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LAARS products, including the 95-plus percent thermal efficient NeoTherm boiler, are now available from Metropolitan.

 
Metropolitan Industries is pleased to announce it has reached mutual agreements with LAARS Heating Systems Company and M&G DuraVent on the representation and distribution of the LAARS and DuraVent product lines. Metropolitan will represent LAARS in northwest Indiana, northern and central Illinois, and all of Missouri.

A subsidiary of the Bradford White Corporation, LAARS specializes in high-efficiency residential and commercial boilers, combination boilers, water heaters and pool heaters. LAARS offers a full line of residential and commercial products designed to fit a variety of applications.

A member of the M&G Group, DuraVent has consistently been recognized as innovators in the venting industry. DuraVent venting products and related accessories are engineered to provide safe and high-quality performances in residential and commercial uses.

“The partnerships we have established with both LAARS Heating Systems Company and DuraVent illustrate our dedication to expanding our capabilities to serve more diverse customer needs than ever before,” said John Kochan Jr., President of Metropolitan Industries. “Both LAARS and DuraVent have displayed a strong commitment to adjusting to industry standards to ultimately provide technologically-advanced and superior equipment. We believe these partnerships with benefit all involved in the short and long-term futures.”

Our expertise in mechanical heating equipment allows us to manufacture sophisticated equipment packages including heat transfer systems.

 
At Metropolitan Industries, broadening our horizons has never been a foreign concept.

Over the past year, we’ve partnered with new businesses and added new team members to enhance our ever-growing services and capabilities.

Perhaps nothing is more reflective of our commitment to meeting the highest of industry standards and adapting to serve the most complex needs of our customers than the expansion of our commercial division.

Due in large part to the division’s expansion, Metropolitan Industries is now equipped with the sales, service, engineering and fabrication prowess to serve a wide range of mechanical heating applications.

A case study depicting one of our many new abilities can be portrayed by a project completed for a local educational institution. Faced with an aging steam bundle used to heat a domestic hot water storage tank, the customer and project contractor turned to Metropolitan for a specialized solution of engineering and supplementation of equipment.

“We were contacted by the project contractor to supply a replacement steam bundle to be used in a tank heater application, which is primarily used during the winter months and provides domestic hot water to the institution’s athletic center, and food and sciences building,” said Metropolitan mechanical salesperson Mike Temes. “Because this storage tank fed two very critical facilities, it was imperative that the replacement steam bundle be sized accordingly to meet the domestic water demand.”

In order to supply the solution most resourcefully, Metropolitan conducted a field visit to appropriately size the steam bundle to be placed in the domestic hot water storage tank. Temes said Metropolitan’s engineering expertise played a decisive role in not only supplying the correctly-sized heat exchangers, but doing so while minimizing the time associated with delivery and installation.

“During the field visit, our engineering division was able to acquire all of the information needed to properly size the steam bundle without having shut down the system, drain the domestic hot water tank, and remove the existing steam bundle,” said Temes. “This radically reduces the time typically spent with the replacement of steam bundles. This was advantageous for our customer not only because the new steam bundle was needed quickly, but also because additional funds related to the labor required to remove the existing steam bundle twice were not incurred.”

Temes said the domestic hot water storage tank required only one day of shutdown for installation and that the new steam bundle transitioned into the domestic hot water storage tank with little to no manipulation.

At Metropolitan it is always of absolute priority to provide our customers with equipment that meets all specifications and industry standards. In supplying the custom-sized steam bundle, Temes said this case was no different.

“Many times, customers seeking to replace heat exchangers that have aged 25 or 30 years may not be aware of state codes that have been implemented since the existing heat exchangers were last installed,” said Temes. “It’s not always as simple as replacing existing steam bundles with new models of the previous kind utilized. At Metropolitan, we consider it a commitment to our customers to monitor all industry standards to ensure all equipment we supply is approved by any and all engineering criteria, and delivers peak performance at a competitive price.”

Metropolitan provides shell and tube heat exchangers that can be customized for a number of applications including domestic hot water, process heating and cooling, condensers, heat recovery, steam to water, water to water, and more. Single and double wall configurations are available in materials including copper, 90/10 cupro-nickel, 304/316SS, carbon steel and specialty metals.

An additional related offering is our plate and frame heat exchangers, which can be designed in multiple configurations for applications including HVAC, domestic hot water, chillers, milk processing pasteurization, domestic heating, brewing, heat recovery, and more. Single and double wall configurations, wide-gap plate designs, and brazed and welded plates are available.

Customized shell and tube heat exchangers are now available from Metropolitan Industries.

 
In conjunction with our engineering, service and fabrication departments, Temes said the mechanical heating proficiency Metropolitan has acquired will allow us to design, manufacture, and provide innovative and multifaceted mechanical heating equipment to new bases of customers.

“Because we have so many exceptional capacities under one roof, the amount and type of intricate mechanical equipment we can now produce as single-source suppliers is nearly limitless,” said Temes. “From heat transfer systems to boiler feed systems, we guarantee our customers will receive the very most out of their mechanical heating systems.”

For more information, please contact Mike Temes at 815-886-9200, ext. 252 or sales@metropolitanind.com.

Various examples of our patented load sharing technology being used in complex pumping situations.

 
Metropolitan Industries Inc. is proud to announce that the company has been issued a system and method patent by the U. S. Patent Office (No. US 8,180,496 B2) which will allow dissimilar variable speed pumps to be controlled in a way never before possible. We have elected to market our programmable logic control systems utilizing this technology by using the term “load sharing.”

The development of load sharing should be very welcome news to anyone attempting to operate any liquid transfer or pressurization system through the use of dissimilar pumps or other challenging hydraulic scenarios. The load sharing process allows Metropolitan to manufacture specialized variable speed control systems for pumping applications which have multiple dissimilar pumps or pumps which need to operate together under varying hydraulic conditions.

Load sharing will eliminate conditions during which one or more pumps operate under high or extremely high energy load conditions, while other pumps within the system are extremely under loaded electrically. These operating conditions are undesirable because they typically cause the pumps to operate well outside of their zone of peak hydraulic efficiency. Load sharing, in essence, is a way of ensuring that all dissimilar pumps within a system tend to operate at peak hydraulic efficiency, regardless of the hydraulic load of the process they are feeding, the hydraulic conditions under which they are operating, and the varying load profile of each pump.

Load sharing defined:

Load sharing is a dynamically-equalizing process by which two or more dissimilar pumps, with dissimilar hydraulic characteristics or operating under dissimilar hydraulic conditions, are operated in unison to accomplish a common task, while drawing a commonality of electrical energy proportional to their individual load characteristics. The process is dynamic because the electrical power load of each pump on the system is continuously compared to the maximum load of the unit. In addition, the electrical power load of each individual pump is also continuously adjusted in proportion to each of the other units, so that the percent load of each unit is proportionally matched by all other units. As such, each of the pumps on the system will very likely operate at rotating speeds which differ from one unit to the next, while attaining the exact same desired set point task.

Common task clarified:

The grouping of pumps must be programmed to accomplish the same set point task, whether the task is to maintain a common line pressure, maintain a common outlet temperature, maintain a common pumped water elevation or, in some instances, a combination of two of these tasks.

Commonality of proportional energy explored:

The load sharing program will adjust the speed of each pump individually while maintaining the common task set point(s), so that the power load (or kilowatt consumption) of each pump in the group is proportional to the load of all pumps in the group.

Example scenario: One 20 HP pump will operate at 10 BHP, while two 60 HP pumps each operate at 30 BHP. In this scenario, each pump in the system operates at 50 percent of its peak load. This process dynamically and continuously varies proportionally, as the demands of the pumped process changes.

Real world examples:

The load sharing process we’ve patented is designed to be very flexible, allowing the technology to be adapted to a variety of applications. The technology will provide us with the unique ability to tackle some of the most challenging hydraulic scenarios in the markets and industries we serve.

Our load sharing program being used in a commercial building application.

 
Multiple pumps with dissimilar flow capabilities:

One or more smaller jockey pumps (or lead pumps) can operate with one or more larger duty pumps (or lag pumps). Possible examples would be a water pressure booster system for a large commercial building or, potentially, a municipal water pumping station. Pumps of various rated flows can work together, each with a shared proportion of their rated horsepower.

Multiple pumps with dissimilar performance characteristics:

One or more pumps with “steep” curve characteristics can operate with one or more pumps with “flat” curve characteristics. This is the perfect process control in a scenario where one or more multi-stage pumps need to operate in conjunction with one or more single-stage pumps.

Multiple pumps, at different geographic locations, feeding a common process:

A municipal pumping station at the east end of town can operate in unison with another pump station at the west end of town. Load sharing is a great solution, especially if the pump stations are at different elevations. Managing this type of application is also enhanced if the water main friction loss profiles are also very different at each end of town.

Multiple pumps, with different suction pressures, feeding a common process:

An exceptionally difficult process-control scenario can be overcome with relative ease. A municipal pumping application, including two or more gravity tanks at varying elevations, feeding a multiple pump system, with a single set point pressure, is an excellent application for load sharing technology.

Multiple pumps with dissimilar motor sizes:

By the nature of the pumps described, many of the scenarios mentioned above will inherently include pumps with various motor sizes. Load sharing will allow all of these systems to operate at their proportionally equal power load, which in itself will tend to ensure operation within the peak efficiency range of their individual performance curves.

Make no mistake: This process program is extremely unique and will be a very valuable asset to our clients while operating their most challenging pumping applications.

For more information regarding load sharing and any potential projects which may benefit from the process, please contact Metropolitan Industries senior systems engineer Brendan Bates at 800-323-1665 or sales@metropolitanind.com.

Faced with a flooded below ground pump station, the village of Chicago Ridge, Ill. looked to Metropolitan Industries for an emergency solution.

 
Confined space entry presents significant hazards to municipalities working with below ground pump stations.

The flooding of below grade stations can lead to an emergency service call and cause catastrophic damage of system equipment, often costing owners greatly for expedited repair or even replacement.

More importantly, confined spaces present health threats to entrants. Atmospheric conditions such as lack of oxygen, dense gases and additional dangers force operators to follow stringent guidelines when entering confined spaces to ensure adverse health consequences are avoided.

At Metropolitan, we believe upgrading below ground pump stations with above grade solutions most effectively protects both the investment of systems and the lives of equipment operators.
While eliminating confined space entry entirely should be the end goal, our above grade solutions can significantly reduce the frequency workers must enter confined spaces. With a comprehensive submersible pump retrofit, the need to enter confined spaces can be completely eliminated.

An illustration of our ability to retrofit below ground pump stations can be demonstrated by the work done in the village of Chicago Ridge, Ill. Faced with severely damaged system equipment, including pumps and controls due to a below ground vault flood, the village turned to Metropolitan to provide a quick solution.

“During a heavy rain event, a sump pump situated in the pump station’s dry pit malfunctioned allowing sewage to flow from the wet well to the dry well, causing the dry well to flood,” said Metropolitan municipal salesperson Keith Girup. “Unfortunately, due to the dry well flooding, the customer’s investment, including pumps, controls and power distribution equipment, was completely submerged underwater and caused irreparable damage. An immediate emergency retrofit solution was required.”

In order to get the pump station up and running in an accelerated fashion, the village elected to bake dry the pump motors, which were eventually placed back into the below ground station. To reduce the occurrence of entering the below ground confined space and protect the investment of system controls, Metropolitan supplied the village with an above grade control traffic box.

Included with the traffic box package was Metropolitan’s new LMS II level management system. Completely off the shelf and designed to provide customers with vital SCADA features at a cost-effective price, the LMS II control package played a key role in supplying the village with a prompt solution.

Developed by Metropolitan’s research and development team, the LMS II is a menu-configurable, constant speed pump down level controller, allowing one to three pumps, single/dual level transducers, 0-20 mA flow meter input, and a completely redundant float backup controller. Seal fails and thermal inputs are available by default.

Metropolitan’s new LMS II level management system contains a standard program to cover nearly all lift station applications.

 
The LMS II can be accessed directly at a lift station on its easy-to-use color touch screen interface or controlled remotely via a laptop. With the inclusion of an internet connection or cell modem, and Metropolitan’s MetroMail™ alarm-dialing system, users can receive alarm notification via any SMS text or email compatible device.

“In developing the LMS II, our goal was to create a standard program with options that covered 90 percent of all lift station applications,” said Metropolitan research and development manager Wayne Barkley. “This program gives us a systematic solution to designing lift station controls, eliminating much of the excessive labor associated with the design, engineering and programming of controls. Right out of the box, this system can serve many stormwater and sanitary stations with one program.”

Girup said the LMS II can fit a variety of lift station uses and is especially advantageous for consumers who seek to one day implement a master SCADA or building automation system. The LMS II can also be used in commercial applications.

“Each LMS II unit can be defined as a distributed SCADA system, providing substantial benefits to owners who may have plans to one day build a centralized SCADA system with master computer,” said Girup. “The LMS II has the capability to communicate with owners via email and/or text message, and can also be viewed via the internet for current system information, as well as historical data trends. The LMS II allows for a phased distributed SCADA approach, which can ultimately be tied into a more sophisticated centralized SCADA system at a future date.”

Due to a below ground vault flood, the pump station’s vital equipment, including pumps and controls, sustained significant damage.

