienced contractors specializing in disaster cleanup, restoration, mold remediation, odor-stench control and insect–pest suppression. The situation at hand is all too often exacerbated by opportunistic start-ups and/or fly-by-night service companies further victimizing the disadvantaged property owners. Under these circumstances is it important to verify a restoration contractors credentials. Due to the multiple varieties of encountered problems within this application criterion, a contractor must have a minimum of 3 years experience. His membership to a trade association may help to verify competent past professional performances. Verifying recommendations of past customer and involved insurance carriers and adjusters, proof of current liability insurance of 2 million dollars and carrying workers compensation insurance for all employees is a identifiable criterion a customer should acquire to before a job walk is initiated. All of the available pressure washing and hydro-blast tool combinations are utilized within this application criterion. Cleaning and remediation techniques are paired with chemical treatment concerning molds, odor-stench controls and insect–pest suppressions. Removing, packaging and transporting of various hazardous materials can require a qualified HAZMAT team, to prevent further contamination by bio, asbestos or lead containing materials as is the correct identification of harmful substances, important within a disaster cleanup procedure, varying with every incident. The fire and smoke damage restoration (Figs. 3.162, 3.163) of wood façades (stain) by high-pressure water is an application which will most often result in a rustic look sometimes astonishingly beautiful compared to appearance prior disaster. Material can be removed to the damaged interface zone, stains treated and burned coatings can be removed. There is a certain possibility as to a customers suggestive perception concerning final façade appearance. This can best be controlled by providing test patches, which might require a staining or coating procedure. Best results are achieved utilizing not more than 2.5–4 gpm and most important the use of high-end precision fan nozzles at pressures up to 3,000 psi.

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Fig. 3.162 Fire damaged wood

Fig. 3.163 Fire damage removed

Fig. 3.164 Mold remediation

Fig. 3.165 Mold, before–after

Fan nozzle degree will be chosen by severity of damage encountered, wood age and its type. The nozzle standoff distance will be adjusted as to the friability point of woods damaged interface. Mold remediation (Figs. 3.164, 3.165, 3.166) following a disaster cleanup is a common occurrence, especially in humid environments. This manifestation can be explosive when past cleaning procedures did not entertain a final rinse cycle introducing a variety of antifungal and mold suppressants. Chemistry chosen must

3.15

Mold Remediation, Disaster Cleanup, Water Damage-Sludge Removal

431

Fig. 3.166 Undisturbed mold on concrete surface

Fig. 3.167 Chem. feed pump

also consider the present environment and its natural spore’s habitat transmitted by air current. Humidity, faulty structures and uncontrolled vegetation-undergrowth, combined with sun starved surfaces makes for a perfect environment, especially when surfaces in question provide an organic food supply besides moisture. Mold can appear on most substrate and does include wood, concrete, sandstone, limestone, cinder-block (CMU) infestations and brickwork in short, most porous surfaces are susceptible to these windswept transmitters or developments and can be as simple as a transference from a nearby infested cedar shingle roof provided by favorable conditions. Inadequate remediation procedures can often be linked to a missing microbial analysis by a qualified environmental diagnostic laboratory. There are substantial differences between moss and mold developments. Odor-stench control is best achieved by removing the source of its development. If possible, the utilization of hot high-pressure water is of a definite advantage. Once odor causing materials are removed and all surfaces are dry an odor neutralizing chemistry and/or materials are available to absorb, neutralize and disinfect areas of displeasure. An active ingredient such as stabilized chlorine dioxide can be quite effective. A variety of fire/odor control products are available, but must be met with skepticism. Besides, chemical treatment there are also industrial solutions, which utilize atomizers which can also be applied for dust suppression requirements (Fig. 3.167).

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3 Application Core Curriculum

Fig. 3.168 Ant–pest control

Fig. 3.169 Hydro-vac unit

The professional water damage–restoration contractor utilizes modern diagnostic equipment, which includes penetrating and non-penetrating moisture meters, digital hydro meters, combined with state-of-the-art infrared thermal imaging cameras utilized to detect damage and moisture pockets in cavities throughout various levels of an affected structure. Applying necessary drying and dehumidification equipment and providing a qualified labor force is of utmost importance as is the correct application chemistry, which is best followed precisely as to manufacturers identified application criteria. Insect–pest suppression requires the penetration of their hiding place by highpressure water combining water velocity with chemistry and/or heat. Cleaning surfaces first and concentrating on crevices and cracks, possibly containing fungus and pests, utilizing hot (above 200F) water can greatly reduce the otherwise necessary volume of pesticides and their penetration-dwell time. In open or confined spaces a precise pesticide metering process to any hot or cold pressure washer unit is quite an effective weapon and especially useful in the agricultural environment.

3.15

Mold Remediation, Disaster Cleanup, Water Damage-Sludge Removal

433

GEAR - LIST AUTHORIZATION Mold remediation, disaster cleanup, sludge removal, pest suppression, odor-stench control Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Fire damage: Water damage:

Chemistry: Chemical injector: ratio:

Specify: Specify:

Wind damage: Vehicle accident:

Turbo nozzles: Vacuum supported spin jet:

Crime scene:

Vacuum supported floor cleaners:

Other: Pressure washer: Hydro-blast unit:

Water recycling equipment: Other: Safety gear: Specific-specify: Respirator:

Jet vacuum-pump: Vacuum hose:

hot:

cold: “

“ 2”

gpm:

psi:

4” 6” Specify:

Microbial analysis: Bio-remediation:

Vacuum tools:

Specify:

Mold removal:

High-pressure hose:

Specify:

Odor-control: Specify: Pump-up chem. sprayer: Electric pump barrel applicator:

Other: Hazardous waste removal:

MSDS:

Specify:

Permits: Hazardous waste site: Tank truck:

Roll-off box:

Mud dump site:

Mud evaporation bed:

Dehumidification equipment:

Moisture-meters : penetrating (non)

Specify: 20, 40, 60, yards: open-closed

Infrared thermal imaging:

Describe application and work procedure: Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

3.15.290

434

GEAR-LIST

3 Application Core Curriculum

Nr.

Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail

Tel: e-mail

Tel: e-mail

Tel: e-mail

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Chemistry:

Laboratory:

Equipment:

Expendables:

Product encountered: MSDS: Hazardous material: Describe application and work procedure:

Specify:

Describe safety procedure:

Itemize equipment, safety gear, expendables, etc.:

3.15.291

In open space, utilizing a hot pressure-washer (200F plus) applying a trigger gun and 6-ft wand fitted (Fig. 3.168) with round jet and a circular ant-guard with center lance access and plate retainer quickly permits the destruction of the fire ants queen and her eggs which are placed deeply in a mounds habitat. Sounds brutal, but it is a much better solution than applying or injecting hazardous poisons into the soil (least environmental impact).

3.16

Oil Lube Systems (Industrial), Tanks, Oil Compressors

435

Sludge removal due to flooding emergencies, and associated mud-sedimentation or pumping water up to 100 gpm (20 hp) in any area of affected buildings can best be serviced by utilizing a mobile commercial hydro-vac unit (Fig. 3.169) utilizing between 20 and 45 hp. Equipment services can be offered immediately because their function does not depend on a foreign power source and only requires a water feed which may be flood water in itself. A 20 hp input may service a radius of 4000 at near-max vacuum performance. The immense advantage is the systems light weight and mobility, where application flexibility may be tested minute by minute (always beneficial in an emergency situation). Water and/or mud-sedimentation transfer and possible receiving locations or containers can be a fluid scenario as required by the emergency. Jet vacuum-pumps can be installed strategically between a 200 and 2000 vacuum-hose assembly by removing the recoil box or with recoil receiver directly placed to any desired dump site discarding water and mud sediment. Automatic draw can be installed by utilization of engine start floats. Functional, equipment can be delivered to any site where a quarter ton pickup truck can operate. Due to the high vacuum and associated air volume performance, tightly adhered mud accumulations are easily removed, liquefied and pumped or discarded to an available evaporation site. Jet pumps and their available accessories cannot prevent a disaster but are unmatched in their application potential for remediation-cleanup procedures (industrial performance). IICRC storm damage, restoration recommendations, http://www.certifiedcleaners. org. American Bio-recovery Association, http://www.americanbiorecovery.com. EPA, fire response and recovery information.

3.16 Oil Lube Systems (Industrial), Tanks, Oil Compressors, Hydraulic Equipment Services, Light Oil Jetting Oil lube systems are designed to lubricate main turbine bearings, compressor gear ends, pump–piston areas and blower bearings, in short, any type of machinery under constant load using oil at a set operating temperature and pressure. In general, this is achieved by circulating turbine oil throughout a unit’s load bearing system. These systems, as such, consist of a pump, filter screens, metering valves, thermostats, oil lube coolers, pressure-regulating devices and a main oil lube tank. A contaminated system can prove costly to power plants, refineries and chemical plants (bearing, valve, fragments and corrosion). Contamination may arise by circulating fatigued bearing materials such as aluminum, cast iron and steel particles. Rust development and subsequent scale contamination which has developed in steel supply and discharge lines may be the result of condensed water admixed with turbine oil. Other culprits include a higher oil viscosity and plugged filters resulting in filter screen ruptures, allowing contaminated oil to circulate freely throughout the system, and thus accelerate bearing, cylinder and o-ring wear.

436

3 Application Core Curriculum

Fossil fuel and nuclear power plants are quite familiar with hydro-blast and high-pressure oil cleaning methods. There it has been proven and accepted by turbine manufacturers as being far superior to the generally-applied oil flushing method, which circulates vast amounts of heated, filtered turbine oil through the oil lube system, removing debris in compressor cavities, bearing housing and pressure discharge lines. Most maintenance engineers in refineries and chemical plants have yet to be exposed to this proven hydro application and are therefore considered prime customers for contractors and hydro-manufacturers alike. Contractors interested in this field should regard this application as a separate identity from their daily pressure washing routine. To achieve a convincing and sound technical background, technicians and salesmen should familiarize and specialize themselves in this global application. An added investment of approximately $2,500 in accessories, minor when considering potential income prospects, will be necessary to allow a complete service capability. Having to replace a corroded oil lube system is far less cost-efficient than employing a contractor at $300 an hour to recondition the system by returning it to full operational status within 24 h. In the mid 1970s, WOMA Corp. tested this application successfully at a major power plant facility in Arizona, setting the first vital technical parameters. Demineralized water was then applied to effortlessly remove corrosion from oil supply and discharge lines and included rust, sediment and gasket debris removal exceeding all achieved expectations and long-term operational status. Applying this technology in the United States resulted in varying opinions. Some engineering and maintenance identities feared most commonly the practice of applying demineralized water in their oil lube systems. This prompted the changeover to compatible light oil as a blast medium which proved favorable. The drying procedures of oil lube systems were eliminated, and with it, removing the possibility of water pocket formations. The nozzle’s standoff distance is tremendously enhanced because of the oil molecule structure, which optically appears similar to polymer blasting, creating a higher nozzle impact, and thus allowing for applying equipment operating at 1,500–4,000 psi. The gpm performance may vary as to nozzle configurations applied. This light oil jetting application was immediately preferred and resulted in a common understanding. Confined application-related oil spillage can be allowed in most refineries; their recovery systems are well equipped to handle the low volume, eliminating further environmental problems. When utilizing this light oil jetting application in power plants and most chemical plants, circumstances are quite different. The blast oil must be considered a commodity purchased by either the contractor or customer. Spillage cannot be accepted under any circumstance, forcing a totally confined cleaning and oil recovery method (Fig. 3.170). The vacuum recovery unit, consisting of a quick-connect pipe flange coupler, providing a flex lance guidance system, is ideal for this type of oil jetting application. The flex lance guiding system also incorporates a vacuum hose connection.

3.16

Oil Lube Systems (Industrial), Tanks, Oil Compressors

437

Fig. 3.170 Oil recovery tool-flange

Fig. 3.171 Light oil product application sheet

The vacuum hose delivers contaminated oil to the holding tank, separating coarse contaminants efficiently. From this point, a high volume 5 lm oil filter (or greater) rids oil of finer contaminants for recycling to oil heating unit which is locked in between the filter

438

3 Application Core Curriculum

Fig. 3.172 Splash guard

assembly and suction tank of the hydro-unit directly delivering blast oil (Fig. 3.171) again to the job site. This system has also proven highly successful when water is a substitute for light oil in all other pipe cleaning facets where the cleaning process must not contaminate the direct surroundings by product or water splash poses an environmental or a health threat. Retrieved materials or contaminants can also be discarded into tank trucks or any vessel, thus allowing the reuse of water or blast medium. An assortment of lance, and flex lance vacuum retrieval systems are available and can simply be modified to most applications. Adjustments are performed on the jobsite with plant maintenance. When large H2O compressors and their like are serviced or are reassembled at their place of operation, further contamination in the compressor’s interior cannot be avoided, or at best, not guaranteed. A last low-pressure wash-down using a compatible light oil is highly recommended before the final system flush is performed, especially in the unit’s low velocity cavities where entrapment of contaminants are practically guaranteed. Accessories used include a combination of 00 trigger gun extensions fitted with quick couplers ranging from 30 to 60 in length, bearing a 20 fan nozzle and not larger than .060 or 1.5 mm diameter orifice. The second lance presents a T configuration, equalizing nozzle recoil forces and allowing cleaning procedures in inaccessible areas. The third lance is a 60 long, ‘00 aluminum pipe fitted with a flex lance and a nozzle featuring two orifices at 45, capable of reaching and cleaning cylinder sleeves, oil intake lines and other inaccessible areas. This aluminum tube must contain a locking device preventing possible lance extraction. A two-man operation is best suited for this procedure; one holding and controlling the aluminum tube and the other controlling the foot valve or hydro trigger gun and lance travel necessary. Disassembled oil lube coolers are cleaned by the usual hydro-blast method using the vacuum recovery system. In place oil lube coolers located and integrated

3.16

Oil Lube Systems (Industrial), Tanks, Oil Compressors

439

in vertical positions such as generator turbines are nowadays serviced utilizing a drip proof splash guard unit (Fig. 3.172), which provides a three-lance operation, cleaning six to nine tubes a minute and returning blast medium to the discharge side of the cooler located below the turbine generator area. These open drip-proof units are also used on all vertical exchangers and condensers, providing an ultrasafe and dry cleaning method at the rate of six to nine tubes per minute. The application requires pump performances from 1,500 to 9,000 psi at 5–16 gpm. GEAR - LIST AUTHORIZATION Oil lube systems, tanks, oil compressors, hydraulic equipment services, light oil jetting Customer & Company:

Date: Address:

Website:

City: State:

P.O. Box: Zip Code:

e-mail:

Job Nr.:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Review Performed by: Oil lube cooler: Main oil lube tank: Oil supply pipes: Oil discharge pipes: Turbine generator: Condenser:

Heat exchangers: Secondary oil tank: Filter screens: H2O compressor: Low velocity cavities: Cylinder sleeves: Other:

Scale debris type: bearing-gasket, corrosion, water condensation Other: Environment:

Industrial:

Commercial

Residential:

Equipment: Drip-proof splash guard unit:

Flex Lance:

Vacuum recovery unit: 5-Micron oil filter: Oil heating unit: Tank truck: Oil tank: (500 gallons)

Aluminum Lance Guide: Rigid Lance Extensions: (4’.) T-Lance: (5’.) Foot Valve: Flex Lance:

Vacuum hose: (2” 4”)

Other:

Blast fluid specification: Return oil to production process: Discard oil: Turbine oil:

Specify:

Explain Method: Turbine Oil Grade: Specific Weight: Other:

Describe application and work procedure:

Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

3.16.294

Viscosity: Flammability:

©

440

GEAR - LIST

3 Application Core Curriculum

Nr.

Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Job Review Performed by: Plant hardware:

Hydro-blast equipment:

Plant location:

Equipment:

Expendables: Product encountered: Hazardous material:

MSDS:

Specify:

Describe application and work procedure:

Describe safety procedure: Itemize equipment, safety gear, expendables, etc.:

3.16.295

Specify:

©

3.17

Ornamental Statuary–Monuments, City Fountains

441

3.17 Ornamental Statuary–Monuments, City Fountains, Theme–Amusement Parks, Hotel–Municipal Pools, Aquatic–Marine Pools and Tanks Statuary and monuments in cemeteries, city parks, on street corners and the occasionally displayed art pieces in town centers or open areas of interest (museums, etc.) are subject to weathering, soot-soiling and various bio-contamination caused by birds and humans. Undoubtedly one of the most famous and probably technically attractive cleaning solutions was provided by Kärcher, C-Tech Industries on the national monument in South Dakota (Fig. 3.173), and the statue of Christ the Redeemer in Río de Janeiro, Brazil. Judging by various South Dakota technical reports the application aspects were intriguing due to the fact that the necessary water had to be delivered to a mobile tank unit installed above the rock statuary fascia supplying the hot water pressure washing equipment by transfer pumps. Commercial climbers were confronted with excessive hose length, which had to be controlled, avoiding hindrance when cross walking substrates fascia. The accumulative water mass resulting from excessive hose length also required the utilization of trigger-guns and hose armatures capable of withstanding water velocity and its resulting pressure peaks in operators’ vicinity. This can also be achieved by incorporating the pressure activating valve within the pressure regulator assembly at or near the unit’s pump head. This type of pressure activation may also reduce momentary start up recoil forces upon the climber. The monument, being granite, offered some growth of moss in crevices, discoloration resulting from bio residual and water leaching downward of fascia and crevices filled with various caulking and adhesives installed by national park rangers in their attempt to control damage by freeze–thaw cycling on all important surface structures. The cleaning itself was performed by utilizing turbo-nozzles providing a sharp edge and wide cleaning coverage. The hot water supported disruption of organic root growth, while jetting crevasses clear off various nourishment-soils diminishing future growth activities. After removing remaining loose or deteriorated caulking products, crevices susceptible to freeze thaw cycling were sealed. Due to the monuments remote location, a timeline of gigantic proportions had been established by Kärcher. Untouched by high-pressure water the remaining mountain substrate will in the future educate as to the severity of an environmentally introduced surface contamination and influence by freeze–thaw cycling in comparison to all surfaces successfully cleaned. Park rangers, scientists, restoration–preservation specialists, pressure washing and hydro-blast equipment manufacturers alike will learn a great deal within the next 20–30 years as to the positive influence affecting granite surfaces treated by high-pressure water and the visually achieved longevity of its beautification by a high-pressure jetting procedure. Granite and architectural marble cleaning and conservation is safely achieved when utilizing high-pressure water either with fan jets or turbo nozzles with

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3 Application Core Curriculum

Fig. 3.173 a, b, c National monument

pressures ranging between 1,000 and 3,000 psi at 2.5–5 gpm hot or cold water without the loss or dulling of existing surface gloss. Most often faded gloss or damage occurs due to pedestrian shoe sole abrasion and environmental impacts that more often than not has been accelerated by improper use of harsh chemicals, failing neutralizing chemistry and inadequate buffing compound applications. The high-pressure water pre-cleaning is particularly effective when introduced to a failing stone gloss prior to a restoration and maintenance procedure. It is especially effective in removing aggressive sharp edged tiny contaminants (silica, etc.) embedded in the gloss seal interface most often introduced by substandard cleaning and seal applications.

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These abrasive contaminants can be responsible for edge-swirl marks when buried into pads of buffer-polishing equipment. Stone specific honing compounds are utilized in a measured application criterion, which cannot be compromised by irregular supply and/or unidentified product contamination. Marble is a crystalline compact variety of metamorphosed limestone. This sometimes is the reasoning by which restoration and preservation specialists nix high-pressure water as a cleaning tool. Often these are the same specialists which will apply a 50–50 water chlorine bleach solution, and combine this with light or heavy brushwork on historic substrates. Neutralization of chemical remnants is mostly marginal and performed with flushing water to a possible porous stone substrate. Applying household vinegar to surfaces in question completes their service cycle. This inadequate circumstance is often enhanced by failure to correctly categorize various stone substrates and the identification of why a cleaning procedure is necessary. Besides making use of abrasive blast techniques this behavior has through the years permanently damaged sensitive stone statuary, building façades and architectural components. As many antiques have been destroyed or lost their antiquity value by incompetent cleaning procedures, as has the conversion or destruction of an aged look or beautiful patina on various stone and metallic substrates, destroyed art or architectural heritage structures, façades and statuary. By the way, these methods also accelerate the usual damaging manifestation by environmental influences which are especially noticeable when competing for work in established cemeteries. The disparity of deteriorated old markers, granite, lime and sandstone or variations of damaged slate stone and concrete units can be impressive as to their state of physical decline, which often also identifies past harmful cleaning– restoration scenarios. These stone credentials also absolve the high-pressure water cleaning technique, simply because the gravestone cleaning application by highpressure water as a tool was at best limited or only available in very few regional areas. Especially when considering the mobile pressure washing industries state of existence and equipment ability–mobility 40 years ago. Therefore a hobby historian’s opinion must be viewed critically as to the creation of long-term damaging effects which cannot be established by anyone regardless of education or application knowledge. Damage and deterioration are more often than not the result of services indifferentism to varying substrates which will change with every memorial-internment site. For business prosperity is it wise to establish and submit to the job walk report a digital photo history of a project at hand (Fig. 3.174). Identify foliage condition around internment site, possible existing damage to stone surfaces or base structure which includes identifying obvious friable stone-face surface conditions and lettering, readily falling away grainy–sandy face structure, or any circumstance indicating a stone’s brittle-friable or otherwise vulnerable state, which can possibly be negatively influenced by the proposed cleaning procedure, categorize and record within the vicinity detached stone fragments, and identify stones to be serviced on a copy of cemeteries map possibly coinciding with picture records. This picture recording only has value if a second copy is produced after the job

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3 Application Core Curriculum

Fig. 3.174 a, b, c, d Mailbox statue

completion (job report) precisely identifying again first photo journals locations. As to safety concern or strategy, gravestones and statues are heavy and mostly not anchored therefore can topple with a minor high-pressure hose pull around their corner base. Destabilizing factors can also be excessive groundwater saturation occurring due to rain or natural high groundwater levels which is considered a warning sign. When cleaning, saturate stone surfaces and maintain a wet condition to permit contaminants to swell and soften. Water dwell time will fluctuate with stone type and weather conditions. This is especially important with marble, sandstone or slate where cleaning intervals are generally less frequent which is approximately every 8–10 years. A soft bristle brush is not advisable. Bristle will agitate interface structure with the result of having to dominate the cleaning procedure by brush stroke only. A 45 advanced fan jet will at 1,000 psi not exert more than 20 psi surface pressure at a 20 stand off distance. With ultra sensitive surfaces the water volume performance can be reduced to 2.5 gpm. When mold-fungi, algae and/or lichens are visible the cemeteries management and/or memorials custodian must be contacted as to their requirements. Aged or weathered gravestones do not necessarily have to look new. The purpose of cleaning is to preserve stone longevity and the innate beauty for others to enjoy.

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Fig. 3.175 City fountains

After water saturation and soaking cycle the cleaning commences from the bottom up to avoid visible streaking after the drying process is completed. If a cleaning solution is absolutely necessary apply as directed only to a prior cleaned and totally water presoaked stone, minimizing the possibility of chemical penetration past contaminated interface structure. After the chemical application by pump-up sprayer and adequate chemical dwell time the jetting again starts from bottom up. Water flushing the cleaned surfaces and neutralizing substrates interface must be performed as required by the manufacturer of detergent supplied. Only utilize products with a satisfactory and verifiable track record and only when accompanied by their MSDS identification. Liquid cleaning chemistry must be biodegradable, non-ionic, non-corrosive, non-flammable, non-abrasive, nonstaining and when drying have a tolerance to high grain-hard water and emanate no odors or colors. Information and guidelines for specific locations and jurisdictions can be obtained from the international cemetery, cremation and funeral associations (ICCFA). City fountains (Fig. 3.175) and their maintenance procedures are seldom controlled by storm water management agencies, simply because water balancing and control will require a chemical intervention probably by chlorine or an alternative such as sodium bromide (never use copper-based algaecides). This means drainage of fountain-water can never be permitted to any street or storm drain. Water content, probably contaminated, must be discharged to the sanitary sewer system. Most localities demand water testing and require chlorine to dissipate to less than 0.1 ppb or total neutralization before this water can be recycled or reused by gradually draining it to a landscaped area. More often cleaning services are only required for seasonal or aesthetic reasons. Moreover large unplanned maintenance on or in fountains is always related to a technical maintenance question, which can be the maintaining of submerged lighting fixtures, nozzles and pump equipment, cleaning aggressive algae contamination due to faulty filtration system and metering devices, and repairing coating failure (Fig. 3.176) or removal of existing coatings to facilitate a new installation.

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Fig. 3.176 Fountain structures

Most often coating failures can be documented due to poorly prepared substrate, and design circumstances relating to negative water entry through cracks or moisture vapor emissions from saturated concrete areas introduced by adjacent wall systems. Coating blisters indicate water-moisture accumulations on the negative side of the a coating system requiring total removal by preferably the UHP jetting procedure utilizing a vacuum head for the direct transfer of coating residual. The hydro-blast application is also practical, especially when a certain degree of surface roughness must be established. Under such a circumstance, the hydro-vac system is utilized to remove and separate coating residual and recycling of the blast water. Some interior concrete surfaces may also require further treatment via high-pressure water abrasive-blast techniques such as those described by the coating manufacturer or the engineering consultant whose methods are most often investigated and determined to be the prior cause of coating failure. This coating removal application requires industrial tooling, which is also utilized for applications found in theme-park facilities, aquatic marine pools and tanks. Tool requirements will vary with every application and coating-substrate encountered. Coating removal applications in theme-parks fountains and water slides are often a seasonal prerequisite, or removing coatings in aquatic and animal habitat housing which deserves specialization can greatly be supported by offering surface cleaning applications starting with pedestrian areas, including bubble gum removal, cleaning and disinfecting of joyrides (Fig. 3.177) which is necessary after an emergency repair procedure and/or specialty work such as dredging pond bottoms supporting aquatic life, etc. by utilizing the hydro-vac system. Inquire through industry resources the ‘‘international association of amusement parks and attractions’’, http://www.iaapa.org. Residential swimming pools, including Jacuzzis, will accumulate fats, bio-film resulting from free-floating micro organisms, oils, calcium-chlorine crust appearances adhering to surfaces and/or obvious waterline and runoff-splash areas. Commercial and municipal pool installations require special attention due to increased contaminating source (humans). Cleaning services will always be

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necessary within this environment therefore the only question is the feasibility warranted for a pressure-washing contractor to participate in this market. Any pool service company under seasonal pressure is well advised to incorporate existing pool cleaning experience by upgrading equipment and tool capacities into the municipal pool, aquatic–marine, hotel and theme park environment, where a customers managerial obligation reflects operational maintenance cost. Professional pool operators of America provide within their association a technical information base concerning all major coatings, contamination and bio-film structures and their removal criteria. This knowledge base can further be exploited and enhanced into the prior clarified statuary–monument and fountain cleaning and coating removal application criteria, http://www.ppoa.org. The pressure washing contractor may consider the pool cleaning application when his overall contract includes surface cleaning applications in business’s parking facilities, arrival and departure areas, brick and stone work in atriums, wooden fencing and gazebos or cleaning of restaurants produce receiving and trash collection areas or restaurants ventilation equipment, etc. For the above-mentioned cleaning applications the rotary spin-jet surface cleaning unit is perfect when operated with hot water at 2008F plus at 3,000– 4,000 psi. Soaps, disinfectants, degreasers or light acids can also be introduced and are of an advantage under various circumstances. A one size fits all chemical application criterion can not be established due to the encountered job varieties. When applying chemicals a material safety data sheet (MSDS) must be present on the job site indicating chemical structure (bio-degradable). Chemicals can be applied with an up-or downstream injector or directly admixed to the float tank (disinfectants). To avoid aggressive behavior in a pressure washer system, acids are either applied manually via a pump-up unit or pulled by a low cost abrasiveblast injector affixed ahead of the gun and lance assembly. Proper acid water ratio is simply achieved by the utilization of a hose clamp restricting the acid flow approximately 4 ft beyond the acid container. The suction hose must be acid compatible and is down sized in relation to existing abrasive hose assembly. Adequate protective clothing and sometimes respirator gear are necessary. Choosing the necessary application process depends solely on area coverage requirement. In high-traffic areas and areas where traffic is difficult to control, signage procedures must be obvious and legal. In a pool bidding process a contractor should also consider the overall pool areas that may include cleaning wooden decks, stone-work, sidewalks, etc. Wood can be restored by a high-pressure water application and supported by chemistry to visually near-new appearance. Whenever possible, expansion joint cleaning of cement floor structures and a resealing process with caulking can often be included in a bid procedure. The hydro-vac system belongs to the pool equipment palette as its application can specifically remove various contaminants in a general product transfer or a dredging function from hotel indoor–outdoor water gardens. Paint removal and concrete resurfacing procedures (Fig. 3.178) including the removal of faulty base aggregate are applications perfectly suited for aquatic–marine tanks requiring a new coating installation. Concrete liner of 00 to ‘00 depth is easily

448

3 Application Core Curriculum GEAR - LIST

Nr.

Customer & Company:

Date: Address:

Web site: e-mail:

City: State:

Job Nr.: P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail: Job Description:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by:

(a)

Hydro-blast equipment:

Equipment:

Expendables: Product Encountered: Hazardous Material:

MSDS:

Fig. 3.177 a.b cleaning and sanitizing rides

Specify:

Describe application and work procedure: Describe safety procedure: Itemize equipment, safety gear, expendables, etc.: Prevent damage from temperature cycling to repaired or restored concrete structures by preparing the old or new poured concrete interface with high-pressure water: For small areas utilize the water abrasive-blast technique at 3000 psi and 5 gpm. On a newly poured interface prepare the surface by applying 15 ° fan-jet at 2500 psi and 5 gpm. For widespread surface areas with an old or new pour interface exploit the available Rotary Spin-Jet Equipment for surface cleaning applications (flat-work). Pressures and gpm performance according to equipment design which can start at 3000 psi and 5.5gpm. Fig. 3.178 preparing concrete interface

removed applying ultra high-pressure creating a new surface structure, while removing the deteriorated coatings or tank liners. Gun barrels featuring a blast screen will aid operators in visual control while adding extra protection from flying debris when a vacuum supported trigger-gun is not available. Typical hydro gun operations are without a limit to the imagination and best performed when the operator has the knowledge to select adequate

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nozzles and psi–gpm ranges according to the products and substructure encountered. GEAR - LIST AUTHORIZATION Ornamental-statuary-monuments, city fountains, hotel-municipal, aquatic-pools-tanks Job Nr:

Customer & Company:

Date: Address:

Web site e-mail

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Job Review Performed by: Cemetery: Statuary: Monument: Theme-park Fountain: Aquatic-marine tank: concrete: steel: fiberglass: Swimming pool: Sewers: Pipes:

Mud: Bio film: Chlorine-Calcium deposits: Bacteria contamination: Fats:

Others:

Others:

UHP equipment: Pressure washer: hot-cold Hydro-blast unit: hot-cold Pipe cleaning nozzle: Vacuum truck: Hydro-vac system: Vacu-box: Pump-up spray applicator: Abrasive-blast injector: Abrasive: specify: Vacuum supported surface cleaner: Water-recycling equipment: Other:

Acid: Rust inhibitors: Caustic: Detergent: Foam nozzle: Wand extensions: Tank coating: Fountain coating: Plastic sheeting: (visqueen) Traffic control: Rags: Other:

Specify:

© yes

specify:

MSDS

Describe application and work procedure:

Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

specify: specify: specify: specify:

no

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3 Application Core Curriculum

3.18 Polishing, Etching, Metal Burr-Flush Removal, Coarse Edge-Weld Seam Polishing, Surface Modulation Developed in the late 1950s this metal modulating application is today fullyautomated, operating between 10 and 90,000 psi and does generally not belong to a service providers–contractors application standard. The process of removing protruding metal burr-flush with high-velocity water or water-jets saturated with abrasives was manually utilized in foundries producing engine blocks (Fig. 3.179) and parts (Mercedes-VW). Due to this awareness hydro-manufacturers and contractors alike tested and experimented with this jetting technology within the manufacturing environment and metal industries (foundries, sheet metal industries, construction sites, etc.). Once the desired results had been achieved the successful manual method quickly gave way to automated remote-controlled systems accommodating and rationalizing the task of high-volume production. Automated processes were first visualized and perfected for the production sequences of engine blocks, crank shafts (Fig. 3.180), pump impellers, and all products requiring (for completion) final removal of casting sands, remaining ceramics, metal burrs-flush, drill burrs and hardened dried drill oils. These automated systems are manufactured in all sizes ranging from cabinets to drive-in or through rooms, accommodating the industrial products physical size and while in operation conceal the developed noise levels, abrasive dust and water-jet emissions. Regardless of pressure-gpm requirements the exterior control panels are designed to permit access to all protruding metal remnants and possible sand filament while at all times providing a safe continuous operation. Equipment designs incorporating hydro trigger-gun and lance fixtures which are either semi-manually or hydraulically controlled while also totally containing water jet’s recoil forces. Product in question is affixed to an rotating tool base which provides the necessary access to all vital problem areas. Acceptable visibility is achieved by an exchangeable center glass or rotating window system designed to absorb, reflect and flush, upon contact, mud from its viewing surfaces. Blast cabinets or designated blast areas also provide water recycling with an adequate filtration–polishing capacity, circulating water back to the suction site of a stationary hydro-pump unit.

Fig. 3.179 Cast sand removal from engine block

3.18

Polishing, Etching, Metal Burr-Flush Removal, Coarse Edge-Weld Seam

451

Fig. 3.180 Cast sand removal from crank shaft

Fig. 3.181 UHP abr. cutting

When manually cleaning oil–water passages filled with sand, loose or partiallyadhered metal flash or burrs in engine crankcases (mechanically developed by drilling procedures) a short 1=800 schedule 80 rigid lance is placed with the nozzle directly on the opening and pointing in line to the passage at operating pressures up to 14,000 psi at 16 gpm. The developed and channeled water velocity removes all baked sands and metal burr-flash. The minor metal flash remaining are so strong in structure that further breakaway during an engines operation are impossible. Cleaning time per passage will not exceed 15 s. Most drilled passages within an engine crankshaft will not permit internal nozzle manipulation to eliminate excessive water-jet ricochet; therefore, manufacturers affix jetting nozzles directly to the lance body enhancing the possible access to the drilled orifice (welded or threaded form). In any case, the crankshaft’s drilled or cast oil passages are short in design therefore cleaning times will not exceed 6 s per passage. Naturally, time parameters will change with size of engine shaft encountered. It must be guaranteed that the utilized vise-fixture can adequately hold and absorb the hydro-jet’s transferred kinetic energy. The effectiveness of any abrasive or, for this matter, blast medium, to enhance remove or otherwise manipulate surface conditions and appearance also depends on the following technical variables: the mix ratio of water and honing-abrasive medium type, hardness, grain shape, sieve-mesh size, injector-nozzle distances from the surface, surface type and structure, and the injector’s ability to produce an adequate blast pattern superior to most common water-abrasive blast injectors and their available support equipment. A contractor wishing to utilize abrasive application technology can verify in chapter ‘‘core applications’’ 23 industrial–commercial-marine applications (Fig. 3.181).

