Freeze protection of water piping located outside or exposed to cold temperatures requires planning and adherence to proper specifications. Thermal insulation alone, even when applied correctly and in the proper thickness, does not necessarily prevent freezing. All electrical heat tracing manufacturers provide a specific heat loss calculation chart for selecting the proper heat trace wattage, based on the pipe diameter and insulation thickness. It is important to use the correct wattage rating from these charts.
The most common wattages used for freeze protection of water piping are 3, 5, and 8 watts per foot. In some instances, 10 and 15 watts per foot may be required. Small-diameter piping (3 inches or less), hung horizontally, is more susceptible to freezing than vertical piping of the same diameter, however, both should be treated equally for the protection of the entire system. Flanges, valves, and instrumentation all must have the electric tracing looped or installed properly to eliminate cold spots or gaps in the system. Environmental factors such as wind speed, minimum ambient temperature, and the location of the piping can require a different level of protection (e.g. piping located on a roof vs. buried in the ground).
Fortunately, many regions of the Mid-Atlantic where Waco operates, do not experience long extended periods of below-freezing temperatures. However, a polar vortex situation like the one that occurred around Christmas in 2022 did not take long to cause serious problems for many businesses and factories.
What are the piping systems that are most susceptible to freezing?
Hydronic water piping on HVAC units and cooling towers
Makeup water piping and exposed plumbing
Wastewater piping at Water Treatment Plants
Water piping at Pump Stations or Industrial facilities
The main type of electric tracing for freeze protection is called self-regulating (SR) and is designed to operate with demand, ﬂuctuating or increasing the wattage as the temperature drops. Another type of electric tracing is Constant Wattage (CW), which is commonly used to maintain a constant specified temperature in water or liquids of a process system. Heat tracing can be powered by any of the voltages commonly found in commercial or industrial facilities (120, 208, 240, and 277) but must be ordered for the specific voltage available.
Insulation contractors like Waco, Inc. are very capable of eﬀectively installing SR electric heat tracing and providing the proper insulation and weather barrier jacketing systems. It is a complete package that clients find more cost-effective than getting separate bids for heat tracing and insulation from diﬀerent contractors. A qualified electrician is required to make the final connection to the power source on any system involved. Waco works with several electrical contractors to ensure that the tracing is properly installed and that junction boxes and thermostats are located in such a way to reduce the lengths of conduit needed to power them. Sometimes heat tracing may need to be located in a hazardous environment, which would require Class 1, 2, or 3 explosion-proof electrical enclosures. Waco can provide systems with additional ground fault protection, in addition to heat trace cable manufactured with corrosion-resistant material or non-sparking, non-metallic design.
Any thermal insulation system must be properly installed so that the heat tracing can perform as designed. Adequate protection from the weather is critical. Waco has decades of experience with heat-trace systems, and we continually train our workforce on proper installation techniques. You can be assured that we will provide a complete system that performs and protects, reducing your worries during the winter months and throughout the year. Don’t wait until cold weather arrives. Contact Waco for your next heat tracing project.
Industrial equipment is designed to perform specific functions, and any deviation from the recommended installation guidelines can lead to malfunction or failure. Ensuring proper installation is crucial to prevent costly downtime and repairs. Investing in professional installation services can eliminate uncertainty and provide businesses with increased productivity while maximizing their equipment’s performance.
For over five decades, Waco Inc. has delivered specialized installation services to various industries, including many Fortune 500 companies. We operate across Virginia, North Carolina, Maryland, and West Virginia.
Preparation Guide for Industrial Equipment Installation
Proper preparation can help avoid delays, equipment damage, and additional costs. Here are three steps that can make the pre-construction installation process more efficient:
1. Establishing a Detailed Scope of Work
Knowing which requirements must be met for a successful installation is crucial. This information can be obtained from the project manager and engineer who can list specific on-site requirements. Some of the key requirements include the following:
Access to Site
Foundation Support and any Modifications
Electrical Power Supply and Capacity
Mechanical Piping Tie in Locations
2. Identifying Onsite Storage Capacity
Locations within a facility where equipment, materials, or supplies can be staged before moving to their final destination.is critical. Proper planning and communication with the project manager and plant personnel can help determine the most efficient location for storage. This will minimize any additional rigging requirements, so that equipment can be more easily placed in the proper location.
