INDUSTRIAL SOLAR MANUFACTURING WWTP DESIGN AND EXPANSION
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1 Location Northwest Ohio Services Provided Engineering, Permitting, Installation of Equipment and Facilities Cost $3 million Size 300 GPM (432,000 GPD) Metal Hydroxide Precipitation WWTP 50 GPM (72,000 GPD) Ultra Filtration WWTP Schedule Professional Services: May 2009 Construction: October 2009 Project Team Michael Atherine, P.E. Roy L. Jackson, CHE Jack A. Jones, P.E. Brad M. Thomas, P.E. Daniel L. Knott, P.E. INDUSTRIAL SOLAR MANUFACTURING WWTP DESIGN AND EXPANSION PDG s environmental engineers and IFM, a subsidiary of PDG specializing in water cycle technologies, were instrumental in developing and managing a design/build project involving two wastewater treatment systems with the following parameters: 300 GPM (432,000 GPD) Metal Hydroxide Precipitation Wastewater Treatment Plant for cadmium removal, followed by multimedia filtration and chelating ion exchange systems designed and built into a final polishing system. The design includes the controls and programming for variable frequency drives and automated valves (electric and pneumatic) for pump and tank level operation. With the chelating resin system, heavy metals will often meet 20 parts per billion (ppb) consistently. 50 GPM (72,000 GPD) Ultra Filtration Wastewater Treatment Plant consisting of tubular membrane technology and crossflow filtration for particulate cadmium and other forms of suspended solids from the client s R&D facility. The ultrafiltration system will produce suspended solids free water with very low turbidity levels (<0.4 NTU), which ultimately will be used in many water reuse applications the facility wants to pursue. The design required robust and varied treatment as the process within the facility will be closely held company secrets, the extent of which could not be divulged to the design crew. more... Project Relevance Research & Development Facility Innovative Design Design/Build
2 Industrial Solar Manufacturing Wastewater Treatment Design Plant and Expansion The client asked PDG to design a chelating resin polishing system to maximize heavy metal removal prior to discharge to the municipal sewer system. To further the clients wish to recapture all the cadmium from their manufacturing process, they requested a design for an in-place regeneration system. By regenerating onsite, the client can retain more Cadmium from its wastewater processes, greatly increasing the amounts of recovered and recycled Cadmium from the client. The unique design includes six large fiberglass pressure vessels riding on-line in pairs. As the first of the pair reaches exhaustion (based on tests and/or gallons processed) a new tank becomes the polisher and the current polisher a worker. The exhausted resin is then evacuated from the service tank and into a tank where an elaborate regeneration is performed in a semi-automatic format. The design included a single power drop and PLC control of all aspects of treatment including flow control, ph correction, clarification and eventual, safe discharge. The design included planning for operation and maintenance of the existing system while the new system is being constructed without causing downtime to the facility.
3 Location Services Provided Master Planning, Civil, Transportation, and Environmental Engineering, Surveying Cost Estimate $1.9 Million (Water and Sewer) Size 19,600 acres Schedule Professional Services 2000 Completion On-Going APEX INDUSTRIAL PARK MASTER PLAN/SITE DEVELOPMENT APEX Industrial Park Master Plan, Poggemeyer is the planner and engineer of record for the 19,600 acre Apex Industrial Park over the last 15 years. The Apex Industrial Park is a heavy industrial property located in the City of North Las Vegas and unincorporated Clark County, Nevada. The primary purpose of the park is to provide a safe location for heavy industry for Southern Nevada and not encroach or affect residents or other sensitive land uses. This property is serviced by I-15, S.R. 93, S.R. 603 and by the UPRR. Our master planning efforts have included all facets of creating the initial concepts through developments of Master Plans for 1) land use 2) water 3) wastewater 4) flood control, and 5) roadways. Key elements in this master planning process included close coordination with the City of North Las Vegas, Clark County, Nevada Department of Transportation, Bureau of Land Management, Union Pacific, Nellis AFB, Southern Nevada Water Authority, NV Energy, Clark County Regional Flood Control District and other stakeholders. Our work included numerous meetings with both Nellis AFB and the City on a Development Agreement permitted land uses and guidelines. Apex Industrial Park is actually more... Project Relevance Industrial Park Master Plan Industrial Park Site Development Water/Wastewater Transportation Storm Drainage Power Generation Plant Reference Mr. Dave Brown Land Development Associates, LLC 9910 West Cheyenne Avenue, Suite 110 Las Vegas, NV (702) DBrown@ipdnv.com