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GEAR - LIST AUTHORIZATION Polishing, etching, burr-metal flash removal, weld seam polishing, surface modulation Customer & Company:

Date: Address:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Job Nr.:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Site Risk Assessment:

Specify:

Job Description: Job Location:

©

Job Review Performed by: Foundries: Sheet-metal industry: Construction site: Casting: Engine blocks: Crank shafts:

Pump impellers: Construction steel: Glass: Aluminum: Granite: Other:

Honing: Etching: Metal burr-flush:

Drill burrs: Casting sand removal: Sand filling: Other:

Abrasives:

sieve-mesh size:

Profile:

Glass beads:

Sieve-mesh size: Aluminum oxide: Silica: Garnet: Sand Soluble abrasives: Sawdust: Grain-shape:

Metal beads: Plastic beads: Nut-shells: Cement dust: Fly-ash: Grit:

mil.:

MSDS:

Equipment: Hydro-blast unit: Pressure washer: Abrasive injector: Abrasive cutting heads:

Pounds:

Profile:

Hardness:

Bulk:

mil.:

MOHS:

Bags:

Bulk container Vacu-jet recovery system: “Wet” Vacu-jet recovery system: “Dry”

Other: Describe application and work procedure: Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

3.19 Sewers, Laterals, Culverts, Sumps, Industrial Pipe Cleaning, Pipeline Cleaning and Cutting Applications Conceived and developed by Wolfgang Maasberg Sr. in 1956 and finally patented in 1958 Germany, the self-propelling (Figs. 3.182, 3.183) sewer–pipe highpressure hose or rigid lance mounted nozzle configurations (USA 1960) where the

3.19

Sewers, Laterals, Culverts, Sumps, Industrial Pipe Cleaning

453

Fig. 3.182 The sewer and pipe cleaning invention 1957

Fig. 3.183 Nozzle invention draft 1960 USA

result of his industrial pipe cleaning method (Fig. 3.184) utilized in dairies and chemical production facilities. The inspiration to first develop and manufacture truck chassis mounted industrial pipe–sewer jetting vehicles followed quite immediately. At the same time manually performing the strenuous pipe sewer cleaning method also produced the motivation to manufacture hydraulically operated hose reels, which were immediately successful. Combining the industrial continues vacuum performance of 4,000 Cfm and 2900 Hg, generated by injector ring pumps then in operation for dredging or product transfer applications (hydrovac system) and combining this equipment and tooling to truck chassis where worldwide the first commercially available so-called combination units delivered in 1960 to municipalities. From the beginning PTO drives were applied to transfer power to 75 and 150 hp pumps. As to the question; did the sewer cleaning application come first or industrial pipe cleaning?, it was industrial pipe cleaning for the removal of hardened industrial products requiring water pressures and gpm performances not jet available in a compact configuration suitable for installation

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3 Application Core Curriculum

Fig. 3.184 Engineered to avoid jet-energy destruction

on a mobile truck or trailer mounted unit. This also channeled future European pump designs to achieve higher performance levels in a much smaller configuration. As within the industrial environment, identifying the encountered pipe–sewer systems age and operational definition which might be or is of a lateral type connecting a private residence or rural business to its sanitary sewer district can sometimes present to the inexperienced an array of bewildering consequences. Due to unforeseen pipe combinations, which can be starting with; cast to ductile iron into an Orangeburg lateral pipe, in areas fixed with vitrified clay–ceramic–crock pipe connected to a new concrete pipe which was installed last year replacing parts of the combination sewer. This type of scenario requires attention as to structural integrity; application technology applied preventing possible damage, therefore acquiring visual proof of system’s condition before a correct tool selection can be introduced (Video inspection). A highway drainage system can also be connected to a storm water detention facility of various design controlling storm water runoff and capacity, however they almost always suffer from mud-silt accumulations which are in comparison the simplest application of jetting and/or refuse removal nature. Storm water systems, which carry typical runoff from any rain event in a watershed, can sometimes be incorporated into a storm water detention facility. Cleaning sanitary sewer systems from generator to a wastewater treatment facility refers to residential, commercial and industrial discharge. This type of liquid discharge carries human waste, chemicals, commercial byproducts, grease, pollutants and various toxins. Some of these discharge events are controlled and licensed such as for instance the discharge of Laundromats, food processing, or various identified manufacturing processes. It is this type of discharge, which can be fatal when neglecting standard safety procedures and under-estimating the possible destructive nature created by sewage accumulations within its confined environment. Flagrantly tossing cigarette butts down a culvert shaft is an unacceptable behavior pattern almost always displayed by a novice claiming professionalism. Due to the generally unknown raw sewage composition and possible development of gaseous atmospheres, safety minded equipment technicians and labor force will adhere to a proven operational sequence which is at all times maintained. It is necessary to identify and confirm the materials and the general environment encountered throughout the sewer pipe system, including the verification of the system’s structural integrity. EPA

3.19

Sewers, Laterals, Culverts, Sumps, Industrial Pipe Cleaning

455

Fig. 3.185 Combination sewer jetting-vacuum truck since 1963

regulations on solid and hazardous waste removal as defined in 40 CFR 261 must be understood by all involved. The labor force may enter a sewer system only after safe conditions are established and all safety-confined space entry procedures are considered, including the supply of adequate ventilation, breathing apparatusegress system, confined space entry permits, etc. Operators with pipe–sewer cleaning experience (Fig. 3.185) will differ in their operational judgment and therefore professional quality. Technical experiences combined with a healthy vivid imagination, or better yet, gut instinct especially in industrial environments to identify downstream–upstream pipe access, line flanges-lids, bends, underground pipe damage and retaining an imaginative typing capability of possible obstructions encountered by the sewer cleaning head will separate the men from the boys. It is very important for operators to monitor the amount and type of debris passing by the service manhole or being removed from a pipe–sewer line. Excessive backfill material and or pipe fragments can indicate a pipe failure requiring job shutdown to facilitate a closed circuit television inspection. This experience to effectively categorize waste-product is nowadays greatly supported by closed-circuit television inspection identifying current sewer conditions for possible problems stemming from pipe deterioration, collapse, defective gaskets and root growth (infiltration), pipe joint damage and/or the nature of general blockages. This camera work can only support a pipe–sewer inspection when pipe systems are either clean or partially cleaned to identify interior obstruction or blockage. This means any sewer system needs a cleaning schedule to facilitate operational security and unhindered CCTV inspection access. In the real world, a contractor is called out when a pipe sewer system fails due to blockage. Regular cleaning intervals are of utmost importance and considered a maintenance necessity in areas where sewer systems are subject to increased calcium-carbonate sedimentation, as generated by liquids from industrial laundries or manufacturing facilities where organic–inorganic materials are delivered in volume and deposited throughout a system accumulating scale and minerals on pipe walls. The reduction of effective flow by increasing interior surface roughness, and the course of developing restrictions can also be a result of a so-called tuberculation, where products react to pipe material in itself often a criterion in industrial environments. These are pipe cleaning circumstances where cleaning by

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3 Application Core Curriculum

mechanical methods utilizing auger or metal cable-rod equipment with lateral cutters, flat or concave blade, milling plates, etc. or a variety of milling heads which are prone to damaging pipe systems were a common practice. In this application the hydro-method differentiates in that mechanical tools and metal snakes lack the capability to conform or adjust to changing sewer pipe profiles and will create a real problem when confronted with a protruding tap-stub extending into a sewer line. This type of equipment should never be employed if a blueprint identifying existing lateral or directional bore connections is not obtainable. Metal rods or snakes also do not ventilate a sewer system during the cleaning process and furthermore, will not remove heavy materials from the lower sewer invert. Contractors in their desire to land a job opportunity often forgo the need to acquire from the prospective customer information regarding a systems repair history, adequately identifying type of pipe material and/or design variation present on site, possible condition of the pipeline and its access locations and detailed information as to past cleaning history and its possible problematic. This information base should be the criteria, which permits the selection of adequate tooling. The type of sewer systems can be referred to as combination found mostly in rural areas, retention and or highway drains, and detention systems for storm water and the cleaning of storm water drains, sanitary sewer systems and their lateral connections. Laterals connecting to sanitary sewer pipe can be Orangeburg to PVC colorcoded pipe, where green identifies sanitary sewer service, leading from a combination of cast or ductile iron pipe to vitrified clay pipe or any combination thereof, to a sanitary sewer main constructed of steel, brick and/or reinforced concrete pipe. In the last 40 years Truss pipes manufactured by Contech are also resistant to chemicals found in sanitary sewer systems and offer a glossy smooth interior with water tight joints, preventing ground water infiltration and root growth starting in diameter from 800 , 1000 , 1200 and 1500 [ can show in certain areas predominance (new developments). Water retention systems constructed of corrugated coated steel, corrugated smooth wall, high density polyethylene pipe (HDPE) and storm drain systems manufactured from brick, steel and concrete (reinforced) starting at 1800 [ pipe diameter to large drainage box culverts are structural generalizations never to be trusted and must be verified before a tooling selection and cleaning-jetting procedure commences. Sewer cleaning techniques (Fig. 3.186) begin and end with the basic understanding that all materials and obstructions must be removed from their inverted surfaces. It is therefore imperative to realize that cleaning procedures started at the elevated side of any given pipe system defeat or severely hamper the created water flushing velocity carrying the generated sewage downstream. Whenever possible, qualified operators simply begin their cleaning procedure downstream from the obstruction within the sewage pipe system, automatically guiding him to the nearest manhole shaft, culvert or service lid. At this point, and in increments the hose-nozzle assembly is sent upstream in the direction of the existing obstruction pulling back settled debris.

3.19

Sewers, Laterals, Culverts, Sumps, Industrial Pipe Cleaning

457

Fig. 3.186 Low profile cleaning

Fig. 3.187 Skipjack directing jet energy to pipes lower inward

The selection of nozzle type will dictate jetting performances, and their intent. A deteriorated and fragile but open unclogged sewer–pipe can gently be cleaned by a stepped and repetitive jetting procedure in the bottom quarter (Fig. 3.187) of pipe radius, utilizing nozzle carriers with jet configuration in a plane pointing and accelerating waste accumulations by water velocity creating no potential jet impact to interior deteriorated pipe walls which also permits an extended jetting hold time mounting water velocity towards waste accumulations (Figs. 3.188, 3.189). The nozzle design must make sure that hose weight and nozzle thrust can not create nozzle jet angulations subjecting pipe wall to a direct jet impact. When cleaning large sewers (above 20 ‘0 [) a so-called ‘‘skip-jack’’ nozzle, designed to direct nozzles available water velocity to the areas most needed (lower sewer invert), proves useful and renders cylindrical nozzle carriers quite insufficient. Cylindrical nozzle carriers can lose in open sewers, up to 70% of the developed jet velocity toward the upper radius of mostly clean sewer inward. A blockage removal in sewers is to propel a nozzle upstream punching through a waste accumulation facilitated by one forward nozzle making way or climbing over the debris field. The rearward facing jets are applied in a repetitive hose rewind method to aggressively breakup in increments and washing the material towards downstream manhole. Once the bulk of blockage has been liquefied a repeated steady sewer-hose rewind of never more then 1 fps is maintained to ensure effective flush-out of materials from the lower sewer circumference. When having to flush from an upstream manhole to remove a blockage extreme care must be taken when placing a nozzle-hose assembly into an upstream sewer access which is most likely obstructed and visually hidden by murky water.

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3 Application Core Curriculum

Fig. 3.188 Calcium deposit

Fig. 3.189 Calcium deposit removed

Nevertheless, all possible safety precautions must be undertaken when deciding on a nozzle placement deep enough into a sewer access, circumventing all accidental back-slippage or failure of containment within the sewer–pipe before hose pressurization occurs. If necessary, the downstream pipe–sewer system is closed off utilizing expandable rubber bladders or netting to prevent further downstream debris accumulation. Before pulling the sewage or debris toward the entered service side the operator should utilize a hydro-vac system to remove accumulated debris, facilitating flow and protecting against further downstream contamination (sewer plug, bladder, and netting). Working from a downstream location such as from a manhole the placement and release of a sewer cleaning nozzle must be exercised with care. If a pipe–sewer system does not present a blockage utilize a nozzle carrier with rearward facing jets. Insert the nozzle carrier to a minimum of 30 before engaging the jetting pump. A noticeable abrupt color change of passing sewage water must always prompt an immediate research criteria and discontinuation of the jetting procedure. The sewer cleaning nozzle has most likely penetrated into an area where pipe damage is present and will move with its jetting velocity soil and pipe fragments, visually identifiable toward or by passing the manhole. Experienced operators will mark the high-pressure hose at its entrance to permit the exact measurement to the probable pipe damage area above the ground after hose retraction and footage

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459

Fig. 3.190 Jet energized root cutter

Fig. 3.191 In operation root cutter

Fig. 3.192 Frontal view root cutter

between the mark and sewer nozzle becomes accountable pointing directly to the area where possibly a trench degradation is visually identifiable. It may not necessarily be a collapsed pipe section but may be a joint failure with loss of gasket beginning to separate from its adjoining pipe. This can cause infiltration of backfill and soil. Also joint separation often reveals vegetative growth, which can be root strands, entering tight gap and cracks mostly growing in the top half of a pipe’s circumference. Hair like roots can be removed with a jetting procedure but fully developed tree roots require the application of a self-propelled root cutter (Figs. 3.190, 3.191, 3.192), energized via high-pressure water (combination of sewer nozzle and circular spring saw), operating between 35 and 60 gpm at no more than 4,000 psi. This equipment performs effectively in pipes ranging from 600 to 2400 [. They will be tricky to operate and require some working experience not obtainable through an owner’s manual (read it anyway). Operators must also realize that cutting equipment only provides a temporary solution to the problem. Roots, if not chemically treated by destroying their plant tissue will come back in a fury. Contractors rely on these units when their available hydro-power and nozzle selection proves ineffective especially in areas where waste products or hardened materials intermix with construction debris and the application of percussion milling cutters may be employed. Storm surges can wreak havoc in sewage treatment facilities when a storm event explosively discharges waste-product combined with rushing high-volume water. An unforeseen or hidden blockage giving way by developing pressure is

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3 Application Core Curriculum

Fig. 3.193 Skipjack nozzle

most likely also the area where odor developments and infectious blood pathogens including bacterial breeding possibilities do exist. To avoid such a circumstance sewer districts tend to utilize a flushing procedure, introducing a heavy flow of water into the upstream man hole of festering waste accumulations flushing floatable and grit waste down stream. This is the most effective when combined with a downstream jetting procedure, moving materials toward the water treatment facility. Typically the larger the pipe diameter, the higher the required equipment flow rate and water volume introduced to sewer system. The industrial service provider is most likely in possession of various industrial pipe and sewer cleaning equipment which is designed to operate within a much higher performance criteria to clean or remove product from within high density polyethylene, concrete and clay pipe systems to cast-iron and steel–stainless steel pipe installations (Figs. 3.188, 3.189). Therefore it is quite simple to add the income potential of the commercial pipe–sewer cleaning environment with a few equipment changes and adjustments enhancing existing hydro-blast unit’s field of operation. To fully compete within this commercial business identity and avoiding the cost of purchasing sewer–pipe jetting equipment, including vacuum truck combinations a simple equipment psi–gpm manipulation or conversion is performed. Nowadays most hydro-blast pumps feature a plunger-piston exchange capability in order to gain water volume in exchange for, or sacrifice psi performance. This change over will result in a combined higher nozzle recoil force (pulling force) and jet impact velocity (mass). This technical requirement for trailer or truck mounted compact hydro-blast equipment gaining a higher water volume configuration is most likely necessary when sewer–pipes exceed 3000 in [ or a excessive sewer incline (grade) must be overcome. Depending on application and pipe material encountered hydro-blast equipments psi capacities may also effectively compensate for the hydro-blast unit’s lack of water volume (Fig. 3.193). To avoid pipe damage, pipe diameter and distance to be cleaned, existing dry sewage volume and structure must by understood to correctly choose a tool-nozzle selection accommodating the application at hand utilizing 5,000 psi plus at 22 gpm plus which is most always sufficient when cleaning and flushing 1800 [ sewer pipes. However, these performances will prove totally inefficient when challenging 40 [ sewers. Regardless of psi applied, a nozzles dwell time most not exceed 30 s. Selecting a nozzle’s jetting angle to protect sewer pipe interior surfaces, influencing propulsion thrust and cleaning efficiency for a sewer-hose assembly is

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461

Fig. 3.194 Centralizer 3D nozzle

Fig. 3.195 Nozzle centralizer

Fig. 3.196 23000 psi 3D nozzle and centralizer

Fig. 3.197 The closer the jet angle to 90, lesser hose propulsion and flushing capacity but high impact to adhering contaminants

today relatively of predictable nature due to municipalities uniform sewer pipe system designs and the general nature of sewage deposits. Be wary of enthusiastic nozzle salesmen (Figs. 3.194, 3.195, 3.196, 3.197).

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3 Application Core Curriculum

Important variables are: the pipe [ to be cleaned, where large [ requiring a wider jet pattern, and higher water volume. A fragile or relative vulnerable pipe condition demands that the water velocity to remove debris be directed to the lower circumference producing a shallow jet pattern, preventing a higher jet impact upon the pipe wall. When there are extensive debris loads deposited on the bottom half of the circumference of a pipe system, jetting power must be directed onto the side walls and pipe bottom inward. Also a possible sewer slope-incline-grade must by correctly calculated and included when choosing a nozzle’s thrust capability adding to a nozzle selection criterion. A typical jet angle of 30 to 35 provides an optimal cleaning capacity with correlating thrust provided by water volume, a jet angle of 15 to 20 provides satisfactory cleaning capacity with higher thrust at the same water volume, and enhanced flushing characteristics, and 10 nozzle provides very good thrust at same water volume but lower cleaning effectiveness up on the pipe’s side wall with high water flushing and atmosphere replacement characteristics when upstream sewer access is opened (venturi effect). On this note to avoid the possibility of a nozzle turnaround and risking injury; it is an excellent practice to employ and install between sewer cleaning nozzles and hose armature a seamless schedule 80 stainless pipe extension 1.5 times the internal [ of the sewer pipe being cleaned. In industrial applications this practice is seldom performed due to tight pipe radiuses encountered within product transfer facilities. Operators must strive to understand the encountered sewer–pipe system before the final tool selection is made. Diameters and profiles of sewer pipe systems, distances between manhole shafts, surface openings and their accessibility, debris classification in terms of viscosity, scale consistency (tensile strength) and adhesion, specific weight, and the overall product volume throughout are the common factors when deciding on a nozzle specification. To reiterate once again, the actual sewer pipe cleaning procedures begin by placing the sewer cleaning nozzle deep into the pipe’s orifice so that accidental dislocation of the nozzle into the service area or man-hole cavity is not possible. If done incorrectly a grave threat to the workers exists when the high-pressure hose is energized and the nozzle becomes mobile. The sewer cleaning nozzle and hose assembly is advanced by 150 –300 increments and is always returned under pressure within 50 ft of pipe access utilizing the hydraulic reel. In its path, all loosened debris is flushed into the open cavity reducing pipe’s surface friction and enhancing velocity factors as the nozzle-hose assembly returns to remove waste deposits within the next 150 –300 of sewer. Hundreds of feet can be cleaned by this repetitious, stepby-step debris pulling method. To avoid a nozzle turnaround, especially possible within in larger pipe radiuses, or a disappearance of the nozzle into a smaller lateral pipe and/or unknown fractures within a sewer system the hydraulic reel operator must never allow hose slack during nozzle advancement only possible when premature hose release is introduced (hose feed outperforms nozzles advancement). To eliminate hose damage while the hydraulic hose reel is operated (retrieving high-pressure hose under jetting mode) a roller assembly is installed to the

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463

manhole-sewer edge or a tiger-tail hose guide is applied. The unit’s hose reel is situated above the manhole shaft in such a way that damage to the high-pressure hose on the manhole’s rim will not occur. The durability of hydro-blast hose assemblies outperforms nylon sewer cleaning hose. Specific nylon sewer cleaning hose effectiveness lies mainly in their light weight, high water volume delivery and low friction factors at given low input performances of 1,500–4,000 psi to 60 gpm. Industrial high-pressure hose assemblies designed with high-pressure water cleaning in mind are generally suited to accommodate the necessary volume and psi performance criteria. Due to hydro-blast hose weight and stiffness most hydro-blast units utilize a hose reel affixed to the rear frame eliminating the strenuous hose retrieval procedure often applied in the industrial application criteria. For sewer cleaning applications, the high-pressure hose assembly must be able to be pulled under pressure which is an absolute requirement for a successful cleaning procedure. To remove debris from manholes or sink basins the wet hydro-vac method energizing a mobile industrial vacuum box has its advantages when compared to a large cumbersome vacu-truck, particularly when work is performed in confined areas (refineries) where pipe sewer systems may also hold flammable liquids or gaseous vapors. The jetting water is supplied to the hydro-unit suction tank or tank truck in tandem and/or directly drawn from a fire hydrant. Operating a fire hydrant’s valves to meter a low water amount may result in severe hydrant valve surface damage. A 2‘00 or 1‘00 butterfly valve with a hydrant swivel is suitable to independently meter water. To avoid unnecessary system contamination the hydrant’s stand pipe is always purged of debris before the fire-hose assembly is connected to an open tank assembly avoiding water contamination by back flush to hydrant. Pipe and sewer cleaning within the industrial environment can challenge a novice’s nozzle selection criterion. Nozzle psi–gpm performance aspects change according to product manufactured, fouling temperatures most often responsible for varying adhesion, viscosity, and/or tensile strength of product to be removed, sewer–pipe design and access including varying radiuses drastically vary with products manufactured and plant process regulations, which include an everchanging safety criterion. When industrial oil or grease traps, septic tanks, chemical and oil skimming vessels, etc., in factories, chemical plants, shops, correctional facilities and so on become part of the sewer–pipe cleaning application the business identity changes abruptly to a waste haulers criteria and its job description due to a number of added constraints which must be considered: A ‘‘generator’’ is a descriptive view of a customer who produces hazardous or non-hazardous products and offers removal of the product to a secondary location. In our case this represents a licensed disposal site. The customer (generator) is therefore interested in determining cost factors of product removal starting with correct load estimates and precise volume recording per load transported. Generally the generator feels most comfortable with the estimation of vacu-truck loads necessary to remove his material rather than determining product volume by mathematical methods. Preferably vacuum

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3 Application Core Curriculum

Fig. 3.198 Tube–pipe cleaning sequence

box equipment provides a calibration method to inform the observer of contained and accumulated product volume. Hydro-guns with lance extensions and a variety of accessories play a vital part in the agitation process of caked products, thus reducing friction factors throughout the vacuum hose assembly while loading. This equipment also supports the final job area cleanup. Before transportation of any product or waste, the generator must guarantee and certify that no hazardous materials are removed from his property or identify, and classify hazardous-waste for a correct disposal and transportation method. This certification is added to the liquid waste transportation trip ticket, also indicating the necessary vehicle permit number, business name, gallons removed, waste hauler registration number, certified product identification and disposal information indicating the disposal site’s business name, address, state waste hauler permit, etc. These transportation tickets will vary from state to state by law and implication. Operational qualifications are tested in industrial pipe cleaning practices where the variety of products, their adhesion factors, viscosity, tensile strength and hazardous classification (safety procedure) are never the same; this includes pipe interior [, and surface condition, location and design, pipes may vary from 00 to 120 [ plus and therefore demand a wide variety of hydro-tools to successfully fulfill the application criterion. Pressures start at 3,000–45,000 psi, utilizing volumes from 2.5 to 80 gpm. Because of service location and general plant circumstance the manual pipe cleaning practice is more often considered and prevails by applying foot valves or trigger-guns with 00 flex lances to ‘00 –’00 [ highpressure hose assemblies. Nozzles are selected depending upon the individual application. One must consider all flow restrictions and water mass movement through hoses and tools. Semi-or automated equipment is also available, but can be impractical, not cost effective and sometimes is too slow. As mechanical or hydraulically controlled sewer cleaning applications, the manual cleaning of tubes (Fig. 3.198), pipes and sewers will require cleaning techniques, psi–gpm performances and equipment choices categorized into five prevailing application techniques differing in tooling and application process quite drastically to automated processes. When the degree of pipe soiling or the nature of product is inconsistent or its structure and physical tendency is an unknown, for reasons of safety the manual cleaning of pipes and tubes must be performed in a progressive method. Normal pipe or tube cleaning endeavors applying ‘00 hose or flex-lance equipment will exploit nozzles with a 45 jetting angle, providing a good trust to

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465

Fig. 3.199 Jet angle

Fig. 3.200 Poor jet formation, jet energy destruction

Fig. 3.201 Pipe nozzle

Fig. 3.202 High impact nozzle carrier

propel the nozzle-hose assembly (Figs. 3.199, 3.200, 3.201) down line (soft material). Where the deposits are thin and hard, a jet angle choice can be 85 applying a more direct impact to soiled pipe wall but delivering enough thrust to pull hose assembly throughout the equipment serviced. Where the pipe is larger in [ and the deposits are also hard and difficult a nozzle carrier with 45, 60 or 80 water jet angle and exchangeable (Figs. 3.202, 3.204) hard-hitting nozzle design (Bernoulli), permitting gpm–psi variances as application requires is utilized. This permits raising the nozzle cleaning efficiency up to 70% when compared to mechanically drilled orifices (Figs. 3.203). When a pipe cleaning nozzle offers a foreword jet, which is only utilized when cleaning U tube condensers or pipes in a situation where blockage of a pipe is a known, a rigid-lance should never be forced nor should a nozzle-hose assembly be

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3 Application Core Curriculum

Fig. 3.203 Hydraulic force development

Fig. 3.204 Carrier interior view

Fig. 3.205 a UHP hose interior [, before armature restriction [, b various highpressure hose models

allowed to enter at its produced or available velocity. Pressures may develop explosively, creating a hydraulic reaction force with the possibility of blowback and again perhaps grave injury to operators. The diameter or length of 00 , ‘00 or ’00 high pressure hose assembly does not matter; the steel-braiding (Fig. 3.205a, b) under pressure will transmit the slightest movement by a hose-loop. When in a progressive cleaning face (Fig. 3.206) and with a little training a 30 to 40 lube turn will provide nozzle-jet coverage down through all surfaces subjected to jetting procedures.

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467

Fig. 3.206 Progressive cleaning rotation

Fig. 3.207 a, b, c 1981 whirl-jet nozzle, first patent draft hard-brittle scale removal, hydro-vac and drill applications

Fig. 3.208 Various whirl-jet nozzle designs and [

Fig. 3.209 Tube-wall cleaning nozzle

Where products are very hard or stubborn and automated equipment cannot be applied, whirl jets (Figs. 3.207, 3.208, 3.209) perform a milling process upon hardened-brittle material encountered and has literally eliminated most predominant applications where the forward facing jet designs, mounted on a rigid-lance once ruled (tremendous physical effort). There always will be specialized applications where these nozzles are a must but are most likely supported or utilized by an automated static or rotating mechanized apparatus (Figs. 3.210, 3.211).

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3 Application Core Curriculum

Fig. 3.210 Rotating, forward cutting mechanized milling nozzle

Fig. 3.211 a Lance-nozzle fixture, b nozzle top view, c nozzle cross section

Pipelines of various size and purpose may require internal cleaning, hydrostatic test-weld testing, and often due to corrosion problematic an exterior coating removal and profiling procedure to facilitate a new installation. Today’s hydrovac-UHP trigger-gun assemblies applying only water or a variety of abrasives are well suited for this application, especially when required in remote locations where water intrusion to surrounding soil or area cannot be permitted. The cleaning of large pipe [ is a straightforward proposition requiring minimum 150 hp pump drive input, large cylindrical nozzle carriers at times utilizing a nozzle centralizer. Cleaning may also be a precursor to hydrostatic test procedures. Cutting pipelines in volatile industrial areas is an expertise most often supported by the equipment manufacturer, as it is mostly also performed by service providers specialized in the oil refining industry. To be on site accompanied by a renowned cleaning–maintenance company within an emergency scenario is naturally of an advantage (Fig. 3.212).

3.19

Sewers, Laterals, Culverts, Sumps, Industrial Pipe Cleaning

469 GEAR - LIST

Customer & Company:

Date: Address:

Web site: e-mail:

Nr.

Job Nr.:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail

Tel: e-mail

Tel: e-mail

Tel: e-mail

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Pipeline cleaning: cleaning of oil and gas pipelines, Pigging products and Services Association, http://www.ppsa-online.com

Hydro-blast equipment:

North American Association of Pipeline Inspectors, http://www.NAAPI.com

National Association of Sewer Service companies, NASSCO, http://www.nassco.org Equipment: The cleaning of sanitary sewer line, http://www.Irwu.com

Product encountered: Hazardous material:

Fig.3.212 various pipe-sewer nozzle carriers

MSDS:

Specify: b.

c.

Describe application and work procedure: Describe safety procedure: Itemize equipment, safety gear, expendables, etc.: Fig. 3.207 b. c. 1981 whirl-jet nozzle, first patent draft hard-brittle scale removal, Hydro-vac and drill applications

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3 Application Core Curriculum

GEAR - LIST AUTHORIZATION Sewers, culverts, sumps, laterals, industrial pipe cleaning, pipeline cleaning and cutting Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Chemical pant: Machine shops: Factories: Commercial buildings-area: Area: Production pipe: Culverts: Laterals: Sink basin: Manhole: Pipe size: ∅

Profile:

Residential buildings-area: Theme park: Industrial laundry: Other: Grease traps: Septic tank: Oil skimming vessel: Storm drain: Other: Length:

Hazardous product: General sewage: Raw sewage: Root growth: Structural damage:

Manhole distance: Chemical product: specify Production related product: Other: Nozzle: Cracks: Defective gaskets:

Overall feet:

Incline-grade°:

specify: specify:

gpm-psi

Other: Equipment: Hydro-blast unit: Plunger piston changer: gpm-psi Skip jack nozzle: Sewer cleaning nozzle: gpm-psi Self-propelled root cutter: Hydraulic hose reel: Wet-dry hydro-vac unit: Vacu-box: Vacu truck: Describe application and work procedure:

Sewer pipe inspector: Remote control camera: CCTV: Electronic pipe locator: Air compressor: Air blower accessories: Rubber bladder: specify ∅ HP hose roller-guide: Tiger-tail: Traffic barricades: Other:

Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

3.20 Steam–Vapor–Gas Flue Stacks, Industrial Elevator Shafts, Laundry–Garbage Chute Cleaning and Sanitizing Flue gases are produced when coal, oil, natural gas, wood or any other fuel is combusted in an industrial furnace. This includes power plants steam generating boilers, air pollution control systems (FGD) flu-gas desulphurization equipment

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Steam–Vapor–Gas Flue Stacks, Industrial Elevator

471

Fig. 3.213 Stack and precipitator

Fig. 3.214 Stack, smelter

Fig. 3.215 Steam generator cooling tower

and its stack, turbine silencers-stacks, and any other large combustion device including flare exhaust units protecting plant hardware. Periodically all are in need of cleaning services deserving equipment-tool specialization and labor force education. Service frequency depends on time and stacks vapor–gas flow rate ft3/s or m3/s volume processed and interiors general corrosive conditions. Stacks are large vertical circular concrete, brick or steel pipe structures (or combination of all) with access from bottom within and/or exterior by ladder or helicopter (Figs. 3.213, 3.214, 3.215). The configuration and bid information provides specifications on stacks external–internal shell and inner external–internal flue structure and dos not necessarily provide information on variations of a stacks cross-section [. Stack height can be from a modest 600 to over 14000 plus yes, feet, therefore when extreme heights are encountered (2000 ) hose runs must be calculated and weight accumulations distributed. Stack-flue plate, flue inlet, false

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3 Application Core Curriculum

Fig. 3.216 a, b 2D nozzle, 14000 psi

Fig. 3.217 2D nozzle carrier extension

bottom and drains must be identified as to their condition, or as inspection guidelines will classify service requirement. Roof and top cone conditions, expansion joints and seals, lateral supports, or ladders, platform, grounding cable, aircraft and electrical lighting are all part of a stacks inspection checklist and record which service providers must obtain to inform him as to the overall condition before a units assessment can commence (Fig. 3.216). A stack cleaning procedure can also be considered a pipe-combination-tank cleaning application. A tank-cleaning nozzle, possibly designed to incorporate lance extensions (Fig. 3.217) which reduces the nozzle’s standoff distances to stack’s internal surfaces resolves this cleaning necessity quickly. Lowering in increments the rotating nozzle from the top configuration of stacks center hosecable guide permits a streak-less surface cleaning and appearance achievable only with a 3D tankcleaning nozzle producing time effective cleaning solutions otherwise not possible. By calculating excessive distances and heights which is a predominant application criterion common to these industrial units, a contractor may find that this application demands more rigging time than the cleaning procedure itself. A ’00 to 100 high-pressure supply hose is sometimes necessary to prevent excessive friction losses and pressure drops requiring added hp availability. When physical circumstances demand a top entrance, the 100 highpressure hose must be strung and affixed to the tower ending with ample slack to accommodate the length of flue from the platform space with its cable-reel unit. A ‘00 to ’00 high-pressure hose of total stack length is then affixed and receives the tank-cleaning nozzle on its end. If not already situated, a center-mounted roller bearing assembly retaining and a profile large enough to bed the ’00 high-pressure

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Steam–Vapor–Gas Flue Stacks, Industrial Elevator

473

Fig. 3.218 Stack rigging

hose circumference and its fittings must be established. A 00 steel cable is affixed to the center of the stack’s circumference. An automated cable reel assembly also often permanently installed to the platform is utilized to lower the tank-cleaning nozzle down to the bottom of the unit (Fig. 3.218). Smooth surface variety hose clamps are sufficient to affix the high-pressure hose to the 00 steel cable as the nozzle is lowered into the stack, distributing accumulative hose weight effectively. When retracting the nozzle hose assembly clamps are removed before reaching the cable drum in rotation. A bottom entrance in larger units to the inner flue may well be possible to permit a significant shorter high-pressure hose run and an altogether simpler application practice. The available tank-cleaning nozzle must feature a utility hook or eye with a sturdy, preferably watertight load-bearing fixture to permit the accumulative high-pressure hose weights to be exerted upon the tank-cleaning nozzle. If there is an excessive scale buildup allowing the possibility of product collapse into the stack’s bottom, the cleaning procedures are best started on top of the unit to prevent nozzle damage by falling debris. Furthermore, the operator ensures the centering of the hose in the bottom of the unit to reduce possible loads to the high-pressure hose, nozzle and cable reel assembly by falling debris. A tankcleaning nozzle functioning only in one circular plane will cut smaller product pieces when slowly lowered therefore reducing the danger of large slab-like objects falling onto the high-pressure hose assembly. Under these circumstances, one might contemplate introducing the nozzle through the top of the stack to eliminate possible product collapse altogether. Ensure that the probably debris hidden bottom stack drain is in open position and features an adequate filter of some sort to separate the water from the debris (such as a rock-filled burlap sack). Stack’s interior acid resistant brick and grout structure is subject to damage when pressures above 6,000 psi are introduced. The higher water volume applied (mass) combined with long-distance nozzle-jet technology to breach stacks interior diameter [ requires a gpm–psi configuration set specifically adjusted to each

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3 Application Core Curriculum

Fig. 3.219 3D nozzle

Fig. 3.220 High-gpm 3D nozzle

individual job criteria. A one size fits all gpm–psi setting does not exist due to variance in scale deposits, tensile strength and adhesion factors and the interior distances [, from center of a stack to be serviced. Under most circumstances this application will not demand more than 5,500 psi. Higher water volumes are essential to accommodate the nozzle standoff distance (according to the tankcleaning nozzle employed). The cleaning process is completed in a one-step, onedirection procedure. Repeat practices are unwise and only necessary when the system’s pressure volume configuration does not match the jet’s rotation and necessary nozzle standoff distance to the stack’s internal surface. When considering heights and distances involved, excellent communication between the pump operator and labor force is essential as is fall protection and the use and wearing of top entrance harnesses lanyard security and utilization of safety language instructions, this is not an application suitable for skirmish individuals. Never enter the stack interior while the cleaning equipment is in suspension or operation. Confined space entry permits, lockout–take-out procedures of all equipment connected to stack must be performed establishing safe conditions. HINT. In operation, tank-cleaning nozzles (Figs. 3.219, 3.220) are often not adequately balanced consequential creating a whipping motion. It is therefore wise

3.20

Steam–Vapor–Gas Flue Stacks, Industrial Elevator

475

GEAR - LIST AUTHORIZATION Smoke stacks, laundry shafts and garbage chutes Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: High-rise building: Power plant: Chemical plant: Refineries:

Commercial ship: Naval ship: Hospital: Other:

Flame stack: Smoke stack: Ventilation pipe stack:

Garbage chute: Laundry shaft: Other:

Stack I.D.∅:

Top ∅:

Center ∅:

Bottom ∅:

Chute I.D.∅:

Top ∅:

Center ∅:

Bottom ∅:

Pipe

Top ∅:

Center ∅:

Bottom ∅:

Brick:

Steel:

Plastic:

I.D.∅:

Concrete:

Stack platform: Stack ladder: Adequate accessibility: Adequate drainage: Cable reel: Equipment: H.P. hose: specify length Tank cleaning nozzle - controlling line: Lance extensions: Center-mounted roller assembly: Electric winch: Hose clamps: Steel cable: (for correct weight of unit)

Hazardous materials: Scale product buildup: Specify thickness: Other:

Communication radio: Chemicals: specify Disinfectants: Deodorizers: Drainage trough: Safety gear: Other:

Describe application and work procedure: Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

to affix a controlling line to offset this motion to allow sufficient time to depressurize the system (resulting from uneven, worn or contaminated nozzles). Consider various vertical pipe-cleaning applications when servicing garbage and laundry disposal shafts found in high-rises; generally these shafts are 2 ‘0 to 3 ‘0 [ or square. Above the 5th to 7th floors a 1 ‘0 to 2 ‘0 -pipe diameter reduction is found. Household, office and hotel debris are known to create an

476 GEAR - LIST

3 Application Core Curriculum Nr.

Customer & Company:

Date: Address:

Web site: e-mail:

City: State:

Job Nr.: P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Plant hardware:

Hydro-blast equipment:

Equipment: Fig. 3.222 open box receiver Specifications for steel stacks ASME-ST-1 2000

Fig. 3.221 funnel receiver

Fig. 3.223 3 D nozzle centralizer

Product Encountered: Hazardous Material:

MSDS:

Specify:

Describe application and work procedure: Various waste stream recovery equipment: Describe safety procedure: Itemize equipment, safety gear, expendables, etc.: Fig. 3.224 pipe cleaning and instantaneous refuse collection

odorous scale which must be periodically removed. In this process the shafts are also chemically sanitized and deodorized. Smooth, straight and easy-to-reach surfaces promise a successful application process. Hydro-blast units with a large volume capability provide the power to operate a nozzle carrier with six fan tips that are able to completely cover the circumference

3.21

Stationary–Portable Industrial–Commercial Equipment, Vehicle Fleets

477

of the shaft. The nozzle hose assembly is pulled by rope from the bottom up throughout the pipe’s interior. Contractors with smaller mobile units can either pull a custom flex-lance with a standard nozzle, 6 orifices 9 ([ gpm?) throughout shaft or clean in increments, depending on the available hose length, from garbage and laundry receiving doors (Figs. 3.221, 3.222, 3.223, 3.224). Disinfectants and deodorizers are metered constantly. Water may be collected in a trough which permits the high-pressure hose or flex-lance to move through its center into the shaft interior. 1,000 psi is generally sufficient in this application and should never exceed 3,000 psi.

