Scaling Up! H2o

"Document everything." Spring startup season exposes more than operational stress. It also reveals what happened months earlier when systems were laid up poorly, maintenance steps were skipped, or warning signs were documented but not acted on. In this episode, Trace Blackmore connects that reality to a broader infrastructure problem: hidden damage inside pressure piping systems that operators often cannot see until a leak, rupture, or budget crisis forces action.     Why hidden pressure pipe problems are so expensive  Chris McDonald, CEO and President of CPM Pipelines, explains why pressure pipe inspection and rehabilitation deserve more attention from utilities and industrial facilities. His core point is practical: many owners are still making repair or replacement decisions without first getting a high-resolution look at the pipe's actual condition.  That creates two risks. First, teams may spend too late, after a failure creates public, operational, or safety consequences. Second, they may spend too

Biofilm is not a fringe issue in cooling systems. As Dr. Jeff Kramer explains, it is a given. That matters because biofilm affects heat transfer, contributes to corrosion, and can serve as a reservoir for Legionella in treated systems. In this conversation, Trace Blackmore and Dr. Kramer examine what experienced water treaters should be looking for when choosing and evaluating a microbiological control program.   Biofilm as an operating problem Dr. Jeff defines biofilm as a community of microorganisms attached to a surface and held together by an external polymeric matrix. From there, the discussion moves quickly into why this matters in the field. He points to research showing that biofilms can be more insulating than mineral scale, then explains how microbial activity and patchy film formation can intensify corrosion risk. He also notes that Legionella can be harbored within biofilm, making clean-looking bulk water an incomplete picture of system condition. Choosing the right biocide program A strong oxi

 Shawn Powell has built a following by doing something wastewater operators have needed for a long time: making practical technical education easier to access. In Episode 470, he explains why that matters, how he built The Wastewater Enthusiast, and what the industry still gets wrong about training, certification, and knowledge transfer. From test prep to true understanding A major thread in this conversation is the gap between passing an exam and actually understanding plant operations. Shawn reflects on his own early experience with certification prep, where classes helped him recognize test questions but did not always help him understand what was happening inside a real activated sludge system. That gap became the foundation for his channel. He makes the case that operators need more than memorization. They need visuals, process context, and practical explanations that help concepts stick. For professionals responsible for training staff, succession planning, or improving plant performance, that distincti

Boiler performance rarely depends on a single decision. It depends on design, controls, maintenance, workforce capability, and, as this conversation makes clear, the quality of water treatment. Scott Lynch and Shaunica Jayson explain how American Boiler Manufacturers Association (ABMA) is addressing those realities by connecting manufacturers, representatives, suppliers, and field stakeholders around education and practical guidance. Why ABMA still matters in a changing boiler market ABMA has been in place since 1888, but this discussion is not about preserving old structures for their own sake. Scott and Shaunica describe an association that has expanded beyond traditional manufacturer membership into a broader supply-chain view of the boiler room. That includes boiler, burner, deaerator, and economizer manufacturers, component suppliers, service providers, consultants, and manufacturer representatives. That broader view matters because boiler performance does not begin and end with the vessel itself. Decis

Tom Brandvold, CWT, has lived industrial water treatment from the inside out. In this conversation, he traces that path from sweeping floors and running sample bottles as a kid to leading Premier Water and Energy Technology and serving as a former president of Association of Water Technologies (AWT). The result is not just a career story. It is a useful look at how credibility, collaboration, and standards are built over time in this industry. How Association of Water Technologies (AWT) was formed One of the most valuable parts of this discussion is Tom's explanation of how Association of Water Technologies (AWT) began. The association did not start primarily as a training platform or networking group. It grew out of a business crisis in the 1980s, when independent water treaters were struggling to secure product liability and pollution coverage at prices that would not put them out of business. Tom explains how that pressure led a small group to create an insurance-focused structure that eventually require

