The Blockbuster Sphere Gives Water Technology a Supporting Role
by Daryl F. Mallett
Ozone has gone to Hollywood and will be starring in a new film, set for release this winter. That's right, ozone.
The
use of ozone as a chemical-free alternative to water treatment is now
widely accepted around the world. The history of using ozone in water
purification applications can be traced back to the late 1800s in
European drinking water plants. More recently, ozone has become a
well-recognized method for the treatment of swimming pools, industrial
wastewater and marine life support systems.
The most
common use of ozone in these various applications is as the primary
disinfectant against bacteria and viruses. However, ozone is the
strongest oxidizer commercially available and it also helps remove
turbidity to clarify water. Turbidity refers to the cloudy or hazy
appearance caused by the suspension of organics or fine solids in the
water.
Cloudy water is a movie director's worst
nightmare. Consequently, water clarity is critical to an underwater
film's success--and it is here, in a new
Warner Bros. film, that ozone
will make its big screen splash.
Making It in Pictures
Warner Bros. has completed filming of
Sphere, based on
Michael Crichton's novel of the same name and originally published in 1987.
The
$73 million movie, which stars
Dustin Hoffman,
Sharon Stone,
Samuel L. Jackson and
Queen Latifah, takes place in the middle of the South
Pacific, a thousand feet below the surface of the water. The premise is
that an enormous spaceship has been found sitting on the ocean floor and
a team of scientists is rushed to the scene. Here, they enter the
depths of the sea to investigate the incredible discovery.
Filming
began in February 1997 at
Mare Island, a former U.S. naval base located
in Vallejo, Calif., near San Francisco. The base was shut down on April
1, 1996, a victim of military cutbacks following 142 years of service.
During its lifetime, the shipyard helped fortify America's sea power,
beginning with paddlewheelers and progressing all the way to nuclear
submarines.
The producers wanted the location for its
huge, high-ceiling hangars, which were perfect for the elaborate sets
needed. Almost all of the movie was filmed in Building 599, an empty
130,000 square-foot warehouse in which the huge sets and tanks were
built to shoot the underwater scenes.
Underwater
filming is not easy. Dan Nosan, aquatics specialist at
Osmonics Inc., a
company that specializes in the purification of water, worked as a
consultant on the film and said, "We learned that, on previous
underwater films, some of the divers had experienced ear infections
during the shoot."
Underwater cinematographer
Greg Voigt added, "Cleanliness definitely counts. There is a magnification
factor underwater and any cloudiness at all can degrade the image as
though there were a fog filter on the camera. The more particles there
are in the water, the more distorted the image will be. Water quality
also is important in respect to lighting the set because any particles
will catch the light and appear on film."
From Disney to Hollywood
Faced
with these potential problems, Warner Bros. turned to Jeff Keaffaber,
president of Entertainment Environments Group Inc. for a solution.
Keaffaber, who formerly worked with
Walt Disney Imagineering at
Disney World Florida, and whose company has a long-standing relationship with
entertainment companies, took up the challenge.
Keaffaber
and Voigt both stressed the importance of remembering that these pools
were work environments and not recreational facilities. "This is not a
backyard swimming pool," Keaffaber said. "We had up to 12 people at a
time underwater for 12 hours at a time. With that many actors and crew,
each with their own safety diver, plus cameras and lights and
equipment...those are a lot of factors to be considered."
After
Warner Bros. explained to Keaffaber what it wanted, he designed a water
purification system to handle the demand. The total system consisted of
2.1 million gallons of water contained in three rectangular concrete
pools and four circular epoxy-coated stainless steel tanks that were
fabricated on-site. Keaffaber, together with Warner Bros. set designers
and his own subcontractors, spent nine months building the sets and the
purification systems. "We were responsible for the system and the piping
right up to the tanks. But we also had to do some piping work in the
tank and in the sets to ensure that the water was well-mixed and
circulating through the system," he said.
Designing for Actors
In
the closed-loop system, the main flow of water circulating throughout
was 3,600 gallons per minute (gpm). The water was drawn through a
filtration unit designed by
U.S. Filter Corp. The multimedia filtration
system consisted of a bank of six sand filters ranging from pebbly to
fine as the water progressed through the system. A 540-gpm sidestream
(15 percent of the main flow) was drawn aside for ozonation.
Keaffaber
and Nosan developed a turnkey ozone system. "A small rental system was
the ideal solution for this application since there was a very good
possibility that Warner Bros. would have to tear the entire set down at
the conclusion of the shoot," Nosan said. He used Osmonics' OREC™ Model
SP-3 ozone generator, which provided a dosage of 0.5 parts per million
to clean the sidestream flow.
John Overby, application
engineer at GDT, provided the contact tanks, gas separator system and
the ozone injection system. The closed-loop system circulated the entire
2.1 million gallons every three-to-four hours.
Temperature
was also a factor to consider, both for the comfort of the actors and
for health hazards--the warner the water, the more chance for a
proliferation of bacterial growth. A steam-fired boiler designed by
Keaffaber kept the water at a comfortable 88°F.
Keaffaber
explained his choice of ozone over the more traditional chlorine. "Too
much chlorine causes equipment deterioration and eye irritation," he
said. "Not enough and you can run into infection problems." Using ozone
not only reduced the water turbidity for filming purposes, it also
disinfected the water, making it safer for the actors and divers.
It
was also helpful financially. "Using ozone saved us thousands in
production costs," explained Mike Meehan, a location manager for Warner
Bros. "By using ozone instead of chemical treatment, the city (of
Vallejo) allowed us to drain the wastewater directly to the sewer
instead of running a pipe across the street to a wastewater run."
It's a Wrap!In
describing the experience, a smile warred with the strain in
Keaffaber's voice. "Most of our experience has been on theme parks and
aquahabitats. This was the first film we've worked on. The Hollywood
mentality is very different. They don't want a bottlenose dolphin
exhibit that will be in place for years; they just want something that
works on their set for five months. They (the crew) threw every
curveball at us. We were working on what amounted basically to a
construction site. One of the sets was right next to a set shop. We'd
come in the next morning and there'd be a layer of crud floating on the
top of the water...steel shavings, sawdust, coffee grounds, even milk!
We had to be very creative and flexible." However, he admitted the
experience was worth all the trouble. "I'd love to do another film!" he
said.
Sphere is scheduled for release in theaters across the country in December 1997. Keep your eyes on the water!
AcknowledgementsThe
author would like to gratefully acknowledge the incredible help of Jeff
Keaffaber, president of Entertainment Environments Group Inc.,
714/494-7065; Dan Nosan, aquatics specialist at Osmonics Inc.,
602/915-5302; John Overby, applications engineer at GDT, 602/587-8858;
Sally Cate at U.S. Filter Corp., 760/340-0098; Diane Sponsler, Nancy
Kirkpatrick and Vivian Boyer at Warner Bros.; and independent
cinematographer Greg Voigt, 602/843-3948.
About the AuthorDaryl
F. Mallett is a freelance writer and editor. He has written everything
from ISO9000 standards to film and TV scripts; a wine and beer column to
international company histories; and film and book reviews to a police
department policies and procedures manual. He can be reached at
480/275-0232 or darylmallett@aol.com.
(Originally published in
Water Conditioning & Purification, Vol. 39:9, October 1997.)