3.21 Stationary–Portable Industrial–Commercial Equipment, Vehicle Fleets, Rail–Car, Truck–Trailer–Tanker Mechanical equipment of any type, which is stored, maintained or operated on open permeable ground should be under scrutiny as to the possibility of oil–grease release creating an ecological endangerment by its petroleum based products essential to its function (Fig. 3.225). In general, producing a known or unknown ground water contamination is in either case regarded illegal when resulting from a process or operation involving oil–grease based content of more then 100th mg per liter water (1 USgal–3.79 L). Protecting the present water conveyance system from accidental release or sloppy maintenance procedures and/or the leaching from contaminated surfaces to the soil of petroleum pollutants is today inexcusable due the general and prevailing education by EPA and various governmental identities as to the inadvertent access of these pollutants to aquifer, rivers and/or lakes. EPA toxic priority pollutants are benzene, cadmium, chromium, toluene, ethylene chloride, mercury, lead, zinc, and copper, to name a few. The pollutants list includes detergents, floatable debris and water turbidity, visible oil and grease sheen, and important to realize, emulsified oils and grease. A contractor must be careful when choosing his cleaning environment, or better location of activity especially in areas where repetitive equipment and vehicle washing operations were a prior sustained activity. Owners of facilities and contractors alike should be aware of the tremendous liability associated with cumulative development in soil conditions (Fig. 3.226). A prior and existing soil contamination at hand does not exempt a service provider. The continued cleaning in one area will result in the buildup of low level contamination to dangerous levels over a period of time and can become obvious due to the introduction of emulsifiers, oil-sheen visually identifiable on surface water runoff or water ground saturation by rain storms, distinctive odor, missing plant life, etc. When considering extended or repetitive cleaning endeavors and/or wash-water cycles within a previous vulnerable location, a savvy contractor guards against possible liability in an unforeseen circumstance by registering and obtaining soil samples prior to any equipment installation or work cycle. The wash water discharge to ground, storm drain or

478

3 Application Core Curriculum

Fig. 3.225 Oil exploration derrick

Fig. 3.226 Railcar storage line

septic system is a practice of the past. It is the utilization of oil–water separation equipment, minimizing the necessary wash water volume and its contaminant levels combined with a wash water recycling capability which permits servicing on–off road equipment or vehicles and the application of a non-toxic-hazardous environmental degreaser derived from naturally occurring bacteria resulting in colloidal dispersion to biodegradability (enzyme free). This is especially important when cleaning needs on equipment occur which naturally are situated within a sensitive environment subject to scrutiny such as for instance, oil–gas well drilling platforms, their operational support and storage facilities, railcar services on various open track or maintenance areas, or asphalt mixing and paving equipment and/or asphalt breaking equipment, etc. Mobile wash water recovery–recycling equipment and prefab catch basins (Fig. 3.227) including tarp procedures must be of a durable design and provide an installation–removal simplicity minimizing time requirements supporting a contractor in his desire to offer a quick and competitive application. Railcars can be found nationwide throughout rural areas and are the only vehicular type which will not move over or across a contractor’s tarp containment which is typically installed underneath and alongside the railcars track (Fig. 3.228). This advantage eliminates the problematic of puncture by weight and sharp edged gravel substrate.

3.21

Stationary–Portable Industrial–Commercial Equipment, Vehicle Fleets

Fig. 3.227 a Prep for coating procedure, b roof access, c prefab wastewater catch basin

Fig. 3.228 Tarp containment, wastewater recovery

479

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The modern locomotive and railcar manufacturing industry has changed its coating technology similar to the automotive and trucking industries. Coating choices are determined by rail car builder, and repair shops, the railroad company itself and private companies identifying their goods and services sometimes choosing a sophisticated coating system. Possibly enhancing their image it is this coating specification, which will dictate gpm–psi, water temperature and chemistry utilized within a wash-down procedure. All railcar coatings can be described as heavy duty, but grime-soiling adhesion to surface interface or resistance to psi–gpm configuration and sensitivity to detergents or chemistry must be evaluated on an individual railcar or unit basis (same identity). On a lesser coating performance product line, the transition from solvent borne to water borne coating for the exterior of railcars is an environmentally friendly decision in reducing or providing a low VOC content. Another type of new technology is the direct to metal (DTM) low VOC exterior coating systems, which can also be designed for chemical splash and spill resistance requirement, a necessity for tank-rail car units. And a third alternative formulation is a exterior epoxy-urethane coating system designed for railcars providing significantly longer product endurance for the typical harsh railcar environment and can provide or incorporate clear-coat technology. In general, the smoother a rail cars coating surface, the easier and least costly a cleaning procedure due to lesser chemical, filtration–disposal cost and possibly lesser psi–gpm performances, multiplying by two the square footage performance. Easy to clean epoxy-urethane systems are frequently encountered. Evaluating these cars for cleaning times and chemistry depends largely on units’ age, and the contaminants penetration into the top surface layer of a coating which includes the possible remnant removal of prior cleaning endeavors and/or statically adhering particulate. Sophisticated types of interior linings are developed for railcars displacing high back phenolic by lower VOC two-part epoxy products tending towards high-end 100% solids formulation for interior tank linings and covered hopper cars. Operators of railcars carrying food and chemicals have increasingly selected high solid products to protect cargo from contamination. Cleaning these cars is considered a tank cleaning application performed most often in maintenance yards or directly in product manufactures location prior to loading, avoiding confined space entry and its regulations. Covered hoppers, open top hoppers, gondolas, equipment box or flat cars, refrigerated or plain box cars are generally serviced on elevated maintenance tracks providing sufficient access for the mobile pressure washing recovery and filtration equipment which must include ground-roadway stability for water tank truck and aerial lifts providing railcar roof access. The amount of cars to be washed can be from a few to many, which considers a unit of between 60 and 150 cars of any design from gondola to box-cars. The logistics to deliver necessary detergents-degreaser and blast-water is part the bid proposal (Fig. 3.229), of which requires a careful assessment as to wastewater capture recycling and/or the correct removal to a disposal site. Most cars are cleaned in a two-step process adhering to rail car owners’ specification as to the detergent type, dwell time requirement,

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481

Fig. 3.229 Oil–greasy removal before coating

neutralization and possible rinse procedure established prior to the bidding process. When scheduling extensive railcar units (60 plus), down times due to equipment failure or needs, labor exchange, movement of wash water containment equipment and tarp procedures and the correct wash water disposal methods are a part of the general services function. Unplanned deviations, holdups, tardiness etc. cannot be permitted within a job criterion of such magnitude. The time constraints result from estimating precisely necessary cleaning times per car multiplied by 10, resulting in a equipment necessity of two minimum 18 hp hot water pressure-washers utilizing 3=800 hose preferably following a detergent applicator down the line. The supportive prerequisite of moving wastewater and containment including operating aerial lifts for roof washing and its procedure must stay ahead of the washing–cleaning process cycle. All supportive requirements must never stop or delay the systematic water jetting procedure from bottom up and down, which will also require the crew to correctly manipulate containment from behind (cleaned cars) to cars not yet serviced. Safety meeting and daily tailgate meetings, safety procedures as to making sure that railcars are not moved or engines appear unannounced for this purpose, providing adequate rain gear, signage and flagging in all important locations is a must and will vary with job location. More often, it is the large bulky and unusual equipment, which are in need of special attention and services (Fig. 3.230). Size, their location and sometimes purpose can require an imaginative application curriculum to provide environmentally correct cleaning procedures which most often will result in an opportunity for equipment specialization. Fleet washing presents such a specialization curriculum, nowadays only possible and advisable when water filtration and recycling procedures are introduced to a customer’s jobsite. There are various opportunities and technical methods available greatly enhancing a potential income through application efficiency in which a fleet can be washed. Ground permeability is the principal deterrent to any washing operation. Removing petroleum based bulk grease, fats and oils from obvious vehicle areas is a simple application criterion where high-pressure hot-water velocity is indispensable (Fig. 3.231). Finding a one size fits all road film removal technique can instead be frustrating. Herein lie’s the problem. The complexity of soils due to

482

Fig. 3.230 a, b, c Specialty heavy transporter

Fig. 3.231 a, b, c, d Various track chassis

3 Application Core Curriculum

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Stationary–Portable Industrial–Commercial Equipment, Vehicle Fleets

483

their varying affinity to oil or water adhering to a variety of surfaces can be surprising. If a soil shows water-solubility the process to clean with high-pressure water is successful in bulk removal and to the extent that only ionic and/or statically charged film-particles adhering to a coated surface are removed in a jettingcombined physical procedure (brush). Within this scenario the detergent-acid application is minimized. Soils containing fatty–oily residual require a cleaning method producing water solubility. Therefore removing road film can only be achieved in combining water velocity with a chemical reaction by changing oily soil molecules into a water soluble road film to sever its bond to the coating surface interface. This is also where hot water equipment is of an advantage activating detergents with a low or high pH. Phosphate, silicates, citrates and polymers are examples of chemistry which will bond to soil particulate rather than to a coating surface. This supports applied water velocity to break particulate bond to the coating interface surface. This is quite a simplistic analysis and must be delicately manipulated according to fleet’s circumstance, its vehicle and coating design and purpose. Cleaning a tractor–trailer fleet will be quite site specific when general road film and diesel stack-exhaust deposits (carbon), or grease accumulation on the running gear must be removed and/or a product oriented cleaning endeavor subject to a trucks utilization is required. The chemical supplier, promising, a one size fits all product must be met with suspicion. Dump trucks, box trucks, and aluminum or stainless steel tankers, etc. always vary in their applicable chemistry. Detergents for cleaning heavy duty tractor trailers, to aluminum brighteners, heavy-duty engine and tire degreasers which may include a brake dust and carbondiesel soot deposit removal formulation, and/or applying polymeric hot or cooled mix release agents to cleaned vulnerable truck surfaces facilitating asphalt tarpitch release etc. can be a job description specific to a customer which does not deserve a chemists generalization (Fig. 3.232). The correct utilization of a reclaim detergent designed specifically to support water–oil separation and filtration units’ technical aspect can also cloud a perception of functionality due to its naturally low foaming formulation. Also the equipment to apply the necessary chemistry must be considered which is important to provide sufficient dwell times in consideration of their necessary rinse cycles concerning overall truck–trailer cleaning efficiency. Services sales endeavors are most likely only successful due to a potential customer’s past inconsistent and unreliable fleet washing experiences. Fleet managers are usually very loyal to an existing service provider. They generally recognize the problems a mobile fleet washing company encounters. Inexperience, resulting in incorrectly identifying a fleets design and cleaning criteria can also be the downfall of a novice service provider, especially when combined with a customer’s possible wishful thinking concerning today’s simultaneous wash-water recovery–recycle procedures, and their possible disposal and price implications. The service provider must also clarify within his proposal as to the extent of detail performance his services will include. Are windows to be washed and dried and to which degree engine compartments must be detailed, etc. (Figs. 3.233, 3.234, 3.235, 3.236)

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Fig. 3.232 a, b, c, d Various and varying truck chassis

Fig. 3.233 Wash water recycling

Fig. 3.234 Truck washing

Commercial fleet owners may require detailing services consisting of interior shampooing, cleaning of floor mats and windows, which at best is a tedious and impractical application criteria when it must be considered in fleet washing proposal procedures. The interior detailing criteria is generally not a part of an exterior fleet washing operation. Exterior detailing includes buffing and polishing

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Stationary–Portable Industrial–Commercial Equipment, Vehicle Fleets

485

Fig. 3.235 a, b Proposal to fleet management

Fig. 3.236 Washing operations, 8 min per truck– trailer unit

painted surfaces, polishing all of the aluminum including bumpers etc., preparing windows and mirrors, which again is an application not often successfully combined with a high intensity pressure washing operation successfully cleaning a tractor–trailer unit within 8–10 min (correct equipment set up). Some contractors do operate an independent crew for detailing requirements, which can follow exterior wash operations. Due to vehicle variety and variable conditions, a proposal for interior and/or exterior detailing services is best established independently from fleet washing operations. Maintenance requirements, fleet scheduling, tractor–trailer access to wash area, educating drivers as to parking requirements and correct spacing on non-permeable parking surfaces, centralized wash water recycling and vacuum shoe recovery position (Fig. 3.237), isolating possible ditchstorm drain and truck delivery-dock drain systems, etc. and providing electricity or light access for possible night work are a general job description which must be integrated to the bid procedure. Any unforeseen deviations will result in tremendous time losses quickly becoming a big business problematic with unhappy consequences. Most tractor–trailer fleet operations are time cognizant with varying

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Fig. 3.237 Vacuum shoe, bladder berm

degrees of emergency procedures requiring a service provider to accommodate job flexibility. Within a proposal procedure these possibly varying degrees of emergencies, arrival and departure times must be addressed to facilitate operational harmony. Vehicles are identified by vehicle number which is best combined with the license plate number, alleviating possible confusion when record-keeping. Trucks are likely to be cleaned twice monthly, including offering an emergency cleaning standard of one or two units per pay period. Fine tuning operations and equipment should be a quarterly-seasonal endeavor, which is also specified within a negotiated contract. Due to changing variety of temperature or seasonal influences, creating varying diverse layers of road film, dirt, ice, carbon and salt deposits, including insect accumulations on radiators, vehicle hood and window surfaces, etc. must be a criterion carefully dissected within a contract negotiation. These factors will also affect the efficiency of detergents, as does the hot water temperature requirement up to or between 140 and 160F. The distance between parked trailers must accommodate the length of the high pressure wand and its angulations between trailers. When distance is too close (\70 ) it will severely hinder washing procedures, resulting in time losses and annoyed wand operators. There are various ways of recovering wastewater simplified when non permeable asphalt or concrete surfaces are designated for washing operations. To assist this can require a permanent water dike constructed in a strategic water runoff area by inexpensively placed road asphalt creating a dike effect permitting a vacuum shoe fixture to its lowest elevation. For drive-through operations a wash pad mobile catch basin, for wash water recovery from trailers and containers a mobile catch basin attached to or placed underneath the rear trailer area allowing a practical application solution. This type of wash water control is very effective, especially when cleaning farm, off-road machinery, construction equipment and railcars, etc. Water filled storm sewer wrap-cover and portable dike systems of various lengths, facilitating custom designed water run-off control on non permeable concrete or asphalt surface designated for cleaning operations with a vacuum shoe placed in its lowest elevation, or the utilization of a vacuum boom which are also applied in parking areas, gas stations, bank and restaurant drive-thru cleaning applications. Services applying a closed-loop wash water recovery system can consider tractor, tractor– trailer the standard revenue initiator which is adjusted upwards when washing cement trucks, garbage and equipment trucks and attains its top revenue potential

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GEAR - LIST AUTHORIZATION Stationary-portable, commercial equipment, vehicle fleets, rail-car, exterior truck-trailer-tanker Customer & Company:

Date: Address:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Job Nr.:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

Job Review Performed by: Tractor: Sleeper: Trailer: Tanker: Container: Railcar: Unit: Tanker, hopper, gondola : Other: Business-medium duty truck: Light-truck: Type: Equipment: Equipment location: Other:

Nr.: Permeable grounds: Non-permeable grounds: Sump-pump: Wash pad:

Asphalt: Concrete: Explain:

Portable wash pad: Portable wastewater containment system: Portable sewer cover: Portable water dike system: Length in feet: 50 gallon vacuum separator-transfer barrel: Vacuum box: Other:

Equipment: Chemicals: Specify: MSDS: Two-step method: Metering method: upstream-downstream Foam nozzle-injector: Hot water: Cold water: Water recovery: Closed-loop reclaim process: Vacuum hose: (Feet) Vacuum shoe: Other: Type of soiling-contamination: Product hardness, adhesion, viscosity: Fouling characteristics:

Nozzles: 15°, 25°, 45°, 65° High-pressure trigger gun: High-pressure trigger gun: duel wand: Wand-lances: Extension: 5’, 6’, 8’ High-pressure hose: ¼”, ”, ½”, Rotary jet: Soft bristle brush: Extension: 6’, 8’’ Box rags: Flashlight: Other: Specify: Specify:

Physical surroundings, safety procedures: Specify: Describe application and work procedure: Itemize further equipment, safety gear, expendables, labor and equipment times, etc.

Others:

©

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when servicing oil and gas tankers at approx. $45.- and/or individually priced specialty transporters at time and cost. Environmentally washing and specializing in pressure washing and hydro-blast application technologies offers many business opportunities in commercial and industrial environments.

3.22 Tanks, Vessels-Autoclaves, Precipitators, Container Cleaning, Volatile Substance Removal and Effluent Separation In the early 1920s, cleaning applications for tanks and vessels applying centrifugal water pump pressure brought about the development of rotary 2D and 3D nozzles utilized to clean, and/or material slurry achieving a product thinning or agitation process. Companies such as Butterworth, Sugino, Lechler and various European manufacturing identities were actively involved in a design criterion facilitating performances between 15 and 350 gpm at pressures of up to 250 psi. The jetting medium can be hot and cold water admixed with detergents or liquid petroleum product developing a jet stand off distance up to 900 . Especially in foodstuff, pharmaceutical and maritime industries (tanks-barges), has this development drastically reduced man entry to vessels. In 1967, with the development of hydro-blast equipment operating above 5,000 psi to 10,000 psi delivering up to 75 gpm, WOMA designed and patented various 2D and 3D nozzle configurations (Fig. 3.238) operating within this performance criteria which included a 3D dual head assembly with four jetting orifices (Figs. 3.239, 3.240).

Fig. 3.238 Twin rotor jetting 3D nozzle

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Tanks, Vessels-Autoclaves, Precipitators

489

Fig. 3.239 Twin rotor jetting 3D nozzle patent abstract

Fig. 3.240 Twin rotor 3D nozzle partial view

Today a contractor can classify cleaning techniques for tanks and vessels into three categories. The dedicated cleaning systems are permanently installed to interior of vessels and tanks. A wide variety of cleaning heads are available, where the simplest is a spray ball, either fixed or rotating powered by the pressurized water or liquid passing through its jetting offices. Pressures range from 40 to 500 psi with wide ranging gpm performances necessary for softer deposits found in foodstuff and pharmaceutical industries achieving product agitation or cleaning procedures. The water-pressure source is often generated by a centrifugal pump

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3 Application Core Curriculum

Fig. 3.241 Telescope fixture

Fig. 3.242 Hose-reel nozzle descend

(multi-stage) capable of developing up to 500 psi and gpm performances pending on horsepower-input (Figs. 3.241, 3.242). Dedicated cleaning systems for process vessels in chemical industries are often utilized for closed reaction processes where V.O.C. and other emissions must be fully contained. Typically cleaning pressures range from 3 to 8,000 psi powering self-propelled, 2D or 3D nozzle stored in a gas neutral chamber above a process and lowered in increments by hose reel, telescope fixture or hydraulics at predetermined cleaning cycles either computer or manually controlled. Due to the nature of a manufacturing process these systems are normally operated on a daily or weekly basis. Besides, today mass produced beer barrel and soft drink container cleaning systems are another example of a dedicated cleaning heads, which are system as is equipment designed to demilitarize warheads-bombs and solid rocket fuel shells and/or motors. This stationary equipment operates between 8 and 12,000 psi at comparatively low water volumes. Rotating shell and/or cutting nozzle-lance assemblies to

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Tanks, Vessels-Autoclaves, Precipitators

491

Fig. 3.243 Incremental adjustment

remove propellant from the interior of shells and bombs directly delivering irregular refuse debris and jetting water to a macerating unit which can be either a mechanical process or a whirl-jet chamber preparing the arriving refuse for the water recovery–recycling and filtration function attaining a product separation into the basic constituents, which are probably highly classified (Fig. 3.243). All due to their portability, rotary head cleaning systems are the most popular with contractors providing the important application flexibility throughout the commercial–industrial environment. Tank entry can often be avoided, especially with process equipment, autoclaves-reaction vessels, mist eliminators, precipitators, stacks, etc. The successful application of these rotary heads and their adjustable installation equipment depend on correct nozzle placement and path within a vessel. Position the 3D tank-cleaning nozzle at the center of the vessel approximately  of the distance from the top to the bottom. Adjustable nozzle armature permits the offsetting to the directly overhead shadow area in increments of the nozzle’s half circumference as can the depth to the bottom of unit be adjusted as the cleaning procedure progresses (Fig. 3.244). Generally residual film of a liquid grows thicker to the bottom of a tank where the washing or product cutting effects must be the most pronounced, which include the areas of farthest corner’s, vessels liquid inlet and structural discharge orifices which are often obstructed by prematurely hardened-viscous liquid product. The distance and starting point of a nozzle should be approximately one quarter of the jets effective cleaning–cutting radius. Standing liquids and residual resulting from a plugged or closed discharge valve will dramatically diminish liquid jet power

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Fig. 3.244 Telescope adjustment

Fig. 3.245 Static affixed 3D nozzle

and cutting capacity. The hydro-vac system directly connected to a discharge flange will greatly enhance product movement and further macerate the dislodged debris when stirring through the jet pump’s concentrated liquid ring piston. This is only possible when the vessel is open to the atmosphere. The longest standoff distances and strongest product hardness, tensile strength and adhesion will most often appear in the bottom corners and coldest or lowest velocity areas of any interior vessel (Figs. 3.245, 3.246, 3.247). The effective jetting performances must be calibrated to these areas by manipulating nozzle’s standoff distance, psi–gpm performance and most importantly, utilizing interior cone-shaped nozzle designs facilitating a tight water-jet formation (Bernoulli). Tank trucks and rail tankers (Figs. 3.248, 3.249) can be of interest to a contractor due to a wide variety of products shipped. Adhering product residue must be removed when an alternative liquid cannot be contaminated by remaining

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Fig. 3.246 Telescope nozzle arm

Fig. 3.247 3D hydro-blast nozzle

Fig. 3.248 Rail-tanker 3D scissor arm, travel adjustment

residue of a prior load. Various nozzle fixtures are available to accommodate the mounting to a tank flange. Nowadays it is not a question that high-pressure water is capable of removing urea calcifications, etc. The question must first be as to the structural integrity and the tanks base material, its thickness and type. Nozzles can operate up to 24,000 psi (plus) and must be adjusted to avoid damage to a tankers skin, lining or coating. Encountered products tensile strength and adhesion to surfaces, elasticity, viscosity and varying brittleness within fluctuating high heat manufacturing processes and the variety of process equipment, their age, design, efficiency and failure rate, interior varying surface sensitivities such as for instance interior

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glass-lined autoclaves are the guidelines as to determine a correct psi–gpm performance criteria, resulting in the choice of the most effective nozzle apparatus for the individual technical circumstance encountered. Performance generalizations as to a typical removal criterion of natural or chemical processes deposits will always lead to an unreliable estimation. The relationship between applicable psi and gpm ratios toward a specific product removal criterion will always change within a process requirement (Fig. 3.250) or its failure and its varying surface interface structure, ambient temperature and encountered process equipment’s physical and/ or hardware design features. On this note, guidelines can be established and are derived from experience: Asphalt–bituminous splatter at temperatures between 45 and 70 on concrete-steel surf. Alkyd resins at temperatures between 45 and 70 Concrete cutting, abrasive assist at temperatures between 45 and 70 Concrete residual at temperature between 45 and 70 Coke product accumulation (refineries) at temperatures between 45 and 70 Crude oils at temperatures between 45 and 70 Butadiene styrene at temperatures between 45 and 70 Calcium-carbonate Epoxy resins at temperatures between 45 and 70 Emulsion polymers at temperatures between 45 and 70 Food processor residual at temperatures between 45 and 70 Fermentation residual at temperatures between 45 and 70 Isocyanate, MDI & TDI at temperatures between 45 and 70 Latex (green state) at temperatures between 45 and 70 Latex synthetic, at temperatures between 45 and 70 Light oils (turbine oil) at temperatures between 45 and 70 Methyl Methacrylate at temperatures between 45 and 70 Phenolic resins at temperatures between 45 and 70 Polycarbonate at temperatures between 45 and 70 Poly vinyl chloride at temperatures between 45 and 70 (PVC) Poly vinyl acetate (PVA) at temperatures between 45 and 70 Paint dried solvent based at temperatures between 45 and 70 Paint epoxy at temperatures between 45 and 70 Paint solvent based at temperatures between 45 and 70 Vinyl emulsion polymers at temperature between 45 and 70

5,000–8,000 psi 8,000–2,000 psi 10,000–4,000 psi 4,000–2,000 psi 12,000–22,000 psi 1,000–3,000 psi 6,000–12,000 psi 5,000–7,000 psi 10,000–14,000 psi 10,000–14,000 psi 3,000–10,000 psi 3,000–10,000 psi 10,000–14,000 psi 3,000–6,000 psi 6,000–14,000 psi 1,000–3,000 psi 6,000–14,000 psi 8,000–14,000 psi 6,000–10,000 psi 4,000–10,000 psi 6,000–10,000 psi 6,000–10,000 psi 10,000 psi to UHP performance 12,000 psi to UHP performance 8,000 psi to UHP performance

In layman terms the psi performance is set to cut a material to the interface adhesion point supported by the gpm performance (water-mass-horsepower-input) offering increased explosive surface area to the high velocity water mass.

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Fig. 3.249 Rail-tanker 3D telescopic travel

Fig. 3.250 Tank cleaning, top entrance

Fig. 3.251 a, b Airpreheater basket

Therefore the necessary indication of psi will never reveal the efficiency of any job description, performance and/or adequacy in surface appearance. This fact becomes very obvious when utilizing mobile 2D or 3D nozzles cleaning distillation trays, cyclone separators and mist eliminator baskets of various designs. The psi performance cuts through the first layers of deposits, facilitating a surface area for the water mass to deeply penetrate throughout an encrusted pack or mesh mist eliminator structure (Fig. 3.251, 3.252) and/or the depth of a fin-fan cooler. Glass-lined pharmaceutical plant vessels (Fig. 3.253) must be handled with care, in that direct pressures to a lining should not exceed 6,000 psi. The pressure produced by nozzle restriction diminishes its impact rapidly when released into the atmosphere. A 6,000 psi pressure gauge reading may diminish to 3,000 psi at a 3-ft nozzle stand-off distance. Glass linings are more susceptible to damage by

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Fig. 3.252 Mist and vane pack structure

Fig. 3.253 Top and side telescope tank access

metal tools dropping accidentally. Nevertheless tank liners must also be protected from imbalanced jetting heads avoiding damage by possible impact. The larger the vessel, the greater will be the flow (gpm) to achieve necessary jetting velocity to remove various caked products. Cooperation of the pharmaceutical and/or chemical plant engineering department is of utmost importance to identify their vessels structural interior design, which can include baffles, props of various sizes, heating elements and intake–discharge fixtures to permit a correct 2D or 3D nozzle navigation. Continuously removing product and sludge can be achieved by applying the hydrovac system. This is made possible by introducing an air intake fixture (isolated or open), to the vessel flange man access providing positive air flow to degas toxic vapors simultaneously within the cleaning and sludge removal process of vessels airborne toxic-volatile organic compounds. Volatile emissions can be controlled removed and separately treated as to plant specifications. Safety must be a never ending concern. A no-entry vessel cleaning procedure must not provoke negligence concerning the possible prior content of a vessel being cleaned. Its trace elements contaminating nozzle assembly can require a decontamination procedure. Customers should never be trusted as to their purging, neutralizing and cleaning endeavors. Hazardous verification, identification and classification of

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products must be a known to the contractor and independently verified facilitating the correct identification of safety procedures, gear and equipment. Qualifying in confined space entry procedures will open a substantial and highly profitable commercial–industrial application opportunity. Commercial and industrial service companies applying pressure washing equipment all too often misjudge this business potential. As to the identification of a confined space, Washington’s is the most concise and says that a confined space is any space having a limited means of egress which is subject to the accumulation of toxic or flammable contaminant or an oxygen deficient atmosphere. Applying highpressure water as a tool with its wide variety of applications, utilizing abrasive blast methods, sludge or product removal by hydro-vac equipment operating injectors as pump identity or employing product separation by a vacuum container and/or pump truck, sewer and pipe cleaning endeavors, coating removal and surface preparation exploiting the UHP method and its manual and automated equipment, or a combination of all will require all applicable safety variations established by the American National Standards Institute (ANSI-Z-117.1-1989) and its bylaws. The National Institute for Occupational Safety and Health (NIOSH), defines a confined space which by design, has limited openings for entry and exit, unfavorable natural ventilation, which could contain or produce dangerous air contaminants, and which are not intended for continuous human occupancy. NIOSH also acknowledges that varying degrees of hazard may exist under different conditions by describing three separate classes of spaces, namely class A, B, and C. For a contractor it is most important to realize that OSHA’s general industry definition for confined space requiring a permit (OSHA-29 CFR 1910.146) does also include regulations for OSHA’s maritime, agricultural, construction definitions and is regulated by a different part of the Code of Federal Regulations (CFR), which are also established for paper mills, telecommunications, chemicals and allied products, primary metals industry, motor freighttransportation, wastewater treatment facilities, etc. and does consider confined space variations in size, shape and function. Within its facets, the mere involvement, and study for confined space entry will produce an application criteria of tremendous variety within the commercial, industrial, marine and agricultural environment. A confined space is not necessarily totally enclosed. An open tank-vessel without a roof structure is also considered a confined space, especially when the job requires agitation or removal of hazardous materials possibly emitting volatile or toxic vapors, the access to this space is limited, and is normally not occupied by people. The cleaning of natural latex product from such an open vessel may stipulate as shown (Figs. 3.254, 3.255, 3.256, 3.257). Another such space, normally not occupied by people are wastewater treatment facilities clarifiers which also require a confined space entry permit (OSHA 20 CFR 1910.146). Wastewater treatment facilities (Fig. 3.258) are prone to hydrogen sulfide enriched atmospheres which must be guarded against and continuously tested for.

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Fig. 3.254 Plant supplied safety cleanup sheet

The contractor operating only one hydro-blast unit to slurry sludge chooses to utilize a sludge pump versus the hydro-vac system. His experience with fly ash (Mt. St. Helens) and admixed city clarifier sludge which proved susceptible to high velocity high pressure water jets emulsifying and causing liquid to free flow at an astonishing effective rate did not justify the mobilization of an additional hydroblast unit nor industrial vacuum truck operation. Two trigger-gun affixed 3=800 –80 T lance assemblies with four slurrifying nozzles were responsible to complete this job in record time. Confined space hazards are: oxygen deficient atmospheres, oxygen enriched atmospheres, ‘‘toxic’’ or irritating atmospheres. Physical hazards are: fixed and portable mechanical equipment sensitive to fogging or water misting, electrically energized conductors, fluids–liquid such as oils diminishing adequate footing, powders and gases, thermal conditions hot or cold creating fog or misting events limiting visual orientation, engulfment by finely divided material, ionizing and non-ionizing radiation, contact with various chemicals and corrosive substances. Mist eliminators in fossil fueled power plants are serviced by hydro-blast jetting technology by cleaning the mesh structure free of lime and calcium accumulations which will also deposit on intake surfaces, undersides of baskets and vessels

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Fig. 3.255 Plant supplied sanitation estimate, confined space entry

bottom including possibly the smokestacks intake surfaces (Figs. 3.259, 3.260, 3.261). If not utilizing suspended automated cleaning equipment while in a plant shutdown mode, the manual cleaning method is still very compatible within the overall job description requiring cleaning the complete vessel from top to bottom. Nozzle rigging times, unequal deposits throughout a basket structure, requiring repetitive cleaning cycles, expense of excessive horsepower input and the operation of basket disc structure are time-consuming, often eliminating the advantages gained by remote basket cleaning operations. Pressures range between 8,000 and 10,000 psi to 26 gpm for basket cleaning which can be reduced to approximately 6,000 to 8,000 psi for vessels interior surface cleaning applications. Bottom accumulated bulk debris is shredded (Fig. 3.262) to fit a hydro-vac vacuum shoe substantially outperforming industrial vacuum truck loading capacities especially when an alternative material disposal sequence is required. The product can be dry loaded utilizing a centrifugal separator, or macerated to be vacuum transferred to a settling or evaporation pond or

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Fig. 3.256 Plant supplied product identification and certification of analysis

directly loaded to an open watertight dump truck delivering the debris-sludge after its simultaneous water recovery function to a landfill. Care must be taken when jetting tank walls and elevated discharge areas. It is important to first determine built up accumulations before a scaffold is put in place. The high-pressure water gun operator must make sure that an inadvertent and uncontrolled release of overhead and overhang products above scaffold will not under any circumstance risk stability of the trigger-gun operators platform. OSHA’s fall protection requirements within a confined space must be adhered to and are identified under OSHA subpart M 1926.500 technicians walking–working with an unprotected side that is 60 or more above lower level must be protected from falling by guard rail, safety net or personal arrest system. Cleaning aboveground storage tanks (Fig. 3.263) can include all exterior– interior surfaces including dome roofs’, or floating roofs seal and drain systems and/or suspended internal deck systems including their components. Heating elements often encountered in the northern hemisphere can be surprisingly complex in an application requirement which demands a full light illumination

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Tanks, Vessels-Autoclaves, Precipitators

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Fig. 3.257 Material safety data sheet

procedure. Product sludge concentrations and bulk adhesion, a product changeover, leak detection requirements, coating repair or a new coating installation can be the itinerary of a required service. Due to today’s accepted UHP coating removal criterion a qualified service provider can encounter a job scenario in that customer requests cleaning a vessel first for inspection and repair, followed by a coating removal in conjunction with an coating installation procedure. Regardless, cleaning comes first requiring a set of safety practices and requirements tightly controlled by plant maintenance, state and federal regulations. When applying high-pressure water or emulsifiers the visibility in tank interiors

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Fig. 3.258 a, b Job description, wastewater treatment facility

Fig. 3.259 Smoke stack intake, before

and within some containment systems on tank exteriors can be very limited. Explosion proof lighting should illuminate an interior vessel totally and not be limited to the blast or product removal area. Limited visibility will not only decrease the ability to produce quality work but also inspections. Needless to say, that with good visibility accident likelihood is also reduced. Once bulk product has been drained and removed the hydro-vac system supported by emulsifying–slurrifying and/or water–detergent jetting techniques will quickly move liquefied waste and sediment to a vacuum boot situated in the vessel’s lowest point. Methodically utilizing squeegees behind a jetting operator permits the visual verification of required cleanliness for the final wash down procedure. Exterior spill prevention within a tank cleaning procedure (Fig. 3.264) is a requirement of utmost importance as is inadvertent litter and contaminant cleanup within empty tanks secondary containment area where equipment storage and its operation is most often performed. This type of pressure washing and hydro-blast application is in itself quite straight forward.

3.22

Tanks, Vessels-Autoclaves, Precipitators

503

Fig. 3.260 Hydro-blasting intake

Fig. 3.261 Smoke stack intake, after

Fig. 3.262 Accumulated bulk debris

Most often a performance reduction or limitation arises due to the complexity of a confined space entry procedure. Safely managing flammable, explosive and toxic atmospheres, including industries physical hazards encountered, always supersede a possible application curriculum as to its efficiency and effectiveness.

