The level of detail an engineer needs to update mechanical and piping systems depends on the scope and complexity of the project. To properly design, prefabricate, and install system updates, many engineers require detailed diagrams of the current piping system, including pipe sizes, materials, and routing.
The Southerly Wastewater Treatment Plant in Cuyahoga Heights, Ohio was updating one of its heat exchangers. This portion of the facility was packed with dense mechanical and piping systems.
GPRS was called to 3D laser scan the Southerly Wastewater Treatment Plant and render an LOD 300 BIM model of the three-level heat exchanger for ABC Piping Co. to update one of the systems.
ABC Piping Co., the mechanical contracting company, required a high-detail 3D BIM model to accurately visualize, design, modify, and manage the update of the heat exchanger system within the facility, enabling efficient updates and modifications without the need for extensive on-site measurements or manual drafting.
What is the Wastewater Treatment Process?
Wastewater treatment is the process by which dirty water—sewage—is cleaned so that it may be safely released into freshwater resources like lakes and rivers. Treatment technologies vary, but most often, wastewater treatment consists of two major stages. The primary treatment phase separates sand, grit, and larger solids from the wastewater through a series of screens and large tanks, but organic solids remain. During the secondary treatment phase, a biological process removes those organic solids from the flow and completes a final disinfection to make the water safe for the environment.
About the Southerly Wastewater Treatment Plant
Situated on 288 acres, Southerly is the largest Wastewater Treatment Plant in Northeast Ohio, serving 530,000 residents, with an average flow of 120 million gallons per day (MGD). Infiltrator Water Technologies defines the average daily flow rate as the average 24-hour volume that is received by the wastewater system for a continuous 12-month period.
The Southerly Wastewater Treatment Plant is one of the largest facilities of its kind in the country. The primary treatment phase sludge process used at the plant is similar to the process described above, like many other treatment plants around the world. However, the secondary treatment phase uses specialized bacteria to remove ammonia and nitrogen, two compounds which deplete oxygen in receiving waters (the fresh water that the treated water flows into). Plus, the facility completes a third step, where the flow passes through filters and is disinfected by a chlorination/dechlorination process.
How Did GPRS Help the Southerly Wastewater Treatment Plant?
GPRS partnered with ABC Piping Co. to 3D laser scan and model the heat exchanger at the Southerly Wastewater Treatment Plant for upgrades. ABC Piping Co. is a comprehensive mechanical contracting company licensed by the State of Ohio for a range of services including HVAC, plumbing, hydronic systems, and fire protection.
Colton Carney, GPRS’ Project Manager for the Cleveland area, utilized the Leica RTC360 laser scanner to capture as-built conditions from 3 different floors around the existing heat exchangers. The Leica RTC360 laser scanner offers a high level of accuracy and fast reality capture speed, recording 2 million data points per second. Colton completed 108 laser scans with the RTC360 from different locations to capture the intricate details of this very dense mechanical facility.
“The Leica RTC360 can generate 3D point clouds in less than 2 minutes, delivering our clients quick data visualization for project planning,” stated Carney.
He added, “Also, the Leica RTC360 scans in color, which is useful when you need a true representation of a site in color detail. This will ensure a precise 3D BIM model.”
What is the Function of a Heat Exchanger?
The primary function of a heat exchanger is to capture heat from the wastewater, which is usually warmer than the surrounding environment, even during colder months. By recovering this heat, wastewater treatment plants can reduce their overall energy consumption by utilizing waste heat for other purposes. The extracted heat can be used to preheat incoming wastewater, heat building spaces, or power a heat pump, ultimately reducing the energy needed to operate the plant.
How is a Heat Exchanger Updated?
Updating a heat exchanger at a wastewater treatment plant typically involves replacing an old or inefficient heat exchanger with a new, more advanced model that can improve energy efficiency by recovering more heat from the wastewater. This often utilizes technologies like plate heat exchangers, designed to handle the unique characteristics of sewage sludge and effluent, while also considering factors like cleaning mechanisms to maintain optimal performance over time.
What are the Key Considerations When Updating a Wastewater Treatment Plant Heat Exchanger?
Assessment of the Existing System
The first step in updating a wastewater treatment plant heat exchanger is conducting a thorough assessment of the current system. This involves analyzing the performance of the existing heat exchanger, identifying areas for improvement, and determining the most suitable updates based on factors like flow rate, temperature range, and the composition of the wastewater being processed.
Choosing the Right Technology
Selecting the appropriate heat exchanger technology is critical for achieving optimal performance. Plate heat exchangers are a popular choice due to their high efficiency and ability to handle a variety of flow rates and fouling conditions. Alternatively, shell and tube heat exchangers may be used for specific applications, although they often require more frequent cleaning. Advanced features, such as automated cleaning mechanisms like "scraped surface" or "hydraulic cleaning," should also be considered to minimize fouling buildup and reduce maintenance requirements.