3. Verifying Environmental Conditions
It is vital to consider all environmental conditions during and before installation. Quite often stricter regulations will be required for the newer equipment. Structural improvements such as containment walls and larger drainage may be needed to handle the increased possible spill capacity of the new equipment.
Our team of experienced professionals specializes in providing the following core services:
Equipment installation refers to assembling and connecting industrial equipment and machinery to enable them to perform their specific functions. It requires adherence to the manufacturer’s guidelines for installation, which may include site preparation, electrical and mechanical connections, equipment assembly, and testing.
At Waco Inc., we provide industrial equipment installation services for various industries and applications. Our turnkey solutions encompass project management, logistics, system testing, and startup. We also have extensive experience in installing different types of industrial equipment, including the following:
Full plant relocation involves moving an entire industrial facility or plant to a new location. This process includes dismantling and disconnecting all the original site’s machinery, equipment, and infrastructure. It is followed by transportation to the new place and then reassembling and reconnecting everything at the new site.
Equipment alignment ensures that machinery and equipment are properly positioned and adjusted to function optimally. The process helps reduce equipment wear and tear, minimize vibrations, and prevent premature failure. It can be performed using various techniques, such as laser alignment or dial indicator alignment.
Structural steel and rigging are two critical processes in setting up and relocating large steel structures and machinery in industrial settings. Structural steel encompasses the installation of steel components that offer support to various industrial systems and equipment. Rigging is the use of specialized cranes, forklifts, chainfalls and techniques to move heavy industrial parts, machinery, and equipment.
Concrete Forming and Finishing
Concrete forming and finishing involves placing concrete into forms and structures to achieve the desired appearance and function. Waco has experience with many different types of grouts, concrete additives and structural components that can ensure a proper placement or supporting foundation for new equipment.
Industrial Installation Projects
Waco Inc. has been a trusted provider of specialized services across various sectors, including energy, chemical manufacturing, food and beverage, and pulp and paper mills. Our commitment to delivering high-quality services has earned us the public’s trust over the years.
Here are some examples of our featured industrial installation projects:
Choose Waco Inc. for Safe and High-Quality Installation Services
At Waco Inc., we have a diversified portfolio of industrial equipment installation, complete plant relocation, equipment alignment, and structural steel and rigging capabilities! From process piping installation and air pollution reduction systems to waste and water treatment equipment, we have the experience to ensure that your project is successful..
Water Treatment and Wastewater Treatment processes are significantly different from each other. This article will explain both and demonstrate some of the differences.
Water Treatment systems are typically designed to take fresh water from a body of water, well or aquifer to a storage tank. Filters systems in combination with flocculant clarifiers and/or coagulants are used to remove sedimentation. Biocides and chlorine treatment may be added to control bacteria and biological microbes. Additional chemicals may be added to balance PH levels.
Wastewater processes, on the other hand, require extensive additional treatment, which involves screening, filtration, aeration and chemical additive equipment. There has been significant new technology involving optimization of the treatment process for both of the solid and liquid components in Wastewater systems.
Waco has been on the forefront of correctly implementing these new engineered designs. The combination of advanced technology and Waco’s construction expertise has provided vitally important environmental improvements to both Water and Wastewater treatment systems. These are the challenges facing today’s growing municipalities, counties and industrial manufacturers charged with Water and Wastewater facility management. We will explain what systems Waco currently constructs and how this is benefiting our communities, parks, waterways and wildlife management areas.
Fresh Water – Pump Stations: These facilities are typically installed to increase the amount of water required for a certain municipality or county’s system. Most require a large holding tank of fresh water, large pumps and a piping system. Typically, Pump Stations receive water that has previously been treated. In some cases, chlorine might be added or additional chemical treatment for ph control may be required. The main function of a Pump Station is to maintain water pressure and water capacity.