504

3 Application Core Curriculum

Fig. 3.263 Fuel–oil tank facility Fig. 3.264 Typical commercial tank farm

An interior toxicity problem or fire and explosion prevention requirement and its curriculum can also engage the exterior concerns due to the proximity of manufacturing hardware providing a possible hazardous emission potential. The wearing of air supplied respiratory protection of continuous flow or demand flow, the bulk of an entry and egress system, somewhat physical restrained by safety and personal protective gear, maintaining a clean face shield while jetting, etc. will slow an otherwise simple cleaning procedure considerably especially when the characteristic of the space is poorly illuminated and its ventilation is inadequate diminishing visual surface orientation by steam or misting. When a cleaning procedure is followed by an interior coating or fiberglass tank lining removal application the following necessary drying and dehumidification procedure may also require the utilization of respirator gear. As a coating is removed and simultaneously a new coating is installed within the drying and dehumidification process the coating will admit its volatile constituents to the interior environment. Cleaning maritime vessels, fresh-water and potable-water tanks, feed water tanks, fuel oil storage and stowage tanks, diesel fuel oil tank, JP-4-JP-5 fuel tanks, barge holding tanks, etc. are tank-cleaning applications most often performed by shipyards and their subcontractors and are of general nature. Taxing are the confined spaces below engine, generator and pump rooms which includes voids below the compressor in auxiliary machine rooms to shaft alley and sewage plant, including the steering gear room bilge voids. The free movement of a lance assembly within these voids can be problematic and is most often frustrating due to operator’s physical confinement. Providing a safe atmosphere, and correctly illuminating voids to facilitate a systematic cleaning procedure and

3.22

Tanks, Vessels-Autoclaves, Precipitators

505

Fig. 3.265 Butterworth, centrifugal pump feed, 3D nozzle design (ca. 1926), still in service today

having available a variety of lance extensions fitted with quick couplers is of the utmost importance. Fan nozzle attachments of varying degree, including a pipe cleaning nozzle assembly with guided straight and 45 light weight flex lance retainer tubes of various lengths are also essential. Within this application criterion a contractor’s relationship with his equipment supplier or suppliers providing this tooling flexibility is of great consequence. This job criterion may also require lance and nozzle manipulation by two operators where a foot valve and trigger-gun operation may be utilized in tandem or individually within a jetting procedure. As a cleaning procedure commences from ship-hull’s elevated area downward through the bilge voids, run-off water and debris must be simultaneously removed utilizing the hydro-vac system. This necessary application procedure will guide the removal of deck plates and gratings from each space which is best decided upon by including the jetting personnel’s experienced opinions. If there are sound dampening tiles installed in bilge areas their protection must be guaranteed. Grates and plates must be tagged as to their correct location and put on hold for reinstallation. Temporary decking in walk and work areas is installed in a manner that injury to vessels personnel resulting from cleaning procedures cannot occur. Mask and cover with moisture repellent material (plastic sheeting) all controllers, electrical components and sensitive machinery. After protecting equipment from possible water intrusion, affix signage to all areas where jetting procedures may produce danger to the unwary. Blank-off all open ends of piping, check and stop oil leaks from machinery into bilge area. The UHP application to remove existing coatings can be supported by a citric acid surface treatment to remove oil–grease remnants and iron oxide (rust). This also requires the correct flushing and passivation of bare steel in its surface drying procedure to prepare for a successful coating application. Prior to this application clean all passageways and ladders, floor boards, etc. of possible oil–grease or overspray preventing re-contamination of cleaned areas. The citric acid treatment is not successful on undetected sound remaining epoxy coatings. In these areas loss of adhesion and delaminating of a new coating is imminent after a citric acid treatment. Regardless, this chemical process is only applicable to surface ships, where chemical surface preparation is authorized. The term bilges describes the portion of an interior hull shell plating, internal support

506

3 Application Core Curriculum

structures, bilge wells and sumps, tank top plating, and boundary bulkhead from keel up to top of existing bilge redline. Included are foundations, longitudinal beams, vertical keel, keel brackets, rider plates, transverse frames, stiffeners, and miscellaneous support structures. Old-school will also identify to tank-cleaning as ‘‘butterworthing’’ (Fig. 3.265). GEAR-LIST

AUTHORIZATION

Tanks, vessels-autoclaves, precipitators, container cleaning, volatile effluent removal Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Monitor environment:

Hydro-blast equipment:

Draeger air-gas sampling: Draeger personal gas monitor: Pressure washing equipment: hot-cold

Heat stress exposure monitor: Radiation survey meter: Emergency planning and rescue review: Emergency shower, eyewash location: Lockout/takeout: Equipment locks: Pipes: Flange cover installation: Valves: Other:

Hydro-vac equipment: Centrifugal sludge separator: Vacuum container: Water filtration-recycling equipment: Equipment: T-dual cleaning head: Turbo nozzle: Coating removal equipment: Hot-cold water: High-pressure gun: Foot valve: Flex-lances: Tube guide: Rigid-lances: 3-Pronged lance manifold: 2-Pronged lance manifold:

Other:

Vacuum support:

Tank location: Vessel entry permit: Self-contained breathing apparatus: Egress equipment: Full face positive pressure respirator: Air compressor: Air purifying equipment: Confined space ventilation equipment:

12-Volt explosion-proof lighting: Rust-inhibitors, metering equipment: Other:

Product hardness, adhesion, viscosity: Specify: Fouling characteristics: Specify: Physical surroundings, safety procedures: Specify: Describe application and work procedure: Itemize further equipment, safety gear, expendables, labor and equipment times, etc.

Product volume:

Others:

MSDS:

3.23

Hydro-abrasive Blasting, Steel Cutting-Demolition

GEAR - LIST

507

Nr.

Customer & Company:

Date: Address:

Web site: e-mail:

Job Nr.:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail

Tel: e-mail

Tel: e-mail

Tel: e-mail

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Storage tank, vessel, bilge: Other:

Dehumidification equipment: Desiccant: Cfm: Necessary relative humidity: 5%, 10%, 15%, 20% Ambient temperature:

Contaminants to be removed: oil, grease, soluble salts, sharp edges and weld spatter, coatings, abrasive, etc:

Necessary interior temperature:

Volatile or chemical substances to be removed: Volume: Dry: Wet: Desiccated: Identify: MSDS: Hydro-blast equipment:

PPM

Equipment: Three-way winch system top entrance: Full body harness: Specify heavy-duty pvc-nylon-polyethylene or disposable coveralls: Other:

Water filtration-recycling equipment: Expendables: Product encountered: Hazardous material:

MSDS:

Describe application and work procedure: Testing for: Carbon monoxide: Hydrogen sulfide: Sulfur dioxide: Nitrogen dioxide: Chlorine: Itemize equipment, safety gear, expendables, etc.:

Specify:

PPM:

3.23 Hydro-abrasive Blasting, Steel Cutting-Demolition Applications, Underwater Hydro-blasting and Dredging Prior to establishing WOMAs, subsidiary in Linden, New Jersey, the company demonstrated its tool capacity to clean pipes, sewers, tanks, and perform the runway rubber-removal application by their ‘‘high pressure water as a tool’’

508

3 Application Core Curriculum

Fig. 3.266 1967 third generation abrasive injector

Fig. 3.267 Hydro-abrasive blasting buoys

perception (1967). This included paint-coating deletion in aircraft parking areas, turbine blade cleaning with aluminum oxide and corrosion-rust removal all by hydro-abrasive blast techniques introducing the third-generation blast equipment. An International harvester truck-chassis utilizing WOMAs equipment, chemical-abrasive-water and sludge tank (hydro-vac system) and included the 150–152 horsepower, PTO powered reciprocating pump with four standard interchangeable plunger set configurations, accommodating the required application range demonstrated in commercial, industrial and marine environments. Supported also by two hydraulically operated hose reels for sewer cleaning and high-pressure hose storage, the application range was at this time exceptional and included trigger gun and/or foot valve operated rigid and flex lance operations. Demonstrating and introducing to Newark, New Jersey’s airport facility, the capacity of runway rubber and coating removal (Fig. 3.266), or cleaning pulp paper industries suction rolls and/or removing kiln clinker buildup in cement plants proved quite newsworthy within these industries. The hydro-vac dredging, pipe and sewer cleaning application and hydro-abrasive water jetting varieties for commercial and industrial maintenance yards was a technically leading and extraordinary demo experience for customers and WOMA alike. The trip started in Newark, New Jersey and followed the coast down to the Miami airport to wash its airports-building facade, to the Gulf Coast demonstrating hydro-blast jetting technologies on condensers which included the introduction to the Navy and Coast Guard the boiler tube cleaning and removal of barnacle growth and corrosion on their ship hulls and buoys (Figs. 3.267, 3.268), etc. This demo trip also facilitated the first contract

3.23

Hydro-abrasive Blasting, Steel Cutting-Demolition

509

Fig. 3.268 Coatingcorrosion removal, ship-hull

Fig. 3.269 Concrete roughening

work by hydro-blasting competing directly with chemical and mechanical cleaning operations. Results justified the decision to commence with the establishment of WOMA Corp. (USA 1968). The often skeptic observer was not sure at all that hydro-abrasive blasting had a future in the coating removal and coating–painting environment. Today, after performing thousands of corrosion and coating deletion applications on all imaginable metallic surfaces and the following experience of successful coating installations and their proven longevity, the skepticism has dwindled. Especially since the manual UHP-AB and automated UHP coating removal applications on surfaces with existing anchor profile moved into the industrial mainstream criteria. Equipment varieties and their varying performance standards, considering horsepower input, functionality of accessories (abrasive hopper and supply), the multitude of abrasives and possible application criterion can be quite confusing. The hydro-abrasive jetting aspect strongly depends on operators and technicians experience level which is a cumulative result from past job performances and their preferably successful established histories. Admixing within a hydro-injector’s chamber, the most advantageous conventional or alternative abrasive media to polish, clean or remove oxidization, accidental product accumulations, paint and/ or a coatings (Fig. 3.269) including fungus growth on surfaces providing nutrition etc. requires a precise differentiation of substrate conditions.

510

3 Application Core Curriculum

Fig. 3.270 a Extended life, vacu-boron chamber; b 3000 psi, 5 gpm abrasivechem. injector; c industrial– commercial extended life; d first-generation 1966 concrete-steel cutting head

Equipment design variations (Fig. 3.270) nozzle-injector technology and psi– gpm–horsepower input are great influences to the performance criterion which involves not only a surface treated and square footage-time performance, but also decisive cost variables for abrasive products. A job classification and bidding procedure depends on the correct identification and classification of the desired surface appearance. This is achieved by cleaning; polishing or roughening attained by high velocity water admixed with various abrasives (anchor profile). Polishing and avoiding a surface profile or to determine a profile categorization for a necessary surface appearance, the required surface treatment, addressed or included into a job-bid procedure must be a steadfast foregone conclusion offered to the contractor by his prospective customer. Besides classifying substrate material and structural configuration, its deterioration, adhering corrosion or product to be removed etc., the existing performance knowledge of conventional and alternative abrasives can by retrieved from manufacturer and their stocking distributors, or trade associations as SSPC and NACE providing visual reference publications for the UHP, hydro-abrasive and water jetting orientation which includes the wet abrasive blast criteria offering similar surface appearances. Wet abrasive blasting differentiates from hydro-abrasive blasting mainly in a harder abrasive impact. Hydro-abrasive blast water can, if so desired, provide a cushioning effect, facilitating a gentle surface preparation which

3.23

Hydro-abrasive Blasting, Steel Cutting-Demolition

511

Fig. 3.271 Patent draft, forth generation recoil-neutral, injector-gun assembly, and its abrasives supply equipment

includes polishing sensitive surfaces avoiding abrasions and environmental contamination. Every encountered substrate will lead to product identification whether it is plastic, fiberglass, wood, glass, brick, granite, concrete, bronze, coated aluminum and structural steel or exotic metals, such as found on statuary, industrial and architectural structures and/or specialty equipment, etc. (Fig. 3.271). Abrasives type and their classification are chosen by identifying substrates surface tensile strength and vulnerability to interface structure when an application calls for contaminant and existing oxidation removal; simultaneously achieving a polishing effect (various grades), coating and/or corrosion removal with or without interface profiling, removal of deteriorated and friable concrete, or structuring wood, brick or stucco surfaces. When an experienced opinion is not available as to choosing a correct abrasive is it best to consider the Mohs scale of mineral hardness. This facilitates a significant baseline for inexperienced and/or novice pressure washing and hydro-technicians, especially when considering all variables encountered matching a ultra soft or otherwise abrasive blast medium to the available equipment identity. Besides polishing a surface the choice of an adequate abrasive may be guided by a surface environment, the corrosion protection, and the coating application criterion. For coating applications an abrasive must be clean, oil–fat free, pH neutral and free of salt residual. Removing coatings in a confined high-tech area, the abrasive can be biodegradable and water soluble adding no dust or product contamination especially when a water recovery–filtration–recycling equipment is applied. In agricultural environments, an agricultural byproduct may be applied as an abrasive, avoiding all further contamination to its environment and as for building restoration and/or architectural components one can apply Portland cement powder, sodium bicarbonate, plastic media, pecan or walnut shells, including corn cob granules, etc. Abrasives: Silicon carbide

a man-made mineral, hard, angular sharp and free cutting abrasive supplied in grain

512

3 Application Core Curriculum

Fig. 3.272 Various steel plate profiles

Aluminum oxide

Sintered bauxite Calcined bauxite Ceramic beads

Garnet

Silica sand

Glass beads

Glass grit

and powder form, 8-1200 grit utilized for lapping, polishing and cutting…MOH: 9.5– 10.0 a tough, iron free abrasive for cleaning hard materials, turbine blades, removing metal flash-lapping, metal and stone cutting applications, 4-1200 grit,…MOH: 9.0 alternative to aluminum oxide…MOH: 9.0 inexpensive alternative to aluminum oxide…MOH: 9.0 spherical beads, 60–325 mesh, produces a satin finish on stainless steel and nonferrous metals, harder than glass…MOH: 7.5–8.5 8-1200 grit, angular to sub angular for paint, coating, rust and scale removal, varies anchor profiling on steel and concrete surface roughening…MOH: 6.5–7.5 4–270 mesh, sub-round for efficient industrial hydro-abrasive blast applications, which includes bridges, tanks, ship hulls, etc…MOH: 7.0 precision made glass sphere, 20–200 plus mesh, sub-round, deburring, cleaning, honing, polishing, and finishing…MOH: 5.5–6.0 18–200 mesh, angular sharp edges, lighter than glass beads, produce a very bright surface when preparing aluminum, brass, copper and stainless steel…MOH: 5.0–6.0

3.23

Hydro-abrasive Blasting, Steel Cutting-Demolition

513

Fig. 3.273 a, b Cast iron after hydro-abrasive blasting

Melamine Plastic media

Corn cob granules

Nut shells

Sawdust Magnesium sulfate

Baking soda (sodium bicarbonate)

Cement powder

cleaning soft metals and composite…MOH: 3.0–4.0 10–200 mesh sub round to angular, cleaning soft metals and composite, metal fabric screens, etc…MOH: 3.0–4.0 blocky, 10–100 mesh, polishing surfaces as aluminum and fiberglass substrate, graffiti, paint and contaminants removal on wood and architectural components, smoke damage deletion, deburring, oxidation and corrosion-rust removal…MOH: 2.5–4.0 angular multifaceted abrasive, 6–300 mesh, for cleaning and mold removal on soft wood or similar materials, cleaning aluminum, plastic, stucco, etc…MOH: 2.5–4.0 clean and polish soft surfaces or remove sheen (Kieserite) soluble, pool tile cleaning, calcium deposit removal on glazed tile…MOH: 2.5 60–180 mesh, crystalline shape, cleaning, paint removal, mold remediation, polishing surfaces, hardness in the talc and gypsum range…MOH: 2.5

514

3 Application Core Curriculum

Fig. 3.274 Water jet angle

(Portland) ideal to remove sheen or gloss on polished surfaces, creating a smooth dull surface, patina removal…MOH: 2.0–4.0 Blast abrasive sizing is described in microns or range of microns (20/30, 40/60, etc.) and/or mesh size. Its shapes described as sharp edge, angular, blocky and round greatly influencing buffing-polishing, cleaning, product removal, surface roughening and anchor profiling performances. With a few exceptions, corrosion-rust removal application methods on steel surfaces must always include their technical application aspect and the follow-up preservation (Fig. 3.272) or coating criterion. The novice best identifies this job aspect first. It does not matter much what quality of work has been performed if preservation procedures, which are designed to be compatible with paint-coatings applied, their application timing, drying and humidity controls on open steel or iron surfaces are neglected (Fig. 3.273). Humidity controls are especially important in a confined space, such as for instance within the interior of storage tanks for liquids, interior high humidity– acidic production facilities as in paper-pulp industries, food production environments and the interior of ship-hulls, etc. As to the question, how much abrasive is required? solely depends on the application encountered and its surface area. Metal pitting depth and mill scale remnants, coating interface depth and adhesion, abrasives specific gravity, its sharpness and high bulk density, injector’s design efficiency, simultaneous two or more injector operation, etc. are all mitigating factors. Performing a test patch procedure in all areas where a structural or physical change can occur, timing and utilizing between 1 and 5 lb/ft2 blast abrasive can best determine the ft2 production quantity per 40 or 50 lb bag possibly recognizing 40 to 200 ft2 per bag and so forth. The desired anchor profile and its peak count can be established by utilizing a profile-meter which incorporates a stylus to trace the distance between created peaks. The traces should be disbursed over the test area as identified and described by equipment manufacturer (in all directions). ASTM D-4417 and D-7127 for

3.23

Hydro-abrasive Blasting, Steel Cutting-Demolition

515

Fig. 3.275 Hydro-abrasive blast angle

Fig. 3.276 Injector angle, glancing over steel or any surface will alter an existing profile

standard test methods for field measurement of a surface profile on steel are established guidelines considered when verifying a performance criterion. Timing a test area, one must include all support activities, which should never interfere with a production blast schedule. This is very important on public construction sites or construction sites where a variety of trades are simultaneously performed involving scaffold safety, cleanup and water recovery and/or recycling procedures. When choosing a new coating system, the specification for its installation identifies the required surface profile as to depth and highest peak count possible while facilitating a complete surface wetting characteristic for the coating in question. The peak count and profile height is created by abrasives impact velocity, size and density (Fig. 3.272). High-pressure water velocity and mass, abrasives surface shape, specific weight the higher the deeper its penetration, creating a wider distance between peaks. Controlling the profile height is therefore a function of abrasive size-sharpness, hardness and density combined with its impact velocity (psi). Starting with the lowest adjustable psi configuration providing an acceptable desired anchor profile, the upward pressure adjustment to the most effective or efficient profiling or coating removal time prevents the utilization of pointless excess power input. Also an abrasive particle, which remains intact upon surface impact, will convey more energy to the surface interface. The type of abrasives employed within the hydro-abrasive blast method is less critical with one

516

3 Application Core Curriculum

Fig. 3.277 a, b Abrasive specifications

exception. Within impact and breakup, agricultural abrasives tend to deposit fat– oil residual upon treated surfaces reducing the possibility of immediate coating. Available hydro-abrasive injector-nozzles operate between 2,500 and 6,500 psi. Anything above this performance is pointless. The destruction and/or friability of abrasive blast material diminishes energy transfer performance which can escalate due to loss of operator efficiency and comfort level induced by excessive recoil force and abrasive jet ricochet (excessive pressure). The applied hydro-abrasive jet angle or degree does also influence the substrates peak count and profile (Figs. 3.274, 3.275). A glancing angle will introduce a lower profile (Fig. 3.276). Most effective is a 60 to 70 angle, with an abrasive barrel stand-off distance at its most efficient cone spread to the substrate interface which should always be the guiding aspect. Near white metal conditions are achieved quickly outperforming air abrasive blast-techniques in their time intensities and material cost criterion and most importantly in an environmentally friendly and correct application procedure, minimizing the hazard burden throughout most application environments. The physical aspect in guiding a hydro-abrasive nozzle over its work piece, structure or flat surface is a skill specifically identifying abrasive blast operations. The pressure washing and hydro-blast jetting technique requires the sideways and forward movement with varying angle of 80 to 50 and nozzle standoff distances adjusted to the adhesion and bulk-volume removal dynamics which includes the avoidance

3.23

Hydro-abrasive Blasting, Steel Cutting-Demolition

517

Fig. 3.278 a Concrete cleaning; b, c stucco polishing; d pumps and abrasive pickup equipment; e abrasive pick-up, injector

or creation of ghosting effects in porous substrate. The quality of hydro-abrasive blasting relies on the constant visual evaluation of blasted surface to obtain a uniform surface structure. A non-uniform surface and peak count can also be the result of particle size variations with varying bulk batch, or from bag-to-bag. Vibration-handling tends to separate fines from coarser abrasive during a bulk storage and/or packaging procedure, resulting in one bag or batch having a higher percentage of fines than the previous lot. During loading, transportation and unloading of bulk material a breakdown and separation of particles can also occur. Excessive loading or unloading velocities are most often responsible for this separation. Often overlooked and responsible are conditions within blast pots, especially large pots. As abrasive flows to the bottom control valve, fines tend to build up within the center of a load and along sidewalls. This can result in sputtering flow introduced by fines which often break loose all at once. Inadvertently, during this time blast productivity decreases and profile is altered. The best preventive measure starts with gentle product treatment and control of product quality while loading abrasives manually or mechanically for approx. 20 min uninterrupted hydro-abrasive blast operations. This time frame also controls excessive build-up of humidity. Surfaces produced from differentiating abrasives will fluctuate both in peak count and height and promotes unreliable production rates. The blast technique controlling the abrasive jet nozzle is responsible for surface uniformity and will very to a certain degree with abrasive type and its job purpose as to its specification. A 55 to 70 hydro-abrasive jet angle is most desirable and will provide with a systematic slow sweeping motion a uniform blast surface. The nozzle standoff distance is 1600 to 2600 which will vary according to abrasives selected. The hydro-abrasive blast method permits the utilization of non recyclable cost effective abrasives such as sand, aggregate, slag (Fig. 3.277), etc. Mostly underrated are the positive results attainable on deteriorated grout, stucco, plaster, and weathered concrete murals. The degree of cleaning is determined by incorporating to a high-velocity water jet an ultra soft medium which cannot under any circumstance result in adding a peak count or deformation to any surface profile. Such an obvious surface sensitivity demands a gentle polishing effect (Fig. 3.278c) to the substrates surface manipulating a range of surface contaminants. The direct advantage in the removal process is preventing scratching or damage by deformation often encountered with mechanical or

518

3 Application Core Curriculum

Fig. 3.279 Today’s injector design

Fig. 3.280 Tank cuttingdemolition applications

physical methods. A qualified hydro-technician will choose possible media variety solely by the correct classification of a substrate encountered. Analyzing substrates surface and tensile strength, coefficient of adhesion and depth of interface contamination can also acquire a multifaceted application criteria involving water dwell time, chemistry and a mild surface manipulation in polishing various detailed work. Stucco, concrete restoration, and/or repair procedures benefit when hydroabrasive blast techniques are combined with various soft blast-media. Preparing a damaged concrete surface utilizing 3,000 psi at 5 gpm and applying a following hydro-abrasive treatment at the identical performance criteria (coarse abrasive) to remove all remaining salts, efflorescence, laitance and other foreign matter which adversely affects a concrete structure can often produce a job classification otherwise slated for destruction or major structural restoration. Due to its porosity and aggregate count, the concrete interface structure can be cleaned, truly neutralized and roughened to a degree that facilitates a total product bond similar to its original strength. For restoration purposes the hydro-abrasive method is ideal due to its equipment mobility. Most often abrasive product delivery does not require compressed air to energize a hopper. Most injectors (Fig. 3.279) create ample vacuum to deliver abrasives conveniently placed within jobsite vicinity. This can be of importance when

3.23

Hydro-abrasive Blasting, Steel Cutting-Demolition

519

Fig. 3.281 1967 the first commercially available concrete cutting head

Fig. 3.282 a, b, c, d Steel–concrete cutting equipment. a Magnetic-belt fixture, b chain drive cutting unit, c chain-belt drive, jet exit, d chain-belt drive, injector-nozzle assembly

Fig. 3.283 Underwater hp-gun and jet safety sleeve

Fig. 3.284 Marine growth removal

520

3 Application Core Curriculum

Fig. 3.285 Underwater abrasive delivery system

GEAR - LIST AUTHORIZATION Hydro-abrasive blasting, steel cutting-demolition, underwater hydro-blasting and dredging Customer & Company:

Date: Address:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

hp-Injector

Purchasing:

Engineering:

Tel: Tel: e-mail: e-mail: Job Description: Job Location: Job Review Performed by:

Job Site Risk Assessment:

Job Nr.:

Specify:

Abrasive type: Abrasive size: Abrasive lbs:

© MOH: Nr.:

Hydro-abrasive blasting: Psi: Gpm:

Steel cutting demolition: Underwater hydro-blasting:

Substrate: Peak count: Profile height: Roughness: Chemicals: Specify: Other:

Underwater dredging:

Other: Equipment: Hydro-vac equipment: Hydro-vac vacuum-hose: Hydro-abrasive injector: Abrasive hose: Abrasive hopper: 2-Pronged abrasive manifold: High-pressure balanced trigger gun: Dive equipment: High-pressure trigger gun: Foot valve:

MSDS:

Vessel entry permit: Yards:

Nozzles: Remote-automated abrasive equipment: T-dual abrasive cleaning head: Turbo nozzle heads:

Underwater:

Rotary jet: Air compressor: Rust-inhibitors, metering equipment:

Hydro-blast equipment: UHP equipment:

Other:

Other:

Divers:

Product hardness, adhesion, viscosity: Fouling characteristics: Physical surroundings, safety procedures:

Specify: Specify: Specify:

Describe application and work procedure: Itemize further equipment, safety gear, expendables, labor and equipment times, etc.

Other:

3.23

Hydro-abrasive Blasting, Steel Cutting-Demolition

521

difficult locations must be reached or long distances between pump equipment and blast area must be breached. After the removal of frost damage, abrasions and/or concrete carbonization, a repeated aggregate discovery as to its overall classification and condition is of importance. Job experience has proven that a distinguishing and suitable restoration procedure can most often be streamlined and enhanced due to overall favorable conditions now identifiable. Generally, substantial and unexpected savings are realized within restoration procedures. Equipment is available to gauge surface roughness, tensile strength, concrete humidity and pH, within a remaining interface structure which is always important facilitating performance warranties for new product installations. Concrete surface preparation reference, ASTM D-4258, standard practice for cleaning concrete, ASTM D-4259, standard practice for abrading concrete and ASTM D-4260, standard practice for etching concrete are guidelines established for mechanical and/or chemical application methods. Today the available hydroabrasive, hydro-blasting and UHP application curriculum has through the years developed into an application criterion most often superior to this preparation reference. Pipeline and steel cutting applications or demolition where fractured tanks or volatile nuclear-refinery-chemical vessels (Fig. 3.280) are in need of dismantling, structural change or repair is a service specialty most often performed by wellregarded identities versed in providing hydro-blasting and UHP application services in hazardous environments. These contractors almost always maintain a close relationship with equipment manufacturers, which can provide tool flexibility and know-how for specific application requirements. High-pressure water jets admixed with abrasives, have absolutely no limitation in their cutting potential. First employed in 1966 the concrete cutting heads (Fig. 3.281) responsible for dismantling bridge pylons and bunker walls by cutting through concrete and rebar structure without delay brought on this awareness. The idea that high-pressure water will not effectively cut steel was quickly rebuffed within this jet cutting procedure. The knowledge that a water stream admixed with an abrasive will not compromise its cutting time throughout an heavily reinforced concrete rebar structure pointed to the developments which today far surpass the experimental stage (Fig. 3.282). The metal and stone available concrete-cutting head cutting input performance range is within 0.05–1.2 gpm at 45–60,000 psi, resulting in a nozzle-abrasive jet size from 0.03000 to 0.8000 ø. Generally garnet is utilized as an abrasive from 0.5 to 1.8 lbs/min. Underwater hydro-blasting or abrasive cleaning is an application also developed in the early 1960 (Figs. 3.283, 3.284, 3.285). The main motivation for its technology development was the possibility of removing marine growth on ship hulls reducing the hydrodynamic friction resulting in enhanced propulsion efficiency. Today ship hulls are serviced regularly, preventing bio fouling buildup, extending the effective life of an anti-fouling coating and sustaining the anticorrosive coating system for longer dry dock intervals. Also hydro-blasting is a

522

3 Application Core Curriculum

maintenance identity most often utilized in shipyards, and/or offshore facilities servicing oil platforms, piers and water dam installations which includes underwater corrosion control (Fig. 3.286) and coating applications, intake wellhead cleaning, zebra mussel, algae-marine growth removal, lock and dam work, etc. Cleaning pressures range from 10 to 14,000 psi utilizing 22 gpm plus. The underwater application can only be as good as the training provided to divers operating high-pressure water equipment. Underwater maintenance repair contractors operate on steel structures from 30,000 to 36,000 psi, for aluminum structures 18,000–20,000 psi. The standard surface profiles by underwater hydroblasting or UHP technology ranges from 40 to 100 lm and produces a NACE, No. 5, SSPC SP 12 surface appearance. The IMCA international marine contractors association (www.imca.com) can greatly provide support as to information on qualifying and testing for divers. Underwater dredging and/or clearing pond bottoms or inspecting and removing silt from community water towers can also be an application only managed by a licensed marine or industrial diver. The hydro-vac system and application criterion in core application chapter #7 is fully employable.

3.24 Wash Water Control, Recovery, Filtration, Recycling, Wastewater Reclamation Technology, Evaporation, Hazardous Materials Cleanup, Chemical Rinse Aids How to catch onsite wash water is probably a question looked upon with distaste by previous hydro-blast and pressure-washing generations. Today, this added necessary feature, or better attribute, does provide a great business opportunity for savvy and technically flexible hydro-technicians. Realizing that a correct environmental cleaning technology not only supports the conventional application variety and business opportunities into the hazardous spill, lead-coating abatement and sanitary emergency response field and/or cleaning endeavors in confined moisture sensitive areas, a novice inquiry often fails to notice a vital technical application divide. The water pollution control permit requirement identifies and considers spent wash water as ‘‘wastewater’’. Therefore a mobile power wash business, cleaning gas station and fast-food restaurant drive thru’s, vehicles, construction equipment, interior or exterior building-structures, etc. discharging spent water which includes unidentified turbid water directly into a storm sewer collection system without a pretreatment permit is considered a violation. Wash water control, its recovery (Fig. 3.287), and filtration for closed loop recycling is one facet which must be separated from available water reclamation technologies which is to remove wash water to gain a concentrate/remnant. These

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Fig. 3.287 Adjustable vacuum shoe, bladder containment

Fig. 3.288 Utilizing concrete berm and water bladder

Fig. 3.289 Secondary drain and manhole containment bladder

accumulations often result in a hazardous material cleanup and its transportation classification. When cleaning on exterior non-permeable hard sealed surfaces, where oil and grease loads are prevalent, the wash water control achieving a closed loop application is simple. Utilizing a natural gravity flow on non permeable grounds and strategically placing water dikes to guide grease and oil laden water to a vacuum shoe (Fig. 3.288) is basic. This type of wash water control is quick and competitive. Guarding against escaping liquid to a storm drain or rain gutter, water filled bladders can be situated into lowest point incorporating a secondary vacuum or pump station (Fig. 3.289) (emergency). Whatever method is utilized the filtration and recycling equipment is based on the effectiveness of silt and oil water separation, and polishing filters to below 5 lm to guarantee pump fluid-end and accessories longevity. This gravity flow (Fig. 3.290) method can also be utilized in parking garage structures where their drainage system is isolated from storm drain or sanitary sewer access. Often, simply installing a blind flange which incorporates a vacuum

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Fig. 3.290 Uphill 2000 wastewater recovery

Fig. 3.291 Wash water interception

access providing direct feed to the oil water separator eliminates the trailer movement throughout a unit. The high-pressure hose assembly is often provided through the center of a parking structure. Cleaning from top down the highpressure hose is disconnected and adjusted to the lower floor and its total width. The garage drainage system will deliver oil–grease laden effluent directly to the vacuum–filtration side of the equipment strategically placed to the nearest pipe access before entering the storm drain-sewer system. Cleaning surface areas close to or within a storm water conveyance system is regulated by their municipality. Their established ‘‘best management practices’’ for mobile pressure washing contractors (BMPs) can include guidelines to minimize improper or accidental discharge into the storm drain system. These areas can be described as sidewalks, gas station surfaces, bank-restaurant drive thru’s, houses or building-façades joined to sidewalks or asphalt incorporating a storm sewer system. Due to a diverse natural runoff and varying grades the operator must plan on how the wastewater will be collected. Vacuum booms of various designs (Fig. 3.291) are flexible dams 400 –600 in height arranged to intercept the wash water flow. Connected to trailers vacuum and filtration equipment they feature gaps in

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Fig. 3.292 Various drive on containment. a Smooth surface containment mat; b heavy-duty drive on rubber bridge; c heavy-duty underlay containment; d wastewater containment basin

increments to the ground surface, sucking up impounded wastewater by accelerating vacuum-air velocity into the inner tube of boom. Portable water or sand packed plastic dams-booms, light or heavy duty wash down containment mats (Fig. 3.292), mobile metal pits incorporating a water filtration recycling capacity, tarps and most importantly, rotary surface cleaning equipment incorporating a vacuum shroud to immediately remove all wash water are tools employed to avoid an uncontrolled discharge onto permeable ground, sidewalks, street gutter and storm drains. A mobile recovery system which removes effluent from its containment area or a vacuum shroud is often energized by a primary vacuum system. A vacuum’s energy may also be utilized to provide a centrifugal separation of all non-buoyant heavy solids (Fig. 3.293), as dirt and sand constituents accumulating in units low velocity bottom area before the remaining effluent is introduced to the pretreatment clarifier, filtration and coalescing unit. A mobile clarifier’s technical aspect within its water recycling performance is the oil–grease separation from the returned blast water. Hydrocarbon molecules or their accumulative remnants (oil/grease) tend to adhere to oil–water separators coalescing plates or structure (polypropylene). Through accumulation developing buoyancy sufficient to overcome waste stream velocity by separating and shearing of floating to units top water plane is the function. At this point where effluent movement is maintained at zero disturbances, the first oil drain pipe is utilized or a skimmer system is applied removing the accumulated oil–grease concentrate. Equipment is also available providing repetitive fine coalescing treatment reducing remaining free oil dispersions. A fine oil filtrate establishes a hydro-tea suitable for various filter technologies polishing the remaining effluent for site-specific or

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Fig. 3.293 2000 mobile wash water recovery, reclaim–recycle system

variations within the pressure washing or hydro-blast application field. Hydro-tea passing through a 5 lm filtrate can often be utilized for surface cleaning applications in areas where a high oil–grease residual can be expected. These areas are found on gas station–tollbooth–bank–restaurant drive-through operations or interior surfaces in machine-shops, vehicle or equipment repair facilities, which include produce, meat and/or agricultural manufacturing environments, etc. Before any water release is introduced on a job site, water barriers must be arranged and covers installed to minimize the possibility of an improper or accidental discharge. First removing dry contaminants from surfaces by sweeping sand and gravel load is absolutely practical, minimizing the refuse accumulation within a sediment filtration chamber. Identifying the approved waste containers and avoiding sweeping these contaminants into adjacent storm drains will be noticed as professionalism. Equipment pending, oil water separation can also be enhanced by eliminating low foaming detergents usually employed when removing heavy oil–grease accumulations by exerting higher psi performances to a surface. After bulk accumulations are removed a hot water application above 185F can be quite effective in removing or reducing stain appearances within a surface interface. Treating a surface with detergent before a pressure washing operation is introduced can result in producing an emulsion which is not only classifiable as a hazardous waste, but its makeup can significantly delay or alter dramatically any clarifiers-oil separation performance. The notion that an oil water separator, filtration and recycling unit can be adequate for all operations and encountered applications is false. A mobile unit must be sturdy in its construction (Fig. 3.293) and provide a closed loop design, with the attribute of being covered, protecting against sloshing or spill out by rain or technical failure.

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Fig. 3.294 Smooth vacuum hose interior

Fig. 3.295 Adjustable vacuum-shoe

Within commercial and residential application environments water supply can be limited, especially when operating more then one pump or rotary surface cleaner. A service provider will find that a mobile wash water recovery system is not only essential for its intended purpose and enhancement of application variety. Much more important is adding the capability to work in remote environments where only marginal make-up water is available. A system should also provide the capacity of adding various polishing filters as deemed necessary, providing the all important application flexibility. Vacuum hose configurations should provide a smooth hose interior (Fig. 3.294), connection between hose sections also smooth avoiding hang up on corners which is always a problem when cam-lock fixtures are employed. The best method is utilizing ducttape and metal sleeves between hose sections (Fig. 3.295). Generally a rotary surface cleaner operates at 3–4,000 psi at 5 gpm plus, which is the basic configuration necessary for a filtration and recycling capacity in its simplest form. Therefore operating two units requires 10 gpm performance capacity. Float controlled fresh water supply is only utilized to replace water lost due to evaporation which in hot or parched dry climates can be up to 40%, especially noticeable when utilizing only 5 gpm on far-reaching surfaces as vehicle parking areas or gas stations, where a controlled gravity run-off can be 1500 plus. This also dictates the direction of cleaning operations, which will follow the natural flow of wash water. The cleaning capacity is 10,000 ft2 hourly, utilizing the above-mentioned 5 gpm performance criteria. The oil–grease water saturation ratio relates directly to the equipment’s filtration capacity which will reach a point of no return thus requiring treatment, evaporation or discharge to an approved facility to receive this hydro-tea. When considering the challenge of removing a dissolved, soluble or emulsified product from its water constituents, technical limitations are quickly recognized and guiding (Fig. 3.296). How to remove dissolved tea from its water should be the appropriate and simple question for design engineers and practitioners when following their entrepreneurial technical instinct considering water filtration, flocculation and evaporation procedures.

