lansing exterior

A control house before delivery to the Village of Lansing. Part of an extensive 14 lift station upgrade to the village.

Back in 2012, when the Village of Lansing, Ill., received approval for a full SCADA upgrade for the village’s lift stations, the Village called on Metropolitan to assist them in their quest to upgrade all 14 of the village’s lift stations.

Along the lines of what Metropolitan’s Infrastructure class teaches, certain equipment, like pumps, controls and accessories can be added to improve present water pumping systems, existing storm water or sanitary lift stations, standby power needs, chemical feed systems and/or water and wastewater process equipment.

Metropolitan has always recommended that villages try to eliminate confined spaces by bringing controls above ground and replacing old “auto-dialer” systems with modern communication methods. Our specialty is “owner-direct” equipment procurement, to expedite the process and save money on the bid-construct concept.

The project began in early 2014 and by the end, the Village of Lansing will have upgraded 14 Lift Stations. The upgrades will include both storm water and sanitary lift stations with a variety of stainless steel traffic boxes, four prefabricated housed buildings, existing control system retrofits, a weather station and a new SCADA system

The project is wrapping up phase 1 of the upgrades and somewhere in the future they will begin Phase 2 which will totally eliminate confined space. The lift stations are designed to sanitary and storm flows to the Metropolitan Water Reclamation District.

The new SCADA system upgrades will for the first time include the lift stations throughout town for the Village of Lansing, which will monitor their system more closely to help avoid emergencies through SCADA, which can now also help to quantify sewer lining needs in attempt to prevent rain water from getting in to the sanitary lift stations. The control system can also determine which pumps are not working efficiently, the proper cycle times and so many more features that will allow the operator to make level changes, view trends, and be more proactive with his system…right on the operator interface/touchscreen, either remotely or at the station.

The majority of the stations will incorporate the LMS II, a pre-programmed level controller with a color touch screen operator interface. The LMS II allows users to seamlessly alter pump sequence options, transducer level controls, even basic flow calculations, and more, providing access to basic SCADA features at a cost-effective price. The new control systems will also include Metropolitan’s Metro-Mail with M2M cellular service which ensures that static IP is maintained, providing a more reliable communication service to the end user.

Prefabricated house features:

-Precast concrete buildings with natural gas service to the new standby generator sets

-Making use of power feeds into above ground control system

-Cellular phone and text devices to communicate alarms and operating conditions

-New duplex level control systems and communication equipment in a secure, climate-controlled environment

Additional accessories where applicable included:

-Safety grates on wet well access points

-Weather station located at East Side Storm station to monitor rain/snow and weather conditions

Control system inside the prefabricated house.

Control system inside the prefabricated house.

Interior of the Village of Lansing control building.

Interior of the Village of Lansing control building.

As published in April 2015 Water and Waste Digest

One of Four pumps installed during the upgrade process.

One of Four pumps installed during the upgrade process.

Chicagoland city upgrades pump station to maintain service

In conjunction with Robinson Eng. Ltd. of South Holland, Ill., Metropolitan Industries of Romeoville, Ill., assisted in the renovation of a critical combined sewer overflow (CSO) pump station in the south suburban Chicagoland area. The pump station, located in Calumet City, Ill., has been responsible for keeping many of the nearby south suburban municipalities from flooding during heavy rain events since it was originally built with Works Progress Administration money in the 1930s.

Pump Station Reliability

Today, during significant rain events that surpass the capacity of the deep tunnel storage reservoir (150 billion gal), the nearby Metropolitan Water Reclamation District (MWRD) must close its influent sewer gate to prevent exceeding the capacity of the collection and treatment system due to the combination of normal sanitary flows and the excessive infiltration of storm water. When this gate closes, the water accumulates at a rapid rate and begins to seek higher elevations, at which point it begins to fill the wet well of the Calumet City CSO pump station. As the wet well fills, the pump(s) start and the CSOs are pumped into the Calumet River in an effort to prevent flooding of the
surrounding community.

The station’s reliable operation during high-capacity rain events is imperative due to the negative consequences the surrounding municipalities would face if the storm water is not conveyed to the Calumet River immediately.

Four new submersible pumps were supplied, including the associated discharge tubes designed to house the pumps and convey the discharged water to the effluent trough that leads to the river.

The city was given three 355-hp pumps and one 215-hp pump, which all discharge at a combined rate of approximately 155,000 gal per minute. It is a large submersible pumping station and one of the larger ones Metropolitan Industries has produced.

In addition to four new pumps, Metropolitan also
supplied all of the power distribution equipment, controls and motor equipment related to the upgrade, including switch gear (to support existing standby generators) and SCADA equipment, all housed in a prefabricated building.

The building houses low-harmonic variable-frequency drives that accelerate or decelerate pump motors to match the influent rate. Regardless of the rainfall event or its severity, the pumps will speed up or slow down to match the influent rate to remove the CSOs in an energy-efficient manner.

The building is a complete prefabricated solution and incorporates energy-efficient R-30 insulation to retain heat during the winter and air conditioning during the summer. It measures 36 ft in length, 12 ft in width and approximately 11 ft in height.

The pump station is integrated into the city’s master SCADA system to provide notification in the event of any alarm condition and archive important historical operational data. This is critical for a system with such important responsibility. Metropolitan has supplied and supported the city’s SCADA system for many years.


Interior of the control building.

Interior of the control building.

Necessary Upgrade

The city’s need for an extensive upgrade of this pump station can be attributed to a number of factors, including corroded power distribution equipment due to hazardous sewer gases accumulating in the 1930s building, and pumping equipment last updated in the 1980s.

The existing configuration had suffered a great deal due to the presence of hydrogen sulfide (H2S), which had significantly attacked the copper within the existing power distribution equipment. The original building needed to be demolished and its removal improved the aesthetics as well as upgraded the ventilation. Throughout the entire project, design concepts were developed to take the necessary precautions to prevent H2S from migrating into the new prefabricated control building.

Due to the pump station’s vital nature to the surrounding municipalities, accommodations were arranged to accelerate the installation process.

Rather than demolish the existing building and construct a new structure on site, Metropolitan was instructed to prefabricate the new building at its facility in a controlled environment. Once the new building was complete and set in its place, the existing building was demolished. Bypass pumping was required during the installation process because the station’s dependable operation is so critical.

View of the completed station.

View of the completed station.

Following delivery of the building, the project contractor, John Burns Construction of Orland Park, Ill., added a gabled roof and an aesthetic finish to the structure to match other Calumet City municipal buildings.

All operators responsible for maintaining the system also received comprehensive training from Metropolitan.

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