4 Apex Industrial Park composed of 14 unique industrial developments ranging in size from several hundred acres up to 3,250 acres for the Mountain View Industrial Park. APEX Waterline Preliminary Engineering, Poggemeyer provided the initial backbone water service to the Apex Industrial Park. The project required connecting to the City of North Las Vegas existing water system. The Phase One water system project connected to an existing 24 water pipeline on Hollywood Boulevard north of Interstate 15 near the Manheim Auto Auction, and extends 16 miles to the northern portions of the Apex Industrial Park south of U.S. 93. The proposed Phase One water system improvements were the initial segment of the required water improvement outlined in the Water and Wastewater Master Plan for Apex Industrial Park. The Phase One Water System Improvements consisted of three (3) pump stations, three (3) water storage reservoirs ranging from 2.5 MG to 5 MG and 16 miles of water pipelines ranging from 20 to 36 diameter. Ancillary improvements included pressure-reducing valves, gate valves, pump station buildings, electrical service, water disinfection by sodium hypochlorite injection systems, and data telemetry. Poggemeyer s responsibilities also included master planning, pre-design services, detailed design, and preparation of construction documents. APEX Industrial Park Wastewater Master Plan, Poggemeyer prepared a wastewater master plan for the large Apex Industrial Park in. The Apex Industrial Park has a total land area of approximately 19,600 acres of which 7,500 acres are developable. The industrial park consists of 16 separate sub-parks with elevation varying from 2,150 to 3,375 feet above sea level. PDG master planned the wastewater infrastructure for the industrial park using the District s Design and Construction Standards for Wastewater Collection Systems (DCSWCS). The average day flow was determined to be 7.8 million gallons per day and that was used to determine maximum day flow and peak hour flow rates based on DCSWCS factors. A total of 49 separate sewersheds were delineated based on location and topography and the design flow for each was established for pipe sizing purposes. PDG performed computer modeling and hydraulic calculations to establish the pipe sizes for the entire collection system. The master planned collection system included the following: 229,000 linear feet of gravity wastewater collection system pipe varying in size from 8 to 48 inch diameter; 44,500 LF of force main varying from 14 to 30 inch diameter; A series of three main lift stations with flow rates ranging from 7,700 gpm to 12,600 gpm plus two other feeder lift stations with capacities of 2,360 gpm and 2,470 gpm; and two planned points of connection to city system for the City s use to determine that which would work best for the City. For wastewater treatment Poggemeyer master planned a wastewater treatment plant with phased capacity increases to approximately 500,000 gallons per day after which the wastewater would be conveyed to the City of North Las Vegas for treatment and effluent disposal. Mountain View Industrial Park (MVIP) and Apex Commercial Center North (ACCN) Water System, Poggemeyer was responsible for master planning, design, permitting, and preparation of construction plans and specifications for the Apex Commercial Center North (ACCN) and Mountain View Industrial Park (MVIP) water and sewer systems. Project objectives included improving and expanding an existing private water system and an existing public water system and connecting the two with an emergency water supply pipeline. Project work included the detailed design of the water distribution system as two separate pressures zones, with approximately 18,800 linear feet of new water main, along with 12-inch diameter, 7,900 foot long pipeline connecting the two water systems with a vault installed pressure reducing valve between the two water pressure zones. The connecting pipeline serves as conveyance for fire protection water from MVIP to ACCN and as an emergency water supply pipeline for water from ACCN to MVIP in the event of a MVIP water supply well outage. Design work also included improvements to two existing water pump station facilities housing fire protection water pumps and domestic use water pumps, installation of surge relief and pressure transient control facilities, conversion of an existing fire storage water tank to a domestic use water storage tank, water treatment improvements, and other typical water system facilities. APEX Commercial Center North and Northern Flats Industrial Park Interim Regional Water System Master Plan, Poggemeyer was responsible for the planning and analysis for a regional water and wastewater system installation for a 730 acre portion of the overall Apex Industrial Park. The system plan included water rights analysis, cost estimating,
5 Apex Industrial Park coordination with the CNLV, and water system infrastructure including source of supply water wells, water treatment, domestic and fire water storage, transmission and distribution system pipelines, pumping systems, and water distribution system appurtenances for the multi-phased proposed development. Apex Vegas Vista Industrial Park Regional Storm Drainage Facilities, The project consists of a master site development plan on approximately 648 acres. Poggemeyer s professional services include Master Drainage Study, Storm Channel Plan and Profiles, Storm Drain Plan and Profiles, Headwall Structural Calculations and Details, Infrastructure Roadway Plans, Topographic Surveys, and Zoning Entitlements. The site is impacted by large offsite flows which are to be conveyed through the site in a single drainage channel adjacent to a UPRR Spur and Pabco Road. The storm water flow is conveyed to an onsite detention basin that will mitigate the flows to equal or less than to pre-development quantity and velocity. APEX Commercial Center North Industrial Park, The project consisted of a master site development plan on approximately 174 acres subdivided into 28 commercial lots by records-of-survey. Professional services included Topographic Survey/Mapping Services, Entitlement Services, Master Drainage Study, and Infrastructure Roadway plans. APEX Central Industrial Park, The project consists of a master site development plan on approximately 520 acres subdivided into 62 commercial lots by records-of-survey. Professional services include Topographic Survey/Mapping Services, Entitlement Services, Master Drainage Study, and Infrastructure Roadway plans. Mirant Power Plant, Apex Industrial Park, Nevada The Mirant power plant is a site comprised of 90 acres located 0.67 miles southwest of the US-93 highway. The