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Fig. 3.296 Hydro-tee

The required paperwork for environmental washing to contain, pick-up and pretreat wastewater to legally release and/or discharge into a sanitary sewer or EPA approved septic and/or treatment facility is the written permission from a POTW or an owner of an EPA approved septic treatment system. A service provider’s written guide as to his washing practice identifying operational safety procedures, detergents utilized (MSDS), the major equipment engaged in the washing and recovery procedure, and how a jobsite is left after a job completion incorporating best management practices (BMPs) will usually guarantee a work permit. This criterion is also a major job-bid component, which should always be considered a companies front-line marketing endeavor within an environmentally correct pressure washing or hydro-blast procedure. Federal laws and regulations enforced by EPA and OSHA cannot be displaced or made lesser by any state, county or municipality. Federal laws can only be more stringent or enhanced in short, more comprehensively regulated by a state, county or municipality requiring a contractor to investigate the established municipality’s guidelines possibly requiring a stricter and detailed job procedure. It is also prudent to retain a copy of said job specific written environmental curriculum to a jobsite’s paperwork and should include best management practices concerning this jobsite, reducing the possibility of work stoppage or interference by inspectors not privileged to this information beforehand. Before any letter of acceptance or permit is issued by a regulatory agency a laboratory test of effluent in question will be necessary. A contract cleaner involved in repetitive surface cleaning applications, for instance provided by gas stations or any area producing excessive petroleum–hydrocarbon and greases–fats, etc. are most likely to provide such a test report. Regulatory agencies are especially interested in wastewaters neutrality (pH 5– 6), total petroleum hydrocarbon count (TPH) less than 100 mg/l, total dissolved solids in wastewater effluent (TDS), total suspended solids in wastewater effluent (TSS) less then 200 mg/l, its oxygen depletion (BOD) less than 100 mg/l, and chemical oxygen demand (COD) less than 200 mg/l including all heavy-metal

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ranges below required limits and the daily wastewater volume generated. Educating a regulatory agency as to the actual low volume (gallons) of wastewater daily produced will reduce a possible misconception so often encountered in their decision-making process. The necessary technology manipulating wash water away from its contaminants, creating semi dry residue or sludge with varying water concentration is a somewhat unpredictable aspect fluctuating with every job description. Identifying type and classifying the hazard in waste-products which are removed by highpressure water from their respective surfaces, their physical semi dry or wet weight and volume will determine the technology necessary to concentrate, package and make ready for transportation. It is the waste concentration produced by effective removal, which will present a problem, not the possibly applied biodegradable chemistry in concentration. The criteria for classification of sludge from wastewater and its disposal under the EPA standard identifying maximum contamination levels in title 40, CFR regulation 257 and general pretreatment regulations for existing and new sources of pollution part CFR 403, and CFR 503 for the use or disposal of sewage sludge is an important information base which requires a contractor’s attention. For disposal purposes, identifying the three main wastewater types is best achieved when confronted with a job description of a surface to be cleaned, its possible manufacturing or accidental process remnants-residual and location. For instance, soaking a wall with freshwater results in a non-hazardous water classification and wastewater which can be neutralized on site by neutralizing the acidic/ alkalinity content of the wastewater may also result in a non-hazardous classification. Today, seldom utilized specialty detergents containing a high phosphate constituent must always be contained and treated. Their release encourages rapid algae growths in ponds streams, rivers and lakes. Also it is important to study the detergents identification within the MSDS description to guard against accidental mixing of applied chemistry in any form containing chlorine bleach and ammonia products as hazardous fumes may be the result. A wastewater stream containing solvents cannot be neutralized and must be treated, concentrated or evaporated. This category most often contains powerful acidic and/or caustic cleaners utilized while in new construction or in a restoration procedure. This can include wastewater carrying acids, detergents; paint-coating remnants found on various structural surfaces, etc. and may incorporate the lead abatement procedures by high-pressure water where phosphoric polishing filters remove lead elements from the recycled blast water. Creating this type of waste stream will most often be a job classification in itself where treatment and disposal costs are a part of the prospective bid procedure. Today’s wastewater source reduction technology renders its liquid remnants manageable for evaporation by incorporating pretreatment methods of the simplest or sometimes old and well documented or new sophisticated evaporation technologies. Wastewater evaporation is of an interest to a service provider in areas where volume of spent recycled wastewater has reached a saturation point where

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the reduction by evaporation becomes a cost effective method. A stationary reclamation system may receive spent wastewater to further remove its water constituents producing a neutralized sludge residual which is stored in a sludge drying bed or is introduced to an evaporator process. High volume waste streams containing excessive levels of Mercury or PCBs and VOCs will require a permit from the local air quality authority. Generally wash water sludge remnants does not contain such waste in measurable concentrations. Besides evaporation, flocculation can be of interest for some pressure washing and hydro-blast applications. There are many flocculants available which are admixed to a waste stream, coagulating suspended solids, which either will precipitate to the bottom or float to the top received by a filter cloth mechanism from its water constituents. Bioremediation, utilizing aerobic microbes to digest oil and grease, electrocoagulation for wash water treatment, reverse osmosis systems separating water from its concentrate through a semi permeable membrane by force are technologies available to the industry but must also be measured with prudence as to validity, flexibility and practicality within a pressure washing hydro-blast application criterion. The applied hazardous material cleanup technology by a power washing and hydro-blast application will always depend on identifying the characteristic of the industrial wastewater encountered or created. Food, dairies, meat and poultry processing waste streams will carry dissolved and suspended organics, protein, lactose, blood, grease and fats, where equalization, aerobic or anaerobic biological treatment and screening, gravity separation, flotation, or coagulation–precipitation of their waste stream can be employed. Breweries and distilleries, fruit and vegetable canneries create highly dissolved and suspended organics from natural products requiring screening, aerobic or anaerobic biological treatment, neutralization, gravity separation and centrifugation. Plastics and resin manufacturing produces dissolved organics, including acids, phenolic, aldehydes, cellulose, alcohols, surfactants and oils utilizing gravity separation, flotation, coagulation, chemical oxidation, solvent extraction, adsorption and biological treatment. Explosives manufacturing will produce organic acids and alcohols, soaps and oils manipulated by flotation, chemical precipitation gravity separation, macerating solids and biological treatment. Leather tanning and finishing operations produce dissolved and suspended organics, fats and oils, organic nitrogen, hair and fleshy tissue manipulated by screening, gravity separation, flotation, coagulation, neutralization and biological treatment, etc. Pharmaceuticals manufacturing processes are high in dissolved and suspended organics, including some surfactants and biological agents and require pretreatment by equalization, neutralization, coagulation, solvent extraction, gravity separation and biological treatment.

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Textile manufacturing processes produce dissolved and suspended organics, fats and oils manipulated by equalization, neutralization, coagulation and adsorption, biological treatment and ultra filtration. GEAR - LIST

AUTHORIZATION

Wash water control, recovery, filtration, recycling, reclamation technology, evaporation Customer & Company:

Date: Address:

Job Nr.:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Sludge type: Parking lot: Multi floor parking facility: Sidewalk: Street: Storm sewer: Building exterior: Warehousing: Machine shop: Food processing: Industrial: Other: Equipment: Mobile wash water reclaim systems: Evaporator: Hydro-blast equipment: psi: Pressure washer: psi: High-pressure hose: 100’ 200’ 300’ Hydro-vac system: Vacuum hose: 100’ 200’ 300’ 400’ Barrel vacuum-pump: Hose: 30’ 50’ Trigger-gun: Fan nozzle: 15° 25° 45° Wand extension: 4’ 6’ 8’ Rotary surface cleaner: Rotary surface cleaner-vacuum shroud: Turbo-nozzle: Other:

Product hardness, adhesion, viscosity: Fouling characteristics: Physical surroundings, safety procedures: Describe application and work procedure:

gpm: gph: gpm: gpm:

Hot water: Sludge drying bed: Holding tank: Clarifier: Ozone generator: Chlorination: Muriatic acid: MSDS: Soda ash: (sodium carbonate) “ : Caustic soda: (sodium hydroxide) “ : Chemicals: Specify: MSDS: pH test kit: Other: Vacuum flange: Trailer clean-out mat: Drive on wash mat: Rail mat system: Sewer covers: Water barrier: 10’ 20’ 30’ Vacuum hose: 100’ 150’ 200’ Vacuum shoe: Tarp: Emergency sump-pump Rust-inhibitors, metering equipment: Permits:

POTW:

Other:

Specify: Specify: Specify:

Other:

Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.

Coke and gas manufacturing processes are high in phenolic, ammonia and dissolved organics, treated by equalization, flotation, adsorption and biological and chemical oxidation or solvent extraction. Sludge treatment and its environmental considerations in terms of hazardous regulatory measure is best identified when listed under the RCRA, Resource

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Fig. 3.297 a Damage by grill-barbecue fire; b close-up of damage, raised grain; c 45 fan jets at 3000 psi to 5 gpm; d dry appearance before staining

Conservation and Recovery Act, which is EPA’s authority to control hazardous waste from cradle to grave, which includes waste generation, transportation, treatment, storage and disposal. Applying chemical rinse aids such as surfactants, acid or base buffer–pH controller, stain or rust removers, water soluble organic solvents, phosphoric acid washes or rinses, chloride-salt removers and/or adding unidentified inhibitors to pressure-washing or hydro-blast water can greatly influence an existing sludge description and its classification, neutralization and its reduction technology. Chemical rinse or water additives are most often job and possibly site specific. Some additives or rinse aids may increase and some may decrease a corrosive emulsion or neutralizing characteristic. Their use and removal from a jobsite must always be tightly controlled and identified within a job procedure.

3.25 Wood Restoration and Preservation, Seal-Coating Applications, Wood Structures-Decks-Landing and Fence Restoration, Roof Asphalt-Composite Tile, Wood Shingle Cleaning, Vinyl, Wood, Aluminum Siding Cleaning A customers desire or reason to clean or undertake a wood care process requires a detailed and correct evaluation of the exterior wood structure in question. The investigative job walk criteria must include the possible imaginative or suggestive perception as to customers foreseen and sometimes unattainable results by promising services and/or cleaning methods offered. Customers often relate to a muddled perception derived from various observations or personally witnessed

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Fig. 3.298 a Deteriorated paint coating cover; b close-up of coating condition; c after jetting, dried, sealed and primed

results on similar structures devoid in consideration of any job decisive factors. The customers preliminary research efforts may enhance this dilemma as a result of scrupulous competitive services and/or chemical product sales endeavors. This can be challenging considering a service provider’s business future greatly depends on customers’ opinion and anticipation as to a final satisfying and longterm enduring result. Professionals can quickly determine a customers position (knowledge) when identifying and describing the appearing problem and general type of pollutants found. The narration or service solution for obvious or hidden tough stains penetrating wood-façade surfaces and possibly their future preventive measure are best of an educational nature. Classifying algae, mildew and fungus growth, categorizing possible origination and preventive care and offering to prospective customers obvious and hopefully necessary added services will create an environment of confidence. Offering these proven successful high-pressure-water application varieties to owners or authorized administrative clientele managing private and commercial residential structures can be an eye opening experience. These include the introduction of cleaning–washing applications for small or large ranch homes, bungalows, contemporary housing, log homes and their landings, decking, garage structures and driveways. The commercial identity includes rental and condominium properties, their driveways, parking facilities and possibly playgrounds, pool and party areas, their private marinas, horse or animal facilities. Adding services to incorporate the cleaning of swimming pools, gutters and installing guards, minor repairs on landings or wooden decks and railings (resetting nail-heads and screws, etc.), concrete sealing–staining applications for driveways, pedestrian ways and garage floors, sealing–staining wood landings, decks, fences, gazebos and similar structures, or offering chimney cleaning, graffiti

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removal, water abrasive blasting, hydro-vac, pipe and sewer cleaning services, and/or possible future crime and disaster cleanup procedures warrant the investment and service providers sales efforts. Also, besides introducing exterior wood care methods, the fire clean-up and wood restoration criteria can be of interest, especially in confined partially damaged areas. The education of customers to the capability proves or disproves the possible opinion that a high-pressure water cleaning method on wood is inadequate or destructive to wood surfaces. Wood, subject to fire, consuming its surface structure (Fig. 3.297), and subsequently developing heat activating and devouring tannins, sap and possibly various staincoating residue will, within the flaming process expose its’ grain (raised). Cured grain will not fray or create splinters protruding from its base when introduced to a fan jet manipulation and the following drying process. The mere fact that a utilization of a qualified fan nozzle, and its specifically chosen gpm–psi configuration correlating to the necessary stand-off distance in consideration to encountered wood type and damaged burned interface zone is capable of bringing the underlying surfaces back to life is a persuasive argument. Reconstituted surfaces are either newly coated or only sealed with a deep penetrating and shielding wood stain preservative fortifying against long-term environmental and UV damages. Beams and columns, the underside of decking and exposed joists, building siding, including a properties fencing are either installed in smooth, semi rough or rough appearances. These products are also called dimensional lumber. More often and price depending smooth surface wood is either finished with a coating procedure or varnished. Rough surfaces are treated, if at all, with a wood preservative incorporating exterior UV protection or coated with a flat appearing stain or varnish to visually enhance the texture of the surfaces. Today the differences in wood products of identical description are often recognized when removing remaining coating from structures created in the early 1900s, which incorporated most often smooth surface boards and likely protection by means of a lead coating system. Also, these boards were generally manufactured from hardwoods, therefore perfectly suited for today’s high-pressure water coating removal and hazardous lead coating abatement procedure (Fig. 3.298). The undesired raising of grain on these hardwood surfaces is, at worst, minimal as aged pine is also most often sturdy enough to be cleaned avoiding raising its grain structure. More over, in the past a building’s prolonged exposure to the elements will direct to a significant change in application criteria also recognizing quite noticeable yesteryears product differences. Wood surfaces made susceptible by neglect or insufficient coating procedures developing rot or dry rot, wood board splitting and felting, mildew, mold and algae development in specifically prone areas, etc. demand a corrective and detailed preventive restoration procedure involving all infected areas. Under these circumstances surface irregularities, damage and the desired coating removal practice on a wood substrate will require a combination of restoration procedures within the application of the high-pressure water cleaning and/or paint-coating removal criterion. Restoration requirements may also change within the inherent differences of particular pieces of wood or the

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Fig. 3.299 a Mildew and mold infestation; b 25 fan jets 3000 psi to 2.5 gpm; c clean, treated, dry and stained

boards reacting accelerated to the environment producing adverse and advanced surface failures. Sporadic and/or firm coating adhesion between a healthy and damaged wood substrate-interface can also be broken chemically (strippers) diminishing further damage to the compromised remaining surfaces supporting a fan nozzle and vacuum head-brush assembly within a coating removal procedure and the following necessary surface neutralization. The evaluation of an aged vertical exterior wall as to its suitability by cleaning with high-pressure water is quite simple. The experienced service provider can find the threshold limit between damaging and adequate cleaning performance within the interface structure by applying a pressure-scratch test with a tool of his choice. The alternative method is to apply a 25–45 to 65 fan nozzles at various standoff distances to the damaged wood interface to be cleaned, testing various pressures and if possible, various water volume configurations similar to patch testing procedures on masonry and brick, block surfaces. It is not rocket science, rather logic combined with experience which will protect a wood surface in depth. The correct evaluation of apparent stains and living organisms like mildewmold and algae are as important as the source identification of stains introduced to wood surfaces in question, resulting from wax, grease, fats, iron and copper fixtures, tannins, tree sap and pitch, etc. To prevent reoccurring problems is it of an advantage to advice customer as to the contaminating source or circumstance of its structure. Minor mildew and mold development such as is often found in humid areas can be removed with sodium per-carbonate based wood cleaner especially when applied after an initial cleaning procedure. Substantially infected wood surface areas are first subjected to a high-pressure water cleaning procedure. Permitting an adequate drying time prior to a treatment with two to four parts of water to one part

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Fig. 3.300 a Moss, fungus, insect infestations; b rafter cleaning, pest control; c cleaned, dried and stained

of chlorine bleach on aforementioned heavily infested wood surface is of an advantage. It is also important to permit a dwell time of the bleach solution, which should be a minimum of 20 min in a wet-humid stage. Neutralizing the surface with an oxalic based wood brightener following the final rinse procedure will produce an optimal result. When assembling a job-gear list, is it also helpful to identify the encountered wood type and possibly its age, and origination. Today siding and fencing are mostly manufactured from softwood such as pine, fir, cedar or spruce. Cedar and redwood board will dissolve some tannin when pressure washed, visually identifiable by yellow brown staining on weathered and naturally bleached wood surfaces. This is only marginally problematic when a cleaned fence board is not stained with an appropriate wood preservative hopefully incorporating a UV protection. This tannin release can also be accelerated by the incorrect use of strong alkaline based solutions. The stains can be removed by an oxalic acid based wood brightener neutralizing the alkalinity within the wood, drawing the tannic acid away from surfaces (Fig. 3.299). Decks-porch-staircase-landings and their preservation–restoration methods are often underestimated in necessary effort and product consumption due to their overhead and vertical components such as railings, simple or intricate spindle and balusters. Materializing rust and copper stains caused by nails, decorative metal fixtures or garden furniture and oil-fats, waxes absorbed in various deck areas introduced by grilling, kerosene spills and dripping candle wax are all mitigating factors. Over-head components like rafters and open underside of decking may entice operators to begin an unsafe operating procedure (Fig. 3.300) in their attempt to reach all corners and hidden surfaces. When performed correctly the job-walk and description present almost always an eye-opening experience to the

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property owner for its necessary cost requirement. Starting with the removal of accumulated grease stains, probably organic oils and animal fats (grills), which often penetrate deeply into the decks surface, requires a repetitive treatment with 1000 psi hot 200F water temperature heating the stained surfaces in the attempt to draw and eradicate reappearing oils from the pores or sponge like interface zone utilizing a detergent to emulsify rematerializing oil–fat remnants. Permitting a repetitive drying time between applications is of an advantage especially before a sodium hydroxide based solution is applied in the attempt to reduce the often diminishing but reoccurring stain formations. The successful hydroxide application must be neutralized from all wood surfaces with an oxalic acid based wood brightener which also neutralizes the tannins acid that has been drawn to the surface. In totaling overall surface cleaning and prep time s followed by a desired wood staining–coating and/or preservation procedure is it clear that job criterion and pricing can quickly escalate. When removing a deteriorated exterior stain–varnish product, it is of importance to first identify the adhesive quality of the binding resin of the remaining coating residual. In general deteriorated stains are highly susceptible to highpressure water introduced by a rotary surface cleaner. Testing the removal effectiveness is simple and should not be steered by a pending chemical sales criterion. Subject to wood type, hardness and/or presence of surface deterioration necessary applicable pressures may range from 1000 to 4000 psi, at 2.5–5 gpm, hot and/or cold water. When a total removal scenario cannot be guaranteed by utilizing high-pressure water only, the following hazardous removal criteria, employing a free caustic application to the varnish remnant enhances deletion effectiveness greatly. The introduction of a high-pressure water procedure to a dry, porous wood surface (boards and/or logs) penetrating the existing crevices or fissures within the wood substrate permit a measurable moisture saturation and absorption application preferably to above 20% moisture content. The degree of absorption can further be controlled when manually operating a vacuum assist rotary surface cleaner, providing a direct water recovery. This absorption is a vital function, especially when a job criteria calls for the utilization of un-buffered or free caustic treatment applied to the woods surface, designed to soak through, the exterior finish and the wood’s stain-coating interface. The water saturation penetrates and swells pores hindering the uncontrolled deep absorption of the damaging caustics. Calculating the timeframe between treatment of high-pressure water and caustic application and its dwell time should always be a controlled requirement. Caustics cannot be neutralized by water but can be blocked within an engorged porous area where access to liquid acidic neutralization is not denied in depth by shrinkage to the present caustic elements. Wood products, such as cherry, mahogany, oak, redwood and cedar contain a high amount of tannic acid which can be drawn to the surface when correct neutralization of the substrate is not achieved (pH 7). Especially when dormant chemistry is reintroduced to humidity will surface discoloration reappear. Newcomers to the industry are best advised to apply buffered chemistry

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Fig. 3.301 a Overhead wood cleaning; b 2 9 45 fan jets 3000 psi to 5 gpm; c dried wood surface before staining Fig. 3.302 a Weathered wood-façade; b wood-façade cleaned, dry, before staining

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Fig. 3.303 a Wood damage round jet, wet surface; b wood damage round jet, wet surface

controlling the pH criterion of a specific cleaning–restoration procedure. Much can be learned when following manufacturers’ guidelines. Log home washing, sealing and/or restoration procedures present an application variety which requires a personal and specific marketing strategy. Log-house owners are finding it difficult to identify qualified service companies restoring and maintaining their homes. The novice service provider will find it difficult to relate to the needs and desires’ a log home owner identifies. Due to specific environmental circumstances, or sometimes a lifestyle oriented criteria the customer requires a unlike job prerequisite in comparison to the proud owner of a city or suburban tract home. Most often is a water filtration, recycling capability very welcomed and identifying job quality as is the inherent equipment capability to operate with fluctuating water supply below 5 gpm due to the rural location of many homes. In many areas log home manufacturers have applied inferior wood treatment, coatings or varnishes to their product later ultimately responsible for premature failure in their unforeseen given environment. Coating companies identified this new emerging market selling products based on a UV protection and water repellency but lack the capacity to control or describe variations of surface and substrate preparation often resulting in an incorrect coating or varnish installation. The prior cleaning, which is best and most effectively performed with high pressure water on interior and exterior surfaces (Fig. 3.301) removing sap and airborne contaminants especially on the top-side of logs, where accumulating contaminants retain humidity providing a fertile environment for moss, mold and algae etc. Periodically performing surface maintenance correctly by washing and rinsing a log home is quite a simple affair achieving the necessary surface cleanliness and acidic neutrality equal to logs neutral pH 7 prior to a probably oil based, solvent borne and penetrating replenishment. It is important not to subconsciously be lured into discounting the guarding against moisture intrusion to solid appearing doors and window frames, roof overhangs, underside and eave components which are probably manufactured from hardwood veneer but bonded to a solid or hollow core structure. Buildings may incorporate a variety of components not of solid nature and therefore more sensitive to humidity. The problem starts when coating maintenance procedures have been neglected over an extended period of time. Environmental influences can separate wood cells in various unforeseen areas from their substrate. These wood fibers cannot retain a stain or coating application (Fig. 3.302).

540

3 Application Core Curriculum

Fig. 3.304 a Weathered wood-façade; b wood surface before and after; c surface before staining

Fig. 3.305 a Floor boards, weathered—mold; b floor boards, clean, dried before staining; c boards, before staining

Besides determining the correct psi–gpm configuration correctly testing the coating or varnish stripper is of utmost importance. Creating test patches on shady and sunny sides are as vital on structures environmental impact zones where wind, rain and ice have varying seasonal surface influences and must be performed and correctly evaluated. Experience has shown that this is best done before an overall job estimate is established. Performing this test patch criteria also permits the evaluation as to necessary protection of landscaping, covering or removal of light

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Wood Restoration and Preservation, Seal-Coating Applications

541

Fig. 3.306 a Building-façade after cleaning and dry; b before; c after-dry; d stained; e buildingfaçade after drying, within staining process

Fig. 3.307 a Weathered floor boards; b 2 9 45 fan jets 3000 psi to 5 gpm; c surface cleaner (Spin-Jet); d before e after

fixtures and various metallic hardware, masking windows, possibly require scaffolding and/or lance extensions, checking for possible inherent dangers such as live electrical wiring, pedestrian traffic, possible windswept influence of coatings on surrounding structure or vehicles and considering the final job cleanup procedures of possible accumulated hazardous waste and its correct identification, storage and transportation to the appropriate facilities. Log homes are often accompanied by wooden decks, terraces, and staircase structures supporting the design criteria of the main buildings architectural identity. Deck staining, sealing and water proofing most often includes servicing and incorporating railings, spindles and staircase structures. Transforming decks to a pristine condition is most often required when an overall renovation is in progress. In their endeavor to save money homeowners frequently attempt to service their decks, underestimating the qualifications a professional high-pressure water application specialist requires within the wood cleaning, preservation and restoration criteria. Renting the necessary equipment and learning on the go often results in damage visually identifiable as a surface discoloration, recurrence of mold and fungus, ghosting and wood carving and/or rising of the grain in their attempt to clean or possibly remove coatings. The severity of occurring damages (Fig. 3.303) can be more visible or enhanced when surfaces are in a damp to dry stage. Identifying wood variety and type, the degree of surface deterioration, overall tool access to surfaces in question, blast water quality and mineral makeup, and securing a functional up or downstream chemical injection is a professionals

542

3 Application Core Curriculum

criterion. Also nozzles, rotary surface cleaner and spin-jet varieties, water recovery, filtration and recycling necessities are tool entities seldom available at an equipment rental facility. This especially is noticeable when researching equipment availability offered by shops for wood stain, coating and restoration treatment products supporting their product sales efforts. A property owner must understand that a qualified surface preparation is managed and achieved by a qualified tool operator understanding the substrate, and its challenges to be prepared for a coating procedure. Removing the gray appearance of aged wood siding and deck-railing surfaces (tannin) represents the simplest form of a wood cleaning procedure. A trigger gun mounted manually operated 25 fan jet applied in corners and on spindle and railing work, a rotary surface cleaner with dual 15 to 45 fan at varying psi–gpm performances, most often eliminates the application of phosphoric and oxalic acids, avoiding the application of neutralizing endeavors. Always permit adequate substrate drying time and be sure that the weather report is favorable before stain and/or penetrating water repellent oil based solvents incorporating UV protection are applied by roller, airless or pump-up sprayer. Allow for penetration time and wipe off excess product and apply brush, avoiding irregular product loading. Provide pictorial samples after pressure washing only and before staining. One after first staining application is shown (Figs. 3.304, 3.305, 3.306). Cleaning composite and ceramic tile, asphalt, cedar, and/or metal roof shakesshingles is ordinarily a simple endeavor often incorporating an advantageous gutter system to collect and operate a wastewater recovery, filtration and recycling unit. ‘‘Roof safety’’ All operations above 60 ft from the ground are subject to contractors’ safety and best practices concerning fall protection. OSHA CFR29 1926.500 and roof safety subtitles are the information base explaining the must do requirements. Safe access to roofs by ladder or any other method is a controlled criterion, which requires training in correctly operating personal protective equipment (top entrance harness, lanyards-lifeline, etc.,) and testing as it requires a safety man overseeing operations. Roof design varieties, placement of roof anchors, and various access methods accommodating the operation of rotary surface cleaning equipment, spin-jet and trigger-gun or fan jet assemblies will vary with every job description. These safety requirements are not confined to a roof surface in question, but must incorporate the whole jobsite including possible influence of surrounding vicinity. Access specialization utilizing high-pressure water tooling and wastewater recovery recycling and filtration systems are a most exciting and lucrative endeavor. The roof cleaning application and its job potential depends on geography and climate. In the Seattle or Portland, Oregon area mosses, mildew and algae are the contaminating source to roof surfaces. In an industrial city like Chicago, weather cycling and general air pollution (Fig. 3.307) and its acidity is responsible for discolorations and fungus development and in dry areas such as New Mexico the roof cleaning business is quite none existent.

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Nevertheless 90% of US homes feature asphalt shingle roofs. Modern shingles are manufactured from organic based fibers or glass-fibers of varying lengths and orientation creating a substrate impregnated with various bituminous–asphalt products and protective mineral granules providing texture and color themes. The disadvantages of these roofing products are sensitivity to physical impact or stress, especially on high heat or very cold days and the susceptibility of bitumen–asphalt to improperly applied cleaning chemicals which is best altogether avoided. Dirt– dust and other organic materials deposited by rain accumulating on low velocity roof surfaces become the breeding ground for algae type spores. Spreading and decomposing algae or fungus is the culprit which discolors a roof surface. A black striking stain development is most likely gloeocapsa magma algae found on asphalt and metal roofs. A rotary surface cleaner incorporating rpm control and a hover-craft like lift permitting unidirectional operation gliding (Fig. 25.10) over irregular shingle surfaces is the ideal tool configuration for this or other roof cleaning operations. Neutralizing the equipment’s weight and mass, nullifying lifting of shingles, incorporating finger light unidirectional control in an often somewhat physical precarious situation can not be replaced by any other tool configuration. Psi–gpm configuration is best adjusted to the low-end of granular adhesion and manipulated by 45 fan nozzles, providing removal of discoloration or bacterial growth only by adjusting the nozzle angulations’ to the surface (only). After the cleaning procedures are completed and surfaces are flooded with an preventive chemical rinse from the bottom up and after their recommended dwell time neutralized, advise customer to install copper or zinc strips on top layer of asphalt shingles. Rain wash introduces small amounts of copper poisoning–killing reoccurring bacteria. Tile roofs are more prevalent today. The lightweight surface cleaner again is the ideal unit. The application of chemicals should only occur if a dialogue with tile manufacture can be established as to the appropriate chemical solution, protecting the tile glaze. The notion that a tile glaze is susceptible to damage introduced by a surface rotary cleaning unit again is a myth perpetuated by competitive chemical salesman. Cedar–redwood, white pine-cyprus, etc. shingles are cleaned utilizing the same equipment but the chemical application, and preservation varies drastically by area, humidity, temperature, wood type, past treatment and present surface degradation, etc. Never, ever start cleaning procedures from the bottom up because water will penetrate to the roof sheeting or worse. There also is little protection and physical hold applied to a shingle system inviting damage by lifting and stepping on. Moss protruding into shingle structure must be removed, and varying by location, molds identified for the correct topical roof treatment and the application of suitable wood preservatives. All materials must be accompanied by MSDS sheet identifying ingredients and safety precautions. Chemicals work most effectively when only trace elements are left to be removed or treated on a dry substrate, if not otherwise explained. Do not apply unfortified linseed oil, fire retardants, the waterproofing sealants or plasticizers. The Cedar Shake & Shingle Bureau (www.cedarbureau.org) is a resource as to roof design, shingles or shake

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3 Application Core Curriculum

type, identification of mold-fungus procedures, etc. Today, in countless communities, plastic-vinyl siding and trim is also applied as architectural construction, such as downspouts, gutters, window frames and fencing, etc. Inherently these products are all susceptible to static bonding of dirt and airborne particles. The wide variety of manufactured vinyl siding also greatly varies in product quality. Porosity and/or composition of siding is drastically varying with exposure to sunlight (fading) and increased heat absorption resulting in inconsistencies ranging or exhibiting flat to glossy surface appearances (dull). Always check the building for missing and loose panels, and choose non penetrating application criteria avoiding water seepage to the interior. Customer must know and be aware of pre-existing damage and structural problematic preferably signing off a disclaimer before a cleaning procedure commences. After first thoroughly and repeatedly soaking vinyl surfaces and buildings immediate vicinity (foliage) apply a mild biodegradable cleaner to vinyl surfaces followed by a manual surface agitation (pole brush) immediately followed by applying the low pressure rinse avoiding lifting of siding components. A 45 fan nozzle at 500 psi 3–5 five gpm is most often sufficient. Apply rinse jet in downward motion avoiding water penetration from bottom up. Air velocity alone may damage vinyl panels, or send water to the interior. It is best to start working on the shady side of the building in progression to the sunny side expanding the water wetting and reducing chemical dwell time. To avoid streaking, the job sequence generally starts on the bottom of the structure. Vinyl’s structural susceptibility to heat will keep operating temperatures below 135F. Areas prone to mildew, infestation, noticeable and obvious especially on vinyl sidings light in color is removed by jetting and followed by a light sodium hypochlorite solution (bleach) applied to the prior infected areas. It is best to avoid the penetration of any cleaning solution to the backfill-surfaces of siding avoiding stain leaching to cleaned surfaces. Oxalic acid can be useful for rust stains, but must be applied with caution. Artillery fungus, a stubborn problem and best carefully challenged with hot water and a spin jet nozzle at reacquired pressures avoiding damage to vinyl. Areas prone to stain and dirt accumulation such as for instance mildew development in the vicinity of attic vents, on top of window-molding and door sills, soffit areas, vinyl under or behind balconies and decks are job specific, as are gutters, down-pipe and spouts, window screens and shutters which must all be considered in the bidding process do to possibly intensive time consumption within the overall cleaning process. When aware this is of no consequence; cleaning vinyl siding is one of the least difficult application criteria within the general house washing field. The aluminum siding business, once prominent, is today virtually nonexistent and includes the ever fading remaining buildings to be serviced. No one building can be compared to another or similar application criterion. Surfaces are painted and oxidize with time requiring a careful analytical application criterion as to chemistry and water pressures applied. Most often a two step cleaning process is necessary in applying systematically and equally a buffered acid solution, followed by a high alkaline soap solution to neutralize all surfaces. The first step when cleaning aluminum siding is to check for oxidation. Direct sunlight accelerates the

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GEAR - LIST AUTHORIZATION Wood restoration and preservation, vinyl, wood, aluminum siding and roof cleaning Customer & Company:

Job Nr.:

Date: Address:

Web site: e-mail:

City: State:

P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Deck-landing-staircase-railing-roof Siding: aluminum wood vinyl

Dimension lumber: fiberglas

Shingles-shakes:

Spruce: Pine: Fir: Cedar:

asphalt

tile

wood

Rough surfaced: Smooth surfaced: Deterioration: Explain: Other:

Redwood: Other: Stain type: soluble tannins, sap, pitch, moss, mold, fungus, fire, graffiti, bird-bug-pest droppings Spot cleaning: Time: Authorized:

composite

mild:

Overall square footage to be serviced: Safety procedures: (explain)

Litmus paper: (pH) Substrate-surface moisture meter:

Acid treatment: Acid neutralization: Detergent: Surface pH: Other:

lbs: yes

aggressive:

Other:

Existing structural damages: (explain)

Blast water source: Blast water discharge:

metal

gpm: no

MSDS: “ “

Equipment: roller, pump-up, airless sprayer Penetrating wood preservative: Semi-transparent stain: Solid color stain: Deck stain for previously stained decks: Exterior deck stain solvent based: Protect from water intrusion:

Water filtration and recycling: Rotating surface cleaner: vacuum-support: Spin-Jet: Extension wand: 6’ 10’ 12’ Telescopic wand: Trigger-gun: Fan nozzle: 15° 25° 45° 65° Protective skirting-cover:

Describe application and work procedure:

Overall height-with:

Scaffolding:

Itemize further equipment, safety gear, expendables, labor time, equipment times, etc.: Environment :

Industrial

Commercial

Residential

Man lift:

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3 Application Core Curriculum

GEAR - LIST

Nr.

Date: Address:

Customer & Company:

Purchasing Tel: e-mail

P.O. Box: Zip Code:

City: State:

Web site: e-mail:

Engineering Tel: e-mail

Job Nr.:

Maintenance Tel: e-mail

Safety Tel: e-mail

Job Description: Job Location:

Job Site Risk Assessment:

Specify:

©

Job Review Performed by: Building type:

Pressure washing - Hydro-blast equipment:

Non-expendable equipment:

Expendables:

Product Encountered: Hazardous Material:

MSDS:

Specify:

Safety procedure:

Work procedure:

Developed by: Authorized by:

Date: Date:

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paint chalking or paint oxidation processes. Surfaces exposed to industrial pollutants, airborne dirt such as auto exhaust and building type pending rust stains, mildew and fungus might al be an accumulative present criterion. Dark aluminum siding, such as dark red or blue is also washed from top down preventing the greater tendency to streak especially important in hot weather. Sealing this type of surface is important extending the longevity of achieved surface appearance. Required equipment includes safety glasses, chemical gloves, chemical suit, hard hat, first aid kit with eyewash, wooden-metal paddle scraper, long-range chemicalacid injector, buffered acid solution, alkaline soap, MSDS sheets, pole brush, various aluminum wands and telescopic wands, 25–45 and 65 nozzles, variable speed rotating nozzles, duct tape and plastic sheeting for masking windows, doors and foliage. Within exterior building cleaning procedures bird droppings-excrement can be encountered in various locations, which are either nesting or habitat locations which must be considered hazardous waste. A number of illnesses to include cryptococcus, histoplasmosis, and psittacosis are associated with dry bird droppings primarily those from birds in areas of nitrogen rich soils, pigeons and bats. The primary mode of transmission of these diseases to humans is via inhalation of disease causing spores-organisms. Personal protective gear, respirator NIOSH approved protection below 0.3 lm, is a must. Misting down-wetting the area of contamination limiting airborne activity before a removal process is initiated or area inspections for demolition work, restoration of historic and/or abandoned buildings is performed. Infected areas, especially in areas or vicinity of food source manufacturing, and a storage facility is this hazardous waste removal criterion regulated.