What happens when a water chemist leaves the lab and heads to the pump room?  Dr. Jake Elliott knows firsthand. A former PhD researcher who studied resource recovery from trade‑waste customers, Jake now manages accounts at Hydro flow in Melbourne, working with cooling towers, boilers, chemical dosing rigs and wastewater treatment systems. He joins host Trace Blackmore to discuss how rigorous research, regulatory compliance and process automation translate into practical field work for industrial water treatment professionals. From PhD Research to Industrial Practice Jake's academic background informs the way he approaches operations. While completing his PhD he investigated how to recover resources from wastewater permits, synthesizing municipal data with bench‑scale testing. Today he draws on that experience to design treatment systems and advise customers on cooling‑tower and boiler chemistry. He emphasizes long‑term efficiency: spending a little extra time or money now can save much more later. This menta

AWT's in‑person technical training is a keystone for developing competent water treaters. Yet classroom knowledge only matters when it survives the drive home and emerges later in the field. In this second conversation with Dan Merritt, CWT—National Sales Manager at CH2O Inc. and head of AWT's education committee—Trace Blackmore uncovers how stories, math, and memorable mistakes turn theory into intuition.  Why training keeps evolving  Dan explains that the Association of Water Technologies rewrites courses every year. Instructors refine content, delivery and demonstrations, not for novelty's sake, but because boilers and cooling towers rarely behave like textbook examples. Recognizing that multiple chemical reactions operate simultaneously helps prevent chasing the wrong problem. Updated program design and operations classes now bridge the gap between fundamentals and advanced topics. Specialized modules for sales, membrane/softener maintenance, ASSE 1280 compliance, and a two‑tier wastewater curriculum en

Industrial water training only works when the knowledge transfers. That means the material lands with the audience, survives the drive home, and shows up later in the field when decisions get made.  Dan Merritt, CWT, Sales Manager at CH2O, brings a rare perspective to that problem. He started as a teacher (chemistry, calculus, physics), entered industrial water treatment on February 5, 2002, and later became part of the AWT training team. This conversation follows the path from classroom instruction to boiler rooms and cooling towers, then uses that journey to examine what makes technical training "stick" for working professionals.  From educator to water treater, then back to educator  Dan shares how leaving graduate study, teaching high school and community college, and stepping into service work shaped his approach to explaining technical concepts. The throughline is simple: the instructor owns the clarity. When someone in the room does not understand, the response is not frustration. The response is tra

"Don't be afraid to say I don't know. - Will Ritter"  Corrosion is expensive, relentless, and easy to underestimate—until a "lasagna battery" turns aluminum foil green and reminds you what electrochemistry can do in the real world. This conversation reframes corrosion coupons as what they actually are: a repeatable field test that can sharpen your decisions—if you treat the process with consistency.  Respect the coupon, protect the data  Trace breaks down why coupons became non-negotiable in his systems: they turn guesswork into usable corrosion-rate intelligence. Will Ritter of MetaSpec (formerly Pacific Sensor) explains the fundamentals—pre-weighed coupons, exposure time, cleaning, and calculating corrosion rate in MPY (mils per year). The point isn't that the coupon is your pipe; it's that the coupon becomes a reliable, relative gauge over time when variables are controlled.  The "five things" that make results repeatable  Will outlines practical failure points that quietly ruin comparisons quarter to q

"If you say something over and over often and enough, it becomes true because perception is reality."  Paul O'Callaghan has built a career at the intersection of water science, wastewater realities, and the practical question every operator and executive eventually faces; what actually moves innovation from idea to adoption.  As Founder and CEO of BlueTech Research, Paul explains how his team helps decision-makers put capital to work more efficiently in water by reducing uncertainty and separating signal from noise. He describes patterns he's watched repeat across water entrepreneurs, pilots, and product market fit, and why "innovation" often breaks down simply because utilities, investors, and founders are using the same word to mean different things.    Capital, fit, and the language gap Paul unpacks what it takes to align an investor's expectations with a technology's true pathway to scale. He contrasts different "types" of innovation and why matching the right investor, entrepreneur, market, and timeli

