The Role of As-Built Documentation in Water Treatment Facility Updates

The level of detail required for engineers to update mechanical and piping systems depends on the project's complexity. Accurate and comprehensive as-built documentation, including detailed diagrams of existing MEP systems—such as equipment, pipe sizes, materials, and routing—is essential for designing, prefabricating, and installing system updates efficiently.

At the Southerly Wastewater Treatment Plant in Cuyahoga Heights, Ohio, a critical update was needed for one of its heat exchangers. The facility houses an intricate network of mechanical and piping systems, making accurate planning and execution crucial. 3D laser scanning captured accurate existing conditions of the plant to render an LOD 300 3D BIM model of the three-level heat exchanger, enabling ABC Piping Co. to proceed with the system update.

ABC Piping Co., the mechanical contracting company, requested a high-detail 3D BIM model to visualize, design, and manage the heat exchanger update. This model eliminated the need for extensive on-site measurements and manual drafting, streamlining the update process.

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Understanding Wastewater Treatment

Wastewater treatment cleanses sewage so it can be safely released into freshwater resources like lakes and rivers. While treatment technologies vary, the process typically involves two main stages:

Primary Treatment: This stage removes sand, grit, and larger solids through screens and large tanks, leaving organic solids in the flow.

Secondary Treatment: A biological process removes organic solids and completes disinfection to make the water safe for the environment.

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About the Southerly Wastewater Treatment Plant

Spanning 288 acres, the Southerly Wastewater Treatment Plant is the largest in Northeast Ohio, serving 530,000 residents with an average flow of 120 million gallons per day (MGD). The plant employs primary and secondary treatment processes, with the latter using specialized bacteria to remove ammonia and nitrogen, compounds that can deplete oxygen in freshwater systems. An additional third stage at the Southerly Wastewater Treatment Plant involves filtration and chlorination/dechlorination for additional disinfection.

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Utilizing 3D Laser Scanning for Accurate Documentation

ABC Piping Co. requested 3D laser scanning services to capture the heat exchanger's as-built environment at Southerly. Using the Leica RTC360 laser scanner, 108 scans were conducted across three floors. The Leica RTC360 3D laser scanner offers unparalleled accuracy and efficiency, capturing 2 million data points per second and generating 3D point clouds in under two minutes. Its color scanning capability ensures true-to-life site representations, enabling precise BIM modeling.

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Heat Exchangers in Wastewater Treatment Plants

Heat exchangers play a vital role in wastewater treatment plants by recovering heat from wastewater, which remains warmer than the environment, even in colder months. This recovered heat can:

• Preheat incoming wastewater.

• Heat building spaces.

• Power heat pumps.

Updating a heat exchanger involves replacing outdated models with advanced systems that improve energy efficiency and optimize heat recovery.

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Key Considerations When Updating a 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.

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Capturing As-Built Environments with 3D Laser Scanning

3D laser scanning employs LiDAR technology to create highly accurate digital representations of existing structures. By emitting laser beams and measuring their return time, scanners generate dense point clouds of spatial coordinates. These point clouds map the geometric details of structures, piping, and mechanical systems with precision. The data is then processed into 2D CAD drawings or 3D BIM models for design and engineering purposes.

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Benefits of 3D BIM Models for System Updates

3D BIM models offer a comprehensive view of facility systems, providing several advantages for engineers:

• Enhanced Visualization: Detailed models allow engineers to understand spatial relationships and system constraints, reducing errors during planning.
• Clash Detection: BIM models enable interdisciplinary coordination, identifying conflicts between systems (e.g., ductwork and piping) before construction.
• Efficiency and Accuracy: Optimizing designs within the model minimizes rework and ensures compliance with performance goals and regulations.
• Collaboration: BIM models facilitate communication across disciplines, streamlining project execution.
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Benefits of Updating Wastewater Treatment Plant Heat Exchangers

Upgrading heat exchangers offers multiple operational and environmental benefits:

• Improved Energy Efficiency: Modern systems optimize heat transfer, reducing energy losses and operational costs.
• Capacity Expansion: Increased wastewater volumes necessitate systems capable of handling higher thermal loads.
• Enhanced Reliability: Replacing deteriorated equipment minimizes downtime and ensures consistent performance.
• Regulatory Compliance: Advanced equipment helps meet environmental standards by reducing energy use and emissions.
• Process Integration: New treatment technologies require heat exchangers that align with advanced processes.
• Cost Savings: Upgraded systems lower maintenance costs and improve long-term operational efficiency.
• Environmental Sustainability: Modern heat exchangers contribute to reduced carbon footprints and support energy efficiency initiatives.

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Why Choose Existing Conditions?

Existing Conditions specializes in documenting architectural, structural, and MEP systems with precision. Our 3D laser scanning services capture as-built site conditions for water and wastewater treatment plants, documenting piping down to ½-inch diameter.

Using point cloud data, the Existing Conditions team produces 2D CAD drawings and 3D BIM models that facilitate precise system upgrades. This ensures seamless integration of new components, reduces errors, minimizes costs, and meets evolving industry standards.

For comprehensive visualization and accurate documentation of your projects, trust Existing Conditions to deliver unparalleled results. Let us help you optimize your engineering solutions.

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