Projects & Case Studies

Textile plant · Selma, AL · 2024

Boiler feedwater rebuild

Repeated boiler tube failures traced to 11 gpg hardness and high alkalinity carry-over. We installed twin-alternating softeners with a dealkalizer, added condensate return polishing and rebalanced chemical feed.

• Tube failures eliminated over 14 months of monitoring
• Gas consumption down an estimated 6% after scale removal
• Blowdown reduced by tightening conductivity control

Poultry processor · Prattville, AL · 2023

Twin-tank softening skid

Time-clock softeners were regenerating nightly regardless of demand. We fabricated a metered twin-tank skid in our Montgomery shop and swapped it in during a Sunday shutdown.

• Salt consumption cut by roughly one third
• Regeneration water use down significantly
• Installation completed inside a single 9-hour window

Rural water authority · Autauga County, AL · 2023

Municipal polishing upgrade

Filter media at end of life with rising turbidity after rain events. We replaced multi-media beds, reset backwash rates and added differential pressure instrumentation.

• Turbidity excursions after rainfall resolved
• Backwash volume reduced with corrected rates
• Operators trained on new instrumentation

Medical campus · Montgomery, AL · 2022

Clinical RO for a medical campus

Sterile processing needed reliable low-TDS water with redundancy. Duplex RO with carbon pre-treatment, UV and storage was installed with alarm dial-out to facilities.

• Redundant trains allow service without downtime
• Documented validation package for accreditation
• Quarterly service with signed reporting

Commercial laundry · Auburn, AL · 2022

Laundry water retrofit

Grey linen and detergent overuse from untreated hot water feed. Softening resized to peak demand plus a blend valve for controlled hardness leakage.

• Rewash rate reduced by operator report
• Detergent dosing lowered after chemistry review
• Payback estimated inside 11 months

Manufacturing plant · Birmingham, AL · 2021

Cooling loop side-stream filtration

Fouled tower fill and dropping approach temperatures. We added side-stream filtration, biocide programme and conductivity-based bleed control.

• Approach temperature recovered toward design
• Fill cleaning interval extended
• Biocide use documented for audit

Figures quoted are drawn from our own commissioning and service records and from client-reported operating data. Results vary with source water, load and maintenance.