Project Summary

United States

Environmental Protection

Agency

Pollution Prevention Opportunity

Assessments of U.S. Army

Corps of Engineers Civil Works

Facilities

National Risk Management

Research Laboratory

Cincinnati, OH 45268

Research and Development

The Pollution Prevention Opportunity

Assessments (PPOA) summarized here

were conducted at the following representative U.S. Army Corps of Engineers

(USACE) Civil Works facilities: Pittsburgh Engineering Warehouse and Repair Station (PEWARS) and Emsworth

Locks and Dams in Pittsburgh, PA; Garrison Dam Hydroelectric Powerplant in

Riverdale, ND; and John H. Kerr Dam

and Reservoir in Boydton, VA. The

PPOAs were conducted under the U.S.

Environmental Protection Agency (EPA)

Waste Reduction Evaluations At Federal Sites (WREAFS) Program and were

funded by the Department of Defense

Strategic Environmental Research and

Development Program (SERDP).

Although the facilities studied were

efficiently designed and employees

have established numerous on-site procedures resulting in the reduction of

waste generation, opportunities were

identified for further action. The PPOA

reports identify and discuss the economic and technical feasibility of potential source reduction and recycling

opportunities at the facilities studied.

The alternatives presented in the reports have application to similar Federal, non-Federal and private sector

facilities.

This Project Summary was developed

by EPA’s National Risk Management

Research Laboratory, Cincinnati, OH,

to announce key findings of the research project that is fully documented

in three separate reports (see Project

Report ordering information at back).

Introduction

This project summary describes three

Pollution Prevention Opportunity Assessments conducted at U.S. Army Corps of

Engineers Civil Works facilities under the

Waste Reduction Evaluations At Federal

Sites (WREAFS) Program. The purposes

of the WREAFS Program are to identify

new technologies and techniques for reducing wastes from industrial processes

at Federal sites, and to enhance the implementation of pollution prevention through

technology transfer. New techniques and

technologies for reducing waste generation are identified through pollution prevention opportunity assessments (PPOA)

and may be further evaluated through joint

research, development, and demonstration projects.

The assessments were conducted using the procedures outlined in EPA’s Facility Pollution Prevention Guide (EPA/600/

R-92/088). The assessments had two major phases. The first phase quantified

waste generation and management practices. The second phase identified and

evaluated the feasibility of opportunities

and techniques to eliminate, reduce, or

recycle wastes.

The facilities studied in the PPOAs were:

a navigation lock and dam; a warehouse

and a maintenance and repair facility; a

hydroelectric power plant; and a flood control dam and reservoir with associated public recreation areas. Other Federal

agencies, such as the Bureau of Reclamation and the Tennessee Valley Authority have similar functions and facilities, as

do states and the private sector. Thus,

EPA/600/S-95/014 August 1995
2

the results of the PPOAs described in the

three full reports have applicability to a

broad audience.

Results and Discussion

Garrison Dam Hydroelectric

Power Plant

The Garrison Dam Hydroelectric Power

Plant (GDHP) is located on the Missouri

River 55 miles northwest of Bismarck, ND.

For the most part the GDHP can serve as

a model for a well-run, clean industrial

facility, but there are two areas in which

the GDHP can potentially reduce waste

generation: (1) wicket gate lubrication; and

(2) antifreeze and bubbler system operations. In addition, there are several less

significant areas of potential improvement,

such as oil sampling, parts cleaning, and

recycling.

Wicket Gate Lubrication

The GDHP has five turbines, each located in a penstock and powering a generator. In the normal operation of a turbine,

the wicket gates, which are inside the

penstock directly above the turbines, control water flow passing from the penstock

to the turbine. The bronze-coated wicket

gate bearings, on which the wicket gates

pivot, must be continuously lubricated.

The GDHP uses approximately 3,200

lb/yr of a grease called Multifak EP2 to

lubricate its wicket gate bearings. Essentially all of this grease escapes into the

water flowing past the wicket gates.

Synthetic bearing systems have been

installed in powerplant wicket gate bearings, as well as turbine main bearings and

other bearings in turbine/wicket gate system. One system studied uses a bronzed

bearing with a coating of a material called

Thordon, which functions as a lubricantimpregnated spongelike matrix. Thordon

systems have been used since the early

1970s, and appear to have an excellent

reliability record. Most of the installations

have been in Canadian facilities; however,

similar systems have also been installed

in one of the wicket gate systems at Tim’s

Ford Hydroelectric Powerplant, a Tennessee Valley Authority (TVA) facility.