 
In addition to the traffic box package, Metropolitan also included a flood switch for installation into the dry well to notify operators via their SCADA system in the event of another dry well flood. This allows for a rapid response in the effort to prevent further flooding of the pump station’s dry pit.

Girup said this project is likely to serve as phase one of an extensive retrofit of the entire pump station. Phase two would be the installation of submersible pumps into the existing wet well, which would allow for the complete elimination of the confined space.

“Metropolitan is typically able to provide customers with an à la carte solution,” said Girup. “When the resources to fund a complete retrofit upgrade of a pump station are not feasible, we have the ability to work with the customer’s budget to supply the equipment and services that are most practical for the owner and application at a given time.”

This, combined with our 24/7/365 emergency service assistance, led to the successful, expedited upgrade solution for the village of Chicago Ridge.

“This project is a perfect example of why municipalities should start budgeting to upgrade existing dry pit pump stations of this type,” said Girup. “Fortunately, we were able to respond to the customer very quickly. In the coming years, I anticipate that many municipalities will continue to call on Metropolitan for a phased retrofit upgrade solution to eliminate confined space, below ground pump stations in the effort to avoid emergency circumstances.”

For more information, please contact Keith Girup at 815-886-9200, ext. 264 or sales@metropolitanind.com.

Metropolitan housed the simplex pump system in a clamshell structure for convenience.

 
At Metropolitan Industries, we take great pride in our ability to design retrofit solutions to meet your needs.  Our engineering expertise and dedicated sales and service staffs can design custom solutions best suited to solve your water and wastewater challenges.

As case study illustrating our dedication to being problem solvers can be demonstrated by the work done in a village located in DuPage County, Ill.   At the request of the owner, the location of the project will remain confidential.

“The customer needed to deliver water pressure to a small housed concession stand located at an outdoor sports complex,” said Metropolitan commercial sales manager Mike Ponx.  “They required a simplex system housed in compact fashion, so we contained the system in a small clamshell structure.  With this solution, the final product isn’t an eye-catcher and still delivers the water pressure needed for the concession stand to function properly.”

Ponx said the system needed to provide enough water pressure to deliver flow to sinks, lavatories, water closets and hoses within the concession stand.  In order to accommodate, Metropolitan supplied a simplex system with a designed flow rate of 59 GPM at a discharge pressure of 90 PSI.

Ponx said the application of the clamshell structure was ideal for the customer due to its cost-effective price.

“From a financial standpoint, this made the most sense for the customer because they did not have the space or housing already in place for the system,” said Ponx.  “An alternative solution, such as a prefabricated housed structure, would have been much more costly.”

Ponx said a number of amenities were included within the housed structure to ensure routine maintenance and checkup would be hassle-free.

“We included a heating system and a drop light for times when service is being conducted,” said Ponx.  “The structure itself comes with a large enough power supply to run not only the pump, but an electric heater as well.  It also runs a convenience outlet that provides the customer with power when needed.  Everything was supplied as a prefabricated packaged system.”

Overall, Ponx said the project depicts Metropolitan’s vast and unique capabilities, particularly within its commercial division.

“This project demonstrates how diverse we are and our ability to solve problems, small or large,” said Ponx.  “Our commercial division has the ability to service high-rise buildings or, in this case, small structures that do not require very large systems.  In any case, we can provide customers with a number of options and custom solutions applicable to their needs.”

For more information, please contact Mike Ponx at 815-886-9200 or sales@metropolitanind.com.

Thanks to everyone who stopped by our exhibit booths during the many trade shows we attended in the month of March!  The ISAWWA WATERCON Conference, IL-PHCC Expo and SMACNA Chicago Trade Show were each a great success, and we appreciate all of the support from the many attendees who stopped by to see our new products and capabilities firsthand.   Below are some photos from these shows.  Be sure to keep checking in for more information regarding the future trade shows we will attend.

IL-PHCC Expo

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At Metropolitan Industries, the month of March signals the start of our trade show season.

As leaders in the residential, municipal, commercial and mechanical water and wastewater industries, we attend a number of trade shows covering these sectors throughout the year.

March is our busiest month, as we attend three major conferences.

Throughout the time leading up to these shows, we have been actively developing and preparing new products and displays to showcase to attendees.

As is always the case with our new product offerings, they are designed to incorporate the latest technologies to help make heating, treating and moving water easier and more efficient than ever before.

We will exhibit at the following shows in March:

Illinois Section AWWA WATERCON
Monday, March 18 to Thursday, March 21
Crowne Plaza Hotel – Springfield, Ill.

WATERCON is the Midwest’s largest water and wastewater conference. We will be exhibiting at booth 503, presenting our newest water and wastewater products.

Illinois PHCC Expo
Friday, March 22
12:00 pm to 5:00 pm
Drury Lane Conference Center – Oakbrook Terrance, Ill.

The Illinois PHCC Expo is Illinois’ premier trade show for plumbing, heating and cooling contractors. Representatives from Metropolitan’s commercial and mechanical divisions will be exhibiting the many new products and capabilities they have added since last year at booths 96, 97 and 98. Also present will be our Ion|StormPro® display trailer, complete with many new additions made to the product line.

SMACNA Chicago Trade Show
Monday, March 26
1:00 pm to 9:00 pm
Drury Lane Conference Center – Oakbrook Terrance, Ill.

The SMACNA Chicago Trade Show will feature the finest vendors in the industrial, commercial, institutional and residential markets specializing in heating, ventilating and air conditioning, manufacturing, energy management and maintenance, and more. Metropolitan recently made a concentrated effort to expand its mechanical heating expertise and our new skills will be presented at booths 85, 86 and 87.

For more information regarding these shows, please contact a Metropolitan representative at 800-323-1665 or sales@metropolitanind.com.

One of the primary ways Metropolitan has been able to raise Navien brand awareness is by hosting educational seminars.

 
As official representatives of Navien America in the territories of Illinois, northwest Indiana and eastern Missouri, Metropolitan supports a network of distributors within the Midwest in providing homeowners with the highest-quality tankless water heating equipment and related accessories.

Our wholesale division was recently awarded the distinction of selling over $2 million in Navien inventory, joining Navien’s exclusive “$2 Million Club.”

Metropolitan’s Navien wholesale manager Mark Brickey attributed a number of factors to Metropolitan’s success, the first being the quality of Navien heaters and combination units.

“One of the reasons our sales team has had such success with Navien is because Navien sets the standard in the tankless industry,” said Brickey.  “Navien heaters and combination units are efficient and perform very well for end users, but what’s equally important is that Navien is committed to enhancing already great products whenever possible.”

One way in which Navien has improved its strong product base was the creation of the new NPE series heater.  With features such as the ability to utilize half-inch existing gas lines and two-inch venting, and the inclusion of an operator interface to view set points and essential system information, and run diagnostics, Navien’s new NPE series heater has garnered much popularity.

“Navien displayed its commitment to persistent improvement when it introduced the NPE series heater,” said Brickey.  “This new heater incorporates smart technology and comes with an abundance of new features our sales personnel can promote.  It truly is a one-of-a-kind heater.”

Brickey said Metropolitan’s sales staff has made a concentrated effort to endorse Navien units and said the training conducted both at and away from Metropolitan has significantly raised both interest in the brand and overall sales.

“Not only will we routinely hold trainings on Navien models to operators and installers at our facility, we have our sales staff conducting additional trainings behind the scenes,” said Brickey.  “Many times we’ll hold trainings after work hours at supply houses and contractor’s facilities.  We’ve made a great effort to not only raise brand awareness, but ensure operators are familiar with units, are comfortable working with them and can adequately conduct service.”

Overall Brickey credits the hard work of Metropolitan’s sales staff as the chief reason why its partnership with Navien has achieved positive results.

“Selling over $2 million in inventory is quite a feat for our sales staff and we were able to achieve this largely due to their hard work,” said Brickey.  “Particularly during this uncertain economic climate, it took a great deal of commitment and creativity on our end to create business, but we developed and executed the right strategy, and made it happen.”

For more information regarding Navien products, please contact a Metropolitan representative at 815-886-9200 or sales@metropoitanind.com.

Metropolitan’s new Metro-Tech II controller.

 
At Metropolitan Industries, customizing solutions to meet the needs and specifications of customers is one of the cornerstones to the way we conduct business.

We believe user-friendly equipment developed to meet precise requirements and suit specific applications leads to the most efficient system operation and results in optimum customer satisfaction.

Adhering to this philosophy, we recently released two new lines of innovative, menu-configurable water booster pump and boiler system controllers, designed to fit specific programs and provide operators with ease of use.

Our “Metro-Tech II” booster pump controller can be customized to meet any requirements, and provides users with the ability to change set and command points, view real-time operating conditions and alarms, and use integrated help screen through the controller’s color touch screen operator interface.

Our “ThermoTech™” cascading boiler controller also features a user-friendly, color touch screen operator interface, and provides users with the ability to set lead boilers, monitor return temperatures and flow meter inputs, track system modulation percentage, set stage delays and more. This controller can be customized to control from one and up to eight boilers.

For a more details regarding each of our new controllers, please visit The Chief Engineer, which recently profiled the Metro-Tech II and ThermoTech™ extensively in its March issue.

Construction of our warehouse doors took place in January.

 
In an effort to further accommodate our customers and streamline the production process of projects, Metropolitan recently completed the major renovations of two warehouse doors.

“Door five, located on the far south side of our warehouse, has been widened from 14 feet wide to 20 feet wide, and door two, located on the north side, has been widened from 12 feet wide to 18 feet wide,” said Metropolitan fabrication department manager Bob Svoboda. “Our belief is that this expansion will not only allow us to ship systems more efficiency, but also allow us to house and ship larger equipment than in the past.”

Svoboda said the extension of both doors will most significantly impact the production of housed structures, allowing Metropolitan’s fabrication and electrical departments to complete housed systems more proficiently.

“Typically, housed systems begin the production process near door five in the fabrication department, are then moved near door two for electrical wiring, and are moved back to door five for shipment,” said Svoboda. “With the expansion of these doors, housed systems can be shipped directly out of door two, eliminating some of the time associated with shipment.”

Svoboda said the expansions have already paid Metropolitan positive dividends, as we recently welcomed the largest housed system in our 55-year history into production.

The expansion of our warehouse doors will allow us to develop and ship larger systems than ever before.

 
“Had we not expanded our warehouse doors, we would have faced several complex challenges in developing and shipping this new housed system,” said Svoboda.  “We’re a customer-first company and when we need to adapt, we are committed to making the appropriate alterations to our facility to serve our customers.  The changes made to our warehouse doors will significantly help with the production of this system and with projects in the future.”

For more information regarding our prefabricated housed systems, including pump, boiler and mechanical rooms, please visit www.metropolitanind.com or contact sales@metropolitanind.com.

An important commitment to the many markets we serve is sharing our knowledge and expertise with water and wastewater operators, plumbers, design engineers, city officials and more to best prepare industry professionals for everyday field work.

After welcoming hundreds of guests to our facility for our number of training programs in 2012, we are pleased to announce our 2013 schedule, complete with many new courses designed to introduce and inform attendees of the latest industry technologies, has been finalized.

Six courses from last year are revitalized with new presentations and demonstrations, while three entirely new classes have been added to the schedule.

Two of our new classes pertain to commercial-plumbing applications, the first focusing strictly on the application, maintenance, operation and repair of pressure reducing valves.

“Our ‘A Discussion of Pressure Reducing Valves’ class offers participants the opportunity to operate, design and repair pressure reducing valves in a safe and monitored atmosphere, which makes the class truly uncommon,” said course instructor and Metropolitan commercial sales manager Mike Ponx. “I’m not aware of other venues that can facilitate moving water, setting pressures, and the full tear down of this type of equipment all in a supervised fashion.”

A second new commercial-plumbing offering details specific methods of improving the energy efficiency of various pumping systems in commercial buildings.  Entitled “Energy Saving Strategies,” the program is intended to provide participants from facilities managers, contractors, owners and maintenance personnel an in-depth look at strategies to improve the overall efficiency of commercial pumping systems.

“With the technology at our disposal today, more and more techniques of improving the operation and energy efficiency of commercial systems are emerging,” said course instructor and Metropolitan commercial salesperson Kent Swanson.  “As premier manufacturers of commercial pumping systems, we are at the forefront of these technologies, tirelessly bringing our business partners new ways to improve the performance of their equipment.”

Our final new seminar relates to two topics Metropolitan has recently acquired extensive familiarity in.  The recent expansion of our commercial division has allowed us to supply and manufacture innovative mechanical equipment, and we’re proud to share this knowledge in our “Basics of Steam/Heat Transfer Applications” course.

“This course will primarily serve as an introduction to concepts in steam and heat transfer applications, covering everything from theory to operation,” said instructor and Metropolitan mechanical salesperson Mike Temes.  “Though exploratory in nature, it has the potential to turn into a very lively course simply due to the surrounding capabilities Metropolitan has.  We’re hoping these new topics will appeal to guests and bring new visitors to Metropolitan who may be unaware of our training services.”

As has always been the case with our training seminars, many satisfy state requirements for continuing education.  All courses are free of charge and lunch is always provided.

Future dates will be arranged, so please check in at www.ilceu.com for updated schedules.   All seminars are conducted at our facility in Romeoville, Ill.

For more information regarding seminars that qualify for continuing education, registration, times and how we can bring courses to your facility, please visit www.ilceu.com.