Industrial water work rewards people who can move between precision and practicality. Katie Holliday brings both. She started as a lab chemist, then transitioned into field service with Apex Water and Process, where much of her work supports healthcare facilities and high-accountability programs.   Lab habits that protect your tools and your data  Katie describes the first surprise of field work: a central plant is "very dirty," and the job demands good technique without chasing lab-level perfection. She shares a couple of simple practices that prevent expensive problems. Use proper lab wipes on glassware instead of shirts or paper towels, which can scratch surfaces and compromise readings. Keep pH probes wet with the correct storage solution, because once they dry out, they often stop working.     Healthcare water: SPD work and Legionella prevention  About 90% of Katie's accounts are healthcare. She defines SPD as the sterile processing department and explains why expectations shift compared to boilers and

Corrosion rarely announces itself as a "big water problem." It shows up as leaching at the tap, residual loss in the field, premature equipment replacement, and the slow, expensive erosion of decision-quality.  Pat Rosenstiel (CEO) and Wolf Merker (chemist/Chief Science Officer) of Great Water Tech lay out a system-wide view of corrosion control—starting with what changed in Flint from a technical standpoint and moving into why many utilities still struggle to meet expectations when standards and risk assumptions shift.  System-wide corrosion control starts with chemistry and consequences  A source-water change can shift corrosivity fast. If corrosion control does not adjust proactively, the downstream effects show in metal release and public exposure. Wolf stresses the distinction between the technical problem and the political challenges, then points to corrosion control as a solvable technical matter when it is treated as a system condition—not a single asset issue.  Why "phosphate-only" isn't the end o

Boilers can feel intimidating the first time you step into a boiler room—the heat, the noise, the pressure gauge, and the weight of knowing that mistakes can be costly. Trace Blackmore opens with a reminder that boilers deserve respect, not fear—and that learning fundamentals is how you replace mystique with clarity.  The talent gap behind the boiler room door Eric Johnson, Founder and CEO of Boilearn, explains why boiler expertise is becoming harder to replace. He points to the shrinking pipeline of boiler-trained technicians—historically strengthened by Navy steam training—and why companies can't rely on "tribal knowledge" and informal shadowing alone to develop the next generation.  Training that scales past the 2–3 day class  Eric shares what pushed him to build Boilearn: technicians and operators need structured, repeatable competency systems—not just scattered classes and a "shotgun approach" to on-the-job training. He lays out why fundamentals can be taught effectively online when it's done well,

Industrial water professionals are increasingly pulled into conversations about scarcity, resilience, and "where the next gallon comes from."  Dr. Veronika Zhiteneva, CEO and Co-founder of Waterloop Solutions frames water reuse as an implementation challenge more than a technology gap—and explains where the practical starting points are when the scope feels overwhelming.   Moving reuse forward when the technology already exists  Waterloop Solutions was founded to accelerate implementation: clarifying end-use quality, identifying post-treatment needs on the back end of existing plants, and building risk management plans that fit real operational and regulatory expectations. The conversation stays grounded in what slows projects down (time, permitting, funding, and public acceptance) and where progress can be made without reinventing the toolbox.  Centralized vs. decentralized: why "less regulated" can move faster  Europe's agricultural reuse regulation (noted as coming into effect in June 2023) created sha

"Stay curious. And you only have one reputation. Guard it with your life." Hiring for judgment, not just rehearsed confidence   Industrial water treatment is full of decisions made with incomplete data—on sites, with customers, and inside the business. JD Roth (Managing Director and Co-owner of Guardian Chemicals) builds his hiring around that reality. His aim is straightforward: protect the team and the culture by selecting people who can think, collaborate, and lead under pressure. JD frames the organization as a group of people choosing to work toward a common goal: building a better future for communities, the environment, and staff. That priority shows how Guardian hires, who they keep, and what becomes a deal-breaker. If a candidate is misaligned with core values, JD is clear: performance elsewhere won't override that mismatch. The "Hiring Olympics" structure For a high-bandwidth, project-based role (their Graduate Business Analyst program), Guardian needed a way to evaluate many strong candidates w