A second system, the Lubron system,

manufactured by Lubron Bearing Systems,

uses a teflon base in a bronze substrate.

The Teflon has lubrication in its matrix,

and additional lubricant can be deposited

in machined recesses in the bearings.

Lubron is being used at the Tim’s Ford

TVA plant in the shift ring for the wicket

gate arms. The Lubron system was installed at the same time as the Thordon

bearings, and has likewise performed without problems.

A general comparison of the bronze

greased lubrication bearing system and

the non-grease lubricated systems is included in the report.

Chemical Antifreeze Use

Ice formation on the spillway tainter

gates prevents their proper working in case

of an emergency discharge, and might

damage the gates or cause them to fail.

To keep ice formation from reaching the

gates, the GDHP spillway was built with

an underwater bubbler system. To supplement the bubbler system and clear the

bubbler lines of ice, the GDHP employs

chemical antifreeze treatment in the bubbler lines. Vaporized Frosto (mostly methanol) is injected into the compressed air

bubbler lines running near the tainter gates.

Table 1 contains a summary of the possible alternative methods of reducing pollution from tainter gate deicing.

Table 2 contains a summary of the most

significant waste streams generated by

Table 1. Options to Reduce Methanol Use at the Tainter Gates

Option to

Reduce

Methanol Requirements for Estimated

Use Introducing Option Costs Advantages Disadvantages

Bubbler system Dredge lake bottom; $1.5 million The repair would allow Very expensive repair; chemical

repair stabilize lake banks; bubbler to operate effect- use might not be markedly decreased

overhaul bubbler system ively; would reduce erosion

of banks ensuring future operation of bubbler

Operational Internal evaluation by Facilities would bear no No additional equipment or Evaluation may take time; USACE

readiness the USACE direct costs if a USACE chemicals required; only may feel operational readiness can

evaluation research group performed procedural changes not be compromised

the evaluation

Physical ice Evaluation of the tainter Equipment cost is about Once installed, units would Data on systems only from 1991

reduction gates preceded by install- $20,000 per gate; electric- generate little pollution and forward, so reliability is not

options (heater ation of system ity costs are hard to pre- allow less antifreeze to be confirmed; increased elecsystem, water dict, but costs would likely consumed tricity consumption

mixer) be around $4,000 per gate

Alternate Assessment of applicabil- Equipment modification costs Toxicity of chemicals intro- Total chemical consumption might

chemical use ity in current system; might are not predictable--they could duced to the environment not markedly change; feasibility

require extensive equip- be minimal or run into many would be reduced of modifying equipment must be

ment modifications thousands of dollars; chemical assessed

costs would be similar to

current chemical costs

Pulse rate Determine lowest reasonable Total costs would likely not Simple, low cost pollution If chemicals are reduced too much,

reduction level of chemical injection; exceed $1,000 per unit; some prevention measure ice might form at tainter gates

make minor equipment units allow pulse reduction by

modifications simply changing their settings
3

Table 2. Summary of Significant Waste Streams Generated by the GDHP and Recommended Options for the Waste Stream Reduction or Modification

Source of Waste Amount of Waste

Waste(s) Generated Generation Generation Recommended Options

Frosto (mostly methanol) Bubbler system Approximately 1. Repair bubbler system

operation 1,650 gal/yr 2. Add heating elements

3. Use alternate antifreeze

4. Lower antifreeze injection pulse rate to bubbler

5. Reassess need for fully operational spillway year-round

Multifak EP2 Wicket gate Approximately Install non-grease lubricated bearings in

lubrication 1,500 gal/yr wicket gate system

Lubricant, transformer, and Oil testing Approximately 1. Reduce sampling volumes to lowest levels possible

OCB oil 30 gal/yr 2. Reduce sampling frequency to lowest reasonable levels

Lubricant, transformer, and Oil transfer and recycling Less than 20 gal/yr 1. Use caution during transfers

OCB oil; filters; oil sludge oil; less than 100 lb 2. Reduce recycling frequencies if feasible

of filter waste; less than

30 gal/yr sludge

Mineral Spirits Parts washing Approximately 1. Use ultrasonic cleaners instead of solvent bath

55 gal/yr 2. Locate acceptable alternate solvent with preferable

 environmental characteristics

the GDHP, and options recommended for

those streams.

