Automated Truck Wash
Automated Truck Wash
NEW JERSEY DEPARTMENT OF TRANSPORTATION 2017 MIDWEST & NORTHEAST EQUIPMENT MANAGEMENT JOINT MEETING
Why? ◦The NJDEP Storm Water Regulations “On March 1, 2009 and thereafter, Highway Agencies shall manage any equipment and vehicle washing activities so that there are no unpermitted discharges of wash water to the surface or ground waters of the State.”
Requirements ◦ Construct dedicated wash bays where waste water is treated, and discharged into municipal sewer system meeting the water quality limitation of the governing authority. ◦ Removal of solid accumulations of salt on equipment involved in snow removal by manual means. The material should be recycled.
Wash Bay Study ◦ Reviewed both manual and automatic washing systems ◦ Looked at existing facilities
◦ Evaluated approaches to: ◦ Water reclamation ◦ Wash water processing equipment ◦ Wash water discharge requirements
Lakewood Public Works
◦ Examined select NJDOT facilities ◦ Life Cycle Cost Analysis ◦ Existing wash bays – Manual wash system ◦ New wash bays - Automatic wash equipment
New Jersey Turnpike Authority
Wash Bay Study Findings ◦ Estimated Costs Not including building renovations, new building construction or service upgrades. System Type
Avg. Wash Equipment Cost
Avg. Filtration Cost of Pits, Drains, Equipment Cost Piping & Utilities
Total Avg. Cost*
Manual
$14,000
$34,000
$57,000
$105,000
Automatic Gantry (7-10 year life span)
$225,500
$101,000
$80,000
$406,000
Automatic Drive-Through (15-20 year life span)
$150,000
$101,000
$80,000
$331,000
Wash Bay Study Recommendations ◦ Share services with existing facilities throughout the State ◦ Retrofit facilities that have sufficient space with a manual wash bay ◦ New building construction with automatic drive-through system at facilities that do not have sufficient space to renovate existing wash bays ◦ The first automatic drive-through was constructed at our Headquarters in Trenton. ◦ Estimated Cost: $1,235,000
New Building Construction Specs ◦ A 30’ wide by 85’ long pre-engineered metal building. Drive through design. ◦ 12’ wide by 16’ roll up doors, operated by the wash control system for automatic opening and closing. ◦ 7’ high block walls. ◦ Interior eave height: 18’ minimum. ◦ Wash bay width: 20’. ◦ An 8’ wide mechanical space the length of the building. ◦ Heating provided by infrared gas heater in the wash bay and unit heaters in the mechanical space.
Automatic Drive-Through Specs ◦ High pressure “touchless” design to accommodate all types of vehicles ◦ Keypad control system and a data logger system with PC programming ◦ Manually operated de-mud/de-icing water cannons ◦ Three arch fixed wash system ◦ Automatic undercarriage wash ◦ Filtration and recycling system ◦ Should be programmable to adjust the amount of discharge to maintain water quality ◦ Blow drying is a nice feature but is not required
SmartWash® Sprite
Keypad Control System and Data Logger System Use AssetWorks Fuel Terminal to access the building
Manually Operated De-Mud/De-Ice Water cannons (high volume/low pressure) to rinse caked debris.
Heated water (low volume/high pressure) to rinse caked debris and grease.
Pre-Rinse and Knock-Out Pit ◦ Vehicles drive through at approximately 2 mph. Each station automatically trigger as the it passes through. ◦ Prewash station will spray a water-soap solution on the vehicle. ◦ Facilitates removal of soil and road grime. ◦ Wash water from the water cannons and first arch will flow to an in-ground knock-out pit where the soils, road grime and any gross floatables will be separated. ◦ Effluent water will gravity overflow from the knock-out pit and be directed to a primary collection sump.
Wash, Automatic Under Carriage Wash and Final Rinse ◦ Detergent wash and final rinse cycles should be freshwater to remove salt deposits and prevent spotting. ◦ Wash water from the wash arch and the rinse arch will each flow to separate grit removal chambers and then to a primary collection sump to be combined with the discharge from the knock-out pit.
Water Reclamation System Wash water collected from the primary collection sump will then be pumped to the wash water recycle system for treatment and reuse.