Waco has installed many of these Pump Stations throughout Virginia and has a solid reputation for competitively bidding and completing this work ahead of schedule. We have a dedicated team that works exclusively on these types of projects. We understand the means and methods used to install the equipment and ensure the proper scheduling of the work. We understand the construction process, how to properly install the equipment and schedule the work. We can foresee potential problems and bring them to the attention of the owner before they delay the project or incur additional expense. We have warehouse facilities capable of storing long lead time parts and equipment, further maintaining our ability to keep the project on schedule.
Waste Water Treatment
Types of Water & Wastewater Treatment Facilities being constructed
Odor Control Stations
Municipal Wastewater Treatment Plants
Industrial Onsite Wastewater Treatment Facilities
Odor Control Stations:
Sewage treatment facilities can be located in densely populated areas. It is critical that the facility operates with the least amount of released odors as possible. Odor control is performed with many methods, but the most commonly used is a Bio-Scrubber system. This system gathers vapors from the wet well using industrial fans, and adds chemicals and water to the vapors which are then sent through a bio filter system. These tanks and filters collect enough of the hydrogen sulfide gas so that any discharge out the stack has a minimal amount of odor.
Municipal Wastewater Treatment Facility
Main processes for cleaning Wastewater
Physical – This involves large screens, centrifuges, clarifiers, aeration or blower air, Nano membranes or filter media types and reverse osmosis.
Chemical – This involves treating the water with chemicals such as lime, bleach/chlorine, hypochlorite, ozone or several other types of disinfectant.
Biological – naturally occurring microbes or organic matter that breaks down the pathogens or wastes into components that can be further treated with less chemicals required. Anaerobic Digestion process.
Newer Technologies – UV Light
Goal: To separate the solids from the liquids
Liquids typically go through a multi stage filtering and aeration process. Chemicals are added along the way until the wastewater is considered fresh potable water and suitable for discharge back into the environment.
Solids will go through a more involved filter pressing and heating process to drive more liquid out of the solid and make it into what is commonly called a “cake”. Once it gets to this stage it is a biosolid or sewage sludge. An anaerobic digestion process uses naturally occurring bacteria to convert organic matter (sewage sludge) into methane and carbon dioxide. These components methane and CO2 are often referred to as Biogas. The methane can be burned off using a thermal oxidizer, or it can be used in a combustion process to convert to a useful energy source for operating segments of the Wastewater Treatment facility.
The biosolids are further chemically treated until the level of pathogens has been reduced to an allowable limit set by EPA and other agencies. This final product (ammonia/nitrogen rich solids) can then either be used on soils for agricultural purposes or for reclamation sites or landfill cover. The current breakdown of biosolids application in the US is – Agricultural – 42%, Landfill or reclamation soil – 43%, and Incineration – 15%
Industrial Onsite Wastewater Treatment Facilities
Many industrial manufacturers are required to pre-treat their chemical discharge before sending it to a municipal or county wastewater treatment plant. Waco’s long history of experience working in industrial plants and our combined wastewater capabilities allow us to provide a combined approach that many other contractors cannot offer.
Waco has the ability to perform major upgrades to existing operational wastewater treatment facilities. We have an extensive completed project list and over 40 years of experience in this segment of the construction business. Our jobs range from minor equipment change outs of $50,000 to large $10 million to $18 million projects involving installation of entire new buildings with filtering and chemical processing equipment. We specialize in increasing the capacity of a wastewater treatment facility, or constructing components to bring an existing facility into compliance with new water regulation codes, or for reissuance of permits, such as the Virginia Pollution Discharge Elimination System (VPDES).
All this work can be done while the facility is operating. Coordinating with plant operators and engineers is critical, especially when the final connections between the older system components are made with newly installed systems. Other factors such as stormwater control measures and modifications to roadways are elements that must be considered before implementation of any construction process.
Water and Wastewater treatment facilities will continue to see increasing demands. Waco incorporates these new technologies into the project, and has the ability to implement those requirements in a coordinated construction process. We work with the top Water and Wastewater treatment engineering firms, and invite you to review our past projects or contact a reference from our extensive list of clients.