 Trace Blackmore opens 2026 with a practical reset: how to plan with urgency, sharpen the fundamentals that make troubleshooting easier, and use the tools around this podcast to keep your development moving all year. The 12-Week Year: urgency you can use Annual goals often feel "far away" until December forces focus. The 12-week year flips that dynamic by treating each quarter like a year—creating urgency sooner and giving you four chances to reset and improve. Trace walks through the structure: start with a vision (he uses a three-year example), then choose 3–5 tactical goals for the next 12 weeks, so you don't overload and quit. He also ties it to a water treatment reality: quarterly customer touchpoints are simply more productive than an annual "re-introduce everything" meeting.  Trace points listeners to planning support and easy on-ramps:  the book link: ScalingUpH2O.com/12weekyear  the planning guide PDF: ScalingUpH2O.com/12weekyearplan  and an Audible option (free month + free book mentioned in the

 A year-end recap is more than a highlight reel—it's a practical reset. In this New Year episode, Trace Blackmore walks through 2025 using a "12 Days of the Scaling Up Nation" format, tying together performance, community growth, listener engagement, and the sponsor support that keeps the podcast and its companion tools available at no cost.   Year-end by the numbers   Trace explains how he used to track every stat closely—and how that shifted into an unhealthy measure of self-worth—so the team now uses numbers as feedback, not validation. He notes the show released 56 brand-new episodes in 2025 (including the additional releases during Industrial Water Week) and explains why the data still matters: it helps confirm what the community is using, such as discussion guides and other tools, and what needs to be improved.  Most-downloaded episodes and what listeners leaned into  Trace shares the three most-downloaded episodes of 2025:  Episode 405 — cooling water innovation using treated wastewater  Episode 41

 "So one thing I never do is try to start giving remediation or advice before I truly have understood and diagnosed the problem."  Mentorship and certifications don't replace experience—but they can accelerate it when paired with the right mindset and a disciplined approach to learning. Nella Fergusson, CWT (District Manager, Southern California, Garratt-Callahan), lays out what "growing up" in industrial water treatment actually looks like: repeated exposure to real problems, strong diagnostic habits, and a willingness to keep learning long after year one.  Learning that keeps you employable  Water treatment evolves. Nella contrasts today's challenges with what she faced 15 years ago and explains why complacency is the fastest path to getting left behind. She describes water treatment as industry-specific by nature—food processing cooling and commercial real estate operations don't behave the same, don't shut down the same way, and can't be serviced the same way.  Diagnosing before prescribing  Her troub

 Industrial cooling is one of the biggest levers industrial facilities can pull on water use—and it's getting harder to ignore as data centers and other high-heat operations grow. Returning guest Dr. Kelle Zeiher (Project Manager at Garratt Callahan) breaks down what water reuse looks like when you move past slogans and into the realities of pretreatment, concentrate management, footprint, and cost.  Cooling water reuse: the scale of the opportunity  Dr. Zeiher reframes "drought" beyond rainfall, emphasizing aquifer recharge and the limits of focusing only on household restrictions. She contrasts domestic use (~12%) with the much larger share tied to cooling (~50%), then connects that to why optimizing industrial cooling matters—especially when operations sit in arid, desert-like regions with limited water availability. She also shares a data-center statistic that puts "the cloud" into physical terms: ~53 gallons of purified water per gigabyte of data stored to keep environments cool enough for microchips. 

Industrial water professionals sit at the intersection of risk, regulation, and community trust. In this episode, Dr. Annette Davison ("the water risk doctor") joins Trace Blackmore to show how disciplined governance, clear supply chain thinking, and community engagement can turn fragmented water systems into coherent, defensible risk management frameworks.  Water risk from source to customer  Annette starts with a simple question most customers never ask: "Where's your water coming from?" She walks through a conceptual supply chain from source to end point—collection, transfer, treatment, distribution, and customers—then layers governance on top. Who holds custody at each handover point? Are water quality objectives clearly defined and documented? What happens when something "stuffs up," and how is that communicated downstream? For leaders, it's a practical reminder that risk isn't just about treatment performance; it's about clearly assigned responsibilities along the entire chain.  Governance, ISO 31000,