Water Reclamation System ◦ Includes sediment basins, filtration equipment, pH adjustment equipment and the ability to regulate the percentage of reclaimed water to fresh water, to regulate the quality of the discharge water.
Carbtrol Wash Water Recycling System ◦ Clarification to remove settleable solids ◦ Oil/Water separation to remove free oil and hydrocarbons ◦ Mixed media filtration, to remove filterable solids and/or soluble, or lightly emulsified, hydrocarbons ◦ Advanced oxidation (ozone and peroxide) to manage odors and provide disinfection ◦ Flow equalization and treated water storage ◦ Automatic blowdown for salt build up and management ◦ Full integration of recycle operations with wash pumping and control system ◦ Designed to treat an average flow rate of 100 GPM, an instantaneous flow rate of 150 GPM and sustained flow rate of 17,000 gallons in a three hour period ◦ No chemicals or supplies required in the operation of the system other than peroxide for odor control. ◦ Filters do not need to be replaced, just vacuumed on an annual basis.
Reclaimed Water ◦ Each wash will utilize 340 gallons of water both reclaimed and fresh water. ◦ It is anticipated that 200-240 gallons of water will be reclaimed and recycled.
Other Back Room Equipment Heated Pressure washer and pumps
Soap Storage Tanks
Discharged Water During snow operations it is estimated that 40 gallons of recycled water will need to be discharged to maintain acceptable salt levels in the reclaimed water. (blowdown) On site sewage disposal system required for blowdown. Recycled water can only be discharged to municipal sewer systems. Discharged recycled water must meet the parameters of the municipal sewer systems. Some sewer authorities will not accept industrial waste water. Discharged recycled water at sites without municipal sewer systems must be retained in above ground storage tanks and utilized for manufacturing brine solution or trucked offsite for disposal. We are required to perform periodic testing and maintain records for compliance for discharge.
Basic In-Ground Kick Out Pit Maintenance Items that are required to ensure a consistent water quality Automated Oil Wick
Vacuum Truck
Maintenance - Contract ◦ Initially we did not have a contract which led to a lot of down time ◦ Assigning responsibilities was a challenge. Facilities, equipment and environmental all needed to take a part. ◦ We now have a maintenance contract with monthly scheduled preventative maintenance. ◦ Cost: Approximately $66,000/year ◦ Consumables ◦ Oil wick ◦ Soap ◦ Peroxide
Water Usage Time Frame
Gallons Time Frame
Gallons Time Frame
Gallons
5/23/14-8/11/14
22,400 5/18/15 – 8/10/15
67,320
5/27/16 – 8/9/16
70,000
8/11/14-11/18/14
15,960 8/10/15 – 11/10/15
29,920
8/9/16 – 11/23/16
15,000
11/18/14-2/13/15
89,760 11/10/15 – 2/10/16
150,000 11/23 – 2/13/17
2/13/15-5/18/15
187,000 2/10/16 – 5/27/16
67,320
166,000
Usage Since March of 2015 – Grand Total: 1277 trucks washed ◦ North Region: 139 ◦ Central Region: 907 ◦ South Region: 231
We have recently entered into an agreement with the NJ Department of Correction for their use of the facility ◦ Charging a fee of $35/wash
Benefits ◦ Employees can clean the vehicle in a heated environment ◦ Easy to operate ◦ Reduces corrosion ◦ Mechanics can degrease equipment prior to working on it ◦ Environmental Friendly
Lessons Learned ◦ Actual Cost: $2,250,000 ◦ Location selected cannot accommodate larger tractor trailer ◦ Not wide enough to accommodate a truck with the plow attached ◦ We do not have the ability to remotely control or diagnose the system ◦ Lack of a maintenance plan quickly lead to excessive downtime ◦ Doesn’t work as well as a brush style system ◦ Wanted to setup for 24 hour operations but didn’t work out controls for opening and closing doors could be better. Electronic eyes are tricky ◦ Addition of spray boom to apply a salt neutralizer would be useful ◦ The use of discharge water as brine to treat the roads wasn’t feasible
Way Forward ◦ Not planning on constructing any new building for Automatic Truck Washes ◦ Will continue to find other agencies to share the service ◦ Cost of existing shared services: $35/wash
◦ Rather have manual systems than automatic ◦ Will rehab existing facilities to include Manual Wash Bays ◦ Will update existing wash bays to be in compliance
NEW JERSEY DEPARTMENT OF TRANSPORTATION 2017 MIDWEST & NORTHEAST EQUIPMENT MANAGEMENT JOINT MEETING
Why? ◦The NJDEP Storm Water Regulations “On March 1, 2009 and thereafter, Highway Agencies shall manage any equipment and vehicle washing activities so that there are no unpermitted discharges of wash water to the surface or ground waters of the State.”