Pittsburgh Engineer Warehouse

and Repair Station (PEWARS)

and Emsworth Locks and Dams

The Pittsburgh Engineer Warehouse and

Repair Station (PEWARS) is located on

Neville Island between the main and back

channels of the Ohio River near the town

of Emsworth, PA. Operations performed

at the two facilities are related, in that

PEWARS performs painting, depainting,

storage, and routine and major maintenance operations for all flood control and

navigation projects in the USACE Pittsburgh District, including Emsworth; however, normal operations are quite different

at the two facilities.

The Emsworth Locks and Dams System is located on the Ohio River, 6.2

miles downstream of Pittsburgh, PA. The

main portion of the project consisting of

two locks and a gated dam, located on

the main channel. The second portion,

which consists of a single gated dam, is

located on the back channel of the river.

The dams are created to maintain a channel depth that will accommodate large vessels, such as commercial barges. The

locks enable vessels to be raised or lowered to the water levels created by the

dams.

Both Emsworth Locks and Dams and

PEWARS have areas of operations that

could benefit from the following pollution

prevention initiatives.

1. Installation of non-grease lubricated bearings, chains, gears,

and other components in the lock

and dam system where possible.

A major task involved during routine maintenance activities conducted on the lock-operating

machinery is ensuring that a proper

amount of lubricant is present on

all bearings and other parts requiring lubrication. Synthetic systems

have been used in water containing relatively high concentrations of

undissolved solids, as might be

found in lock and dam systems;

however, there is no proven history

of the application of synthetic materials in lock and dam systems. Its

use in this situation could be studied and demonstrated.

2. Replacement of the current centralized hydraulic system with localized units incorporating

accessible oil flow lines. Hydraulic pressure is used in the daily

operation of the Emsworth Locks

and Dams to open and close the

lock gates and butterfly valves in

the lock system. If a break occurs

in one of the hydraulic lines, a significant spill could occur in a short

period of time. It would be environmentally preferable to install a system with localized hydraulic oil units,

like the system currently used at

Emsworth to operate the tow haulage and retriever system.

3. Substitution of the current

depainting method with a lowerwaste generating alternative.

PEWARS utilizes a product called

Black Beauty (made up of bituminous coal) applied with a Chemco

sandblaster for paint removal. Once

a gate is depainted, the blast material is tested for lead content. If the

lead content is greater than 5 ppm,

the waste must be disposed of as

hazardous waste. The possible substitutes for the current depainting

method at PEWARS are: (1) open

abrasive blast cleaning with recyclable abrasives; (2) high pressure

water jetting with abrasives; and

(3) ultra-high pressure water jetting

with abrasives. Table 3 contains a

direct comparison of these three

methods.

4. Substitution of the current paint

and application method with a

lower VOC-emitting system.

PEWARS has already undertaken

major steps to reduce pollution generated by painting. The use of an

airless spray system with epoxy

paint complies with requirements for

VOC levels in paints, which must
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Table 3. Comparison of Recommended Alternative Paint Removal Methods

Method Method Equipment Removal Production Environmental Environmental

Number Name INvestment Efficiency Speed Advantages Disadvantages

2 Open abrasive blast Very Excellent in all Very high Recycling of abrasive Waste may be hazardous

cleaning with recycl- expensive areas results in lowest vol- due to potential for inable abrasive ume of waste gener- creased lead concenation of tested meth- trations

ods

6 High pressure water Expensive Good to Moderate Much less debris More debris than method

jetting with abrasive excellent in to high than current method 2; waste may be hazardous

injection all areas due to potential for increased lead concentrations

8 Ultra-high pressure Very Good to High Much less debris More debris than method

water jetting with expensive excellent in than current method 2; waste may be hazardous

abrasive injection all areas due to potential for increased

lead concentrations

contain less than 2.8 lb/gal. This

system is also easily applied and

has shown reasonable durability.

However, there are alternative systems being developed which may

prove to be reliable and reduce

waste generation. These alternatives are shown in Table 4. Any of

these three methods would produce

significantly less solid waste than

the current operations at PEWARS.

5. Further implementing the centralization of and tracking system

for the inventory control process.

This would help prevent purchasing duplicate materials, and therefore reduce shelf-life losses.

