Water and wastewater processing is a major operation in the United States, handling more than 34 billion gallons daily. Many existing treatment plants were built in the 1970s following the passage of the Clean Water Act in 1972. With the average water and wastewater treatment plant having a lifespan of 40-50 years, most of these plants are reaching end-of-life and require considerable overhauls to stay operational.
These plants are known for harsh conditions that lead to the degradation and deterioration of electrical distribution systems. Combined with the age of these facilities, this means frequent and expensive repairs and replacements to prevent failures.
This article explores three major challenges of aging electrical systems in water treatment and how Emerson provides modern solutions.
Challenge #1: The Environment is Ripe for Corrosion
There’s one natural truth in any kind of manufacturing facility: where there’s moisture, there’s the threat of corrosion. In water and wastewater treatment plants, there’s plenty of moisture. Harsh chemicals like ferric chloride, chlorine, acids, and alkalis accelerate the breakdown of metal components. It’s estimated that corrosion costs the industry $1.3 billion annually in damages, including replacement of failed equipment, poor power quality, lost productivity, and increased maintenance.
Emerson set out to fight the corrosion battle on the front lines and is the only electrical manufacturer that uses a patented triple epoxy powder coat finish on the majority of their Appleton iron electrical products. The powder coat is drawn to the metal like a magnet, covering equally and reaching into even the smallest crevices. It’s then cured in an oven to ensure a strong bond. This creates a thick, even protective layer, reducing corrosive exposure and extending the lifespan of metal electrical components.
For more insight into how Emerson’s innovations are pushing the boundaries of performance in harsh environments, check out our article on Appleton Powertite by Emerson, a solution designed to withstand demanding conditions while delivering reliability and durability.
Challenge #2: The Presence of Hazardous Materials
The second challenge is as much of a safety hazard as it is an equipment hazard. As waste decomposes, it generates methane and hydrogen. Purification chemicals like hydrogen peroxide and chlorine dioxide are also readily present. These are all flammable gases, even in relatively low concentrations. Hazardous areas like this require products rated explosionproof by the National Electrical Code (NEC) to ensure safety.
Emerson offers a complete line of explosion proof Appleton light fixtures, control stations, fittings, plugs, receptacles, and motor starters to minimize the risk of disasters. These products are subject to rigorous testing to adhere to ATEX, IECEx, NEC, and CEC certification, ensuring compliance regardless of your geography. The company also offers a wide variety of hazardous and ordinary location products that meet NEMA weatherproof standards.
Challenge #3: Dated Equipment Lacks Energy Efficiency
Operational costs continue to rise while budgets aren’t keeping pace in the water and wastewater sector. This means energy efficiency has become a top priority. Operators and government officials are constantly seeking strategies to reduce energy costs while lessening environmental impact. Emerson is helping facilities make a sizable impact on both fronts with energy efficient LEDs to replace existing HID and fluorescent lighting. Combined with photocells, occupancy sensors, and dimming capabilities, these solutions can reduce the energy draw of lighting by up to 70%. Most Appleton LED luminaries have options for every area of water and wastewater treatment facilities, both indoors and out.
Agilix Solutions & Emerson: Modernizing the Water & Wastewater Industry Together
The pros at Emerson are the trusted experts when it comes to electrical equipment in water and wastewater facilities. With a reputation like that, they’re particular about who they choose to partner with. Agilix Solutions is your local authorized Appleton products distributor. Reach out to your Account Manager or your local branch to take the first step toward updating your water and wastewater treatment operations for performance and safety.