Our recent Navien NPE series training, which took place in December of last year, was received very positively.

 
Due to the overwhelmingly positive reception from our most recent Navien NPE series training, Metropolitan is excited to announce two future trainings to take place in February.

The first will take place at the St. Louis, Mo. branch of Connor Co. on Tuesday, Feb. 5. The training will be held from 2:00 p.m. to 6:00 p.m. at the branch location of 2374 Grissom Dr. Those interested in attending can contact Brandon Storm at 314-994-9799 to register.

The second will take place at Metropolitan Industries, Inc. on Thursday, Feb. 7. The training will begin promptly at 8:30 a.m. and conclude at 12:30 p.m. Metropolitan Industries is located at 37 Forestwood Dr. in Romeoville, Ill. Those interested in attending can visit www.ilceu.com to register.

Navien’s new NPE series heaters contain a number of new features and benefits, including a front panel command center with user interface, and the ability to utilize two-inch PVC venting and existing one-half-inch gas lines.

Space is limited, so please register in advance to learn more about this exciting new model.

Metropolitan supplied the municipality with a prefabricated housed system, including all associated pumps, piping and controls.

 
At Metropolitan Industries, our reach extends far beyond the Midwest. Our national sales team can supply customized pumping solutions shipped fully assembled for ease of installation. Over the years, we have provided domestic water booster systems, complete sump and sewage lift station packages and many more of our cataloged products to customers not just nationwide, but around the globe as well.

Our ability to deliver solutions to pumping challenges to all is demonstrated by the work done in the city of Marianna, Fla. Working with an existing pump system over 25 years old and in need of more pumping capacity, the city turned to the team of Blankenship Contracting, Inc., Pump and Process Equipment Company and Metropolitan Industries to provide a custom solution.

“The customer required a custom pump system package that would not only provide more flow to account for increased demand, but could also supply the fire flow if needed,” said Pump and Process Equipment’s Eric McGee. “To meet these specifications, we designed a three-pump system housed in a prefabricated steel building, all of which was supplied by Metropolitan.”

Each of the three pumps is designed to provide a flow of 750 GPM at 134 feet of TDH. Each pump motor is rated at 40 HP and performs at 3500 RPM at 76.6 percent efficiency.

The prefabricated galvanized steel building includes a 72-inch by 84-inch double door entry to the pump room and a “pebblestone” exterior finish for an attractive design solution.

The system will primarily serve a nearby health department and surrounding residents.

McGee said initial design discussions planned to incorporate a two-pump system, but after discussing options with Metropolitan salesperson Mike Tierney, the group came to a resolution to implement a three-pump system housed in a prefabricated structure.

“We originally planned to build a system with two large pumps, but instead, designed a system with three smaller pumps for a variety of reasons, one of them being energy-efficient operation,” said McGee. “With three pumps, we can run just one at low loads. If the demand increases at any time, the other pump(s) will kick into gear.”

McGee said one of the primary challenges faced was meeting a short lead time, which forced the team of Metropolitan, Pump and Process and Blankenship to complete the project in a quick and well-organized fashion.

“From start to finish, we only had around 8 to 10 weeks to complete the project,” said McGee. “It required a team effort from everyone involved and thanks to a well-executed plan, we were able to deliver the system to our customer on time.”

In order to ensure water operators were familiar with the new system, Metropolitan sent service technicians to the job site to conduct training.

“Training provides a good start for customers when becoming acclimated to a new system,” said McGee. “Knowing the major do’s and don’ts of a system can make for a smooth transition.”

McGee said working with a single source provider was critical to Pump and Process and a chief reason why Metropolitan was involved with the project.

“We wanted to partner with an organization that had all capabilities under one roof,” said McGee. “Metropolitan was able to provide manufacturing, controls, pumps and service. We were comfortable having to contact one sole organization if any issues arose.”

Since installation, McGee said the system has run “flawlessly” and described his overall experience of working with Metropolitan as positive.

“When working with Metropolitan, the word professionalism comes to mind,” said McGee. “We’ve worked with many businesses in the water and wastewater industries and appreciate the way Metropolitan communicates with its customers. The ‘no excuses’ approach they take to developing a system ensures quality is of supreme concern.”

For more information, please contact Metropolitan’s Mike Tierney at 800-323-1665 or sales@metropolitanind.com.

From left to right: DRF’s Scott Schnurr, Dominican University president Donna M. Carroll, and Nicor Gas president Beth Reese pose with the check Dominican University received through participating in the Nicor Gas Business Custom Incentive Program.

 
Through participating in the Nicor Gas Energy Efficiency Program, Dominican University was given the opportunity to upgrade existing heating equipment in its facilities, and save significantly in the process.

Developed to offer large businesses the opportunities to improve the energy efficiency of their facilities and save money, Dominican participated in the Nicor Gas Business Custom Incentive Program, which provides financial incentives for the installation of high-efficiency equipment not covered by the Nicor Gas Energy Efficiency Program’s Business Rebate Program. Through the program, businesses can receive up to $500,000 on their gas-savings projects per year.

According to Nicor, incentives are paid based on energy savings beyond baseline energy performances, such as state or federal codes and standards, industry-accepted performance standards, or other baseline energy performance standards as determined by the Nicor Business Custom Incentive Program.

The current cycle of the program is available for projects installed from June 1, 2012 through May 31, 2014, or until funds are depleted. Per Nicor requirements, post-installation inspections must be conducted and final applications must be submitted to the program by June 30, 2014. Businesses seeking to participate in the program must attain pre-approval in order to become eligible.

Detailed information regarding the program can be found in the Nicor Gas Business Custom Incentive Program handbook.

Dominican began working with DRF Trusted Property Solutions of Plainfield, Ill. in 2010 when DRF observed a large amount of gas being used during the summer months. After developing an initial project design that did not qualify for the Nicor Gas Business Custom Incentive Program, nor provide the desired financial benefits, DRF turned to Metropolitan Industries to help provide a custom solution.

The final project design included three individual point of use systems customized to handle specified heating demands.

Metropolitan HVAC salesperson Matt Brickey praised the program’s ability to assist businesses seeking to conduct retro-fit upgrades progress in an expedited fashion.

“In the case of Dominican University, this program not only helped cover some of the costs of the custom equipment and installation, the gas savings realized will continue to give back for years to come,” said Brickey. “Because of the financial benefits the rebate program offers, it can help prospective customers who may be facing budget constraints get projects moving in the right direction.”

For complete information regarding this project, please visit The Chief Engineer, which profiled the project in its December issue.

For information regarding our custom HVAC solutions and how you may be eligible to save through the Nicor Gas Business Custom Incentive Program, please contact a Metropolitan representative at (800) 323-1665 or visit www.metropolitanind.com.

To supply the desired cooling water to the facility, Metropolitan provided a customized triplex booster pump system.

 
One of the primary aspects of our company that makes Metropolitan Industries an ideal partner for business is our dedicated design and service staffs. No matter how complex your job may be, Metropolitan is determined to meet your needs and requirements. At times we are faced with projects in which strict specifications must be followed. We take customer specifications with great seriousness and can customize projects to meet important guidelines.

A premier example of our ability to provide customized solutions can be illustrated by the work done at a large municipal water treatment facility that conducts o-zone generation.

Metropolitan was first contacted by Symbiont Science, Engineering & Construction, Inc. in 2011 to provide a Metro-Varipac triplex booster pump system to supply cooling water to the facility. The existing pressure boosting system the customer had been using ran at a constant speed. Metropolitan implemented the triplex system with a design point of 300 GPM at 185.5 feet of TDH to become the primary system. The system runs at a maximum of 425 GPM at 120 feet of TDH, and each pump is rated at a minimum of 25 HP. A 200 PSI rated hydropnuematic pressure tank was also included.

Project specifications called for custom programming.

“One of the unique aspects of Metropolitan is our ability to provide both standard and custom programmed controls,” said Metropolitan salesperson Tim Laskowski. “This particular project was very job and system specific, but we were able to supply everything the customer needed.”

Metropolitan was also able to provide the customer with a specialized startup and certified test of the system on-site. A flow meter and all certified pressure gauges were included to meet project specifications and Hydraulic Institute standards.

Metropolitan’s Paul Larson, P.E., said stainless steel features were added to the system to provide corrosion resistance.

“We integrated a stainless steel skid, stainless steel control panel and galvanized piping which will prevent corrosion, and thus extend the life of the system,” said Larson.

Stainless steel features were added as a customized element to the system.

 
The system also came complete with variable frequency drives, eliminating the constant speed control the previous system had utilized. Variable speed controls can save customers thousands in energy savings and eliminate the need for pressure reducing valves.

“Metropolitan is completely dedicated to providing energy efficient products to our customers,” said Laskowski. “We can design systems to pump at the lowest possible pressure, which saves in energy costs and can even pay for an entire system with savings accumulated over time.”

Project engineer Pat Carnahan of Symbiont said Metropolitan’s ability to test a system on-site was a nice change of pace when working on this type of project.

“It was a welcomed experienced to work with a vendor with skilled people who can think on their feet,” said Carnahan. “The test went very well and we were able to verify the majority of the control features during one day of testing.”

Carnahan also noted that Symbiont was pleased to find that the pump skid was constructed and delivered to their precise layout and control requirements.

“In the past we’ve purchased pump skid systems and our specified control sequences were not provided,” said Carnahan. “A level of comfort was established with Metropolitan on this project because the system supplied matched our specifications and expectations.”

Part of Metropolitan’s commitment to customer service is sharing our expertise with customers, operators and engineers. Metropolitan provided on-site training for the customer to ensure the transition from the previous system to the new system was proficient and easy.

Overall, Laskowski said the project demonstrates Metropolitan’s flexibility and dedication to providing customers with projects that match precise requirements.

“This job illustrates how we’re able to handle whatever comes at us and get the job done correctly,” said Laskowski. “We take the specifications seriously and we’re very careful in supplying exactly what the customer has asked for at a very competitive price.”

For more information, please contact Tim Laskowski at 800-323-1665, ext. 255 or sales@metropolitanind.com.

Metropolitan commercial sales manager Mike Ponx instructs attendees during our recent pressure reducing valves training seminar.

 
In an effort to educate our business partners on the workings of pressure reducing valves, we recently hosted a training seminar on the subject, with our state-of-the-art test lab playing a decisive role in its success.

Instructed by Metropolitan commercial sales manager Mike Ponx and long-time service technician Mike Ihnat, the course was designed to provide entry-level plumbers with a basic understanding of pressure reducing valves.

“At times, contactors will request training classes on pressure reducing valves for members of their organization that are unfamiliar with the function, design and maintenance of the equipment,” said Ponx. “This class provides significant benefits for those who attend, primarily because they’re able to operate on pressure reducing valves in our test lab.”

Ponx said courses typically being with a PowerPoint presentation in a classroom-type setting. The presentation covers the sizing, installation, positioning, operation, features and benefits of pressure reducing valves. The second portion of the course takes place in our test lab, where guests are given the opportunity to service pressure reducing valves in a controlled environment.

“The fact we can offer attendees the opportunity to operate, design and repair pressure reducing valves in a safe and monitored atmosphere makes the class truly uncommon,” said Ponx. “I’m not aware of too many other venues that can facilitate moving water, setting pressures, and handling the full tear down of this type of equipment all in a supervised fashion.”

Ponx said the setting ultimately creates a sense of comfort for participants, and that the hands-on aspect of the class best prepares them for field work.

“When you’re under pressure in the field, your thought process can get lost quickly if you aren’t very familiar with pressure reducing valves,” said Ponx. “We try to keep the course setting relaxed and strictly educational. This gives guests the opportunity to work at their own pace and ask any questions when complications occur.”

Led by Metropolitan service technician Mike Ihnat, guests were given the ability to operate on pressure reducing valves in our test lab.

 
Ponx said the end goal of the course is to ensure all guests leave with a better understanding of pressure reducing valves and are prepared to develop solutions for the challenges associated with the equipment in everyday field work.

“At the end of the day we’re trying to establish a level of familiarity between attendees and the pressure reducing valves they will be servicing,” said Ponx. “The setup we have in our test lab is absolutely critical, simply because this is where knowledge and comfort are truly attained. We keep these courses limited to around 10 to 12 guests, which gives everyone the worthwhile experience of working on equipment.”

Ponx said he recommends all attendees return for future sessions in order to retain all topics discussed throughout the course.

As pumping systems leaders, we are committed to providing training to industry professionals. We are more than happy to schedule training for pressure reducing valves and a variety of topics for all engineers, water/wastewater operators and others interested.

For more information regarding this course or to inquire about other training programs Metropolitan offers, please contact 800-323-1665 or sales@metropolitanind.com. For additional courses we provide, please visit www.ilceu.com.

Entering a confined space for system repair is a dangerous procedure, particularly due to accumulated gases that may be hazardous. At Metropolitan, we can provide solutions to decrease the frequency of entering a confined space.

 
Now more than ever, municipalities are addressing the dangers of below ground pump stations to protect both entrants into confined spaces and the investment of systems themselves. The United States Department of Labor requires a permit for those seeking to enter confined spaces for system repair, accompanied by rigorous guidelines those involved with the entry must follow.

Moreover, flooding of below ground pump systems can lead to catastrophic damage of the systems themselves, often costing municipalities a great deal for repair or even replacement, and can lead to an emergency service call.