Chapter 4

Associations

Abstract Raw material, energy production, petrol-chemical and general product manufacturing and their distribution alliances most always fund and support an association specializing in industry promotion, up-to-date marketing and newsworthy content formed by their constituent and membership. They assist and provide a great inside as to their industry specific plant locations, their size, and production processes, the variety of products manufactured, identification and typing of their manufacturing hardware and/or maintenance intervals due to plant shutdown schedules or emergency response strategies, etc. Following the industries contact information in chapter introduction these associations are listed specifically within the commercial industrial resource criteria before revealing the industry specific safety regulation and criteria to facilitate a direct and pertinent information resource criteria. Services sales endeavors, prior technical qualification and classification, customer contacts and job-industry specific safety information can be accrued. ACI AAC ACGIH ACPA AAMP ANSI AAFCO

American Concrete Institute, http://www. concrete.org Aluminum Anodizers Council, http:// www.anodizing.org American conference for governmental industrial hygiene, http://www.acgih.org American Concrete Pipe Association, http://www.concrete-pipe.org American Association of Meat Processors, http://www.aamp.org American National Standards Institute, http://www.ansi.org American Association of Feed Control Officials, http://www.aafco.org

W. Maasberg, Commercial-Industrial Cleaning, by Pressure-Washing, Hydro-Blasting and UHP-Jetting, DOI: 10.1007/978-0-85729-835-5_4, Ó Springer-Verlag London Limited 2012

549

550

AAR AASP AAIA ABA ABRA ADA AERA AFDO AFIA AF&PA AGI AIW AISI Air Barrier Association of American, ANSI APA APHIS APRA ASA ASA ASA ASAE

4 Associations

Association of American Railroads, http: //www.aar.org Alliance of Automotive Service Providers, http://www.aaspi.org Automotive Aftermarket Industry Association, http://www.aftermarket.org American Bakers Association, http:// www.americanbakers.org American Bio-Recovery Association, http://www.americanbiorecovery.org American Dairy Association, http://www. ilovecheese.com/default.htm Engine Builders Association, http://www. aera.org Association of Food and Drug Officials, http://www.afdo.org American Feed Industry Association, http://www.afia.org The American Forest and Paper Association, http://www.af.andpa.org American Geological Institute, http:// www.agiweb.org Association Italiana Waterjet, http:// www.aiw.polimi.it/page.htm American Iron and Steel Institute, http:// www.steel.org http://www.airbarrier.org American National Standards Institute, http://www.ansi.org At Sea Processors Association, http:// www.atsea.org Animal and Plant Health Inspection Service, http://www.aphis.usda.gov Automotive Parts Remanufactures Association, http://www.apra.org Automotive Service Association, http:// www.ashop.org American Soybean Association, http:// www.amsoy.org American Sugar Alliance, http://www. sugaralliance.orc American Society of Agricultural Engineers, http://www.asae.org

4 Associations

ASIA ASLRR ASME AREMA

AVME ARMA ASTA ASHRAE

AHPWJA AWDA ASTM API AIChE AWS AWT

AWWA B&CMA BIA BOR CSSB

551

American Sheep Industry Association, http://www.sheepusa.org American Short Line & Regional Railroad Association, http://www.aslrra.org American Society of Mechanical Engineers, http://www.asme.org The American Railway Engineering and Maintenance-of-Way Association, http:// www.arema.org American Veterinary Medical Association, http://www.avma.org Asphalt Roofing Manufacturers Association, http://www.asphaltroofing.org American Seed Trade Association, http:// www.amseed.com American Society of Heating, Refrigeration a. Air-Conditioning Engineers, http: //www.ashrae.org Australian High Pressure Water Jetting Association, http://www.ausjetinc.com.au/ Automotive Warehouse Distributor Association, http://www.awda.org American Society for Testing and Materials, http://www.astm.org American Petroleum Institute, http:// www.api-houston.org American Institute of Chemical Engineers, http://www.aiche.org American Welding Society, http:// www.aws.org German Working Group of Water Jet Technology, http://www.iw.uni-hannover. de/awt/index.html American Water Works Association, http://www.awwa.org Biscuit and Cracker Manufacturer Association, http://www.thebcma.org Brick Industry Associations, http://www. gobrick.com Bureau of Reclamation, http://www. usbr.gov Cedar Shake & Shingle Bureau, http:// www.cedarbureau.org

552

CGA CISPI CCI CCR CSI CVSN DKI D-U-N-S Federal Housing Administration, EDI EIA EIFS-synthetic stucco, EPA EPRI ETA FDA FRA FSCT FWS FPA FWS FCC

4 Associations

Compressed Gas Association, http:// www.cganet.com Cast iron soil pipe Institute, http:// www.cispi.org Cotton Council International, http:// www.cottonusa.org Central Contractor Registration, http:// www.ccr.gov Construction Specification Institute, http://www.csinet.org Commercial Vehicle Solutions Network, http://www.cfshq.com Disaster Cleanup International, http:// www.disasterkleenup.com Dun & Bradstreet (D&B), http://www. dnb.com http://www.hud.org Exterior Design Institute-synthetic stucco, http://www.exterior-design-inst.com Energy information Administration, http: //www.eia.doe.gov http://www.exterior-design-inst.com Environmental Protection Agency, http:// www.epa.gov Electric Power Research Institute, http:// www.my.epri.com Cleaning Equipment Trade Association, http://www.cera.org Food and Drug Administration, http:// www.fda.gov Federal Railroad Administration, http:// www.fra.dot.gov/ Federation of Societies for Coatings Technology, http://www.coatingstech.org Fish and Wildlife Service, http:// www.fws.gov Food Processing Association, http:// www.mwfpa.org Fish and Wildlife service, http://www. fws.gov Federal Communications Commission, http://www.fcc.gov

4 Associations

FAACO

FAA FHA FHWA FWPCA GANA IAAPA IARW IAQA ICGA ICCF

ICMA ICRI ISRI ISO IMCA INGAA IKEKA IFC ISSA IOOC

553

Federal Aviation Administration Contract Opportunities, http://www.faa.gov/ ?=7482 Federal Aviation Administration, http:// www.faa.gov FEMA, Federal Emergency Management Agency, http://www.fema.gov US Federal Highway Administration, http://www.fhwa.dot.gov Federal Water Pollution and Control Act (Clean Water Act), http://www.epa.gov Glass Association of North America, http://www.glasswebsite.com International Association of Amusement Parks and Attractions, http://www.iaapa.org Refrigerated Warehousing Associations, http://www.iarw.com Indoor Air Quality Association, http:// www.iaqa.org Infiltration Control Grouting Association (NASSCO) http://www.sewergrouting.com International cemetery, cremation and funeral association, http:// www.iccfa.com State and Local Government Management Associations, http://www.icma.com International Concrete Repair Institute, http://www.icri.org Institute of Scrap Recycling Industries, In., http://www.isri.org International Organization for Standardization, http://www.iso.ch International Marine Contractors Association, http://www.imca-int.com Natural Gas Association of America, http://www.ingaa.org International Kitchen Exhaust Cleaning Association, http://www.ikeca.org International Finance Corp., http:// www.ifc.org International Sanitary Supply Association, http://www.issa.com International Olive Oil Council, http:// www.internationaloliveoil.org

554

JSA

MIA MIA MSHA MPI NADCA NACE NASSCO NCPI NCMA NEMA NPDES NPRA NFPA NFPA NMA NIOSH NGA NTPEP NRC NUCA

4 Associations

Joint Subcommittee on Aquaculture (federal), http://www.epa.gov/agriculture/ anaquret Marble Institute of America, http:// www.marble-institute.com Masonry Institute of America, http:// www.masonryinstitute.org Mine Safety and Health Administration, http://www.msha.gov Master Painters Institute, http://www. mpi.net National Air Duct Cleaners Association, http://www.nadca.com International Corrosion Association, http://www.nace.org National Association of Sewer Service Companies, http://www.nassco.org National Clay Pipe Institute, http:// www.ncpi.org National Concrete Masonry Associations, http://www.ncmaetek.org National Electrical Manufacturers Association, http://www.nema.org National Pollutant Discharge Elimination System National Petrochemical and Refiners Association, http://www.npradc.org National Fire Protection Association, http://www.nfpa.org National Food Processes Association, http://www.foodinfonet.com National Mining Association, http:// www.nma.org National Institute for Occupational Safety and Health, http://www.niosh.org National Glass Association, http:// www.glass.org National Transportation Product Evaluation Program, http://www.ntpep.org Nuclear Regulatory Commission, http:// www.nrc.gov National Utilities Contractors Association, http://www.nuca.com

4 Associations

OSHA PCA PDA

PSPA PPSA PPSA PPFA PPOA PERA PIMA PWNA SAE SNAME SSPC SFM SMA SMA SPRAT TAPPI TIA WJTA

555

Occupational Safety and Health Administration, http://www.OSHA.gov Portland Cement Association, http:// www.cement.org Pump Distributors Association No 5, Chapelfield Orford, UK., http:// www.the-pda.com/ Pacific Seafood Processors Association, http://www.pspafish.net Pigging Products and Services Association, http://www.ppsa-online.com Pulp and Paper Safety Association, http:// www.ppsa.org Plastic Pipe and Fittings Association, http://www.ppfahome.org Professional Pool Operators of America, http://www.ppoa.org Production Engine Remanufacture’s Association, http://www.pera.org Paper Industry Management Association, http://www.pimaweb.org Power Washers of North America, http:// www.thepwna.org Society of Automotive Engineers, http:// www.sae.or Society of Naval Architects and Marine Engineers, http://www.sname.org The Society for Protective Coatings, http://www.sspc.org Society for Food Service Management, http://www.sfm-online.org Stucco Manufacturing Association, http://www.stuccomfgassoc.com Steel Manufacturers Association, http:// www.steelnet.org Society of Professional Rope Access Technicians, http://www.sprat.org Technical Association of the paper and pulp industry, http://www.tappi.org Tire Industry Association, http:// www.tireindustry.org Water Jet Technology Association, http:// www.wjta.org

556

WJT UK UL USACE USDA

4 Associations

The Water Jetting Association 17 St. Judiths Lane, Sawtry Camps PE28 5XA United Kingdom, http://enquiries@ waterjetting.org.uk Underwriters Laboratories, http:// www.ul.com United States Army Corps of Engineers, http://www.usace.army.mil United States Dept of Agriculture, http:// www.usda.org

Chapter 5

Safety Information

Abstract Introduced are the job walk principles which must first consider the industries and/or customers specific environment, rules, regulations and safety procedures concerning their operation and/or production which include in-house labor or possible effects on secondary trades? Assigning a probability or likelihood and possible severity of an accidental mishap in an area or application criterion can be identified as a certainty, probability and possibility, or remote and improbable. This type of risk assessment is most often controlled within a customer’s environment and its operation. However, often underestimated are risks and hazards encountered within an unfamiliar job environment where unidentified threats to safety are the result of an application specific condition? These possibilities are discussed in detail throughout chapter Introduction and the Application core criteria combined with the introduction of recommended practices for the use of manually operated high-pressure water jetting equipment. The following contractor’s basic bid-paperwork illustrations consider this safety oriented principals.

5.1 Contractor’s Basic Safety Information Bid and Paperwork Illustrations UHP, hydro-blast and pressure washing applications are never offered or performed without a subjective jobsite risk assessment, its management and cost criteria. Profit margins are greatly susceptible when day-to-day operations do not consider concealed risks within an application procedure. Unanticipated and/or belated elimination of hazards to protect operators and labor force within the direct or indirect vicinity of services performed can be costly to everyone involved. Assigning a probability or likelihood and possible severity of an accidental mishap in an area or application criterion can be identified as a certainty, probability and possibility, or remote and improbable. This type of risk assessment is W. Maasberg, Commercial-Industrial Cleaning, by Pressure-Washing, Hydro-Blasting and UHP-Jetting, DOI: 10.1007/978-0-85729-835-5_5, Ó Springer-Verlag London Limited 2012

557

558

5

Safety Information

Fig. 5.1 a Recommended practices, b medical information card

most often controlled within a customers environment and its operation. However, often underestimated are risks and hazards encountered within an unfamiliar job environment where unidentified threats to safety are the result of an application specific condition. A job walk principle must first consider the industries and/or customers specific environment, rules, regulations and set safety procedures concerning their operation and/or production which include in-house labor or possible effects on secondary trades. This will require a contractor’s labor force participation in the education as to plant-locations specific safety procedures. This includes recognizing plant equipment and its maintenance consequences, safe behavior in various plant environments, their process equipment, machinery and possible production processes before high-pressure water application technologies can be fine-tuned for safe onsite or in plant operations. The pressure washing hydro-blasting and UHP technician cannot afford to make a risk assessment as to probable, possible or the remote possibility of injury by tooling manipulating high-pressure water and/or by the resulting industrial product or waste removal technique which includes the environmental consequences of toxic and flammable-volatile materials (Fig. 5.1). A positive identification by risk assessment of possible hazardous inhalation, bruising, minor lacerations, injection injuries or broken bones must always result in the total elimination of such a possibility. Personal protective gear, providing non-skin contact protection starting with gloves, rain gear, eye protection, face shield, boots specifically designed for high-pressure water cleaning applications,

5.1 Contractor’s Basic Safety Information Bid and Paperwork Illustrations

559

APPLICATION REVIEW Date:

Customer, Company:

Nr:

Address: City:

Web site: e-mail:

Purchasing Tel: e-mail: Area:

P.O. Box: ZIP Code:

State:

Engineering Tel: e-mail: Area:

Maintenance Tel: e-mail: Area:

Safety Tel: e-mail: Area:

Job Description: Job Location:

Job-Site, Hazard Risk Assessment::

Specify:

Jobsite Review:

Expendables: Safety equipment and procedures: Developed by: Authorized by:

Date: Date: WORKSHEET- ENGINEERING - FIELD-TECH

560

5

Safety Information

Fig. 5.2 Best management practices

fall and respiratory protection including a possible respiratory program, which may require air supplied respirator equipment, etc. are requirements sometimes in part also considered expendables within a bid procedure for a variety of applications. With every job narrative general hazards are eliminated by providing safe access and egress to the jobsite, protecting labor force from slips, trips and falls, falling objects from overhead structures by secondary trades, and the correct handling of heavy equipment. Industry specific safety guidelines and job related safety criterion is always an application guiding circumstance varying with every job description explained and recorded in chapters ‘‘introduction’’ and ‘‘application core’’. Information for safe operation of pressure washing, hydro-blast and UHP equipment can be found in various publications as to the recommended practices for the use of manually operated high-pressure water jetting equipment published by the WJTA Association which includes a medical alert note to physicians, or the Power Washers Association of North America (PWNA), providing best management practices for pressure washers within various applications. The UK’s water jetting Association publishes the code of practice for the safe working and use of water Jets (Fig. 5.2).

5.2 Application Register Catalog Marine–Agricultural–Aquatic–Industrial–Commercial–Residential ‘‘Register’’ numbers are ‘‘branded by’’ business and industry identification or manufacturing hardware and process, identity of an service industry and particular business practice, type of product to be removed, area identification, or environmental and disaster terminology. Secondary ‘‘register’’ numbers apply either to application similarities or an application criterion necessary within a specified primary job description. With a job curriculum derived from an ‘‘application review’’ its application core ‘‘gearlist’’ authorization will support and/or fine-tune a gear-list derived from an application review (Figs. 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 5.10, 5.11, 5.12, 5.13, 5.14 and 5.15).

5.2 Application Register Catalog

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“

”

(a)

(b)

Fig. 5.3 Application register a A, b S, c C, d P (continued)

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5

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(c)

(continued)

5.2 Application Register Catalog

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(d)

564 GEAR - LIST

5

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Nr.

Customer & Company:

Date: Address:

Web site: e-mail:

City: State:

Job Nr.: P.O. Box: Zip Code:

Purchasing:

Engineering:

Maintenance:

Safety:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Tel: e-mail:

Job Description: Job Location:

Job-Site, Hazard Risk Assessment:

Specify:

Job Review Performed by: Plant hardware:

Hydro-blast equipment:

Plant location:

Equipment:

Expendables:

Product Encountered: Hazardous Material:

MSDS:

Specify:

Describe application and work procedure:

Describe safety procedure: Itemize equipment, safety gear, expendables, etc.:

Developed by: Authorized by:

Date: Date:

5.2 Application Register Catalog

Fig. 5.4 Bid proposal form

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Fig. 5.5 Daily time ticket

5

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5.2 Application Register Catalog

Fig. 5.6 Sample confined space entry permit

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568

Fig. 5.7 Page 2, confined space entry permit

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5.2 Application Register Catalog

Fig. 5.8 Waste stream, chemical product chain of custody record.

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Fig. 5.9 Pre-job safety meeting record and signature sheet

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5.2 Application Register Catalog

Fig. 5.10 a, b Taligate safety meeting and signature sheet

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572

Fig. 5.11 Down time work sheet

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5.2 Application Register Catalog

Fig. 5.12 Repair work order-sheet

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Fig. 5.13 Drivers’ inspection check list

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5.2 Application Register Catalog

Fig. 5.14 Verbal quoted price record

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576

Fig. 5.15 Road expense and disbursement record

5

Safety Information

About the Author

Wolfgang Maasberg started his career at WOMA Germany in 1967. Soon his field of expertise resulted in demonstrating to potential customers advanced high-pressure water tools and equipment (up to 10,000 psi). The 1968 expansion of WOMA to the United States extended this activity into the Americas. Also involved in the application advancements of commercial-industrial hydro-vac systems and rotary surface cleaning equipment (25–600 hp), Wolfgang following WOMAs employment utilized the newly developed highpressure water tool variety for service providers involved in the introduction of application technologies to navy-marine, industrial and commercial business identities. Providing commercial and industrial cleaning services integrating hazardous waste abatement and dredging applications, paint coating removal, concrete surface abrasion-roughening and/or demolition applications the sewer, pipe, boiler and condenser maintenance criterion concluded the field of activity. The development and prototyping of mobile hydro-vac systems, wastewater recovery, filtration and recycling equipment (18–300 hp) enriched the existing application variety. Today, these successful technologies support an array of applications flourishing also within the lower horsepower ranges. Wolfgang developed his

W. Maasberg, Commercial-Industrial Cleaning, by Pressure-Washing, Hydro-Blasting and UHP-Jetting, DOI: 10.1007/978-0-85729-835-5, Ó Springer-Verlag London Limited 2012

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About the Author

business model based on practical, hands-on experience applying experimental and most up-to-date equipment and tooling varieties. Recording all bid and practical job application aspects in the commercial and industrial environment does sustain the constant expansion of the established business model and correlating instructional manual.

Glossary of Acronyms, Abbreviations and Symbols, Industrial Language Discovery

In consideration acronyms, abbreviations and symbols directly pertain to the application criterion influenced by pressure-washing, hydro-blast and UHP jetting procedures developed for commercial and industrial environments. This includes technical standards for jetting equipment, commercial industrial manufacturing hardware and process. The commercial industrial language discovery also extends into books Index content revealing commercial and industry specific vocabulary not relating to a specific core application vocabulary found within the application register criterion Abrading Surface preparation of concrete, intended to roughen the surface profile of the concrete subsequent removing foreign material, UHP, hydro-blast and water abrasive blasting are methods of surface abrading Abrasive A fine granulated material used for hydro-abrasive blasting Abrasive jet Solid-soluble abrasive particles admixed to a water jet Abrasive water jetting-blasting-abrasives Admixed to one or more water jets in a venturi configuration Absorption The uptake or absorbing of water, other fluids and dissolved chemical Abatement Reducing the degree or intensity off, or eliminating pollution Abatement debris Waste from remediation activities ABS Acrylonitrile butadiene styrene, a common thermoplastic Accumulator A pressure chamber absorbing-equalizing reciprocating p. pressurecycles pulsations, and fluid mass-shock

W. Maasberg, Commercial-Industrial Cleaning, by Pressure-Washing, Hydro-Blasting and UHP-Jetting, DOI: 10.1007/978-0-85729-835-5, Ó Springer-Verlag London Limited 2012

579

580

Glossary

Adhesion is called the bonding strength of a coating, the degree of attraction between a coating and substrate or between two coats of paint that are held together by chemical–mechanical force Adsorption Removal of pollutant from air or water by collecting the pollutant on the surface of a solid material, treating waste in which activated carbon, nutshells, etc. remove organic matter from wastewater Adsorption (2) The result of an material (filter media) capable of extracting a substance from a mixture of gases and/or liquids and gathering it on the surface of the media in an condensed layer, the process is not accompanied by physical or chemical changes Acid A corrosive solution with a pH less than 7, and has the ability to react with bases or alkalis in water solutions. Litmus paper turns red, a pH of 1 indicates as strong acid. Orange-lemon juice and vinegar also contain acids. Specific acids are applied for phosphatizing and aluminum brightening, concrete etching, etc. Acid gas scrubber-air handling system To remove acid gas exhaust from various industrial processes Acid inhibitors Chemicals greatly reducing the attack of acids on metals, inhibitors may also prevent damage caused by acids Acid resistant brick-tile Suitable for use in contact with chemicals, foodstuffs, etc; usually laid with acid resistant mortars Acid resistant, cast iron pipe Cast iron pipe containing between 14.25 and 15% silicon, small amounts of manganese, sulfur and carbon manufactured in same dimensions as cast iron pipe Acidic Said of igneous rocks (brick’s), containing more than 65% silica Activated sludge A primary effluent is mixed with bacteria-laden sludge and then agitated and aerated to promote biological treatment, speeding the breakdown of organic matter in raw sewage undergoing secondary waste treatment acfm Actual cubic feet per minute AC Alternating electric current that reverses its direction at regular intervals, the number of times per second the current completes its flow in both directions is called the frequency and given the unit in hertz (Hz) ACM Asbestos containing materials Aeration Exposes to circulating air, adds oxygen to the wastewater and allows other trapped gases to escape, the first step in secondary treatment via activated sludge Aflatoxin Naturally occurring mycotoxin produced by two types of mold

Glossary

581

Agribusiness Agriculturally related businesses that supply farm inputs such as fertilizer or equipment or are involved in the marketing of farm products, such as warehousing, processors, wholesalers, transporters and retailers Agricultural pipe drain Porous or perforated pipes lay in a gravel filled trench draining subsoil Aggregate Inert granular material such as natural or manufactured sand, gravel, crushed gravel and stone, vermiculite, perlite, air cooled blast furnace slag bound by concrete or mortar utilizing a matrix form or an inert granular material that is added to gypsum plaster Air pollution scrubber-system Built to remove contaminants from air, utilizing water and/or chemicals ALARA As low as reasonably achievable, a radiation safety principal for minimizing radiation doses Alternator Alternating electric current generator Algae Various aquatic plant life forms Algae discoloration A type of roof discoloration caused by algae, commonly called fungus growth Alkaline builders Starting with the strongest, caustic soda, sodium ortho-meta silicate, Trisodium phosphate, soda-ash, borax, bicarbonate of soda Alkali Chemical substance such as potassium hydroxide or sodium carbonate that neutralizes acid Aluminum brightener An acidic cleaning solution, etching aluminum surfaces, a brightening effect Ambient conditions The weather including air temperature, relative humidity, dew point and wind velocity Anaerobic digester Vessel for digesting the organic matter in a waste treatment plant by organisms which do not use oxygen Anti siphon valve Utilized to prevent contamination of drinking water when pump equipment is connected to city supply, equivalent to a check valve Anodized aluminum (Anodic coating) A coating chemically bonded to an aluminum surface to prevent oxidation Atm Atmosphere Asbestos abatement Procedures to control fiber release from asbestos containing materials in a buildingvessel or industrial property, to remove them entirely, encasement, encapsulation, repair, or enclosure ASCS Air systems cleaning specialist

582

Glossary

Airless spraying A coating method utilizing hydraulic pressure between 2 and 3,000 psi to atomize paint Air band -air shutter A band or disc on a fuel burner that adjusts and regulates air to combustion chamber Artillery or shotgun fungus A growth identified by small black dots of various sizes creating stubborn or permanent stains on most surfaces Asphalt-based paints A specialized cut back asphalt product that can contain small amounts of other materials such as lampblack aluminum flakes, or mineral pigments, they are used in water proofing operations and other similar applications Asphalt plastic cement Asphalt based sealant material meeting ASTM D4586 type one or two used to seal and adhere roofing materials. Also called mastic, blackjack, roof tar and bull Asphalt-concrete primer Asphalt–based primer used to prepare concrete and metal for asphalt sealant applications ASU Air separation unit Atmospheric tanks Rectangular or cylindrical vertical or horizontal are used for liquids, whose vapor pressure is atmospheric or below at storage conditions Autogenous flash point Called also self ignition flash-point or auto ignition, the temperature at which a substance will self ignite. No outside source, flame or heat is required Auto-start An automatic startup system built into some pressure washers and hydro-blast units configured so as to start up when a electric or pneumatic signal a pressure drop or the trigger gun is operated AWT Advanced wastewater treatment Automatic cool-down Automatic shutdown sequence, continuous cool down of heating coils preventing excessive calcium buildup Back-flow valve To prevent contamination of city drinking water when utilizing city water source as a hydrant or valve assembly Bag-house unit Utilized for dust collection from massive air streams throughout the industrial-commercial environment it is the final portion of a dust collection system Ballast Water stored in tanks onboard ships utilized to trim and stabilize a vessel Ball valve Is a quarter turn on-off valve Baking soda Sodium bicarbonate Bar A metric unit of pressure

Glossary

583

Barrier coatings A layer of a material that obstructs or prevents passage of something through a surface that is to be protected Baume Baume scale is a measure of a solution’s specific gravity not its concentration Bentonite A colloidal clay commonly used to provide a tight seal around a well casing, soil remediation-stabilization and honing applications Bio-accumulation The increase in concentration of toxic chemicals heavy metals, and certain pesticides in plants and animals as they take in contaminated air, water, nutrition or food Biodegradable A natural process by which an organic or carbon containing material is decomposed by Micro-organisms producing carbon dioxide, water and inorganic salts Befouling Biological encrustation of surfaces in seawater by flora and barnacles Biological monitoring By means of living organisms to test the quality of either effluent to be discharged into receiving waters or waters downstream from a discharge Biomass Is anything derived from plant or animal matter and includes agricultural, forestry waste and energy crops. It is burnt as fuel, or combustible oils are extracted from it Bioremediation Use of living organismsnormally bacteria, bugs, snails, etc. to alter a compound into a non-hazardous substance, also applied to clean up oil spills or remove-convert other pollutants from soil, water, or waste water Biosecurity Agricultural practices intended to reduce or prevent the introduction of infectious disease on a farm or other production facility bbl/day Barrels per day Blackwater Water that contains animal human or food waste Blasting pressure Pressure usually expressed in pounds per square inch (psi) or kilo Pascal (kPa) Bleach A product that will whiten, brighten and remove stains on wood, hard and porous surfaces Blow-down valve A valve as utilized on car tires to introduce compressed air to dewater pump equipment Blushing A dulling effect caustics and acids can have on finished or painted surfaces seen often as a ‘‘whitening agent’’ Blush rust First formation of iron oxide found on a steel surfaces following exposure to high-pressure water coating removal-cleaning applications by the passivated surfaces to moisture

584

Glossary

BTU British thermal unit-unit of heat energy equal to the amount of heat required to raise the temperature of 1 pound off water by 1°F at sea level BMP Best management practice(s) Burst pressure The pressure at which a component will fail BFW Boiler feed water Brackish Mixed fresh and salt water Brick-stone beam Several courses of bricks or stones (lintel) held together by iron straps Bridge deck The portion of a bridge that provides direct support for vehicle and pedestrian traffic Brush-off blast cleaning A blast-cleaning standard with the lowest quality requirements BOD Biochemical Oxygen Demand: biological oxygen demand Boson’s chair A suspended device from a single cable or rope for use by a single individual in sitting position Bottom ash Non-airborne combustion residue from burning pulverized coal in a boiler Boiling point Temperature in degrees Fahrenheit or Centigrade at which any given liquid bubbles or gives off vapors Boot-top Area on the exterior hull of a ship between the light load line and the deep load line Bore-pump The diameter of a pumps piston or plunger Builder A material that enhances or maintains the cleaning efficiency of the surfactant in a detergent Buffer Compounds when contained in a solution causes the solution to resist change in pH Bug hole Irregular or regular cavities usually not exceeding 15 mm in diameter, resulting from entrapment of air bubbles in formed concrete surfaces Burnish Polish or rubbing to a smoother or glossier surface Burst-plate Burst plate assembly; a safety device installed to the discharge side of a hydro-blast system and is generally only activated when accidentally exceeding pumps operating pressure by one third before a catastrophic plate failure will explosively eliminate system pressure and possibly the full water volume produced (never ever exchange burst plate with a penny nickel or quarter)

Glossary

585

Burner Burner blows fuel over the electric arc igniting a flame inside of coil assembly Burner gun Removable assembly within an oil burner housing that typically contains oil line nozzle adapter, nozzle, static pressure plate/fins, electrode support and electrodes Burner drawer assembly Same as burner gun Butadiene styrene (Acrylonitrile) ABS is a common thermoplastic used to make light rigid molded products By-pass Water flow diverted from a pumps pressure side to the suction side By-pass plug A small plug that must be installed in a commonly used version of a oil burner fuel pump if the pump is to be used in a to pipe system (suction and return) CCTV Closed-Circuit TV Cadmium Toxic cadmium compounds have been used as color pigments often mixed with other heavy metal compounds Calcium carbonate Insoluble compound that results from the reaction of sodium or potassium carbonate especially in hot water soluble with acid Calcium carbonates-2 An environmentally friendly powder-light abrasive used with high-pressure water as blast-cleaning agent correctly applied without damaging or adversely affecting stone surfaces Calcium hypochlorite Specific chlorine bleach used in deck cleaning products also marginally effective against mildew Calcium oxide Chemical name for lime or quick lime CAFOs Facilities with a capacity of 2,500 or more swine subject by the EPA to point source pollution permit requirements Carbon dioxide percentage When measured in oil or gas burner flu-gas indicates efficiency of combustion Catwalk A often narrow walkway to facilitate plant structure access Caulk To fill and joint with mastic or asphalt cement to prevent leaks Caustic Strong alkaline substances eroding many types of materials with a pH generally greater than 12.5 (sodium hydroxide). Caustic materials have a corrosive effect on human tissue Caustic embrittlement Corrosion from acidic media couples’ with internal stress to form a brittle alloy particular at grain boundaries. This causes reduced ductility and metal failure, if the metal is subject to bending stress

586

Glossary

Cavity flashing A sheet of waterproofing material installed across the gap of a cavity wall can be of ferrous or nonferrous continuous material Cavitation The formation and implosion (collapse) of gas bubbles created within the contact area of an high velocity water stream causing metal pitting, sometimes deformation on high pressure water valves, plungers etc. Cavitation damage (2) The pitting of concrete caused by implosion (collapse) of gasses bubbles in high velocity flowing water C° Degrees Celsius metric scale of temperature Class ‘‘A’’ The highest fire-resistance for roofing as per ASTM E-108 indicating roofing is able to withstand severe exposure to fire originating from sources outside the building Class ‘‘B’’ Fire-resistance rating that indicates roofing materials are able to withstand moderate exposure to fire originating from sources outside the building Cloud point The temperature a detergent-concentrate or solution separate into two distinct phases Cleaning units An arbitrary measure of effectiveness which is the product of psi and gpm resulting from? an actual horsepower input, arbitrary due to nozzle design efficiency and stand off distances to various surfaces Cleanser A powdered cleaning product usually containing an abrasive, surfactant and sometimes a bleach Clean Water Act The principal law governing pollution of the nation’s rivers lakes, estuaries and coastal waters CCR Central contractor registration is the primary registrant database for the US Federal Government CAA Clean air act—federal law governing efforts to control air pollution CGCC Coal gasification combined cycle CCI Cotton council international CEM Continuous emission monitoring CERCLA Comprehensive environmental response compensation, and liability act Check valve Allows flow-through in one direction only Chlorination In wastewater treatment plants used as a pretreatment to keep effluent from turning septic CH4 Methane

Glossary

587

Chelating A substance has the ability to chemically bind calcium and/or magnesium ions to form a water-soluble third substance Chiller Cools a fluid to a temperature below that obtainable if water only were used as a coolant utilizing a refrigerant such as ammonia or freon CIP Clean-in-place system and procedure CIPP Cured-in-place pipe lining CMU Concrete masonry units smooth or split-faced concrete block walls CMRS Certified microbial remediation supervisor Coils Mounted in vertical or horizontal position transferring heat from fire side area to the high-pressure water and only when in operation Combustible liquid A liquid with a flashpoint above 148°F but less than 200°F Combination machine Equipment that can function as a cold and hot pressurewasher and/or steam cleaner Combined-cycle system Utilizes gas from heating coal which operates a combustion turbine connected to a generator and the exhaust gases from this turbine heat water that in turn operating a steam powered generator Clarifier A clarifier is a active process tank that allows solids to settle out of solution Cooler Cools liquids or gases by means of water C.O.C. and C.C.C. Cleveland open or closed cup method to establish and express the flash-point or fire-point of a substance COD Chemical oxygen demand CO Carbon monoxide CO2 Carbon dioxide Complex phosphates Utilized in detergents to overcome water hardness to break up and suspend water-insoluble material, Condenser Condenses a vapor or mixture of vapors Contactor A heavy-duty relay that allows a low power control signal to turn on/ off a much higher power load Corrosion inhibitor A product in a cleaner that protects against an attack on metal or living tissue or inhibits a discoloration of aluminum, magnesium, zinc and chrome Crevice A narrow opening or fissure CSS Chloride scrubbing system

588

Glossary

CTB Coal tar pitch cementitious solid that is obtained as a residue in the partial evaporation or fractional distillation of coal tar and used in coatings, paint, roads, roofing, coal briquettes, and sealants Coal tar A tar that contains polycyclic aromatic compounds and is produced by the destructive distillation of bituminous coal CT Combustion turbine CFM Cubic feet per minute CFR Code of Federal Regulations (www.access.gop.gov/nara/cfr) CFSAN Center for Food Safety and Applied Nutrition (vm.cfsan.fda.gov/list.htm) Conveyance loss Water loss in pipes channels, conduits, ditches and surfaces by leakage or evaporation Cut-back A coating binder as coal tar or asphalt in an organic solvent to provide easy application CVI Certified ventilation system inspector CWA Clean water act 1972 CWS Cooling water supply CWR cooling water return DBB Double block and bleed Decontamination Removal of harmful substances such as noxious chemicals, harmful bacteria or other organisms, or radioactive material from room, equipment and structural surfaces Deflocculating The breaking up of solid soil aggregate into small particles to be flushed Degreaser A product that emulsifies grease and oil Demulsify Breaking down an emulsion of its insoluble material forming a separate layer (oil–water) Dermal toxicity The ability of a pesticide or toxic chemical to poison people by contact with the skin Descaling High-pressure water cleaning technique for removal of hard water deposits detergents or chemicals from interior of a condenser or heat transfer tubes Descaling pump Acid resistant pump circulating acid solution through a boiler or heating coils dB Decibel(s)

Glossary

589

Density A measure of how heavy a specific volume of a solid liquid, or gas is in comparison to water Deflagration Dispersion of dust particles in sufficient quantity and concentration which can cause a rapid combustion if the event is confined by an enclosure as building vessel or equipment and ignited by heat, flame or static electricity Deflocculating agent A material added to a suspension to prevent settling Degasification A water treatment that removes dissolved gases from the water Demineralization A treatment process that removes dissolved minerals from water DEQ Department of environmental quality Dew point The temperature at which a gas or air at atmospheric pressure is saturated with a condensable component Digester A large cylindrical vertical pressure vessel, where wood chips are steamed with caustic cooking solutions Dilution ratio That amount of water mixed with a chemical Direct belt drive Refers to the transfer of power between motor and pump Direct current (DC) Electric current that flows in one direction only such as the battery current Diaphragm pump A positive displacement pump Dissolved solids The quantity of dissolved material in parts per million (ppm) DOC Dissolved organic carbons DOE Department of Energy Double acting plunger, piston A pump design in which fluid is discharged during both directions of stroke Down-fired burner Oil burner that fires downward into a vertical heating coil Downstream The pressure-discharge side of every pressure washer or hydro-blast equipment Downstream injector Chemical injector installed on the pressure-discharge side of any pressure-washer Double lance-wand Manually variable-adjustable pressure wand with chemical applicator nozzle-jetting Draft diverter Utilized in a flue discharge diverting possible downdraft allows combustion gases to escape from the equipment regardless of flue draft conditions and preventing back-draft from entering the combustion chamber and/or controls excessive up-draft in flue by drawing air through the diverter, rather