Requirements ◦ Construct dedicated wash bays where waste water is treated, and discharged into municipal sewer system meeting the water quality limitation of the governing authority. ◦ Removal of solid accumulations of salt on equipment involved in snow removal by manual means. The material should be recycled.
Wash Bay Study ◦ Reviewed both manual and automatic washing systems ◦ Looked at existing facilities
◦ Evaluated approaches to: ◦ Water reclamation ◦ Wash water processing equipment ◦ Wash water discharge requirements
Lakewood Public Works
◦ Examined select NJDOT facilities ◦ Life Cycle Cost Analysis ◦ Existing wash bays – Manual wash system ◦ New wash bays - Automatic wash equipment
New Jersey Turnpike Authority
Wash Bay Study Findings ◦ Estimated Costs Not including building renovations, new building construction or service upgrades. System Type
Avg. Wash Equipment Cost
Avg. Filtration Cost of Pits, Drains, Equipment Cost Piping & Utilities
Total Avg. Cost*
Manual
$14,000
$34,000
$57,000
$105,000
Automatic Gantry (7-10 year life span)
$225,500
$101,000
$80,000
$406,000
Automatic Drive-Through (15-20 year life span)
$150,000
$101,000
$80,000
$331,000
Wash Bay Study Recommendations ◦ Share services with existing facilities throughout the State ◦ Retrofit facilities that have sufficient space with a manual wash bay ◦ New building construction with automatic drive-through system at facilities that do not have sufficient space to renovate existing wash bays ◦ The first automatic drive-through was constructed at our Headquarters in Trenton. ◦ Estimated Cost: $1,235,000
New Building Construction Specs ◦ A 30’ wide by 85’ long pre-engineered metal building. Drive through design. ◦ 12’ wide by 16’ roll up doors, operated by the wash control system for automatic opening and closing. ◦ 7’ high block walls. ◦ Interior eave height: 18’ minimum. ◦ Wash bay width: 20’. ◦ An 8’ wide mechanical space the length of the building. ◦ Heating provided by infrared gas heater in the wash bay and unit heaters in the mechanical space.
Automatic Drive-Through Specs ◦ High pressure “touchless” design to accommodate all types of vehicles ◦ Keypad control system and a data logger system with PC programming ◦ Manually operated de-mud/de-icing water cannons ◦ Three arch fixed wash system ◦ Automatic undercarriage wash ◦ Filtration and recycling system ◦ Should be programmable to adjust the amount of discharge to maintain water quality ◦ Blow drying is a nice feature but is not required
SmartWash® Sprite
Keypad Control System and Data Logger System Use AssetWorks Fuel Terminal to access the building
Manually Operated De-Mud/De-Ice Water cannons (high volume/low pressure) to rinse caked debris.
Heated water (low volume/high pressure) to rinse caked debris and grease.
Pre-Rinse and Knock-Out Pit ◦ Vehicles drive through at approximately 2 mph. Each station automatically trigger as the it passes through. ◦ Prewash station will spray a water-soap solution on the vehicle. ◦ Facilitates removal of soil and road grime. ◦ Wash water from the water cannons and first arch will flow to an in-ground knock-out pit where the soils, road grime and any gross floatables will be separated. ◦ Effluent water will gravity overflow from the knock-out pit and be directed to a primary collection sump.
Wash, Automatic Under Carriage Wash and Final Rinse ◦ Detergent wash and final rinse cycles should be freshwater to remove salt deposits and prevent spotting. ◦ Wash water from the wash arch and the rinse arch will each flow to separate grit removal chambers and then to a primary collection sump to be combined with the discharge from the knock-out pit.
Water Reclamation System Wash water collected from the primary collection sump will then be pumped to the wash water recycle system for treatment and reuse.
Water Reclamation System ◦ Includes sediment basins, filtration equipment, pH adjustment equipment and the ability to regulate the percentage of reclaimed water to fresh water, to regulate the quality of the discharge water.