proposed flood control facilities for the Mirant Power Plant include a series of culverts along the Mirant Access Road to pass the 100-year flow underneath the roadway. FLO-2D has been used to determine the flow path of the existing topology. At the points of concentrated flow, a culvert system has been designed to bypass the flow underneath the Access Road. The Access Road s upstream side and channel will be used as a levee system to pond and direct the flow to the low points along the Access Road drainage channel. An 8 foot wide by 2 to 3 foot deep trapezoidal channel has been designed on the upstream side of the Access Road to direct the off-site flow to the low points. Silver Hawk Power Plant, Apex Industrial Park, Nevada The Silver Hawk power plant is a site comprised of approximately 85 acres located 1 mile southwest of the US-93 highway. The proposed flood control facilities for the Silver Hawk Power Plant include a privately maintained channel along the northern and western boundaries of the Silver Hawk power plant site. The northern channel has been designed to convey a 100-year flow of between 150 and 350 CFS and is 2000 feet long. The western channel has been designed to convey a 100-year flow of 705 to 1100 CFS and is 2500 feet long and curves around the south boundary for discharge to the existing wash. The channels are designed with 3H:1V side slopes and a 10 to 15 foot bottom width varying in height from 2 to 3 feet. The channel embankment adjacent to the site shall be covered with a Reno Mattress to protect from erosion. A cutoff wall shall be placed underneath the embankment by extending the Reno Mattress below the channel bottom. KAPEX Mountain View Industrial Park, Phase I, Building I, The project is located in Kapex Industrial Park, City of North Las Vegas, and was the first building in the proposed 3,250-acre industrial park. The project was comprised of one Commercial / Industrial Building of approximately 500,000 square feet in size on 31 acres with approximately 4,000 feet of off-site sewer mains. The civil engineering services included preparing site plans, grading plans, utility plans (water & sewer), storm drain plan and profiles, sewer plan and profiles, traffic plan, and civil details. We also prepared and processed the required technical drainage study and structural plans for concrete headwalls. KAPEX Industrial Park, Poggemeyer provided master planning, surveying, mapping, and engineering for the infrastructure of the 3,250-acre industrial park. Infrastructure projects included: water transmission, water network, groundwater treatment, water storage, water pump stations and reclamation plants, sanitary sewer, flood control systems (detention, channelization, roadway box culverts, and bridges) including alluvial fan analysis,
6 Apex Industrial Park property onto and through the subject site. The relocation of the thoroughfare significantly reduced construction costs and eliminated conflict with existing power transmission lines. The detention basin re-design was done at the developer s request for the purpose of providing maintenance by the private sector in lieu of regional maintenance, thereby reducing construction costs. APEX Central Industrial Park Roadways, Poggemeyer was responsible for the design of a 1.7 mile access road at the northern portion of the industrial park. The design included acceleration and deceleration lanes on US-93 and several large multiple barrel storm drain crossings. The access road included two all-weather travel lanes, full halfstreet improvements adjacent to the property for a future 100-foot right-of-way. A 1.2 mile access road was designed for Apex Central. This 80-foot right-of-way included NDOT permit design and coordination, several culvert crossings, and future grading coordination. Included were the design of the railway roads for access to the planned heavy industrial site between SR-604 and I-15. The design included 1.7 miles of two-lane frontage road, a 0.2-mile two-lane connector to SR-604, an at-grade intersection with a Union Pacific Railway, culverts of varying sizes, and traffic improvements on SR-604. An NDOT right-of-way encroachment permit was undertaken along with utility coordination. Mountain View Industrial Park Water and Wastewater Improvements, Poggemeyer provided master planning, surveying, mapping, and engineering for the new infrastructure of the 3,250-acre industrial park. Infrastructure projects included: water transmission, water network, groundwater treatment, water storage, water pump stations and reclamation plants, sanitary sewer, flood control systems (detention, channelization, roadway box culverts, and bridges) including alluvial fan analysis, roadways, permitting, environmental assessments, and BLM coordination. The Water System includes 10,600 l.f. of 12 water mains, 20,100 l.f. of 16 water mains, 18,650 l.f. of 24 water mains and 13,050 l.f. of 30 water mains; one 3.0 MG water reservoir, one 5.0 MG water reservoir and rehab of an existing 1.2 MG reservoir; rehab of 2 existing wells and development of 2 new wells; 3 new water pumping stations and rehab of one existing fire pumping station and 2 water treatment plants at the new wells. The wastewater system consists of 20,530 l.f. of 10 sanitary sewer, 11,260 l.f. of 12 sanitary sewer, 2,000 l.f. of 15 sanitary sewer; 860,000 GPD Wastewater/Water Reclamation System; and 3 wastewater lift stations. This project included construction staking, design topography, utility conveyance, boundary verification and establishment, legal descriptions and establishment of easements, geodetic positioning, and mapping. A 13-mile utility corridor survey for water conveyance was performed which included aerial topographic mapping, alignment survey, PLS land corner ties, and horizontal and vertical control surveys.
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