590

Glossary

than through the combustion chamber, generally a draft hood provides the same function Drip leg A gravity sediment and condensate collection by a vertical pipe installed before pipe enters a gas-fired appliance Drum kit A prepackaged quantity of concentrated chemical which can be diluted with water to equal a 55 gallon drum of normal strength chemical Dry Rot Wood rot caused by certain fungi dry rot can result from condensation build-up, dry rot will not remain localized and can damage any lumber touching the affected area Dryvit A registered trade name for exterior siding known as EIFS referred to as synthetic stucco (pressure sensitive) Dry steam Steam that does not contain velocity transferring water droplets DSI Pilot-less ignition system for gas burners a direct spark ignition [ Interior diameter D-U-N-S Dun & Bradstreet (D&B) provides a unique nine digit identification number for each physical location of your business location Dump-gun A trigger gunwhich switches the water flow from nozzle orifice two a muffled nozzle orifice of equal size within the gun housing or dumps the pressurized water directly to atmosphere Dwell time The active penetrating time necessary for a chemical application to a surface before pressure-washing hydro-blasting, rinsing and/or substrate neutralization commences EPA Environmental Protection Agency Effluent Wastewater treated or untreated that flows out of a treatment plant sewer, or industrial discharge, generally refers to waste discharge into surface water Effluent limitations Restrictions established by a State or EPA on quantities rates and concentrations in wastewater discharges Eaves Lower edge of a sloping roof of a building which projects beyond the wall Eaves fascia The vertical board attach to the end of roof rafters EIFS Exterior insulation low-maintenance synthetic-stucco wall finish-systems (water jet sensitive) Environmental site assessment the process of determining whether contamination is present on parcel or real property Enclosure Putting an airtight impermeable, permanent barrier around asbestos containing materials, to prevent the release of asbestos fibers into the air

Glossary

591

Emulsifier A chemical that aids in suspending one liquid in another usually an organic chemical in an aqueous solution (water) Emulsification The breaking up fats oils, grease and other soils into small particles which are then suspended in water Entrain To trap bubbles in water either mechanically through turbulence or chemically through a reaction Environmental exposure Human exposure to pollutants originating from facility emissions threshold levels are not necessarily surpassed, low-level chronic pollutant exposure, one of the most common forms of environmental exposures Elastomeric Materials having rubber like properties Electrode An insulated conductor that carries high voltage for ignition from the rear area of an burner gun to the combustion area. They are usually used in pairs with ignition spark occurring between them located near the fuel nozzle (in fuel vapor-spray) Electrostatic static precipitator Is a device that gives coal dust particles an electric charge to be attracted to a collector plate precipitators help to prevent air pollution Equivalent orifice size The orifice of a qualified jetting nozzle is not a round hole. Various nozzles performance charts list the relevant orifice size which is the diameter capacity of a round hole (water passage) Etching A solution reacting with a surface it is on and either removes a microscopic layer of the metal or dissolves-dulls glass Evaporation pond Areas where sewage, industrial liquid waste is pumped or dumped and dried Exposure level The amount (concentration) of chemicals at the absorptive human skin surfaces Exposure concentration The concentration of a chemical or other pollutant representing a health threat in a given environment Exposure assessment Identifying the pathways by which toxins may reach individuals, estimating how much of a chemical an individual is likely to be exposed to and estimating the number likely to be exposed Exposure pathway The pass from sources of pollutants via, soil, water, clothing, and or food to humans Excess air Air supply to a burner over and above what is needed for combustion Fabric filter A cloth device that catches dust particles from industrial emissions (bag house) Ft.2 Square-foot

592

Glossary

°F Degrees Fahrenheit the scale of temperature used in the United States Farrow-to-finish A confinement operation where pigs are bred and raised to their slaughter weight Fascia girder Exposed outermost girder of a structure often treated architecturally providing an attractive appearance FCOJ Frozen concentrated orange juice Filters and strainers Intended to protect fluid end (pump head) by removing high velocity contaminants extending valve bodies plunger-packing surfaces and nozzle offices operational cycle FDA Food and Drug Administration Feed lot A confined area for the controlled feeding of animals Ferric iron corrosion A form of galvanic corrosion in which the reduction of iron III (Ferric) to iron II (Ferrous) is coupled to oxidation of iron 0 (metal) to iron II (Ferrous) FGD Flu-gas desulphurization process Fillers Ingredient that adds weight volume and/or lower the cost of a chemical product Fines Crushed or powdered material such as blast abrasive residual Fire point Temperature at which vapors of a solvent will ignite and continue to burn when the external source of flame is removed Filter A porous material through which a fluid is past to remove matter in suspension Flash point The temperature at which vapors of a solvent will ignite when an external source of flame is introduced Flash rusting Occurs on metal within minutes to a few hours after hydro-blast cleaning procedures Flow-actuated unloader Often incorporating a pressure regulation capability permitting continuous jetting operations when maintaining trigger gun in open or water jetting operation. Stopping water flow in the high-pressure hose and trigger gun assembly (closed trigger position) diverts-bypasses and returns pumps continuously produced water volume from valve body directly to suction-float tank and this preferably under near negative pressure creating the least possible water turbulence-air saturation and heat Flow switch An electric switch with the provision to sense fluid flow Float tank-suction tank The water tank on a pressure-washer or hydro-blast unit. The water level is maintained by a float valve or sensor regulating water supply

Glossary

593

receiving recycled water from pump head and pressure regulators or flow actuated Unloader. Suction tanks also reduce waters air-gas saturation and temperature before returning to the pressure cycle of equipment Float valve Operates by buoyancy of a float attached to a lever arm in operation maintaining fluid level of suction tank Flow The amount of water forced through the pressure-washer hydro-blast or UHP equipment measured in gpm and for steam cleaning equipment in gph fpm Feet per minute Flue-gas desulphurization system or scrubber is the device that removes more than 90% of the sulfur dioxide emissions from the burning process of coal Flue gas desulphurization Employs a sorbent usually lime or limestone, to remove sulfur dioxide from the gases produced by burning fossil fuels Fly-ash The airborne combustion residue from burning coal or other fuels FSIS Food Safety and Inspection Compliance services USDA FTIR Fourier Transform Infrared Spectroscopy- can be used to identify the generic resin of existing coatings. Most coatings are carbon based revealing in a test procedure their organic make-up Food borne illnesses Human illnesses caused by food borne pathogens Food borne pathogens Disease causing microorganisms, usually bacteria, fungi, parasites, protozoan and viruses Fuel pump A fuel pump is used to pressurize fuel oil vaporizing-atomizing oil through burner nozzle g Gram(s) Gables Triangular portion of the end of a building having a double sloping roof from the level of the cornice or eave to the ridge of the roof gal Gallons Galvanic corrosion Metal corrosion that occurs because of an electric contact with a more noble metal or nonmetallic conductor in a corrosive electrolyte Gas jet Gas orifice Gas orifice A fixed size gas nozzle incorporating air inlet holes and a mixing tube Gate valve Screw action from a handle shaft to move a solid gate across the flow path to shut of flow

594

Glossary

Gate A door or mechanical device utilized on locks and dams to control passage of water Gasification Conversion of solid materials such as coal into gas for use as a fuel General corrosion Uniform metal loss from entire exposed metal surface this form of corrosion is often the result of metal exposure to strong acids Generator A burner requires either a 12 V direct current or 120 V alternating current to develop the electric arc Germicide Any agent that will kill bacteria especially those causing disease GFCI Ground fault circuit interrupter same as GFI Gloeocapsa magma is a species of cyanobacteria this particular algae feeds on limestone present in asphalt shingles, etc. Gooseneck A portion of a water service connection between the distribution system a water main and a water meter (pig tail) Governor A regulator devise used on internal combustion engine to maintain constant engine speed with variable loads often applied to avoid installation of a flow actuated Unloader GPM Gallons per minute GPH Gallons per hour Graving dock A fixed basin for dry-docking ships composed of reinforced concrete, steel sheet pile, or masonry near waterways GTC Gasification Technologies Council Graying The bleaching and drying out of a wood surface produced by sun’s rays Gravity feed Suction conditions for a pump where pumped water is drawn from a reservoir or tank higher than pumps suction inlet Gray water Domestic wastewater composed of wash water from kitchen bathroom, laundry sinks, tubs and washers Gun or trigger-gun A pistol like handle with a hand sized trigger assembly (on/off) ergonomically designed to effectively distribute nozzles-lance recoil forces upon operator incorporating a valve mechanism to shut off a water jet at will. Dump-gun designs only internally divert systems high-pressure water to a guns low-pressure side, thus eliminating recoil forces HACCP Hazard Analysis and Critical Control Point (www.cfsan.fda.gov/ *lrd/haccp.html) Hale concrete Concrete whole from defects micro fractures, disease, and deformities

Glossary

595

Hardness Natural water characteristic due to the presence of dissolved calcium and magnesium HASMAT Hazardous Material Regulations HAZWOPER Hazardous Waste Operations Emergency Response HAZCOM U.S. regulation governing hazardous chemicals in the workplace HVAC Heating Ventilation and Air-Conditioning systems or processes Hazardous waste Any solid waste that is ignitable, explosive, reactive or toxic and which may pose a substantial hazard to human health and safety or to the environment when improperly managed Heating coil Metal coil tubing used in pressure washer and hydro-blast equipment conveying heat to pressurized flowing water Heat exchanger Performs a double function by heating a cold fluid utilizing a hot fluid which it cools High limit switch Senses excessively high water discharge temperatures reducing or turning off heat generation HP-WC High-pressure water cleaning is performed at pressures from 70 to 207 MPa 5,000–30,000 psi with or without the addition of other liquids or abrasives, to remove unwanted matter from various surfaces. Where the term high-pressure water cleaning is used without further qualification, it is considered to be describing hydro-blast or water jetting operations below 30,000 psi (2,041 bar) High-pressure water cleaning Hydro-blasting water blasting Hg Vacuum level measured in terms of inches of mercury (Hg). One standard atmosphere equals 14.69 psia (29.92 in-Hg) any fraction of an atmosphere is a partial vacuum and equals with negatives gauge pressure. A torr is defined as 1/760 of an atmosphere and can also be thought of as 1 mm-Hg where 760 mmHg equals 29.92’’ in.-Hg. Even smaller is the micron, defined as 0.001 torr Hydraulic horsepower Pressure derived at a jetting nozzle = psi 9 gpm: 1714 Hydro-blasting-1 Hydro-blasting is derived from the German language hydrodynamic—fluid forming Hydro-blasting-2 Strahlläppen-combined with US dictionaries explanation for blasting Hydro-blasting-3 Blasting—a forcible stream of water (steam) from an opening therefore = ‘‘Hydro-blasting’’ expression developed in 1967 by Wolfgang Maasberg, Jr. commissioned and approved by Wolfgang Maasberg Sr. identifying his high-pressure water as a tool technique to the North American market

596

Glossary

in 1968 at 5–10,000 psi today identifying applications performed at equipment operating pressures of 70–207 MPa, 5,000–30,000 psi or (340–2.041 bar) Hydraulic cement That sets and hardens by chemical interaction with water being capable of doing so under water Hydrocarbons Any of a large class of organic compounds containing only carbon and hydrogen crude oil and natural gas are often referred to as hydrocarbons or hydrocarbon fuels Hydrofluoric acid (HF) One of the most potent acids available HF cleans aluminum by disintegration Hydrogen embrittlement Corrosion from acidic media couples with internal stress to form a brittle alloy particularly at grain boundaries. This causes reduced ductility and metal failure if the metal is subject to bending stress Hydrolysis Chemical reaction in which water reacts with another substance to form one or more new substances Hydrophilic Having an affinity for water in accepting or wetting and/or capable of uniting with or dissolving in water Hypochlorite In sodium salt form the active bleaching ingredient in liquid chlorine bleach H2O water H2S Hydrogen sulfide H2SO4 Sulfuric acid Horizontal machine A pressure-washer in which the axis of the heating coil is horizontal Horsepower hp, the measure of the rate that work is done, 1 hp = 550 ft-lb/s; 1 hp = 746 w; 1 hp = 42.4 Btu/min; hp High-pressure hr Hour(s) HRSG Heat recovery steam generator HTHRU High-temperature heat recovery unit IAQA Indoor air quality association ID Inside diameter of a hollow round hole such as in a nozzle pipe-lance or highpressure hose fitting IDEM Indiana Department of Environmental Management Igniter, solid-state A solid-state device used to convert a DC or AC voltage supply to high voltage in order to provide ignition spark Inert A material that will not react to a particular cleaning compound

Glossary

597

Inhibition The process in which a thin-film organic compound is deposited on a metal surface reducing the corrosion potential of the metal while the metal is exposed to an oxidizing environment after pressure washing, hydro-blasting or UHP application procedures Inches mercury (in. Hg.) 1 in. Mercury is the pressure at the bottom of a column of mercury 1 in. deep (1 Hg. = ‘ psi) Inches water column (in. W.C.) 1 in. water column is the pressure at the bottom of a column of water 1 inch deep (1 psi = 27.700 W. C.) Inorganic Any material not made with carbon except carbon dioxide and carbonates Impact nozzle Nozzle employed by a steam cleaner wand which covers pressure produced by nozzle with a tapered steam expansion nozzle Injection ratio Is the rate of chemical injected into a water stream the ratio of water to the ratio of chemical flow Intensifier pump A hydraulic driven double piston pump the pressure increase of water at multiple hydraulic pressures Ø ø IPM Integrated pest management IPP Independent power producer IRM Integrated resource management ISEP Ion separation unit Isocyanate Are toluene diisocyanate (TDI) and diphenylmethane diisocyanate (MDI) a reactive material for polyurethane manufacturing Jar Test A laboratory procedure that simulates a water treatment plant’s coagulation/flocculation units with differing chemical doses, mix speeds and settling times to estimate the minimum or ideal coagulation dose required kg kilogram(s) Kilowatt A unit of power equal to 1,000 w kW kilowatt(s) Laitance A weak and nondurable material containing cement and fines bleeding from aggregates Lance-wand Various lengths of tubing used to clean heat exchangers and/or retain water jetting nozzles to a trigger gun (wand) Leaching The process by which chemicals are dissolved and transported through the soil by percolating water LEL Lower explosive limit

598

Glossary

LFL Lower flammable limit lb or lbs Pound or pounds Lime Calcium-carbonate appears as hard white deposits inside of hot water piping derived from hard water and as various discolored residues on surfaces in need of cleaning Liter (L) Liter a metric unit of volume measure (1 gallons = 3.79 L) Litmus test The use of litmus paper to measure the acidity or alkalinity of a water solution (pH) LNG Liquefied natural gas is cooled to a temperature of approximately -160° (Celsius) at atmospheric pressure it condenses to a liquid. This liquid takes up 600 times less than the volume of gas Lotus effect The measure of resistance to the wetting of a surface on a nanoscale a rough surface more hydrophobic than a smooth surface reducing contact area between water droplet and surface Locking type Unloader Utilizes operating pressure to unload and bypass water back to suction tank while maintaining static operating pressure within highpressure hose and trigger gun assembly Lockout The means to protect workers from injury or death caused by accidental startup or the release of stored energy from equipment LP–WC Low pressure water cleaning-performed at pressures less than 34 MPa– 5,000 psi up to 25 hp and is also called ‘‘power washing’’ or ‘‘pressure washing’’, NACE-SSPC-WJTA LOX Liquid oxygen LP Low-pressure LP Gas Liquefied petroleum gas LPG Liquefied petroleum gas is usually propane or butane and is derived from oil LTHRU Low temperature heat recovery unit Magneto An alternator with permanent magnets generating current to drive a high voltage ignition coil commonly used to generate ignition spark for small engines and sometimes oil burner ignitions Material Safety Data Sheet (MSDS) A government required form that must be on file for each chemical manufactured describing the hazards precautions and ingredients present within the formulation Manifest A form used by haulers transporting waste that lists EPA identification numbers type and quantity of waste, the generator it originated from, the

Glossary

599

transporter that shipped it and the storage or disposal facility to which it is being shipped. It includes copies for all participants in the shipping process Manifest system Tracking of hazardous waste from ‘‘cradle-to-grave’’ (generation through disposal) with accompanying documents known as manifests Masonite Siding resembling a wood grain surface but is a composite material consisting of wood and various alternative fibers bound by resins Masonry Primer An asphalt-based primer used to prepare masonry surfaces for bonding with other asphalt products mg milligram Metering pump An accurate positive displacement pump that can be constant or intermittently operated at various specific adjustable chemical flow rates Metering valve Generally a venturi operated valve adjusting chemical flow rate by mechanical restriction Methyl methacrylate Polymerization to produce various polymers clear plastics, molding putty, etc. Micro-switch Small momentary electric action switch min Minute(s) Mildew-mold Plantlike growth visually identifiable as small black dots or grayish dark patches often when active also green in appearance Millimeter (mm) One-thousandth of a meter (metric) 100 = 25.4 mm Mill scale The various oxides of iron formed in the milling of iron and steel MSW Municipal solid waste MW Megawatt(s) MWe Megawatt(s)-electric MWH Megawatt-h(s) Modified bitumen Rolled roofing membrane with polymer modified asphalt and either polyester or fiberglass reinforcement MSH A scale of hardness named after F. Mohs, German mineralogist 1773–1839 Mohs Scale A scale of hardness used in mineralogy the degrees increasing in hardness, is: talc 1; gypsum 2; calcite 3; fluorite 4; apatite 5; feldspar 6; quartz 7; topaz 8; sapphire 9; diamond 10’ Moleing US interpretation for Wolfgang Maasberg Sr. 1958–1960 patented tube drain, pipe, conduit and sewer cleaning technique by various self propelling nozzles affixed to an hp-hose assembly

600

Glossary

Mopping To apply hot asphalt or coat tar using a hand mop or mechanical applicator MRF Material recovery system Multi pass coil Heating coil configuration permitting combustion gases to pass along the length of the coil more than once in different directions Muriatic acid An acid used to remove concrete and mortar also called hydrochloric acid NAAQS National ambient air quality standards ND Non-detectable Needle valve Some applications justify the irregular utilization of an comparatively inexpensive high-pressure needle valve assembly permitting its manual pressure regulation as in the function of a bypass valve (never ever operate as a pressure regulator) NESHAPS National Emission Standards for Hazardous Air Pollutants NEPA National Environmental Policy Act NETL National Energy Technology Laboratory N2 Nitrogen gas NH3 Ammonia NiO Nickel oxide NONO2NOx Nitric oxide, nitrogen dioxide, nitrogen oxides Nozzle number Orifice size designation for a nozzle manufacturer identifying gpm-psi performance criteria what subsequent horsepower prerequisites NP None-prior proprietary NPDES National Pollutant Discharge Elimination System (permit) NPT National pipe taper-thread Number 1 and number 2 Fuel oil normally used in oil fired pressure washers. Number one essentially kerosene, number two oil, essentially home heating oil or diesel fuel. When sold as diesel fuel a variety of additives are present NV Non-visible contamination is the presence of organic matter, such as a very thin film of oil or grease and/or soluble ionic materials such as chlorides, ferrous salts and sulfates remaining on a substrate after water removal or evaporation-drying procedure OD Outside diameter, the external diameter of a round object such as a pipe, drain, piston, hose or nozzle

Glossary

601

ODP Open drip proof, electric motor construction resistant to dripping from above O&M Operating and maintenance OEM Original equipment manufacturer Open gun A pressure washing, hydro-blasting or UHP gun operating a trigger activity to open position O2 Oxygen, gas Orangeburg pipe Two varieties exist, one with homogeneous solid walls, and one with laminated walls, cellulose fibers (wood, etc.) impregnated with hot coal/tar pitch, today considered obsolete but still in service, manufactured by fiber conduit company in Orangeburg USA, today replaced by PVC Organic A substance composed of hydrogen and carbon Over the ditch Pipeline work that is executed after the pipeline is welded together but before lowering into the trench OWM Office of wastewater management Oxalic acid based wood brightener Unique in removing stains formed by iron screws, nails and tap water, lightens the graying effect from environmental exposure to wood Oxygen deficiency Low oxygen in atmosphere generally below 19.5% is a health hazard Pancake Coil A coil in which the pipe is wound in a flat spiral, more commonly designed in one or more pancakes situated on the outlet side of a heating coil Packing The seal between a pump plunger and cylinder Passivation A process which involves the deposit of a metal compound film on the surface of the same metal reducing the corrosion potential of the surface after pressure washing, hydro-blasting or UHP cleaning procedures Pasting A process which suppresses, fuses and seals or confines industrial dust and powder like products PEL Permissible exposure limits Permeability The rate at which liquids pass-through soil or other materials in a specified direction Peptizing The breaking up of solid particles into extremely small particles to a size as to mimic a true solution Pharmaceutical manufacturing process Any process involving the manufacturing of pharmaceutical products, and intermediates, including but not limited to the following operations: manufactured by chemical synthesis, separation of

602

Glossary

medical chemicals including but not limited to antibiotics and vitamins from micro organisms, manufacturing of botanical and biological product by the extraction of organic chemicals from vegetative materials or animal tissues and/or the formulation of pharmaceutical into various dosage forms, such as capsules, inject-able solutions, or ointment form, etc Phenolic resin Can include any of various synthetic thermosetting resins such as Bakelite obtained by the reaction of phenols with simple aldehydes such as formaldehyde, for producing coatings adhesives, countertops and molded products, etc Pickling Cleaning of metal oxides from metal surfaces applying acidic solutions before further processing of the metal Piston cup Piston seal between piston and cylinder Piston pump A pump in which the high-pressure seals are part of the moving piston Pitch diameter The diameter of a pulley the v-belt makes drive contact Pitting Non-uniform distribution of corrosion potential across a metal surface which results in a selective attack on areas of high corrosion potential P& IDs Piping and instrument drawings pH The relative acidity and alkalinity of water or chemical solution from 0 to 14 (potential of hydrogen) The term pH tells how many hydrogen atoms (H+) are in a liquid, pH of 7.0 is neutral, higher values indicate increasing alkalinity and lower values indicate increasing acidity Plating A form of galvanic corrosion in which a more active metal is oxidized from its metallic state to a dissolved ion, while a less active metal is reduced from dissolved ion to a metallic solid Plastic yield The yield point of drilling mud measures the pressure necessary for drilling mud to flow Plunger-pump A pump in which the high-pressure packing is part of the stationary cylinder assembly Pollution Contamination of air, water, land or other natural resources, creating a nuisance or harmful to public health and livestock, wild animals, birds, fish or other life Pressure gauge Gauges are liquid-filled (oil–glycerin) to dampen reciprocating pumps pressure fluctuations, gauges are reliable when operated within the ’ range off their indicated pressure range Positive displacement pump Within its operating range there is a fixed relation between input shafts rpm and volume of liquid pumped

Glossary

603

PPE Personal Protective Equipment Phosphatized Metal surfaces, chemically treated with an acidic phosphate solution, providing an protective coating on metal surfaces. Applied as a corrosion inhibitor and surface treatment for enhanced paint adhesion Phosphoric acid An inorganic acid that is commonly used for metal cleaning and rust removal Pot-holing Uncovering buried utilities to visibly confirm their location before any type of excavating or construction commences Polycarbonate Thermoplastic polymers, which are easily worked or molded or thermoformed Polyvinyl chloride Commonly abbreviated as PVC, most widely used thermoplastic polymer after polyethylene, and polypropylene Polyvinyl acetate PVA is a rubbery synthetic polymer utilized to manufacture wood glue and adhesives, etc. Poultice method Removal of deep set stains, by a soft moist mass (slurry or paste), pooled with various cleaning agents causing the stain extraction Pop-off valve A safety device, relieving pressure and water volume explosively by safely abolishing all designed restrictions POTW Publicly owned treatment works (permit) PMOC PMCC Pansy’s Martins Open and Closed Cup methods of establishing and expressing flash and fire points used by refineries in particular PM Preventive maintenance PMP Project management plan ppm Part(s) per million (mass) commonly used to represent the level of pollutant concentrations where concentrations are small ppb Parts per billion, units commonly used to establish the maximum permissible amount of a contaminant in water or air Precipitating builder A chemical water softener converting hardness in minerals to an insoluble form Precipitate The process in which an insoluble solid formed by chemical reaction in a solution falls to the bottom of the reaction vessel Pre-mix Chemical mixing process of concentrates, prior to application Pressure Amount of force per unit of area over which the force is acting as psi and bar and does not relate to cleaning effectiveness of an orifice or nozzle

604

Glossary

Pressure actuated Unloader An Unloader that switches to the bypass mode when its discharge pressure is slightly surpassed such as for instance when closing the trigger mechanism on a pressure-washing, hydro-blast or UHP gun. Can be an air, hydraulic, mechanical or pressure trapping function. Can also incorporate an automatic or manual pressure regulation Pressure cleaning The use of high-pressure water, with or without other substances with pump pressures below 5,000 psi at max 25 hp Pressure controls Pressure–volume relief valves, regulators, Unloader’s and burst plates must only be serviced by qualified personal Pressure feed Pressure washer supply a direct feed, generally tap pressure range 50–90 psi, and often not sufficient in gpm performance for commercial equipment requiring a charge tank Pressure regulator Maintains a set psi configuration with varying flow rates and inlet pressures Pressure spike A minute pressure surge that occurs, in an unloader’s discharge side actuating the bypass mechanism Pressure relief valve Installed to pump head’s discharge side, preventing pressures exceeding rated maximum operating pressure of pump (equipment). Care must be taken, because various available units will not permit the full passage of produced water volume. Most often critical when plungers are exchanged for a higher water volume configuration (change of application), mismatching the pressure relief function Pressures switch An electric switch sensing fluid actuated pressure at a preset or an adjustable pressure range Pressure trapping Unloader An Unloader that switches to the bypass mode when its discharge pressure exceeds a minute set psi value. First developedpatented by Wolfgang Maasberg Sr. WOMA Corp. supporting the operation of 10,000 psi trigger guns. (Discontinuing water flow on jobsite) Primary containment The main method of storing a wastewater stream psig Pound(s) per square inch gauge; therefore zero psig equals approximately 14.7 psia psia Pound(s) per square inch absolute, without deducting atmospheric pressure PTO Power take-of pump drive, generally placed on rear of tractor engine-trans Pump protector temperature operator relief valve Preventing excessive temperature build up when running in bypass mode Psi Pound(s) per square inch Psia Absolute gauge pressure

Glossary

605

Psig Negative gauge pressure Quench tank A water filled tank used to cool incinerator residue or hot material o products during industrial processes Quality assurance–Quality Control A system of procedures, checks, audits and corrective actions to ensure that all EPA research design and performance, environmental monitoring and sampling, and other technical reporting activities are of the highest achievable quality RCRA Resource Conservation and Recovery Act Raw Sewage Untreated wastewater and its contents R1, R2 etc. See SAE 100R1, 100R2, etc. Reaction, recoil thrust The back thrust produced by water forced out of an orifice (Nozzle), continuous thrust in pounds is =0.0526 9 gpm 9 psi Reactivity Characteristic of a material to produce a chemical reaction Reduction Paint fading and spotting of aluminum surfaces through the use of harsh acidic or alkaline products, breaking down surfaces substrate Reboiler Connected to the bottom of a fractionating tower, providing the reboil heat necessary for a distillation process Reed switch Low current electric switch, utilizing two magnetic alloy wires sealed in a glass tube, actuated by a magnet Regeneration rate The volume of water, expressed in gallons per minute (gpm) or gallons per hour (gph), which a well produces independent of well water storage Relief valve A valve that automatically opens if pressure applied exceeds its specific set limit Reserve alkalinity The measure of buffering capacity above pH 9.5 of an alkaline cleaning product, also expressed as the equivalent amount of sodium hydroxide Retro-reflectivity The capacity to return light (paint-coatings) Refractory Usually a high temperature insulation material as brick, tile or glass, etc. Rinse agent It aids in the spot-free drying of a painted or vehicle surface after a wash cycle Rotating nozzle Either in zero or twin fan nozzle configuration, set to rotate by various degreed impact positions to a surface, rpm regulated by psi-gpm flow to possibly ultrahigh rotating speeds rpm Revolutions per minute

606

Glossary

Rust and corrosion inhibitors Reduction of iron and steel flash-rust development, during and after a cleaning procedure with high-pressure water RV valve Pressure relief valve, set or adjustable S Sulfur, elemental Saturated felt An asphalt-impregnated felt used as an underlayment between the roof deck and roofing material SAE Specifications for hydraulic hose, often classifies pressure washing hose by identifying numbers of braid layer reinforcements to inner tube Safety factor The ratio of burst pressure to working pressures, safety factor of four to one of a component or hose (4,000 psi working pressure times for equals a burst pressure of 16,000 psi) Salt The by-product of reaction of on acid and base Sanitizing Reduces the number of bacterial contaminants to a safe level as required by the public health department guidelines Saturated steam Steam at the exact ‘‘boiling temperature’’ Schedule 60, schedule 80 Designation for the two strengths of steel-stainless pipe most often used as gun barrel-extension-wand, lance-nozzle retainer and heating coil materials Settling tank or sedimentation tank or clarifier A vessel in which solids settle out of water by gravity during waste water or drinking water treatment processes Seal coat A liquid asphalt treatment used to waterproof and improve the texture of an asphalt substrate Sedimentation the process of depositing matter that settles to the bottom of a liquid medium Sequestering agent An aqueous solution combines with a metallic ion forming a water soluble ombination in which the ion is substantially inactive Sewer nozzle Various nozzle designs and techniques patented by Wolfgang Maasberg, WOMA Corp. 1958–1960 introducing to world the self-propelling pipe, drain and sewer cleaning application Shore Shore durometer hardness, testing rubber and softer plastics SJW Standard pressure washing, hydro-blast or UHP water which is of sufficient purity and quality that it does not impose any threat to proper extended function of pressure producing equipment and will not impose additional contaminants to a surface being cleaned by introducing additional impurities or possible soluble sediments harmful to a surface treatment

Glossary

607

Steam table A table of numerical values relating to the boiling temperature of water to its pressure Example: at 100 psi, water boils at 338°F, at 200 psi water boils at 388°F Steam cleaner Similar in construction to a hot pressure washer, except that the water is usually heated to a higher temperature at 300°F or more Steam trap A device, which removes water droplets from steam Straight through machine Equipment of the past, continuously operating a highpressure hose and wand assembly (water-steam) avoiding the operation of a trigger gun Stress corrosion cracking corrosion reduces the ability of metal to distribute static stress, resulting in localized areas in which the static stress exceeds the yield point of the metal, producing a metal failure with little loss of metal Stroke, pump The distance traveled by a pump piston or plunger between a pressure and suction cycle Stucco Often a concrete textured surface applied by hand trowel Stylus A device to measure the distance between peaks and valleys to determine a profile, hydro-abrasive blasting on steel surfaces, supporting the correct choice of an abrasive and method Sludge Solid, semi-solid, or liquid waste from municipal, commercial or industrial waste-watertreatment facilities, waste water treatment plants, or air pollution control facilities Sludge Is the muddy waste produced during processes to remove sulfur from coal Slurry Is coal that is ground to a powder and mixed with water and pumped through a pipeline Soap Water soluble cleaning compound, made by treating a fatty acid with a caustic chemical Soda ash Commercial form of anhydrous sodium carbonate Sodium hypochlorite Specific chlorine bleach used in deck cleaning products Sodium per-if carbonate A powder ingredient present in deck cleaning product Soffit Exposed undersurface of an overhead component on buildings, such as a balcony, lintel, beam, cornice, vault or arch Soluble Substance capable of being dissolved in a liquid Solution Formed by dissolving one or more substances in a liquid resulting in a homogenous mixture Solvent A liquid that has the ability to dissolve, suspend or extract other materials

608

Glossary

Solvents Organic chemicals added to detergents to remove soluble dirt, break-up and suspend, and they can range from harmless to extremely toxic to humans and property SO2, SO3, SOx Sulfur dioxide, sulfur trioxide, combined sulfur dioxide and trioxide Specific gravity Is the ratio of a material to the density of water SPF Refers to the isocyanides and resin components used to make polyurethane foam SRU Sulfur recovery unit Stack liner The protective lining for flues, or other exhaust interiors subject to a high temperatures or corrosive conditions Sulfuric acid cleaner Used in solution with water to remove light cement smears, excess grout, efflorescence or mineral deposits Surface Tension Expressed in ‘‘dynes’’ per square centimeter the force required to penetrate the surface of a non agitated liquid Surfactant An active biodegradable agent, that increases the emulsifying, dispersing and surface wetting properties of a solution, ranging from non foaming to extremely high foaming Sump Low-lying collection point, for an effluent or water, which may require neutralization or other treatment before discharge Super-concentrate A concentrate initially diluted that becomes a concentrate that is diluted again before use Super-heater Heats vapor above the saturation temperature Superstructure Part of the ship above the main deck Surge hose A high-pressure water hose utilized as pulsation dampener and/or accumulator Surge ball Compressible sphere placed within a chamber used to absorb pressure pulsations Surge tank-surge chamber Area or tank receiving medium velocity air saturated and sometimes heated water from pressure regulator bypass functions Surface profile The surface contour established by hydro-abrasive blast cleaning, classified by depth and its texture, average peak to valley height on steel surfaces Synergism Two chemicals are combined and the combined effect of the chemical reaction is greater than either one acting independently

Glossary

609

Synthetic detergent Cleaning products manufactured based on synthetic surfactants Tannin The resin that leaches out of wood, creating a brownish to black stain TCLP Toxicity characteristics leaching procedure TEFC Totally enclosed fan cooled electric motor TEDE Total effective dose equivalent Temperature limit switch Shuts off the heat if it senses excessively high discharge temperatures Temperature rise For hot and cold pressure washers and/or hydro-blast equipment the difference in water temperature between the equipment’s suction and/or bypass-discharge side Tertiary treatment Any level of wastewater treatment beyond secondary treatment and can include filtration, nutrient removal, removal of nitrogen and phosphorus, toxic chemicals or metals and also called advanced treatment when nutrient removal is included Thermo One thermo equals 1000,000 BTU Thickening agents Increases the viscosity of liquid detergent Time delay shutdown Automatically turns the machine off if they trigger gun is not in use for a set interval time Transformer control Low power transformer used to step down the voltage supplied to lower the value for operations of controls Transformer ignition Low power transformer to step up a supply voltage, such as 120 or 240 V to high-voltage such as 10,000 V to provide ignition spark Trigger lock A locking device incorporated into a trigger gun, preventing accidental operation Trigger gun Versus dumb gun design TSP Trisodium Phosphate an alkaline substance containing phosphates encouraging growth of mildew and mold Total circulating volume Volume of liquid which will be contained in the equipment being cleaned plus the volume of liquid contained in hose or piping, including settling-suction tanks, etc. and the equipment needed to connect to a fluid recycling-circulating truck, pressure washing and hydro-blast equipment, etc. Toxic waste Waste that poses as substantial presents or potential hazard to human health or the environment when improperly managed TLV Threshold limit value

610

Glossary

TSCA The toxic substances control act gives EPA the ability to track industrial chemicals produced or imported TSS Total suspended solids in waste or drinking water, measuring the quantity of pollutants TOC and TCC Taglibue open and closed cup method of establishing and expressing flash and fire points TOC Total organic carbon Turbidity Indicates the degree of water cloudiness caused primarily by the presence of colloidal matter Two-step machine A cold pressure washer or hydro-blast equipment, which applies two different chemicals in separate applications UHP-WJ Ultra high-pressure water jetting performed at pressures above 210 MPa or above 30,000 psi UL Underwriters Laboratories, independent organization for standards and product testing UL 1776 Product standard for pressure washers, issued on 9 October 1992, recognized by ANSI Ultra high-pressure water cleaning High-pressure water as a tool with or without substances for cleaning, coating removal or demolition applications with pressures exceeding 210 MPa–30,000 psi (2.041 bar) Unloader A valve developed by WOMA Corp. (late 1950s) sensing that water is not discharged from the trigger gun, in response directing pumps total water output pressure-less into pump-heads by-pass circuit (suction side of pump heads valve assembly) in doing so maintaining the operating pressure between pump head discharge and trigger-gun assembly. Activating the trigger gun resumes operation at precise system pressure Upstream injector Chemical injector installed on the water suction side of any pressure washer Upper detection limit The largest concentration that an instrument can reliably detect U.S. gallon Equal to four liquid quarts, eight liquid pints, 231 cubic inches (in.2), or 3.785 l, weighs 8.33 lb (3.78 kg) Vacuum hydro-blasting A vacuum shroud support to simultaneously capture debris and water ricochet within a cleaning process facilitating water recoveryfiltration-recycling procedures Vac switch Electric switch sensing a vacuum actuated by a diaphragm