Metropolitan Industries recently renovated three below ground pump stations, giving each customer the ability to interface with the controls without entering the confined space. Another advantage of “above grade controls” is the avoidance of control system damage caused by a vault flood. Potential future projects such as submersible pump retro-fit into the existing wet well would be the next appropriate step to completely eliminate confined space entry.

City of Calumet City, Ill.

The City of Calumet City, Ill. recently came to Metropolitan for an emergency rehabilitation project following the flooding of a below ground water pump station.

“Metropolitan suspects the reservoir fill valve stuck open causing an overflow condition, thus filling the below ground pump station with water,” said Metropolitan salesperson Keith Girup. “The existing booster station was constructed many years ago when below ground systems were common. Metropolitan was able to repair and replace equipment quickly, and in the process improve the operation and energy-efficiency of the station by implementing variable frequency drives for constant pressure control.”

Another new piece of equipment included in the upgrade was a low-flow shutdown bladder storage tank.

“The new bladder tank supports the water system leak loads during low flow periods of time,” Girup said.

The system was also integrated into a city-wide SCADA system for enhanced monitoring and alarm notification. A flood switch was added to the pump room to ensure notification is provided in the event of a flood since the pumps remain in the below ground vault and are subjected to the hazards associated with such a location.

The primary advantages of the system upgrades are the reduced frequency of entering a confined space and overall protection of the equipment.

South Palos Sanitary District

Metropolitan recently completed a similar project for the South Palos Sanitary District.

“In this project, the customer decided to keep their drywell pumps below ground, but implemented above grade controls into a new prefabricated concrete building with an exposed aggregate finish,” said Girup. “The prefabricated building contains the controls, generator and a temperature control device, essentially eliminating the need to enter below ground in order to interface with the controls.”

Girup said that because the customer has decided to keep the drywell pumps below ground, it will still be necessary to go below ground to maintain the pumps. However, the frequency of confined space entry has decreased dramatically with the implementation of above ground controls.

“Safety and common sense are the reasons for upgrading to above grade systems,” said Girup. “Going into a confined space requires special procedures with two individuals, safety harnesses and gas monitoring equipment at a minimum to ensure safety. If precautions are not followed, consequences could be fatal.”

Village of Burr Ridge, Ill.

The Village of Burr Ridge, Ill. also called upon Metropolitan for a below ground lift station upgrade.

Metropolitan implemented an above ground traffic box for this particular project, placing all controls and electrical distribution equipment above ground.

“The customer has intentions to replace the existing pumps with submersible pumps, however, this project was phase one, which included the above grade controls to significantly reduce the amount of times they would need to go below ground,” said Girup. “In the previous configuration, the customer was going down into the pit quite often to monitor controls, but with our upgrade, they no longer have to do so.”

Conclusion

With each upgrade, the customer not only gained capital investment protection by implementing above grade control systems to protect controls from potential below ground flooding, they also improved safety conditions by reducing the frequency of confined space entry.

Entering a confined space is a major process with strict guidelines which, if not followed, can produce fatal consequences. Metropolitan can provide both investment protection and overall safety with above ground system retro-fit solutions.

For more information, please contact Keith Girup at 800-323-1665, ext. 264 or sales@metropolitanind.com.

MetroMail™ is an economical option for customers seeking basic monitoring equipment.

 
Metropolitan Industries recently completed a stand-alone version of MetroMail™, the company’s very own “alarm dialing” system.

When implemented to monitor any pump or electrical system, MetroMail™ has the capability to send email alerts to notify users of equipment status or problems, and can assist customers in avoiding potential disaster when troubles arise.

“Users can configure MetroMail™ to send an email at an interval completely configurable by users out through the device’s Ethernet jack and through the Internet,” said Metropolitan Industries software engineer Joe Burza. “In other words, if you have your laptop on you or you’re carrying a device with email capability, you can receive a message that a problem with your pump has occurred instead of waiting for the water to back up and start flooding.”

MetroMail™ features eight optically isolated dry inputs accepting 10 to 30 volts of AC or DC power. The unit’s status light tells users whether the unit has power, is properly configured and is sending emails, whereas network lights indicate LAN activity and connectivity. Its onboard web server allows for the configuration of messages, addresses and other settings via any web browser.

A MetroMail™ unit was recently installed at a jail located in northwest Indiana. Metropolitan was contacted by Keough Mechanical for the project, who wished to upgrade the existing lift station due to clogged pumps reported by detention center officials.

The lift station in need of attention was responsible for all of the sanitary waste from the facility. Detained members knew of its function and would routinely disrupt the operation of the pump system by flushing items that would typically be disposed of in a garbage can.

After Metropolitan salesperson Keith Girup made a field visit with the owner and contractor to discuss the problem with the operators and evaluate the obstacles associated with the retrofit upgrade, it was determined that an impeller change would be the most suitable solution to significantly reduce and potentially eliminate the clogging issues.

While Metropolitan was helping solve the mechanical issues the facility faced, new controls with email notification were also proposed.

In order to provide this notification, Metropolitan included MetroMail™, which contacts personnel by email in the event of a lift station alarm condition. An operator interface with Internet connectivity via a cellular modem was also included.

These control features allow for quick response during an alarm condition with 24-hour supervisory ability.

MetroMail™ offers customers a cost-effective option for basic monitoring equipment when more expensive options are not practical. Its convenient size also gives customers the flexibility to monitor equipment when space is a concern.

For more information regarding MetroMail™, please contact Keith Girup at 800-323-1665, ext. 264 or sales@metropolitanind.com.

With the help of Metropolitan Industries, the Village of Romeoville, Ill. implemented major upgrades to its O’Hara Woods lift station.

 
Metropolitan Industries has extensive experience in the implementation and upgrade of lift stations. For over 50 years, we have provided components and even complete prefabricated lift stations as single-source systems that include all equipment required for operation.

Services such as design assistance and a 24/7 service department help ensure systems are engineered to meet the owner’s specifications in a variety of sizes. For the complete system, a station can be combined with a “MetroFab” custom-designed, prefabricated housed system. Housed systems are factory pre-piped and wired, and are shipped fully assembled for easy installation. Like a prefabricated lift station, these systems can also be customized to meet any specifications you require.

A recent example of a customer’s desire for a significant upgrade to their existing facilities is the work completed at the Romeoville, Ill. O’Hara Woods lift station.

Working with an existing duplex sanitary lift station, the village decided to make many custom upgrades to the site.

“The existing 20-year-old duplex system was still functioning fine, but an upgrade was needed due to village growth and the planning for future development,” said Metropolitan salesperson Keith Girup. “To keep up with the demand, the station was upgraded to a triplex system by utilizing the existing duplex wet well and a parallel existing manhole for a simplex wet well to house the three new pumps. We also supplied three precast concrete enclosures which, when installed on the concrete pad, were made to look like one common building. The three separate rooms make up the building, and house the new lift station controls, standby generator and chemical dosing system all under a common 28-foot by 28-foot roof.”

The previous configuration did not feature enough pumping capacity to keep up with the station’s increased demand.

 
In total, the system now has three eight-inch submersible, non-clog, explosion-proof sewage pumps each with a capacity of 2,084 GPM at 99 feet of TDH. Each pump motor is rated at 125 HP, 1750 RPM, 60 Hz, 480 volt, three-phase.

Control system upgrades were made to replace obsolete equipment not capable of operating the new horsepower and new quantity of pumps. In addition, the prefabricated concrete buildings gave the customer a more secure and attractive solution. Metropolitan supplied the three prefabricated buildings and provided a simulated “Ashlar Stone” finish as an attractive exterior design. Inside walls are painted concrete and the owner chose an aesthetically pleasing metal roof to complete the buildings.

In addition to housing the new controls, another primary benefit of the lift station upgrade was the addition of new variable frequency drives.

“All pumps are variable speed meaning they will speed up or slow down to match the influent rate,” said Girup. “This type of application only uses electrical consumption as needed, thus saving energy.”

Another upgrade included in-place standby power.

“When power loss would occur in the previous configuration, the customer needed to mobilize personnel and a portable generator unit to support the remote lift station,” said Girup. “In the new configuration, the permanent standby 400 kW, diesel-fueled generator will support all three pumps during a power failure automatically.”

An additional advantage of including a permanent generator is phase protection. If any phase of power is dropped at any time, the generator’s automatic transfer switch will recognize the power failure and supply clean power from the generator to the pumps until the full power supply is regained. Because pump motors may burn up during dropped phases, or brown outs, the permanent generator provides further investment protection to the lift station.

In addition to the standby generator, a chemical dosing system was supplied to replace the existing system. The new chemical system provides accurate feeding of treatment chemicals via a dosing pump that paces the total sewage discharge flow rate and reduces the frequency of chemical replenishment by increasing the volume of the storage tank, thus reducing fees associated with chemical delivery. The implementation of a chemical tank was deemed necessary per customer specifications. The chemical is used for odor control and to start the biological process of the sewage, assisting in the treatment process.

Surveillance cameras and anti-graffiti coating were also part of the new control and SCADA system upgrades.

New equipment was needed to monitor flow and tie in the third pump. A polyurea-coated, prefabricated meter and valve vault with measurements of 16 feet in length and 8 feet in diameter was also included to connect the new simplex pump system with the existing duplex system and also includes flood-proof hatches. Flood-proof hatches were provided due to the fact the lift station is located directly next to a large pond. The hatch elevations now all exceed the 100-year flood event elevation, however, if the customer does encounter significant rainfall, the hatches are water tight and will not allow water into the wet well, valve vault or meter vault.

A number of accommodations were made for the customer while upgrades were taking place, the most important being the need to keep the station functioning during construction.

Among the many upgrades provided to the O’Hara Woods lift station was the addition of new controls.

 
“A great deal of planning was done ahead of time to make the field installation, start-up and integration into the SCADA system seamless,” said Girup. “All of the buildings were pre-wired and all controls were programmed before arrival on-site, making the transition as efficient as possible. The prefabricated components of the project allowed the contractor to save on bypass pumping due to the expedited nature of prefabricated system installation.”

An existing control enclosure also needed to be moved to a strategic location for installation to occur simultaneously with the existing lift station still in service. The existing control box was located close to where the prefabricated buildings would be installed. The contractor and supplier made sure the entire transplant of controls remained reliable and the customer did not miss a beat in regards to system operation, data acquisition and potential alarm notification.

“The prefabricated buildings were chosen for a variety of reasons, including cost and security,” said Girup. “Alternatives such as a large steel traffic box enclosure would have been nearly as costly, but would not have provided the same level of security that the buildings provide.”

The project reflects Metropolitan’s commitment and ability to meet the customer’s needs with ease of installation and peace of mind while making a smooth transition to an upgraded system.

A large upgrade project such as the Romeoville O’Hara Woods job is a large undertaking for all involved not only financially, but in regards to keeping the existing system in operation while upgrades are taking place. Metropolitan’s expertise, customer service and fabrication abilities helped to ensure the best possible transition from the old existing system to a first class facility.

The new improvements include a total of three sewage pumps, and provide housing along with surveillance cameras and anti-graffiti coating for further protection.

 
Project engineer, Jon Zabrocki, P.E., of Robinson Engineering, LTD praised Metropolitan’s ability to supply and support all of the equipment needed for this installation.

“When you’re dealing with a project as complex as this, it’s comforting to know you’re working with a single-source provider who is willing to take on the responsibility of supplying and supporting anything you might need throughout the job,” said Zabrocki. “The end result is that the new system has exceeded our expectations and it shows what can be done when owner, contractor, supplier and engineer are all on the same page.”

Village of Romeoville, Ill. wastewater superintendent Bob Stoppenbach credited the village’s confidence in all parties involved for establishing a strong level of comfort throughout the entire rehabilitation process.

“We’ve worked with Metropolitan on many projects and knew they were very capable of delivering the quality of upgrades that we required,” said Stoppenbach. “We were very pleased at the project’s conclusion and look forward to working with them again in the future.”

For more information, please contact Keith Girup at 800-323-1665 or sales@metropolitanind.com.

Metropolitan will host training on the new series in early December.

As an official representative of Navien America, Metropolitan is at the forefront of innovations in tankless water heating technology.

For years we’ve supplied customers with energy-efficient Navien tankless water heaters and combination units designed to provide the premier hot water experience.

Making the Navien brand even more exciting is the introduction of the new NPE premium condensing gas tankless water heater, with new and advanced features making the unit truly the best choice in tankless.

Many of the new features are designed to reduce installation cost and time, make operation of units simple and intuitive, and provide a high-performance.

New heaters utilize existing one-half-inch gas lines, which Metropolitan salesperson Mark Brickey said makes installation of tankless water heaters easier than ever before.

“The NPE is the first tankless model that can utilize a home’s one-half-inch gas line for lengths up to 24 feet,” said Brickey. “Many tankless alternatives do not have this capability which may require the installation of any entirely new gas line. With the NPE series, units employ existing gas lines, saving customers time and cost.”

In addition to utilizing existing gas lines, NPE units come with two-inch PVC venting, a cost-effective option for installation.

“Because Navien units exhaust low gas temperatures, customers can use PVC, CPVC and Polypropylene vent systems, which can significantly reduce costs associated with installation,” said Brickey. “Systems can use two-inch venting for up to 60 feet, which often allows those installing units to apply without constructing additional holes.”

For ease of usability, a front panel command center with user-interface makes units easy to set, run diagnostics and view essential system information.