Carbtrol Wash Water Recycling System ◦ Clarification to remove settleable solids ◦ Oil/Water separation to remove free oil and hydrocarbons ◦ Mixed media filtration, to remove filterable solids and/or soluble, or lightly emulsified, hydrocarbons ◦ Advanced oxidation (ozone and peroxide) to manage odors and provide disinfection ◦ Flow equalization and treated water storage ◦ Automatic blowdown for salt build up and management ◦ Full integration of recycle operations with wash pumping and control system ◦ Designed to treat an average flow rate of 100 GPM, an instantaneous flow rate of 150 GPM and sustained flow rate of 17,000 gallons in a three hour period ◦ No chemicals or supplies required in the operation of the system other than peroxide for odor control. ◦ Filters do not need to be replaced, just vacuumed on an annual basis.
Reclaimed Water ◦ Each wash will utilize 340 gallons of water both reclaimed and fresh water. ◦ It is anticipated that 200-240 gallons of water will be reclaimed and recycled.
Other Back Room Equipment Heated Pressure washer and pumps
Soap Storage Tanks
Discharged Water During snow operations it is estimated that 40 gallons of recycled water will need to be discharged to maintain acceptable salt levels in the reclaimed water. (blowdown) On site sewage disposal system required for blowdown. Recycled water can only be discharged to municipal sewer systems. Discharged recycled water must meet the parameters of the municipal sewer systems. Some sewer authorities will not accept industrial waste water. Discharged recycled water at sites without municipal sewer systems must be retained in above ground storage tanks and utilized for manufacturing brine solution or trucked offsite for disposal. We are required to perform periodic testing and maintain records for compliance for discharge.
Basic In-Ground Kick Out Pit Maintenance Items that are required to ensure a consistent water quality Automated Oil Wick
Vacuum Truck
Maintenance - Contract ◦ Initially we did not have a contract which led to a lot of down time ◦ Assigning responsibilities was a challenge. Facilities, equipment and environmental all needed to take a part. ◦ We now have a maintenance contract with monthly scheduled preventative maintenance. ◦ Cost: Approximately $66,000/year ◦ Consumables ◦ Oil wick ◦ Soap ◦ Peroxide
Water Usage Time Frame
Gallons Time Frame
Gallons Time Frame
Gallons
5/23/14-8/11/14
22,400 5/18/15 – 8/10/15
67,320
5/27/16 – 8/9/16
70,000
8/11/14-11/18/14
15,960 8/10/15 – 11/10/15
29,920
8/9/16 – 11/23/16
15,000
11/18/14-2/13/15
89,760 11/10/15 – 2/10/16
150,000 11/23 – 2/13/17
2/13/15-5/18/15
187,000 2/10/16 – 5/27/16
67,320
166,000
Usage Since March of 2015 – Grand Total: 1277 trucks washed ◦ North Region: 139 ◦ Central Region: 907 ◦ South Region: 231
We have recently entered into an agreement with the NJ Department of Correction for their use of the facility ◦ Charging a fee of $35/wash
Benefits ◦ Employees can clean the vehicle in a heated environment ◦ Easy to operate ◦ Reduces corrosion ◦ Mechanics can degrease equipment prior to working on it ◦ Environmental Friendly
Lessons Learned ◦ Actual Cost: $2,250,000 ◦ Location selected cannot accommodate larger tractor trailer ◦ Not wide enough to accommodate a truck with the plow attached ◦ We do not have the ability to remotely control or diagnose the system ◦ Lack of a maintenance plan quickly lead to excessive downtime ◦ Doesn’t work as well as a brush style system ◦ Wanted to setup for 24 hour operations but didn’t work out controls for opening and closing doors could be better. Electronic eyes are tricky ◦ Addition of spray boom to apply a salt neutralizer would be useful ◦ The use of discharge water as brine to treat the roads wasn’t feasible
Way Forward ◦ Not planning on constructing any new building for Automatic Truck Washes ◦ Will continue to find other agencies to share the service ◦ Cost of existing shared services: $35/wash
◦ Rather have manual systems than automatic ◦ Will rehab existing facilities to include Manual Wash Bays ◦ Will update existing wash bays to be in compliance