Glossary

611

VC The visible surface cleanliness is the visible condition of a substrate when viewed without magnification after a high-pressure water cleaning or abrasive treatment procedure is concluded Vapor barrier A moisture impervious layer which prevents passage of water into a material or structure Vapor pressure The absolute pressure at which a liquid, at a given temperature starts to boil, (flash to gas–vapor) Vapor Retarder Any material used to prevent the passage of water vapor Vapor Space Corrosion Attack of volatile corrosive materials on concrete and metal surfaces above the level of liquids containing the volatile materials in solution Vapor transmission rate The rate moisture passes through a material, structure or coating Variable pressure wand A jetting wand equipped with two tubes and an adjustable selector valve for low-pressure chemical applications Varnish A liquid that is converted to a transparent solid film after being applied in a thin layer Varnish stain A varnish that has a transparent color added, generally less penetrating power than a true stain Vinyl emulsion polymers Paint and coating raw material, vinyl based chemistry Viscosity The property of a fluid that resists internal flow by its interacting liquid thickness V2O5 Vanadium pent oxide VOC Volatile organic compounds Volume percent Expressing concentration in which the volume of an individual component of a mixture is divided by the volume of the total mixture and this result is multiplied by 100 VSMR Ventilation system mold remediator Watt 1 watt = 3.4 Btu/hr, 1 W = 44.3 ft-lb/min, 746 W = 1 hp Water-borne coatings The carrier which is a water emulsion, water dispersion, or ingredients that react chemically with water Waste-heat boiler Steam production similar to a steam generator, except the heating medium is hot or a liquid producing a chemical reaction Water hardness Soluble metal salts, generally those of calcium and magnesium and/or iron and manganese, are often responsible for cleaning problems. Soap can turn into insoluble soap curds or it can reduce the ability of surfactants to

612

Glossary

perform their cleaning function. Expressed in grains per gallon (gpl), grains per liter (gpl), or parts per million (ppm), as one gpg equals 17.1 ppm. water free of calcium and magnesium is described as soft and if appreciable amounts of either or both are present, it is called hard Water Jetting The terminology developed by WOMA England, from German technical dictionary, Strahl geschwindigkeit—jet speed—therefore ‘‘jetting’’ and (Wasser) Strahl—flüssig—jet-stream, therefore ‘‘Water Jetting’’ (1964), 5,000–30,000 psi Waterjetting NACE-SSPC terminology for water jetting is the use of a standard water jetting discharge from a nozzle at pressures of MPa 70 (10,000 psi) to 207 MPa to prepare a surface for coating or inspection. This description of pressurized water jetting performance with a velocity greater then 335.3 m/s or 1,100 ft/on a nozzle orifice does not identify a job classification or capability. As to the jetting performances for corrosion, coating and concrete substrate prep, cleaning or removal requirements can only be correctly identified by recognizing necessary gpm-hp-and psi configurations relating to a jobs individual tool selection most often in variance between contractors Waterproof underlayments Modified bitumen–based roofing underlayments, which are designed to seal wood decks and waterproof critical leak areas Water pollution The introduction of substances that makes water impure compared with undisturbed water, usually, this comes from soil erosion, introduction of poisonous chemicals from industries and spills of domestic sewage or industrial and agricultural waste Water logging Soaking of agricultural land caused by rising of the water table WC Water cleaning—the use of pressurized water discharged from a nozzle to remove unwanted matter from a surface Wand Seamless aluminum, steel and stainless pipe extending a trigger gun’s barrel reach Wetting Agent The ability to displace air from a surface, improving the process of wetting that surface by reducing the surface tension of water to spread or adsorb or absorb more freely Weep hole Small holes or openings used to permit water and condensate to drain to a building exterior Weep hole (2) Openings, or installed pipes near the bottom of a retaining wall, permitting free drainage from backfill and gravel material, preventing build up of pressure behind a the wall Weight Percent Expressing concentration in which the weight of an individual component of a mixture is divided by the weight of the total mixture and at this result is multiplied by 100

Glossary

613

Wet scrubbers Designed to remove contaminants from an air stream using water or an aqueous chemical solution WJ Waterjetting-water discharged from and nozzle at pressures of 70 MPa (10,000 psi) or greater to prepare a surface for coating or inspection, water velocity is greater than 340 m/s (1,100 ft/s) when exiting nozzle orifice WJ-1 Clean to bare substrate when viewed without magnification proves free of oil, grease, unidentified foreign matter, rust, previous coatings, and/or prior identified mill scale in/on specified surface areas. Various surface discolorations are possible due to unidentified environmental conditions and steel to steel surface variances WJ-2 Very thorough or substantial surface cleaning to a matte (dull, mottled) finish which when viewed without magnification, is free of all visible oil, grease, dirt and rust except for randomly dispersed stains of rust, tightly adherent thin and other tightly adherent foreign matter. The staining or tightly adherent matter is limited to maximum of 5% of the surface staining WJ-3 Thorough cleaning the surface to a matte (dull, mottled) finish, which when viewed without magnification is free of all visible oil, grease, dirt, and rust except for randomly dispersed stains of rust, tightly adherent thin coatings and other tightly adherent foreign matter. The staining or tightly adherent matter is limited to and maximum of 33% of the surface WJ-4 Light cleaning of a surface which shall be cleaned to a finish, when viewed without magnification, is free of all visible oil, grease, dirt, dust, loose mill scale, loose rust and loose coating. Any residual material shall tightly adhere Vinyl Today a common but varying type of exterior surface, home–industrial structures Zephiran A chloride solution (benzalkonium) used when skin comes in contact with any acidic product used for aluminum brightening ZLD Zero liquid discharge

Through the years, vanished and surviving equipment manufacturers, and/or contractors applying high-pressure water as a tool, including the industrial– commercial engineer establishing application requirements coined a vocabulary identifying tooling, application oriented techniques and processes. Industry associations such as the AWT, BHRA, WJT, CITA, PNA, NACE, SSPC and WJTA work hard to unify and create an unbiased vocabulary standard. The most common terms have been gathered and explained so as not to cause excess confusion in identifying neutral and impartial acronyms, abbreviations and commercial–industrial language or terms.

Trade Related Publications

1. Andreas W. Momber (1998) Waterjet applications in Construction Engineering, by A.A. Balkema, Rotterdam, NL, http://www.balkema.nl 2. ACI- American concrete Institute and, BRE, ICRI (2003) Concrete repair manuals volume 1 and 2 published jointly, http://www.concrete.org 3. Cyril Harris (1993) Dictionary of Architecture & Construction, McGraw-Hill, Inc. http://www.mhprofessional.com 4. DOT, Emergency response guidebook for first responders during the initial phase of a hazardous material incident, http://www.hazmat.dot.gov/gydebook.htm 5. Joe Harrington (2001) Industrial cleaning technology, by Kluwer Academic Publishers, 101 Philip Drive, Norwell, MA 02061, http://www.balkema.nl 6. Jonathan M. Whitt (1999) Power-washing 101, A manual for operating a residential and light commercial, pressure washing business, Advantage publishing company, Little Rock Arkansas 72205-3823, Tel. 501-280-0007 http://www.adpub.com 7. Master Painters Institute (2002) Maintenance Repainting Manual, by MPI, exterior systems evaluation, surface preparation, http://www.mpi.net 8. Nalco Chemical Company (1988) The Nalco Water Handbook, McGraw-Hill Inc., http://www.mhprofessional.com 9. NASSCO (206) Jetter Code of Practice, WRc Swindon, Frankland Road Blagrove, Swinden, Wiltshire SN5 8YF, England http://nassco.org 10. Raymond E.F. Weaver (2003) Practical Math for the Protective Coatings Industry, The Society for Protective SSPC, http://www.sspc.org 11. The Society for Protective Coatings (2004) Surface preparation and coating of concrete, surface preparation and considerations for concrete substrates, SSPC, http://www.sspc.org 12. The Society for Protective Coatings (2002) Good painting practice, Painting manuals volume 1 a. 2 http://www.sspc.org SSPC 13. The Society for Protective Coatings (2001) The inspections of coatings and linings, SSPC, http://www.sspc.org 14. The Society for Protective Coatings (2000) Protective coatings, fundamentals of chemistry, corrosion and its control, http://www.sspc.org 15. The society for Protective Coatings (2004) The fundamentals of cleaning and coatingconcrete, Common mechanisms of concrete deterioration SSPC, http://www.sspc.org 16. The Society for Protective Coatings (2001) Paint Film degradation, mechanisms and control, Failures related to particular substrates SSPC, http://www.sspc.org 17. Steel Structures Painting Council (1998) Protective Coatings for Pulp and Paper mills, The Society for Protective Coatings, SSPC, http://www.sspc.org

W. Maasberg, Commercial-Industrial Cleaning, by Pressure-Washing, Hydro-Blasting and UHP-Jetting, DOI: 10.1007/978-0-85729-835-5, Ó Springer-Verlag London Limited 2012

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616

Trade Related Publications

18. The Society for Protective Coatings (1992) Maintenance coating of weathering steel, field evaluations and guidelines, http://www.sspc.org 19. The Society for Protective Coatings (2002) Surface preparation and cleaning of metals by Waterjetting prior to recoating, Joined surface preparation standard SSPC-SP 12/NACE No. 5, http://www.sspc.org 20. The Society for Protective Coatings (2004) Supplements to systems and specifications, SSPC painting manual volume 2, cleaning metals by Waterjetting, surface cleanliness requirements, dehumidification and temperature control during surface preparation, http://www.sspc.org 21. SSPC (2000) Standard Method of Evaluating the Degree of Rusting on Painted Steel Surfaces, http://www.sspc.org 22. SSPC-NACE (2001) Guide and Reference Photographs for Steel Surfaces Prepared by Waterjetting, http://www.sspc.org 23. SSPC-NACE (2001) Guide and Reference Photographs for Steel Surfaces Prepared by Wet Abrasive Blast Cleaning, The Society for Protective Coatings, SSPC, http://www.sspc.org 24. SSPC (2002) Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning, The Society for Protective Coatings, SSPC, http://www.sspc.org 25. SSPC (2004) Guide and Reference Photographs for Steel Surfaces Prepared by Power and Hand Tool Cleaning, The Society for Protective Coatings, SSPC, http://www.sspc.org

Index

A Abrasive contaminants, 443 Absorption–adsorption rate, 263 Acidic–corrosive environments, 84 acid-caustic rich interiors, 180 acid etching, 57 acidic produce, 114 ACM products, 409 Abattoirs, 38 abrasive blast techniques, 11 abrasive sizing, 514 acid damaged surfaces, 57 adhesives-mastics, 10 adhesion parameters, 10 adsorption, 530 aerobic microbes, 530 after coolers, 290 aged wood siding, 542 aldehydes, 530 Aluminum Lance Guide, 439 aluminum siding, 544 ALARA, 415 Alkaline, 111 aluminum smelting, 129 Agricultural environments, 1 agricultural sector, 38 aggregate façades, 258 air barrier designs, 269 airborne toxic-volatile organic compounds, 496 airborne activity, 30 air-conditioning, 22 air sampling, 411 air-slurry-water-abrasive, 12 aircraft cowlings, 22

Aircraft engine parts, 26 air filtration systems, 88 Airports, aviation industries, 22 Alkyd resins, 494 Alumina, Mill scale, 92 Aluminum oxide, 512 aroma preservation, 81 American Fire Hose Manufacturing Company, 199 anaerobic biological treatment, 530 anchor profile, 57 Andreas W. Momber, 60 Animal pounds, 1 animal fats (grills), 536 Animal rendering, 38 anti-graffiti coatings, 322 ‘‘Application Index’’ ‘‘Application Core Curriculum’’ APPLICATION REVIEW, 559 ‘‘APPLICATION INDEX CATALOG’’ Aquatic-marine pools and tanks, 441 asbestos abatement, 411 asphalt-bituminous mats, 12 Asphalt-mastic-coating, 12 Asphalt-bituminous splatter, 494 Asphalt-tar-mastics industries, 9 auxiliary boilers, 298 Avian pathologists, 7 Aquaculture water treatment facilities, 105 ATÜMAT (High Pressure Water Jet Equipment), 93

B Backer rod, 379 Bacteria and biological effects, 374

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618

B (cont.) Bacterial-salmonella, 2 bacterial growth, 1 backfill-surfaces, 544 Baking coal, 126 Baking soda, 513 barge cleaning process, 143 ball valve assembly, 422 Barnacles, 154 Battery manufacturers, 29 Bernoulli theory, 62 Bernoulli’s nozzle design, 122 Bernoulli, reversed nozzle-venturi, 275 best management practices (BMPs), 528 Beverage, bottling facilities, 32 Bid and paperwork illustrations, 557 bilge wells, 506 biological effects, 374 biodegradable detergents, 415 Biomass powered power-plant Bioremediation, 530 Bilge voids, 504 Biosecurity, 2 biosecurity guidelines, 99 biological oxygen demand situation (BOD), 181 bird control fixtures, 48 Bituminous product installs, 305 boatswain’s chairs, 48 Blank-off, 505 black liquor by-product, 177 blast furnace operations, 126 blast media, 312 blood lead laboratory, 31 Boilers and steam generators, 115 bottom-top felts, 177 Breweries and distilleries, 32 Brick-block-stone-stucco and masonry façade cleaning, 250 brick glaze, 250 brick reversal, 255 brick substrate, 309 brick failure (refractory), 88 bridge decks, 56 Briggs & Stratton, 108 brush technique, 55 buffer-pH controller, 532 buffered acid solution, 544 buildup fragmentation, 86 Buildings, washing exterior-interior, 44 bulk manufacturers Butadiene styrene, 494 Butchers-slaughterhouse operations, 38

Index C Cable-reel unit, 472 CCTV inspection access, 455 Calcined bauxite, 512 Calcium sulfate areas, 267 Calcium carbonate, 494 calcium oxide product, 87 candle wax events, 536 carbonation-salt-rust, 57 Carbonation, 194 ‘‘CASTÜMAT’’ catalytic-cracking, 384 catch basins, 478 Cattle-hog-poultry operations, 1 Cattle-hog-poultry slaughterhouse operations, 38 Cascading water, 267 Caustic exposure, 180 Caustic soda, 258, 415 cavitational influences, 290 clay formations, 378 cement and lime manufacturing, 86 cement-lime kilns, 86 Cement-concrete film, 310 Cement powder, 514 City fountains, 445 Chain of Custody Record, 569 charge water, 422 chart recorder, 422 chemical metering, 4 chemical attack, 259 Chemical applications, 112 Chemical application specifications, 256 chemical exposure, 159 chemical injectors, 275 chemical oxygen demand (COD), 181, 528 Chemical rinse aids, 523 Centrifugal charge pump, 427 Ceramic beads, 512 chilling and hanging facility, 38 chicken stock breeding classifying substrate, 510 clear-coat technology, 480 clinker cooler, 92 Clinker removal techniques, 185 Clinker-slag development, 286 clinker burning process, 88 closed-loop wash water recovery, 486 coagulation, 530 Coal gasification plants, 71 mobile wash water recovery, 527 Coalescing oil–water separator Coal Mines, 71 coke oven gas, 126

Index Cocoa, 81 cocoa plant, 82 Coffee, tea, 81 Coal-rock drilling, 71 Coal-rock stratospheres, 71 Coarse contamination (mass), 415 Coarse edge-weld seam polishing, 450 Coating-asbestos removal, 64 Coating blisters, 446 Code of good practices, 38 Cold storage facilities, 35 Coke product accumulation, 494 Colloidal dispersion, 478 Commercial–industrial structures, 54 Coke product accumulation Cementitious wall board, 303 Compact triplex pumps, 61 Competent person training-certification, 61 Concrete cutting, 494 Concrete batch equipment, 90 Concrete residual, 494 Concrete surface slurry, 141 Concrete and clay masonry, condenser or small tube heat exchangers Confined work spaces, 58 Confined space entry, 159, 497 Confined space entry permit, 567 Construction joints, 379 Construction cycles, 25 Construction industries, 54 Construction safety, 59 Contracting bid status, 23 Contractor’s basic safety information, 557 Convenience stores, 49 Copper stains, 536 Corn cob granules, 513 Coating failures, 159 Cosmetic process industry, 174 Corrosion inhibitors, 318 Convenience store, 393 Cradle to grave, 409 Crash floors, 55 Crude oils, 494 Cured grain, 534

D Daily Time Ticket, 566 debris pulling method, 462 Dairy foods, byproducts and derivatives, 93 dairy breed associations, 101 Data Universal Numbering System, 397 de-boning area, 38 Decaffeination, 82

619 Decommissioning–decontamination, 193 decontamination practices, 410 Deck staining, 541 Deformed-damage tubes, 301 Dredging ponds, 106 dehumidifying equipment, 4 degreasers, 447 Demineralized water disaster demilitarize warheads-bombs, 490 Demolition-rehab procedures, 54 demolition-restoration, 48 deodorized, 476 dampener, 427 dense mineral powders, 134 DELEADING, 31 deteriorated brick, 254 Dietary supplement industry, 170 cleanup, 429 discharged to storm sewers, 391 disinfecting, sanitizing contaminated areas, 46 dissolved, 528 dissolved organics, 530 dissolved organic carbons (DOC), 181 distilleries, 36 deteriorating coating, 57 dolomite lime (hydration), 86 double bottom, 146 downstream chemical injection, 541 downstream equipment, 78 Down Time Work Sheet Dolomite lime (hydration), 572 DRI plant, 122 DRI top gas scrubbers, 128 Drivers Inspection Checklist, 574 drive-thru (flat work), 11 duel wand, 487 dump-metering valve, 425 Durable traffic markings, 304 drying processes, 55

E Elasticity-tensile strength electronic certified chart recorder, 78 Electronic pipe locator, 470 effluent transfer reservoirs, 55 effluent filtration-control, 134 effluent intake and solids separator efflorescence, 56, 255 Emulsified asphalts, 9 emulsifiers, 11 emulsified product, 528 Emulsified oil–water separator

620

E (cont.)

Index

F Façade inspectors, 47 façades performance issues, 48 false bottom, 472 Fat smear accumulations, 41 feed mill equipment, 5 feed water quality requirements, 192 FGD stack cleaning, 194 felts, 384 Fermentation residual, 494 fertilizer manufacturing, 35 Freon HNS-200C, 416 fiber–plastic structure, 385 fiberglass tank lining, 504

fire hydrant’s, 463 flammable–combustible cargo, 143 flare exhaust units, 471 fleet washing, 121 flex lance operation, 62 Flight deck substrate, 406 flocculation, 528 flock replacement, 3 flue inlet, 471 fluidized bed drying facilities, 84 fluid filtration systems, 389 fluid pulsation dampeners, 72 fluorescent dyes, 421 FDA-USDA, 115 Foaming-soaps-detergents-acids, 272 food grade high-pressure hoses, 36 Food-produce retailers, 114 food and produce manufacturing processes, 58 Food processing companies, 108 Food processor residual, 494 Food service industries, 108 foodstuffs, 115 foundries’ melt process, 129 foreword jet, 465 Foundries, steel mills, forging shops, 122 Fountain coating, 449 friable asbestos, 413 friction losses, 275 freeze–thaw cycling, 378 friction and texture testing, 25 frozen-refrigerated fruit, 115 frozen juice, 36 FSH Confined Space Entry Permit, 568 fugitive lead emissions, 30 Fungus-mold, 271

5-l filtrate, 526 filter plates, 389 Filters, 384 fin structure, 386 Fish-farms hatcheries-nurseries, 102 Fish processing, 101 fish farm water source, 102 fish-waste, 103 filter cloth, 389 filter cake sedimentation, 88 fire brick damage (refractory), 87 Fire-disaster cleanup, 46 fire hazard control, 110 fire proofing material, 413 fire suppression systems, 113 fire triangle, 386 flat glass, 131

G Gas and vacuum vessels, 421 Garnet, 512 gear-blowers, 142 gear-up, break-down times, 44 GEAR – LIST Nr., 564 General surface preparation-restoration, 250 generator, 463 geotechnical investigation, 372 graffiti removal applications, 250 Glass beads, 512 glass fiber manufacturing, 90 glass–ceramic–porcelain, 131 Glass grit, 512 Glass-lined pharmaceutical plant vessels, 495

Emulsion polymers, 494 energy-shock, fluid epoxy resins, 494 epoxy-urethane coating, 480 Epoxy–resin–vinyl–latex-paint manufacturing, 61 erratic injector operation, 275 evaporation coolers, 114 evaporation procedures, 528 Evisceration room, 38 excavating method, 372 Exhibition and sport arenas, 157 Extraction-processing, 81 Extraction methods, 81 Expansion-control joint cleaning on rigid pavement, 378 Expansion joints, 25 explosive constituent, 418 exterior weathering

Index Glass linings, 495 Gas and vacuum vessels grain elevators, 5 ghosting event, 327 grain (raised), 534 granulated milk producers, 81 gravity separation, 530 grout strength, 257 grout-mortar product, 262 ground-roadway stability gravity feed procedures, 274 grease extraction, 113 grease interceptor, 114

H H2O compressors, 438 (H2SO4), 158 HACCP system, 2 Hazardous materials cleanup, 523 hazardous waste identification, 44 hazardous waste site, 55 Hazardous waste removal, 58 Hazardous industrial waste recovery, 409 hazardous communication course (HAS-COM), 155 HASMAT regulations, 204 HAZMAT team, 429 high-rises, 48 historic masonry, 268 healthcare organizations, 110 Heating hardware, 81 HEPA filtration, 412 heat exchanger deck hardware, 78 herbs, 81 herbal oils, 84 hazardous analysis, critical control point system (HACCP) hazardous air pollutants, 129 high density clay, 376 hog operations, 4 High temperature paint-coating removal hochdruck wasser strahl pistole (high pressure water jet gun), 93 hold times, 422 homicide and self-inflicted death, 417 hood-duct fires, 113 Honda, 108 Horse stables, 1 hotel-municipal pools, 441 hose damage, 462 hydraulic roof shoring, 71 hot-cold water pressure-washer and systems (1,500 to 9,000 psi), 110

621 humidity, 114 Humidity controls, 514 hydraulic systems, 421 Hydro-abrasive blasting, 507 HYDRO-BLASTING 5,000-30000 psi hydrogen fluoride, 134 Hydrofluoric (acid), 261 hydrogen peroxide, 177 hydroxide application, 537 Hydrostatic testing, 421 Hydro-tea, 526, 528 hydroxide solution, 262 hydro-vac application criteria, 409 hydro-vac dredging, 103 hygiene departments, 41 hygiene practices, 93 hydro concrete mill, 57 hydro-coke drum cutters, 63 hydro-vac wet mode system, 414 Highway-road services, 157 HVAC duct insulation, 410

I Industrial–commercial equipment, 477 Insect–pest suppression, 429 Inspection video interchangeable piston-plunger combinations, 108 interior linings, 480 interface adhesion factors, 405 Icicle-shaped ring deposits, 287 interface strength, 308 Isocyanate, MDI & TDI, 494

J Jet bridge areas, 24 jet fuel, 146 JP-4-JP-5 fuel tanks, 504 Juice processing, 32

K Kawasaki steel works, 123 kiln, 86 Kiln-boiler-furnace cleaning, 285 Kiln & preheater & precalciner, 92 kitchen exhaust hood cleaning, 35 Kennels-zoos-aquariums, 1 kerosene spills, 536 Kobe, 123 Kohler, 108 Kubota, 108

622 L Labyrinth technique, 74 labyrinth valve body, 72 lanyards, 146 lateral thrust advancing, 372 Laundry-garbage chute cleaning and sanitizing Large tube heat transfer units, lateral cutters Latex (green state), 494 Latex synthetic, 494 lead rich coating removal, 58 lead oxide, 131 leak detection, 421 leakage analysis, 422 Lechler, 488 licensed hazardous waste site, 55 Lake & pond management, 101 light oil jetting, 435 Light oils, 494 limestone, 443 liquid filtration, 83 liquid or gaseous state, 86 Lydia M. Ph.D. and Charles A. Frenzel, 397 locomotive, 480

M Marble, 443 Material Recovery Systems (MRF), 178 Magnesium sulfate, 513 MAGNOMAT, 138 Make-up water, 527 Maritime vessels, 137 marketing strategy, 45 mastic-polymer elasticity, 380 Max-vacuum standard, 142 Microbreweries, 35 micro brewery industry, 82 micro-organisms, 94 Micro-organisms Microbial analysis, 433 mildew and/or mold growth, 269, 535 Milk processing, concentrates, powders, 93 milk solids, 99 milk reception, 99 mineral extraction processes, 76 mechanical extraction from random rock, 74 Melamine, 513 Methyl methacrylate, 494 metallic activity, 262 metallurgy stations, 128

Index Metal pitting, 514 milk concentration, 81 mobile wash water recovery, 527 Mold remediation, 429 ‘‘monitor-hole watch’’, 155 misting events, 498 mud-sedimentation, 435 multilayer coating system, 307 Multimedia filtration Municipalities, 157 muriatic-hydrochloric acid, 257 moss and mold developments, 431

N Natural gas combined cycle power plant, 191 NATO airports, 24 Navy vessels, 145 naval job specifications, 319 negative airflow, 412 neutralizing the recoil forces, 288 non-destructive test procedure, 422 nozzle assemblied, 374 nozzle standoff distance, 430 Nonferrous metal industries, 122 Nonskid coating, 400 non-hazardous wash water, 120 Non-ionic detergent, 265 nonselective germicide (1% active iodine), 102 non-permeable surfaces nonskid coatings, 308 NPDES discharge permit, 424 nitrogen oxides, 134 nozzle-injector technology, 510 nozzle-lance configuration (angulations), 87 NPDES, 119 Nuclear Power Plant decontamination, 193 nuclear material-handling industry, 414 Nut shells, 513

O Odor-stench control, 429, 431 Offshore oil platforms, 137 oil–fats, 112 oil–grease filter, 112 Oil lube systems, 435 oil compressors, 435 oil rigs, 57 oil jetting application, 436

Index oil/water separation, 393 open drip-proof, 439 organic oils, 536 Ornamental statuary-monuments, 441 Orangeburg lateral pipe, 454 Oil skimming vessel, 470 organic waste, 4 Organic–inorganic filtration, 409 organic chemicals, 170 organic stains, 265 Oscillating speeds, 380 Otto Teufer, 9 oxidation, 530 oxidization of topcoats, 399 oxygen deficiency, 35 oxygen deficient atmospheres, 498 oxygen enriched atmospheres, 498 oxygen depletion (BOD), 528 oxidation, 257 Ozone generator, 531

P Package boiler services, 290 paper machine, 180 paper-pulp mill, 178 painting-coating-liner resurfacing, 57 Paint dried solvent, 494 Paint epoxy, 494 Pasting, 282 pasteurization processes, 81 patina, 251 peak count, 514 PCBs and VOCs, 530 Pelletizing plant, 129 Pellet types, 127 pest development, 1 penetrating wetting, 421 Penetrating wood preservative, 545 Permissible exposure limits (PELS), 411 pest suppression, 429 Phenolic resins, 494 piers, 57 pipe-sewer inspection, 455 Pipeline cleaning and cutting applications, 452 pile driving applications, 373 pile sections, 376 pile driving method, 377 porous profile, 11 polishing filtration, 527 Polymer jetting methods, 280

623 Polymerization, 281 potable water source, 406 plant food safety-hygiene regulations, 86 plant infrastructure, 158 Plastic media, 513 plastic dams-booms, 525 plastic–vinyl siding, 543 plate processing, 31 pharmaceutical outsourcing, 174 pharmaceutical products, 82, 170 Pharmaceutical bulk manufacturers, 176 phenolic, 530 Phosphatized degreasers, 415 phosphoric filtration, 30 phosphoric polishing filters, 529 pH values, 255 Pipe, brick and block manufacturing, 86 pipe radius, 457 Polycarbonate, 494 Poly vinyl chloride, 494 Poly vinyl acetate (PVA), 494 Pre-cast companies, 90 Prefabricated building assembly, 86 Pre Job Safety Meeting, 570 Premature brick failure, 88 Pre-qualifying, 157 Pressure-leak testing, 421 pretreatment clarifier, 525 primary–secondary–tertiary clarifiers, 181 Product cutting nozzles, 61 product recovery equipment, 36 Produce retailers, 108 product warranty guidelines, 57 profiling procedures, 468 profile height, 515 proposal, 565 pollution prevention hardware, 132 pond liners, 76 porous stone substrate, 443 poultries, 41 pulp-paper industry, 87 Psi x Gpm: 1,714 = Hp, 247 Pulp-paper, 176 paperboard, 176 cellulose, 176 pull off parameters, 161 purification, 170 Polishing, etching, metal burr-flush removal, 450 poultice concentrates, 315 powder operations, 81 Power-plant service, 135 pylon structures, 56

624 Q Quarantine restriction, 3 Quick exchange plunger-piston, 71

R Radiation protection, 194 Radiation-protection technician, 194 Rail accident site-emergency response, 198 Rail bridge, rail maintenance departments, 198 Railcar coatings, 480 Railcar units, 481 Railroad-commuter-light rail maintenance yards, 98 Railroad inspection, 208 Repair Work Sheet, 573 Railways historical associations, theme parks, 98 Rail safety and signage procedure, 203 Raymond E.F. Weaver, 67 Rebar systems, 48 Reddish-brown stains, 257 Red meat producers, 5 Ready-mix concrete industries, 86 Ready mix plants, 89 Rehabilitation process, 57 Refinery-oil-polymer-chemical manufacturing environments, 61 Refrigerated-frozen dairy products, 93 Refrigeration, 35 Regulatory agencies, 410 Repair cycles, 422 Rigid steel lance, 61 Rigid lance operator, 62 Remington cannon, 86 Remote control camera, 470 Resetting nail-heads and screws, etc., 533 Restoration projects, 315 Retail-processing environment, 115 Respiratory protection, 31, 417 Restoration, waterproofing, 44 Road deck installation, 57 Road film, 483 Roof safety, 500 Roof asphalt-composite tile, wood shingle cleaning, 532 Roots, 459 Rubber bladders, 458 Runways, 22 Runway cleaning, 24 Rubber build up, 24 RV valve, 424 Rx cavity floor, 416

Index Rx cavity refueling, 416 Rx head stud-ring, 416

S Sacrificial coating, 322 salt deposits, 56 sanitation program, 96 Sawdust, 513 sawed groove, 378 scaffold primary access, 14 scarifying method, 57 screens, 384 self propelling of flex lance assemblies, 61 Secondary fish processing plants, 101 secondary spill containment, 203 Self-contained breathing apparatus, 506 sectionalized rinse, 263 Seasonal batch requirements, 170 semi-full production cycle, 86 septic and/or treatment facility, 528 Sewer cleaning techniques, 456 Sewers, laterals, culverts, sumps, industrial pipe cleaning, 452 Sidewalks, decking, tank and pool construction, 378 silica sand, 131 Siliceous stones-rock, 265 Silica sand, 512 Silicon carbide, 511 Sintered bauxite, 512 sheet point friction, 376 shellfish producers, 105 shellfish and crustacean products, 105 Shopping zones, 157 Shot Crete, 59 shellfish, 101 skip-jack nozzle, 457 Slag’s, Fly-ash, 92 slaughterhouse-meat processing operations, 201 sludge or slurry pumping, 76 staging facilities, 55 Standards for Hazardous Air Pollutants 40 CFR, 414 stack-exhaust deposits, 483 Stack-flue plate, 471 Stack height, 471 standoff distances, 492 Static extraction, 76 static pressurized water–oil charge, 424 steel–concrete rehabilitation, 198

625

Index Steel cutting-demolition applications, 211, 507 Steam generators, three drum water tube boilers, 290, 421 Steam–vapor–gas flue stacks, industrial elevator shafts, 470 Storm surges, 459 storm water runoff, 154 spill prevention response plan, 141 Spin-Jet technology sterilization–pasteurization-manufacturing cycles, 96 STOP-GO command, 296 subsoil conditions, 26 substrate-interface, 534 Surface modulation, 450 surface-soil-ground-aquifers, 119 surface roughness, 446 suspended organics, 530 soaking cycle, 445 soda pop manufacturers, 36 sodium carbonate, sodium hydroxide, 41 sodium-hypochlorite NaOC1, 375 soft drink container, 490 soil contamination, 477 solid rocket fuel shells, 490 soluble, 528 Soluble abrasives, 452 solvent borne coatings, 480 solvent extraction, 82, 530 solvent rich solution, 75 soil profiles, 377 soil treatment, 409 spawning facilities, 103 structural steel joints, 48 Sugino, 488 sulfite pulping process, 177 Surface prep, graffiti removal, 44 surface preparation reference, 521 supermarket chains, 114 sugar refineries, 87 Surface pasting, 272 Surface preparation, 54 surface profile, 515 surface roughness, 57 Surface tension reducer, 427 Synthesizing-combining, 182

Tanks, vessels-autoclaves, precipitators, container cleaning, 488 tarpaulin methods, 44 T-assembly, 388 T-dual abrasive cleaning head, 301 taconite rock, 127 tank fog, 4 tea, 81 Tank car cleaning applications, 202 tarpaulin-covering procedures (splash proofing), 112 temperature cycling, 421 tensile strength-elasticity-stickiness, 63 tear-off visors, 292 3D tank-cleaning, 446 theme-park facilities, 285 Thermal-hot scale removal (cracking), 441 Theme-amusement parks, 180 thermal environment, 86 thermal shock fragmentation, 55 thermal shock method, 311 thick-film adhesion, 401 Tile-brick-grouts, 472 top cone conditions, 528 (TPH), 312 total suspended solids in wastewater effluent (TSS), 528 3M foils, 312 total dissolve solids in wastewater effluent (TDS), 528 total petroleum hydrocarbon count towers and tanks toxic priority pollutants, 477 Traffic control, 55 transfer hose technology, 81 transit car manufacturing industries, 208 Tracer concentrate, 427 Trade Related Publications, 615 trench degradation, 459 Traffic barricades, 470 trace elements, 543 Tropical marine livestock centers, 101 Trucks-trailers-tankers-railcars, 108 Turbine flow meter, 427 turbine fouling, 192 turbine oil, 436 two-step chemical cleaning method, 261 two-Pronged abrasive manifold

T Tailgate Safety Meeting, 571 Tannins, 534, 537 Tank top plating, 506

U Upstream manhole, 457 UHP trigger-gun, 468 Urea, 271

626

U (cont.) U-tube condensers, 191 Underwater hydro-blasting, 521 UV damages, 534 UV protection, 534

V Vacuum booms, 525 vacuum chill box, 64 Vacuum-dredging tools, 4 vacuum assist water recycling, 36, 51 vacuum shoe, 413, 526 vacuum shroud, 525 volume-psi metering, 423 valve flange joint, 374 vegetative materials, 170 Vehicle fleets, rail-car, truck-trailer-tanker, 477 ventilation valve, 424 Verbal Quoted Price By Phone, 575 vertical pipe-cleaning, 475 Veterinary associations, 7 Veterinary facilities, 1 vinegar, 443 Vinyl emulsion polymers, 494 Vinyl, wood, aluminum siding cleaning, 532 viscous-sticky products, 9 Volatile substance removal and effluent separation, 488 volatile-gaseous environment, 394 volatile organic compounds, 170

W Waste product (biomass), 182 waste transportation trip ticket, 464 wastewater treatment facility, 134, 161, 175 Wastewater reclamation technology, evaporation, 523 waste-refuse handling, 319 wash water discharge, 477

Index Wash water control, recovery, filtration, recycling, 523 Washing exterior-interior surfaces, 53 wastewaters neutrality (pH 5–6), 528 water abrasive injectors, 276 water bladders, 401 water based coatings, 325 water borne coating, 480 water compressibility, 11 water/air droplets, 11 water barriers, 526 water-effluent run-off, 55 waterproofing, 14 water filled bladders, 524 water pollution control, 523 water purification systems, 33 water saturation ratio, 528 water solubility, 483 water soluble road film, 483 Well casing walls, 377 well drilling platforms, 478 weld tagging, 376 wet-end exposure, 180 wet/dry interface to scrubber vessels, 188 whirl jets, 467 whirl-jet chamber, 491 whitewater tanks, 177 whitening, 261 wire mesh-plate-vane mist eliminators, 384 wood-façade, 533 Wood restoration and preservation, seal-coating applications, 532 wooden fencing, 447 wood stain, 534 Wood structures-decks-seal-landing and fence restoration, 532 Wolfgang Maasberg Sr., 61 WOMA Corp., 61 WOMA designed 2-D and 3-D nozzles

X X-ray fluorescent analyzer, 270