Lastly, intelligent preheating technology recognizes hot water usage patterns, adapting to your daily trends to provide hot water when needed.

“This intelligent sensing technology recognizes when users are likely to use hot water and will automatically heat water and deliver to your fixtures without any complex programming involved,” Brickey said.

As has always been the case with Navien heaters, an industry best warranty package is included with the new series. In residential applications, labor is backed for one-year, parts for five years and heat exchanger for 15 years. In commercial applications, labor is backed for one-year, parts for three years and heat exchanger for five years.

As industry leaders, we’re committed to providing training for installers to ultimately ensure end users get the most out of equipment. To show this commitment, we’ll be hosting training on December 11, 2012 for all interested in learning how to both service and install NPE units.

For more information regarding the Navien NPE series, please contact a Metropolitan representative at 800-323-1665 or sales@metropolitanind.com. To register for training, please visit www.ilceu.com.

Metropolitan customers now have access to a new line of boilers, water heaters and combination units.

 
Metropolitan Industries, Inc. is officially a representative of LAARS® Heating Systems Company, giving us a new line of residential and commercial boilers, water heaters and combination units.

LAARS® regional manager Van Culberson has held training at Metropolitan on separate occasions over the past month to ensure Metropolitan’s sales and service divisions are fully equipped with the information needed to maximize the partnership and best serve customers.

“This partnership will give Metropolitan access to our full line of residential and commercial products, which can be used in a variety of ways,” said Culberson. “We have units sized from 50,000 BTUs all the way up to 2.4 million BTUs that can be used in residential, commercial and industrial applications.”

Residential products include boilers, water heaters and combination heaters for indoor use.

“Some of our offerings on the residential side include our Mini-Therm gas-fired hydronic boiler and Endurance combination boiler, which are both 85 percent AFUE rated products,” said Culberson. “Another exciting item is our NeoTherm water heater, which is 95 percent efficient in operation and sized for both residential and commercial uses.”

Products such as the 95 percent efficient NeoTherm are now available from Metropolitan.

 
Commercial products include an assortment of boilers and water heaters for indoor and outdoor uses.

Much like residential merchandise, commercial systems are energy-efficient and sized to meet a number of challenges.

Culberson said company structure, customer service and an array of products help LAARS® distinguish itself from others within the marketplace.

“Today, customers require instantaneous solutions and at LAARS®, we can provide them,” said Culberson. “We operate in a flat company structure which ultimately allows us to service customers in an adept and timely fashion.”

Much like Metropolitan, LAARS® employs a full service department for premier reliability when issues arise.

“Our customer service is as good as, or even better than, anyone else,” said Culberson. “Our technical support, both pre and post-sale, is outstanding and we have full-time service managers that assist customers in remedying problems whenever they arise.”

Lastly, its full range of products and diverse uses give LAARS® the ability to service many needs.

“With products that range from 82 percent to 95 percent efficient and sized from 50,000 to 2.4 million BTUs, we’re able to serve a large market of customers and fill a wide range of needs,” Culberson said.

In regards to the partnership with Metropolitan, Culberson cited our company structure and personnel as primary factors as to why the joint venture makes sense for LAARS®.

“We can now develop packaged systems thanks to Metropolitan’s manufacturing abilities, which is something we’ve never had access to in the Chicagoland market,” said Culberson. “Metropolitan’s in-house service department is very beneficial to us as well. Keeping all capabilities under one roof makes servicing equipment efficient.”

Metropolitan president John Kochan Jr. believes the LAARS® line brings further diversity to Metropolitan and can allow our company to move into new markets when combined with our manufacturing, fabrication, sales and service departments.

“At Metropolitan, we’ve never been afraid to expand our horizons and we believe representing the LAARS® line can introduce us to new markets of customers,” said Kochan Jr. “The LAARS® line, combined with our manufacturing, fabrication, sales and service divisions, make us a good match.”

For more information regarding the LAARS® line please visit www.laars.com or contact a Metropolitan representative at 800-323-1665 or sales@metropolitanind.com.

 
Working with a below ground pump system and faced with the dangers associated with entering a confined space, the village of Hoffman Estates, Ill. turned to the trio of Metropolitan Industries, Inc., of Romeoville, Ill., engineer Burns & McDonnell of Chicago, Ill. and Bolder Contractors, Inc. of Deerfield, Ill. to deliver an above ground solution.

“The previous system the village employed was a below ground pump station in which water operators needed to travel below ground, and service the station in a confined space,” said Metropolitan salesperson Ken Turnquist. “Our design team not only supplied three brand new submersible pumps, we also provided new controls consisting of a control panel with a color operator interface, SCADA panel, flow meter converter, submersible transducer and three 100 HP variable frequency drives. All controls were housed in a large stainless steel mounted traffic box.”

Each of the three pumps has a pumping capacity of 1900 GPM at 100 feet of TDH, and four-inch diameter solids handling capability. Each pump motor is rated at 100 HP, 1750 RPM, 460 volt, three-phase and 60 Hz.

A large stainless steel traffic box housing all controls and permanent standby generator were part of the supplied package.

 
Installation included the addition of a new valve vault and the reuse of an existing oval-shaped wet well to accept the new triplex system. A permanent standby 250 kW diesel-fueled generator was also included with the package. The generator’s 600 amp automatic transfer switch was placed in the traffic box.

Additional accessories included a 48-inch by 108-inch safety grate hatch for wet well access and a 36-inch by 64-inch safety grate hatch for valve vault access.

To ensure safety, access hatches were added for wet well and valve vault access.

 
Turnquist said the above ground traffic box provides the village with a safer method of interfacing with controls.

“Confined spaces present serious dangers for those who need go below ground to service pumps, interact with controls and more,” said Turnquist. “If safety precautions are not followed with great care, consequences could be serious. The implementation of above ground controls significantly reduces the frequency water operators will need to enter a confined space.”

An additional advantage of above ground controls is investment protection.

“Having controls below ground opens the door to potential system damage with the danger of vault floods,” said Turnquist. “Placing controls above ground eliminates the hazards associated with placing them below ground and ultimately improves the longevity of equipment.”

Turnquist said the variable frequency drives, which slow down or speed up pumps, can possibly offer a reduction in energy costs.

Controls were specified by engineer Burns & McDonnell and supplied by Metropolitan Industries. Metropolitan also supplied the traffic box complete with all controls, which was transported to the village in two parts and eventually combined into one onsite.

“Because of the nature of the specified controls, we needed to construct a double, back-to-back traffic box,” said Turnquist. “It was one of the largest Metropolitan has ever provided and Bolder Contractors, Inc. did a great job ensuring its delivery and installation was well-organized.”

For more information, please contact Ken Turnquist at 800-323-1665 or sales@metropolitanind.com.

Metropolitan Industries, Inc. is proud to announce the addition of a new line of pumps that provide versatility and cost-effective prices for customers.

Our new “X-Series” line includes four pumps that, when combined, can fill sump, effluent and sewage applications.

The X-33 is the line’s lone submersible sump pump with a motor that runs at 1/3 HP.  Features include a mechanical shaft seal, for premier reliability, and high impact thermoplastic construction.  Models are available with vertical switches.

The X-33 sump pump draws low amperage and is designed for residential uses.

 
“The X-33 is an entry-level 1/3 HP pump that draws low amperage, which can ultimately improve pump efficiency,” said Metropolitan salesperson Brian Drafke.  “If you’re looking for a light, inexpensive sump option, this is the pump for you.”

The X-40 and X-50 pumps are cast-iron sewage pumps designed for both residential and light commercial markets.

The X-40 has a pumping capacity of 90 GPM at 10 feet of TDH and pumps up to 26 feet of head.  It operates at 115 volts, 11 amps and has a 10 foot power cord.  The X-40 contains a 4/10 HP motor.

The X-50 has a pumping capacity of 110 GPM at 10 feet of TDH and pumps up to 27 feet of head.  It operates at 115 volts, 12 amps and has a 20 foot power cord.  The X-50 contains a ½ HP motor.

Both pumps have oil-filled and permanent split capacity motors to ensure reliability and a long life.  The pH range of each is between 5 and 9 and models contain a piggy-back Ion™ Digital Level Control float switch, the most reliable pump switch on the market.

Both the X-40 and X-50 pumps are designed for residential and light commercial markets.

 
“The X-40 and X-50 are both cost-competitive offerings tailored for residential and light commercial uses,” said Drafke.  “They both have the same overall appearance, impeller and cast iron design.”

The final pump of the X-Series is the X-ONE sewage pump.  In regards to its diversity, the X-ONE is the most flexible pump within the series, capable of handling any residential and light commercial application.

“What makes the X-ONE such an exciting product is the concept that it can be used in sump, effluent and sewage work,” said Drafke.  “It’s an economical choice for sewage installations, but due to its weight and carbon footprint, it’s also a viable option in residential applications.”

Rugged cast iron and thermoplastic, the X-ONE submersible sewage pump contains a vortex impeller and solids handling capability up to 2 inches.  Available with a 1/2 HP, 115 volt, single-phase motor, the X-ONE comes complete with a 10 foot power cord and an Ion™ Digital Level Control float switch.  The X-ONE also draws low amperage, which can improve the overall efficiency of pump operation.

Versatility is the X-ONE’s greatest strength, as it can be used in sump, effluent and sewage applications.

 
Drafke said the idea to develop the X-ONE was conceived after Metropolitan took notice of customer desires to shrink inventory.

“In regards to stocking, the X-ONE could theoretically replace many pumps on the shelf,” said Drafke.  “We developed it as an ‘all-in-one’ type of pump to fill just about any need in the residential and light commercial sector.  Thus far, reception has been very positive.”

For more information, please contact Brian Drafke at 800-323-1665 or sales@metropolitanind.com.  For information regarding our other residential products, please visit www.sumpro.com.  For information regarding our Ion|StormPro® line of durable, oil-filled, cast-iron sump and sewage pumps, please visit www.ionstormpro.com.

October 11, 2012 proved to be a very busy, but enjoyable day at Metropolitan Industries as we hosted our 55-year Anniversary Celebration and Open House. The turnout was fabulous as we welcomed guests to tour our 100,000-square-foot facility and see our capabilities firsthand.

Product displays and demonstrations from our residential, commercial, municipal and HVAC divisions were located in our warehouse. Outside, we were fortunate enough to have a beautiful sunny day as we hosted a bags tournament, and tours of our Ion|StormPro® display trailer and MetroGreen energy-independent facility.

Following our Open House, we welcomed the Will County Governmental League, as it held its 2012 meeting.

We’d like to thank everyone who attended our Open House and the Will County Governmental League for choosing our facility for its recent meeting.

Below are photos taken throughout the day.

We held three individual one-hour training seminars; the first being “Water Harvesting Innovations” from 11 am to 12 pm.

Our “Retro-Fitting Your SCADA with the Latest Technologies” seminar was our busiest, with nearly 40 people in attendance.

Metropolitan’s Mark Brickey instructs during his “Residential-Commercial Plumbing Applications” seminar.

In our warehouse, many of our municipal capabilities were on display.

Metropolitan salesperson David Miller explains the workings of our 2100-DC battery backup system to guests.

Many new products, including our Ion Endeavor and Ion Gateway, were on display as well.

Metropolitan’s Mike Schiazzano handled prize wheel duties throughout the event.

Our newly renovated test lab featured our patented load sharing technology and self-priming pump demos.

Outside, we were lucky enough to have nice weather.

Metropolitan’s Bob Bukowski gives a tour of our Ion|StormPro® display trailer.

A bags tournament began at 2:00 pm, with the winning team receiving prizes.

The Metropolitan-sponsored Budd Road Boyz Racing Team was also on hand for the event.

A number of Metropolitan-manufactured booster systems were  on display.

Food was served throughout the day.

Our busy day concluded with the Will County Governmental League hosting its 2012 meeting at our facility.

Mike Temes (left) and Neil Vogel (right) bring new offerings to Metropolitan’s HVAC division.

 
In an effort to expand the capabilities of its HVAC division, Metropolitan is proud to announce the additions of Mike Temes and Neil Vogel. Mike and Neil bring over 15 years of industry experience to Metropolitan and both are experts in the heat transfer and industrial process businesses.

Metropolitan’s HVAC division specializes in products including gas-condensing boilers, high-efficiency heating systems, gas-fired boilers, modular condensing hot water systems, high-efficiency air and dirt separators, hydronic pumps and more. The additions of Temes and Vogel will help expand our product line and further enhance our HVAC offerings.

“One of our goals is to simply enrich what is already a unique and diverse HVAC division at Metropolitan,” said Temes. “Neil and I bring expertise in the applications of steam, hot water and heat transfer to further expand the division’s capabilities.”

Many products including boiler feed packages, heat transfer packages, customized heat exchangers, condensate return units specifically for steam applications, prefabricated boiler skids (hot water and steam), pre-piped PRV stations and pre-piped control valve stations are now included in Metropolitan’s HVAC product index with the additions of Vogel and Temes.

Part of our commitment at Metropolitan is providing equipment to best suit our customer’s particular applications. Customer specifications are of paramount priority and the knowledge Temes and Vogel bring to Metropolitan further extends our commitment to providing products tailored to meet customer’s needs.