Selecting Corrosion Resistant Materials
The choice of materials for the heat exchanger plays a vital role in ensuring durability and performance. Materials should be selected based on the characteristics of the wastewater, with a focus on corrosion resistance. For instance, stainless steel is often preferred in aggressive environments to withstand corrosive conditions and extend the lifespan of the equipment.
Proper Installation
Proper installation is essential for the successful integration of a new heat exchanger into the wastewater treatment system. This includes seamless connections with existing piping to maintain wastewater flow. Additionally, available space within the treatment plant must be assessed to accommodate the new equipment, particularly in plants with limited room for expansion.
Control System Integration
To optimize the heat transfer process, it is important to implement a control system that monitors and adjusts operational parameters in real time. This ensures that the heat exchanger operates at peak efficiency, reducing energy consumption and enhancing overall system performance.
How Does 3D Laser Scanning Capture the As-Built Environment?
3D laser scanning captures the as-built environment by using advanced LiDAR (Light Detection and Ranging) technology to create a highly accurate and detailed digital representation of existing structures, spaces, and systems. The process involves emitting laser beams from the scanner, which then measures the time it takes for the beams to bounce back after hitting a surface. This time-of-flight data is used to calculate distances and create a dense point cloud of spatial coordinates.
The point cloud is a collection of millions of data points that collectively map the physical features of the scanned environment. It captures precise geometric details, including walls, floors, ceilings, piping, mechanical systems, and other structural or architectural elements.
This data is then processed using specialized software to clean and organize the point cloud, allowing for the creation of accurate 2D CAD drawings, and 3D Building Information Models (BIM).
What are the Benefits of using a 3D BIM Model to Make System Updates?
A 3D BIM model provides a detailed and accurate representation of the existing heat exchangers within the facility, enabling engineers and designers to clearly understand the spatial relationships, constraints, and interdependencies between various components. This level of detail reduces the risk of errors and oversights during the planning and design stages.
MEP updates often require seamless integration with architectural and structural systems. A 3D BIM model will allow all disciplines to work within a shared platform, facilitating clash detection and resolution before construction begins. This proactive approach minimizes costly rework and project delays caused by on-site conflicts between systems such as ductwork, piping, and electrical conduits.
The use of 3D BIM models also improves efficiency in decision-making and project execution. This provides optimization of the heat exchanger systems before implementation, ensuring that updates align with performance goals and regulatory requirements.
“We are delivering an architectural/structural 3D BIM model and MEP 3D BIM model for design and engineering, providing a 3D space for all disciplines to work together to identify and resolve clashes before system integration begins, ensuring a smooth retrofit with minimal rework,” Belinda Thompson, GPRS CAD Technician stated.
What are the Benefits of Updating a Wastewater Treatment Plant Heat Exchanger?
A wastewater treatment plant might update a heat exchanger for several practical and operational reasons, including:
Improved Energy Efficiency: Modern heat exchangers are often more energy-efficient, reducing operational costs by better transferring heat and minimizing energy losses.
Capacity Expansion: Increased wastewater volumes due to population growth or industrial activities may require a heat exchanger with greater capacity to handle higher thermal loads.
Enhanced Reliability: Old or deteriorated heat exchangers can lead to frequent maintenance and unexpected failures. Corrosion, scaling, or fouling in older units can degrade performance. Upgrading ensures more reliable and efficient heat transfer and consistent performance, minimizing downtime.
Regulatory Compliance: Environmental regulations may require more advanced equipment to minimize energy use or greenhouse gas emissions. An updated heat exchanger helps meet these standards.
Integration with New Processes: New treatment technologies, such as anaerobic digestion or advanced thermal processes, may require upgraded heat exchangers for optimal operation.
Lower Maintenance Costs: Replacing an outdated heat exchanger can lower maintenance costs, energy consumption, and overall operational expenses in the long term.
Environmental Goals: Plants aiming to lower their carbon footprint or improve sustainability may update heat exchangers as part of broader energy efficiency initiatives.
Why Choose GPRS?
GPRS 3D laser scanning services documents the exact architectural, structural, and MEP system layout and dimensions of existing water treatment plants and wastewater treatment plants. We have captured as built site conditions from 40 MGD to 1 BGD, documenting the interior and exterior of buildings; foundations; structural, mechanical, electrical and plumbing features; equipment, motors, conduit and piping down to ½ inch diameter.
GPRS is a leading provider of 3D laser scanning and BIM modeling services, delivering accurate as-built documentation of buildings, facilities, and sites. Laser scanning captures precise layout, dimensions, and locations of existing architectural, structural, MEP, FP, and HVAC system elements in a point cloud. The GPRS Mapping & Modeling team can transform point cloud data into 2D CAD drawings and 3D BIM models to aid system engineering. This ensures that system upgrades are designed to fit precisely within the existing structure, optimizing processes, minimizing errors and rework, reducing costs, and ensuring compliance with evolving industry and environmental standards.