Of the five initiatives given above, Numbers 1 and 2 are applicable to any lock

and dam site. Numbers 3, 4 and 5 would

apply to any facility that performs major

maintenance or storage. Number 3 appears to be an excellent candidate for a

demonstration project. Initiative 4 could

also prove beneficial if powder or 100%

solid coatings progress to the point where

they are suitable for conditions such as

those found at PEWARS and Emsworth

Locks and Dams.

Table 5 provides a list of waste streams

generated at Emsworth and PEWARS, and

options recommended for those waste

streams.

John H. Kerr Dam and

Reservoir

The John H. Kerr Dam and Reservoir is

located on the Roanoke River 55 miles

north of Raleigh, NC and 100 miles southwest of Richmond, VA. The project was

authorized by the Flood Control Act of

1944, and was constructed for flood control and aquatic recreation needs. Additional purposes of the project include

domestic water supply, water supply for

hydroelectric power generation, water quality control, wildlife management, and navigation.

The facilities discussed in the full report

are: (1) North Bend Park maintenance

facility, spray irrigation water treatment

system, marina, and campground, all operated by USACE; (2) Longwood Park,

operated by USACE; (3) the pump station

at Island Creek Dam, operated by USACE;

(4) Satterwhite Point State Park maintenance facility and wastewater treatment

system, operated under lease by the State

of North Carolina Department of Parks

and Recreation; and (5) the Clarksville

Marina, a privately owned concession under lease.

There has been substantial cooperation

between these Federal, state, local, and

private organizations. However, several

specific areas were identified which could

benefit from pollution prevention efforts.

These areas are summarized in Table 6.

Conclusion

For the most part, the majority of environmental effects from USACE Civil Works

facilities occur during construction. Less

pollution is generated as a result of the

operation, maintenance, replacement or

repair of these facilities; however, several

areas can be targeted for pollution reduction. At Garrison Dam Hydroelectric

Powerplant, the six areas identified for the

greatest potential reduction in waste generations were wicket gate lubrication,

tainter gate maintenance, oil sampling and

recycling, parts washing, consumer product recycling, and inventory control. The

greatest potential for pollution reduction at

PEWARS and Emsworth Locks and Dams

were lubrication and the hydraulic system

used to transport the oils; painting and

depainting, and inventory control practices.

At John H. Kerr Dam and Reservoir, the

areas of greatest pollution prevention potential were expanding the use of recycled

plastic timbers instead of creosoted railroad ties, oily rag generation, antifreeze

for toilets and piping, parts washing and

degreasing, solid waste separation and

recycling, and inventory control.

The full reports were submitted in fulfillment of Contract No. 68-D2-0181, Work

Assignment No. 1-011 by TRC Environmental Corporation under the sponsorship

of the U.S. Environmental Protection

Agency.
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Table 5. Summary of Significant Waste Streams Generated by Emsworth and PEWARS and Recommended Options for Waste Stream Reduction or Modification

Source of Waste Environmental Recommended

Wastes Generated Generation Disadvantages Options Advantages Disadvantages Recommendations

Emsworth

Lubriplate, Never Lubrication of lock and Lubricants eventually Installation of non-grease No grease allowed to es- Cost can be very high Installation should only be considered

Seez®, transmiss- dam equipment escape into environ- lubricated systems cape into environment due to loss of operation during necessary overhaul

ion and engine oil ment

Hydraulic oil Main hydraulic system Oil escapes into Installation of localized Reduced chance of oil Cost would be high Installation should only be considered

leaks and line breaks environment oil-sending units with leakage to environment during necessary overhaul

accessible lines

PEWARS

Depainting wastes Paint removal from lock High waste volumes Alternative, lower waste Drastic reduction in solid Disposal costs may go up, Alternative methods would be excellent

gates with expendable generated using volume methods waste volume generation equipment investment demonstration projects

abrasives current process would be costly

Painting waste Painting of lock gates VOCs are increasingly Powder or 100-percent No VOC and low paint Paint and application Alternative method would be excellent

and VOCs using epoxy paint and regulated, spray system solids paints and HVLP waste generation system still under demonstration project

spray system has fairly large overspray system development

Various chemicals Excess purchases Materials that could be Further centralizing pur- Reduced waste Purchasing system must Continue centralization and inventory

and other materials used at other District chasing; accessible, up- be updated and personnel control