“One characteristic Metropolitan is known for is providing the most practical equipment to customers designed to fulfill their needs,” said Vogel. “Mike and I are fully committed to not just supplying customers with equipment, but breaking down the project, determining what the customer is trying to accomplish and getting the right piece of equipment for the applications, whether it’s in or outside of the box.”

Adding Vogel and Temes gives Metropolitan the design skill set it can now combine with its fabrication and manufacturing capabilities, truly making it a one stop shop for your HVAC needs.

“The design experience Neil and Mike bring to our company is the perfect complement to our manufacturing and fabrication abilities,” said Metropolitan Industries President John Kochan Jr. “We’ve always prided ourselves on being a single source provider due to the fact it makes customer service easy and fosters a team environment in which all customer specifications are met.”

To learn more about our HVAC division and all of its capabilities, attend our Open House, where products will be on display and seminars, such as our “cutting thermal energy costs/Nicor Rebates,” will be held.

For further information, please contact 815-886-9200 or sales@metropolitanind.com.

One of two prefabricated housed booster systems supplied to the Village of Park Forest, Ill.

 
Metropolitan Industries recently supplied two prefabricated housed booster systems, along with components for a third system, to the Village of Park Forest, Ill.

The project was funded by a state grant and the station in need of repair was the village’s lime softening water treatment plant, which had been designed in the 1930s.  The village was experiencing main water breaks close to the treatment plant and called upon Baxter & Woodman Consulting Engineers to help develop a solution.  Working with Metropolitan, Baxter & Woodman determined the implementation of two prefabricated housed systems, and components for a future third system, would remedy the problem at a cost-efficient price.

“With the existing configuration the village was working with, it wasn’t able to generate the 70 pounds of pressure it needed to fill its elevated tanks,” said Metropolitan salesperson Keith Girup.  “By providing our booster systems at the elevated tanks, it was able to dial the treatment plant back to around 50 pounds of pressure to reduce the risk of experiencing more main water breaks.  Each of our booster systems provides the extra 20 pounds needed to fill the elevated tanks.”

Girup said that while these fixtures are ideally temporary solutions, they’ve eliminated the need for the village to make a very expensive purchase it may have not been able to finance.

“Ideally, this should be a temporary solution because water mains that are in dire shape like the ones in this particular system need to eventually be replaced,” said Girup.  “However, that could be a very expensive venture and the customer decided it was financially practical to purchase more costly efficient boosters and finance the very expensive project over time.  In some cases, additionally booster stations aren’t necessarily a positive, but here, they were the practical answer.”

For more information, please contact Keith Girup at 815-886-9200, ext. 264 or sales@metropolitanind.com.

Our commitment to providing training to industry professionals is one of the many reasons why Metropolitan makes an ideal business partner. By sharing our expertise with engineers, water/wastewater operators, city officials and more, those working in the field are fully prepared to best meet needs and challenges.

With this goal in mind, we recently held a Navien tankless water heaters training course at our facility. Metropolitan is the representative of Navien tankless water heaters, which are 98 percent efficient in operation. For residential applications, Navien heaters can lead to increased gas savings, save space, and provide an instant/endless supply of hot water. These features have led to increased popularity and demand of Navien heaters, making training for installers more and more pertinent.

Navien America’s David Hoskyn was on-hand to conduct training during our most recent course. Hoskyn, who has been involved in the wholesale business for nearly 20 years and has conducted Navien training throughout the Midwest for over a year, said all sides of the business benefit from training courses.

“Training is very important to Navien America since we understand the benefit to all of us, including Navien, the representatives, distributors and the contractor,” said Hoskyn. “This helps the contractor be more profitable by reducing callbacks due to misapplied or incorrectly installed products. It will also reduce service time due to a greater understanding of the components, their function and operation. Lastly, it helps everyone understand the service and warranty process, and how we as a company handle support and warranty issues.”

Hoskyn said the most recent training fostered the type of learning environment he strives for as an instructor.

“The most recent training that we held at Metropolitan was another example of a well-coordinated, well-executed class,” said Hoskyn. “The people attending the class were involved and interested in attaining a better understanding of the product. The class was not only a great mix of both installers and service technicians, but also people that have installed the product before and those who have not. This makes for a great variety of questions and comments, which helps everyone in the class, including myself.”

Overall, Hoskyn credits Metropolitan’s commitment to training as a primary reason why it makes a model partner in business for customers and suppliers.

“Metropolitan is an extremely valuable partner for Navien America,” said Hoskyn. “They understand the importance that training holds to not only our product, but all of the lines they carry. The sales and support that they provide to their customers are keys to the success we have in the market.”

For more information regarding Navien tankless water heaters or to inquire about Metropolitan trainings, please visit www.metropolitanind.com or contact 815-886-9200.

Metropolitan’s MetroGreen energy-independent facility features the latest advancements in Green technology.

 
At Metropolitan we’ve always said we’re committed to developing “Green” technologies, but nothing demonstrates this dedication more than our MetroGreen energy-independent facility. Located on-site at our headquarters in Romeoville, Ill., MetroGreen serves as a facility where both Metropolitan employees and visitors can learn basic and advanced concepts of Green technologies.

“We conceived the idea to develop MetroGreen around three years, with the end goal of not just educating visitors, but ourselves as well,” said Metropolitan’s Dick Harned. “We discussed acquiring Green products from some of our distributors via donations to use in the facility, and the idea was well received. Just a few months after we constructed the idea, everything was in place and we were conducting tours.”

Some of the energy-independent features of our MetroGreen site include:

Rainwater harvesting system: Water from the gutter system fills a 1500-gallon harvest tank needed for storage. A booster pump runs on either AC power or solar power depending on the homeowner’s preference. The system also includes a filter system, which removes 99.9 percent of contaminants before entering MetroGreen.

Solar and/or wind powered water well: Water well operates by using either wind or solar power, completely off the electric grid. Water well is only used when rainwater is not available.

Wastewater treatment system: A 500-gallon per day, three-step treatment system:

• Step one: Waste moves through trash tank for removal of any non-biodegradable materials.

• Step two: Tank allows for 3.5 CFM of diffused air that promotes the growth of aerobic bacteria that breaks down waste.

• Step three: Pump tanks to drip irrigation system located in field for release – drip line allows ½ gallons per hour into soil about 8 inches to 10 inches below the surface.

The wastewater treatment system feeds directly into the drip irrigation system.

 
Solar heating system: Solar bulbs turn sunlight into usable energy to heat water. Solar system heats water tank for distribution to fixtures and radiant floor heating system, if needed.

Standby natural gas boiler: Backup system for radiant flooring and domestic hot water heater. Boiler is high-efficiency, condensing-type and provides supplemental heat to solar system.

Automatic charging sink and fixture: When motion is sensed, sink will run and automatically charge battery that runs the motion sensor. Sink saves hundreds of gallons of water per year. Water-saving toilet uses less than 1.6 gallons of water per flush.

Sump and Sewage Backup System: Powered by SUMPRO® backup system.

In addition to these products, we have recently added new features MetroGreen, including a solar-heated hot tub, LED lighting and products from our Ion|StormPro® product line.

Harned said the recent addition of products reflects the changing nature of the Green market and that alternations will continue to be made to MetroGreen as new technologies are introduced.

“From the time we developed the concept to present day, this project has always been a work in progress in learning about Green products,” said Harned. “As new innovations are commenced, we will continue to update MetroGreen as a training module for the Metropolitan family and for our customer partners.”

While this development has been a monumental commitment for Metropolitan, it has given our employees a plethora of knowledge of Green products to work with, allowing us to expand our product base and expertise into new areas to better serve our customer partners.

“Our employees have certainly been big beneficiaries as MetroGreen’s development has progressed along the years,” said Harned. “We’ve been able to attain a great deal of knowledge regarding Green products, which has assisted us in developing a product line of applications designed to save energy and utilize renewable sources of energy.”

The other primary beneficiaries have been our customer partners and visitors.

“Many of the visitors we’ve had taking tours have a knowledge base of Green technology that only scratches the surface,” said Harned. “Our facility and sales staff can help visitors leave more informed and may ultimately assist them in deciding what Green products to invest in. It has been a win, win project for us.”

Full tours of our MetroGreen energy-independent facility will be available during our Open House on October 11, 2012.

For more information regarding MetroGreen, facility tours and Metropolitan’s Green products, please contact 815-886-9200 or sales@metropolitanind.com.

The new pump station was designed for ease of installation and a proficient transition from old system to new system.

 
When Arsenal Technical High School made the de­cision to upgrade an old submersible dry pit pump system, the Indianapolis, Ind.-based institution called upon Metropolitan Industries to renew its system through both effective and convenient means.

“Metropolitan built a triplex self-priming pump system that closed in a house and contained a gener­ator inside,” said national salesperson Tim Laskows­ki. “The packaged unit essentially sits on top of the existing wet well, which made the installation process very efficient.  All in all, the transition from the existing system to the new system was very convenient for the customer.”

Metropolitan removed the existing pumps that were no longer in function, left the wet well where waste collects, dropped the suction lines for the self-prim­ing pumps, and packaged it all up in one convenient unit.

The system, which is designed to collect sewage and transport it to the appropriate destination, start­ed out as a very small project that eventually turned large, incorporating a prefabricated steel building.

It total, Metropolitan supplied a complete station with pumps, motors, valves, fittings, wiring support bases and incidentals with the prefab­ricated steel building, which includes a simulated brick finish as an attractive design solution.  A total of three pumps, each with a TDH of 33 feet and a capacity of 500 GPM were supplied. An 80 kW generator was also included with the package.

Metropolitan manufactured the entire system on-site and shipped ready for installation.

 
One of the differences between this particular unit and alternative solutions for enclosed structures was the implementation of the imitation brick, which was chosen to match the surrounding campus of Arsenal Tech.

“The material we used was very thin, almost like sheets of plywood, and was routed to look like brick,” said Laskowski. “It provided a very nice design solution and complemented its surroundings very nicely.”

Laskowski said the construction of the program went smoothly and that the customer was ultimate­ly satisfied at the project’s conclusion.

“We actually had the engineers who specified the product at our facility in Romeoville, Ill.,” said Laskowski. “They were able to witness the construction process firsthand were very impressed by our work. We delivered and installed the new system without any problems.”

For more information please contact Tim Laskowski at 815-886-9200, ext. 255 or sales@metropolitanind.com.

Metropolitan Industries recently assisted in the upgrade of several existing lift station control systems for the City of Rock Falls, Ill. Metropolitan municipal salesperson Dan Howorth was on-hand to see the last of the six lift stations improved begin operation. Included within the systems are Multitrode level probes with new PLCs, including Trihedral’s VT SCADA software. This technology gives the city the ability to monitor each system on a station-by-station basis at a cost-efficient price.

Metropolitan was first contacted by the consulting engineering firm Willett Hofmann & Associates, Inc. of Dixon, Ill. for design assistance. For a relatively small city such as Rock Falls, the integration of this type of control system in its lift stations made ideal sense. For municipalities that generally do not utilize a full SCADA system, the panels Metropolitan provides can operate independently or as part of a complete SCADA system.

“Many small towns today may not have the economic resources for city-wide SCADA systems, but can afford this type of control system upgrade and gain the ability to access such locations through the internet via computer, smart phone or any device with e-mail capabilities,” said Howorth. “If you’ve got a small town has two lift stations or well sites and/or a very small plant, these are ideal because our control panels can be implemented at a modest cost when compared to complete SCADA systems.”

Another benefit of these systems is flexibility. Though the city of Rock Falls will begin operation of each station independent of any SCADA communication, these systems are SCADA compatible if customers wish to employ them into a more comprehensive SCADA system in the future. The city of Rock Falls has chosen to activate each unit using VT SCADA capabilities, but had previously developed a large wastewater plant and can now connect each lifting station to a city-wide SCADA system if they eventually choose to do so.

“Metropolitan excels at this type of ‘a la carte’ solution for SCADA integration,” said Howorth. “Our competition may only promote a complete SCADA system and focus on conducting a fully integrated (and often very expensive) system, as opposed to building a system ‘one block at a time’ or as budget and/or time allows. We offer our customers flexibility in these types of situations.”

For more information, please contact Dan Howorth at 815-886-9200, ext. 281 or sales@metropolitanind.com.

Continuing our residential flood control series, the name SUMPRO® has been synonymous with dependability for over 20 years. UL recognized and a favorite among contractors, plumbers and homeowners around the country, the SUMPRO® battery backup system is the premier fully-automatic auxiliary power source available.

Performance tested for optimal functionality, SUMPRO® systems can be used in conjunction with pumps of the published horsepower ratings.

“What makes SUMPRO® such a high-end piece of equipment is its ability to take DC battery power and convert it into 115 VAC power,” said Metropolitan salesperson Brian Drafke. “This allows users to eliminate unreliable 12 VDC powered pumps and continuing using a standard 115 VAC pump without any modifications or piping changes.”

SUMPRO® systems install in minutes as users simply plug units into a standard wall outlet. Once detected, SUMPRO® will continue to use utility power until a power failure is detected. When a power failure is detected, SUMPRO® will instantaneously begin to supply standard household electricity to any connected appliances. Once utility power is restored, SUMPRO® automatically switches your appliance back to utility power and immediately begins to recharge its internal batteries in anticipation of the next power failure.

“Unlike some uninterrupted power supplies, SUMPRO® is designed to handle inrush power demanded by pumps,” said Drafke. “Without proprietary programming, SUMPRO® can start pumps even in long power outages when the battery power has diminished. The testing we’ve conducted has shown significant additional run times due to this feature.”

The typical installation of a SUMPRO® battery backup system.

 
SUMPRO® has input levels of 60 Hz, 120 VAC and 12 AMP, and output levels of 120 VAC and 15 AMP at a .80 service factor. Units can be shipped anywhere and come with a full one-year guarantee.

For premier performance, SUMPRO® can be combined with Metropolitan’s maintenance-free AGM Power+ batteries. By adding an extra set of Power+ batteries, users can double or triple their run times.

In addition to SUMPRO®, Metropolitan’s residential division offers full packages which include battery backup systems, pumps, float switches and pump controllers needed for complete flood protection.

As we move forward and continue to introduce new products into the markets we serve, we’re excited to announce a new and improved version of SUMPRO® will be introduced in 2013.

New features include an LED screen, which displays critical system information, an improved charging circuit and more. Metropolitan has also developed a new line of batteries which, when combined with the new version of SUMPRO®, will give users an increase in run time by 25 percent.

The new SUMPRO® will be introduced next year and includes many new features.

 
Most important, the new SUMPRO® will offer users the ability to work in conjunction with the latest green technologies.

“What’s most exciting about the new model is that it comes with both solar and wind inputs,” said Drafke. “This further adds to the diversity of SUMPRO® and opens the door to new users who can benefit by utilizing the product.”

For more information regarding the SUMPRO® battery backup system and our residential division, please visit the official website of SUMPRO® or call 800-323-1665.

A view of the renovated water pump station in Franklin Park, Ill.

 
At Metropolitan Industries, we pride ourselves on service that exceeds customer specifications. Over the years, we have modernized the fabrication process to complete projects that include even the most difficult of challenges.

The Village of Franklin Park, Ill. recently made the decision to upgrade an existing pump station and contractor Dahme Mechanical Industries, Inc. of Arlington Heights, Ill. called upon Metropolitan to assist in addressing their needs.

The facility was more than 40 years old and served as a main water pump station for the village. The project required specialized fabrication of certain parts to aid in installation of the new booster pumps.

Following an initial field visit, Metropolitan Salesperson Ken Turnquist came to the conclusion that specially fabricated spools would be required for the project to function upon completion. To accommodate the village’s needs, Metropolitan’s Bob Svoboda designed several custom-dimensioned offset spools to ensure the new pumps would work in the existing configuration.

“We needed to design special 12-inch by 8-inch spools, so I essentially started with a 12-inch diameter pipe and constructed it on a segment by segment basis” said Svoboda. “By the time we had finished, the other end of the spool matched the 8-inch connection and bolted in perfectly.”

In total, eight specially fabricated spools were required to complete the project.

Turnquist says the need to specially fabricate a system is an opportunity Metropolitan faces on a routine basis. Lift station adapter flanges for rail systems are one of many special fabrications Metropolitan creates regularly.

Metropolitan’s Fabrication Department designed eight offset spools for the upgrade.

 
“We’re often faced with projects where existing wetwells have all of the piping and suction elbows mounted,” said Turnquist. “In many instances the customer elects to utilize one of our pumps, but a stock flange cannot fit in the existing rail system. This is where we have to specially fabricate a new flange that will allow the new pump to seal on the existing base elbows.”

For more information, please contact Ken Turnquist at 815-886-9200, ext. 261 or sales@metropolitanind.com.

Metropolitan’s Ion Genesis® smart sensing controller gives users control of all vital pumping options.

 
The development of our Ion™ Digital Level Control float switch opened the door for the development of new products within the Ion product line including our user-programmable smart sensing controller, the Ion Genesis®.

To put in the most simplistic terms possible, the Ion Genesis® is the most complete pump controller on the market, providing the most features and safeguards against the devastation of flooding.

The Ion Genesis® comes complete with dual Ion™ Digital Level Control float switches which continuously diagnose and report real-time critical pumping information to the controller.  The controller itself gives users control of all vital aspects of pumping and efficiently cycles pumps to minimize pump turn-on cycles, ultimately adding life to the pump itself.

Metropolitan Salesperson James Spurney said everything starts with Ion™ Digital Level Control float switches, which are used in place of standard float switches.  These sensors are the most reliable on the market and incorporate no moving parts, which is associated with 98% of mechanical switch failures.

Basic features include a high water alarm and easy installation, but Spurney contends the Ion Genesis’® advanced features of protecting against floods are what distinguishes itself from similar products on the market.

“For starters, you have the redundancy of not just two pumps, but two of the most reliable float switches available,” said Spurney.  “Even if one of the float switches were to fail, a high water alarm will notify the user and will also keep both pumps operating.  This feature is not available anywhere else and will ultimately give users the time to replace a failed switch and still prevent flooding.”

Another unique feature of the Ion Genesis® is the ability for users to manually adjust the pumping level.  The level can be adjusted from 2” to 24” in 0.5” increments using the controller without entering the pit.  Spurney said this not only gives the product versatility, but can also extend the life of pumps as well.

“The ability to adjust the level differential is only available on the Ion Genesis®” said Spurney.  “Users can also set the level to produce the longest cycle time which is ultimately going to extend the overall life of the pump.”

Installation of the Ion Genesis® involves no hard-wiring or complex programming and can be used in small or large volume sump pits.

 
The combination of versatility, value and multiple fail safes make the Ion Genesis® the premier product in flood control.

“A pump alternator that is capable of testing the primary switch, the backup switch and has a high water alarm that can still run the pumps if switch failure occurs is a one of a kind piece of equipment,” said Spurney.  “In addition, the flexible nature of Ion™ Digital Level Control switches and the ability to adjust the pumping level ensures this product can be used in nearly any residential application.  Simply put, this is the best pump alternator available.”

For more information regarding the Ion Genesis®, please contact 815-886-9200 or visit us on the web.

Mike Schiazzano instructs seminar attendees during a recent “Control and Pump Repair 101” course hosted at Metropolitan Industries, Inc.

 
Part of our commitment to the industries we serve is sharing our expertise with engineers, water/wastewater operators, city officials and more by conducting educational seminars tailored to provide attendees a full understanding of both new and existing technologies.

Many of the seminars we conduct satisfy state requirements for continuing education and are completely free of charge.

We recently held a seminar developed to educate pump industry professionals entitled “Control and Pump Repair 101.”  Metropolitan’s Mike Schiazzano served as the course instructor and has been conducting the class for over 25 years.  Schiazzano, who has over 30 years of experience in the pump industry, said the course was developed to give attendees a basic understanding of a submersible pump and control panel, and to discuss basic troubleshooting of equipment.

“When we first started the class in the 1980s, it was primarily conducted in the field,” said Schiazzano. “Since then, we’ve moved it to our facility and interest has skyrocketed due to the fact we can offer a more in-depth course on-site.”

Schiazzano said that moving the course to Metropolitan’s Romeoville, Ill.-based facility has given attendees the ability to operate on both a submersible pump and control panel firsthand with the end goal of preparing them for everyday field work.

“Though this seminar is introductory in nature, we have attendees physically working with pumps and control panels, which provides depth they would not experience in a simple classroom setting,” said Schiazzano.  “We like to keep these classes limited to a small number of people so attendees can work with the equipment and the instructor one-on-one. The primary goal is for attendees to leave with a better understanding of equipment so if a problem does occur in the field, they’re prepared.”

Village of Wheeling, Ill. Utility Superintendent Jeff Wolfgram sent five members of the municipality to the recent course and said the village’s long-standing relationship with Metropolitan led to his decision to send the attendees.

Schiazzano demonstrates the workings of a control panel to Village of Wheeling, Ill. water operators.

 
“We’ve used Metropolitan to service our pumps and equipment, and have attended their seminars for years which has led to a sense of trust,” said Wolfgram.  “Municipalities often rely on their suppliers to introduce new technologies and Metropolitan has done just that over the years.”

Wolfgram said the “Control and Pump Repair 101” seminar provides distinct advantages over other forms of training largely because it’s hosted at Metropolitan.

“What’s great about the course is that equipment can be ‘troubleshooted’ in a controlled environment,” said Wolfgram.  “This type of setting can give attendees the ability to learn and experiment with equipment in a way they couldn’t in the field.”

Wolfgram said an overlooked benefit of Metropolitan seminars is the free price which can help attendees who may be facing a tight budget.

“Often times when municipalities are constructing a budget, training can get cut-out very quickly,” said Wolfgram. “The fact Metropolitan can not only provide worthwhile training for credit hours, but can do so at no charge is huge for us.”

While our “Control and Pump Repair 101” is designed to educate water operators, Metropolitan also offers courses designed for other professionals.

“The diversity among our seminars ensures anyone within the industries we serve can find something for them,” said Schiazzano.  “We have courses that offer continuing education units for water operators and plumbers, and professional development hours for engineers, but what’s most important is that attendees can count on learning valuable information they can apply to their profession when they attend a seminar.”

For more information regarding Metropolitan’s seminars, please call 815-886-9200 or visit www.ilceu.com.

According to the National Flood Insurance Program, floods are the most common natural disaster in the United States. Flash floods can occur in all 50 states and everyone lives in a Federal Emergency Management Agency (FEMA) identified “flood zone”- it’s just a question of whether you live in a low, moderate, or high risk area.

Based on NFIP data, floods have caused nearly $2.7 billion in U.S. losses over the past 10 years (2001-2010) and anyone can be financially vulnerable to floods: People outside of high-risk areas file over 20% of NFIP claims and receive one-third of disaster assistance for flooding.

While flooding may be overlooked in comparison to other natural disasters, the destructive nature of such an event is catastrophic. To minimize the risk of flooding, it is of the upmost importance to have dependable, high-quality equipment protecting your property and other valuable assets.

Metropolitan Industries’ Ion Product Line is designed to do just that. Our top of the line products incorporate the latest technologies designed to minimize the risk of flooding and have become the industry leaders in flood prevention.

As we move forward, we’re excited to announce the addition of new, innovative products to be added to our Ion Family. Each of these products has been developed with one constant goal: Incorporating new technologies to enhance the overall effectiveness of the product.

The Ion Family started over two years ago when Metropolitan Industries President John Kochan Jr. conceived the idea of developing the most reliable sump pump float switch. Since the development and release of the product, Ion™ Digital Level Control, the Ion Family has grown into the most dependable line of products in the flood control industry.

Ion™ Digital Level Control

When Metropolitan Industries launched their patented Ion™ Digital Level Control over two years ago, the entire dynamic of pump switch operation changed. Replacing traditional mechanical float switches and providing advantages over alternative types of pump switches, Ion™ Digital Level Control gives customers the reliability, operation and extended switch life no other product can provide.

“Generally speaking, the primary reason a sump pump will fail to evacuate the water is not because of the pump itself, but because of the float switch,” says Metropolitan Salesperson Brian Drafke. “Mechanical switches, which incorporate moving parts, will experience a great deal of wear and tear over time and are susceptible to failure.”

Switch failure, of course, leads to pump failure which can produce flooding in residential, commercial and industrial locations.

Ion™ Digital Level Control incorporates no moving parts, which is associated with 98% of mechanical switch failures. You’ll never have to worry about flooding during high periods of rain due to the design that handles high inrush pump loads and protects the electrical contacts.

Tested over two million cycles, Ion™ Digital Level Control adds life to your pump and provides a safeguard against switch failure due to its overall design.

In addition to its first of a kind solid-state sensing technology, it is leak resistant and extremely durable due to its proprietary enclosure, while multiple stainless steel screws supply optimized pressure to ensure superior sealing properties and durability.

What Ion™ Digital Level Control also provides is a diversity and quality customers never before have experienced.

• Comparison to the mechanical float switch: “With mechanical float switches, you’re limited in how many suitable applications they fit,” says Drake. “In small sump pits, these switches can be problematic and may not be usable. With Ion™ Digital Level Control, the switch can be placed in any size pit.”

• Comparison to the vertical float switch: “Vertical level float switches are limited in regards to level differential and where the unit can be placed in a sump pit,” says Drafke. “Ion™ Digital Level Control gives users the flexibility to place the switch anywhere and has standard differential heights of 6 inches for standard sump applications and 10 inches for sewage applications.”

• Comparison to the traditional pressure switch: “Without a doubt, the primary advantage of choosing Ion™ Digital Level Control over traditional pressure switches is the fact it comes without any moving parts,” says Drafke. “Not only does that eliminate one of the largest causes of switch failure, it simply gives the customer a higher quality product and adds life to the pump itself.”

Simply put, Ion™ Digital Level Control provides versatility and advantages over alternative pump switches the competition simply cannot match.

Metropolitan is committed to bringing the highest quality of products to the industry. The beginning was the development of Ion™ Digital Level Control and since then, our product line has grown even stronger. For more information regarding Ion™ Digital Level Control, please contact 815-886-9200, sales@metropolitanind.com or visit www.ionstormpro.com.

The Wyndham Hotel of Lisle, Ill. is located just outside of Chicago and includes 242 rooms spread across eight floors.

 
At Metropolitan Industries, we have the capability to bring the most up to date, energy efficient pump system to your commercial facility.

Whether you require a retrofit substitution of a previous design or an entirely different pump system in general, Metropolitan has the experience, adaptability, and customer service to design and service the most complex commercial projects.