facilities could expire dated inventory of materials must make effort to follow

system

Table 4. Comparison of Paint Methods

Preferred

Application

Paint Life Expectancy Cost ($/ft2 ) Method VOC Content Advantages Disadvantages

Vinyl resins 20-40 yr $1.00 brush, roll, spray 70-75% by weight Short cure, easy to apply, excell- Large source of VOC emissent durability ions, significant surface

preparation

2-part epoxy 15-20 yr $1.60 spray <2.8 lb/gal Easy to apply, good durability Long cure, temperature sensitive,

abrasion sensitive, chalking in

sunlight

Coal tar epoxy 15-20 yr NA* spray 20-30 % by weight Excellent durability, less significant Toxicity

surface preparation

Air-cured urethanes <5 yr $2.00-$3.00 NA* <2.8 lb/gal Low VOC emissions, not Current life expectsensitive to sunlight ancy not high

Moisture-cured Currently under NA* NA* <2.8 lb/gal Short cure, less significant surface Moisture sensitive during

urethanes testing by USACE preparation application

100 % solids Currently under NA* spray none No VOC emissions Difficult to apply, not

testing by USACE water resistant

Powder coatings <5 yr NA* spray none No VOC emissions Very sensitive to abrasion, poor

durability

* NA - not available, paint and application method is currently under development.
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Table 6. Summary of Pollution Prevention Recommendations for John H. Kerr Dam and Reservoir Areas

 Site for Activity Recommended Benefits of

Implementation Description Current Practice Alternative Practice Alternative

All locations Railroad tie replacement Wood, creosote, and recycled Use recycled plastic ties as Reduces use of virgin

plastic tie replacements much as possible materials

North Bend State Park- Oily rag generation from Disposal in 55-gal drums Wringer system to recover oil Reduces amount of

Maintenance Facilities car oil changes and allow reuse of rags oil and rags consumed

North Bend State Park- Antifreeze for toilets and Ethylene glycol used as Use of propylene glycol instead Much lower toxicity

Maintenance Facilities, piping an antifreeze of ethylene glycol

Satterwhite Point State Park

North Bend State Park- Parts washing and Mineral spirits used in Alternative solvent, such as Reduced VOC emissions

Maintenance Facilities, degreasing parts washer various DuPont® solvents

Clarksville Marina

North Bend State Park, Solid waste separation Many recyclable materials Encourage recycling, allow civic Reduced solid waste

Satterwhite Point State Park are disposed of as solid groups to collect recyclables, generation

waste provide bins

Island Creek Dam and Inventory control Materials are not always Ensure adequate recordkeeping, Reduced solid and

Pump Station accounted for and can be allow unneeded chemicals to be hazardous waste

allowed to expire distributed generation

Clarksville Marina and Human waste disposal Boaters must haul wastes Put sewer hookups near boats, Reduce unsanitary

other marinas up hill and pay fee recoup fee in a less waste disposal

direct method
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This Project Summary was authored by the staff of TRC Environmental

Corporation, Chapel Hill, NC, 26514.

Theresa Hoagland is the EPA Project Officer (see below).

This Summary covers research documented in three separate reports:

(1) "Pollution Prevention Opportunity Assessment United States Army

Corps of Engineers Pittsburgh Engineer Warehouse and Repair Station

and Emsworth Locks and Dams, Pittsburgh, Pennsylvania," (Order No.

PB95-260261; Cost: $19.50, subject to change).

(2) "Pollution Prevention Opportunity Assessment of the United States

Army Corps of Engineers Garrison Dam Hydroelectric Powerplant,

Riverdale, North Dakota," (Order No. PB95-260253; Cost $27.00,

subject to change).

(3) "Pollution Prevention Opportunity Assessment at the U.S. Army Corps

of Engineers John H. Kerr Dam and Reservoir, Boydton, Virginia,"

(Order No. PB95-260246; Cost: $17.50, subject to change).

The above reports will be available only from:

National Technical Information Service

5285 Port Royal Road

Springfield, VA 22161

Telephone: 703-487-4650

The EPA Project Officer can be contacted at:

National Risk Management Research Laboratory

U.S. Environmental Protection Agency

Cincinnati, OH 45268

United States

Environmental Protection Agency

National Risk Management Research Laboratory (G-72)

Cincinnati, OH 45268

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POSTAGE & FEES PAID

EPA

PERMIT No. G-35

Official Business

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$300

EPA/600/S-95/014