A premier example of our commitment to delivering this type of system is demonstrated by the work done at the Wyndham Hotel of Lisle, Ill.

Working with a constant speed system that was over 10 years old, the hotel turned to Metropolitan Industries to deliver a solution that would save in energy costs.

“The previous system the hotel was using was a constant speed triplex system utilizing two large pumps and one small pump,” said Metropolitan Salesperson Mike Ponx. “With this configuration, the pumps would run even during the lowest demand periods. This type of system is quite wasteful from an energy consumption standpoint and we replaced it with a system that is more energy efficient.”

Metropolitan replaced the existing system with a Metro-Varipac System 2100 Triplex Variable Speed Pump System designed to provide a flow rate of 600 GPM at a constant discharge pressure of 90 PSI. A total of three pumps were supplied, each designed to perform at 200 GPM at 115’ TDH. Each pump motor is rated at 15 HP, 3500 RPM, 60 Hz, 460 volt and three phase.

Metropolitan’s Triplex Variable Speed Pump System will not only save the Wyndham Hotel funds in energy savings, it also freed up space for the hotel to utilize differently.

 
Metropolitan’s Metro-Varipac systems are available with options including, but not limited to, touch screen control, stainless steel piping and hydropnuematic tanks.

The smart pump technology incorporated by Metropolitan extends the life of the pump system. The compact packaged design allows for easy maintenance and gives customers the ability to place systems virtually anywhere. Variable speed controls can save customers thousands in energy savings and can virtually pay for the entire system over time.

“The use of variable frequency drives ensures the pumps are not running at full capacity during low flow periods,” said Ponx. “This is when energy savings are maximized.”

The compact design of the new triplex system not only allows for easier maintenance, but also saved a great deal of space for the hotel.

“The previous configuration the hotel was using had actually taken up two rooms,” said Ponx. “By removing an old, out of commission water softener and incorporating the compact design of the new triplex booster system, they only needed to reserve one room for the new system, allowing them to use the additional space for whatever they please.”

With the installation of the new variable speed booster system, the hotel can expect an energy reduction of 30% to 40% in domestic water system operation. For more information, please contact Mike Ponx at 815-886-9200, etc. 265 or sales@metropolitanind.com.

At Metropolitan, we can supply all equipment needed to keep your pump system functioning as efficient as possible.  Our adaptability and knowledge of new technologies give us the ability to supply the most cutting-edge equipment, which can extend the life of a system, save end users funds and make maintenance easier than ever before.

The typical installation of a “Metro-Prime” model 35-45 MPC self-priming pump system.

 
A premier example of this technology is demonstrated by the work done at a large commercial building located in Lake County, Ill.  At the request of the owner, the building name and location will remain confidential.

Metropolitan completed a retrofit application in which a total of eight self-priming sewage and sump pump systems were installed to replace aging equipment that was over 25 years old.  Metropolitan was the supplier and designer of the retrofit project, crossing over the old style of pumps with the new of style pumps.

“We upgraded the customer to our new model 35-45 MPC self-priming pump system where they had been previously using the older 30 MPC model,” said Metropolitan Commercial Salesperson Kent Swanson.  “The new system is more efficient, incorporates new and improved changes to the design of the impeller and provides larger housing for the pump among many improved features from the previous model.”

Swanson said Metropolitan was contacted at the project’s inception at the end of 2010 and that pumps officially went into operation in August of 2011.  Swanson said the systems were built and shipped to the job site at once, accommodating the customer’s installation date request and ultimately assisting in the installation process.

“It helps coordinating with the customer when all systems are built and shipped before installation,” said Swanson.  “With this type of approach, the plumber knows what materials they have to acquire and if any changes need to be made to the system design, we’re not finding out the day of the installation.”

Among the many improvements the new model 35-45 MPC provides in comparison to older models, Swanson named a few in particular that were illustrated in this project.

“The new design of the impeller makes it much easier to service the pump, so it’s more maintenance-friendly than the existing configuration,” said Swanson.  “With the old style, you had to make more adjustments to the impeller to ensure the system would function properly.  The new model system also provides for a more efficient operation, low installation cost and low repair cost.”

The “close coupled” design of the self-priming sewage pump allows for easier maintenance and installation.

 
Swanson said the systems were installed in a number of locations at the facility.

An interesting aspect of the project was the utilization of stainless steel basin covers for systems installed in the facility’s parking garage pump rooms.

“Parking garages have a tendency to get a lot of water, often times just water seepage on the ground,” said Swanson.  “We noticed the old covers were rusting away which is dangerous because anyone could fall right through and sustain a serious injury.  What we did was incorporate stainless steel basin covers on the new systems with the benefit being corrosion resistance.  Stainless steel will not rust and the customer will no longer have safety issues looming.”

In all, the customer made the choice to conduct a retrofit upgrade due to the advancements the new model provides.

“The customer was happy with the old pumps and the existing configuration,” said Swanson.  “However, the pumps were aging and the new technology our new model provides made the decision to upgrade practical for the customer to make.”

For more information, please contact Kent Swanson at 815-886-9200, ext. 253 or sales@metropolitanind.com.

In addition to the equipment we supplied to the Joe Orr Road Lift Stations of Chicago Heights, Ill., Metropolitan was also chosen to supply equipment to the 71st Street Stormwater Pump Station in Bridgeview, Ill.  The control and power distribution equipment was housed in a prefabricated concrete building with outside dimensions of 10’6” in length and 10’4” in width.

The addition of variable frequency drives will provide the pump station with efficient operation, which will lead to energy savings for the customer.

 
Three Hydromatic model S12L4000 non-clog pumps with 100’ cords and silicon carbide seals were supplied.  Each pump has a capacity of 3142 GPM at 29.2’ TDH for a total pumping capacity of 9,426 GPM when operating in parallel.  Each motor is rated at 40 HP, 1150 RPM, 460 volts, 60 Hz and three phase.  A 125 kW natural gas, sound attenuated Caterpillar generator was also included in the equipment package.

Metropolitan’s Keith Girup said Metropolitan was contacted to take part in the project at its inception, and that the eventual place where the building would be placed and function had much to do with its overall design.

“This pump station is on the southwest side of Toyota Park on 71st Street in Bridgeview where an IDOT viaduct is being constructed so that traffic can flow under the railroad tracks,” said Girup.  “The pumps will displace stormwater during rain events to prevent the viaduct from flooding.”

Girup said additions of variable frequency drives and enhanced controls with SCADA components will provide the municipality with both energy efficient operation and alarm notification if procedure encounters a malfunction.

Control upgrades were made at Metropolitan and the building was shipped fully assembled and ready for installation.

 
“This station has been designed with variable frequency drives which will vary the speed of the pumps to match the rainfall event,” said Girup.  “By varying the speed of the pumps, the motors will only consume the amps needed to match the influent rate, thus saving on electrical costs.”

For more information, please contact Keith Girup at 815-886-9200, ext. 264 or sales@metropolitanind.com.

To further expose our Ion|StormPro® product line, we officially introduced our Ion|StormPro® display trailer at the Illinois-PHCC show in late March of this year.  Complete with a water display, pumps and control equipment, the display trailer can best be described as a “trade show on wheels” with features that allow customers to learn about the full Ion|StormPro® product line firsthand.

Metropolitan’s Ion|StormPro display trailer features a water display, pumps and control equipment giving visitors a unique way to learn about the product line.

Since its premier appearance at the Illinois-PHCC show, Metropolitan has a conducted a number of counter days at plumbing supply houses featuring the trailer.  Participating in such counter days assists both customers and suppliers in learning more about the product line and new products soon to be released.

“Thus far, reception toward our display trailer has been very positive at counter days,” says Metropolitan Salesperson James Spurney.  “It’s a different, but unique and effective way for customers to learn about the product line from those who know it best.”

Spurney says that while visitors of supply houses are often left impressed, those employed at supply houses also benefit from trailer exposure.

Late last week, Metropolitan held a counter day at the Kankakee, IL branch of Connor Co.  Branch Manager Lonnie Surprenant found Metropolitan’s participation in the counter day both rewarding to visitors and his staff.

“The trailer itself is very impressive and the set-up is great because people are able to learn about the products face to face with Metropolitan employees,” says Surprenant.  “It also brings a lot to the table for us at Connor because we too can learn from the Metropolitan sales staff.”

In addition to the Ion|StormPro® trailer, the Budd Road Boyz Racing Team dragster was also present for this counter day.

“At the end of the day it’s all about the quality of our products and customer service,” says Spurney.  “With the display trailer, we can demonstrate both and hopefully educate customers and supply house personnel on Ion|StormPro® products.”

For more information regarding the Ion|StormPro® product line, please call 800-323-1665 or visit www.ionstormpro.com.

One of our commitments at Metropolitan Industries is bringing innovative technologies to the marketplace every year.

Three years ago, Metropolitan developed the Ion Switch, a first of a kind solid-state sensing technology with no moving parts, and we’ve never looked back.  We are now building a family of products using technology never before available.

Products such as the Ion Genesis®, a first of a kind digital pump controller designed to operate one or two pumps, incorporate new technologies that have allowed Metropolitan to become leaders in the pump industry.

The Ion Genesis® incorporates smart sensing technology that sends critical system information such as water level and many more features direct to the Ion Genesis® controller.  Users can collect and analyze system data never before possible, such as pump amp draw and level trends with the controller. Any change or variation in your system performance will sound an alarm to alert of possible equipment failure before flooding occurs.

The Ion Genesis® is just one of many Metropolitan products that have introduced new technologies, giving customers unique capabilities they never before had access to.

As we move forward, we’re excited to announce the development of new products to be added to the Ion family.  As has become the standard with Metropolitan, we’ve developed each product with the end goal of introducing new technologies to customers.

To learn more about the new products to be added to our Ion Product Line in 2012 and 2013, check out our video below.  We know you’ll be impressed with what is coming your way from Ion|StormPro®.

In its distinctive role among the many institutions of learning in America, Iowa Wesleyan College adheres to the ideals of its founding vision of social justice and human welfare on the local and international level by seeking to decrease its carbon footprint. In an attempt to bring a cleaner, greener and a more cost efficient heating system to their school, Iowa Wesleyan, in conjunction with Energy Systems Group, decided to replace their existing, centralized hydronic heating system with several more efficient, complete packaged boiler and primary piping pump systems from Metropolitan Industries.

ESG designed a system so that each building’s heating system would have equipment pre-assembled and manufactured for ease of installation. ESG decided Metropolitan Industries, the leading manufacturer of complete boiler and primary piping pump systems, was the right supplier for equipment development and construction. The campus upgrades also included additional geothermal heating/cooling facilities.

“After a few discussions about the design, we decided to provide high-efficiency, pre-packaged hybrid boiler systems assembled on prefabricated skids with the associated primary piping and pumps,” said Metropolitan’s HVAC Sales Manager Matt Brickey. “This type of design would allow for ease of installation by the contractor and reduce installation time dramatically. We realized moving the prefabricated system through the tight hallways and doorways posed a challenge, so the system was designed so that it could be manufactured in a way that split the skid in three different spots allowing for easier moving and maneuvering around tight spaces.”

The custom designed and engineered boiler systems were installed in five campus buildings: The McKibbin Dormitory, Student Union, Science Hall, Campus Library and the newly-renovated Chapel. In the McKibbin Dormitory and Student Union, hybrid boiler systems with heat exchangers were also packaged on the systems to satisfy the domestic hot water load.

High efficiency air separators manufactured by Spirotherm® were utilized to remove unwanted air that may have found its way into the system during the installation process. Spirovent® technology is designed to address all forms of air (entrapped, entrained and dissolved) that can be found in closed loop systems and remove nearly all of it. The coalescing medium creates a low velocity area inside the Spirovent® that allows air bubbles to rise and dirt to sink. There are no strainers, filters or replacement parts that can potentially become clogged. The flow always remains constant, without a high-pressure drop.

The end result is increased distribution efficiency, component life and heat transfer capabilities, along with decreased oxygen-based corrosion and pump cavitation, and the elimination of air related noises within the entire piping system.

Pictured are the new hybrid boiler system package and the primary piping pump system recently installed at Iowa Wesleyan's Science Hall.

How can you benefit using two different boilers?

In regards to Iowa Wesleyan’s energy consumption concerns, the primary reason for utilizing a modulated conventional boiler AND a condensing boiler is simple–together they are more efficient, have a lower initial cost and last longer.

For Iowa Wesleyan, the implementation of the hybrid boiler system was the ideal solution for their new heating system. They were able to save some upfront costs by purchasing a “standard” efficiency boiler, but were still able to benefit with the energy savings through the use of the high efficiency condensing boiler when conditions would allow.

Combustion air temperature also affects the net efficiency of the combustion process. Cold combustion air will absorb more energy released from burning the fuel than warmer combustion air; meaning colder combustion air reduces the efficiency of the appliance.

Lower return water temperatures and lower flue gas temperatures provide the best condensing operation. The condensing boilers recover the latent heat that is usually lost by harvesting the energy that is created when the water vapor in the flue gas is turned into a liquid.

When a customer’s boiler system is more efficient, it will not only save the customer money each year, it will also decrease their carbon footprint. The efficiency of the boiler system in part depends on the temperature of the return water. When the return water temperature is 130 degrees Fahrenheit (54.4 degrees Celsius) and above, the control system will run the conventional boiler. At 129 degrees Fahrenheit (53.9 degrees Celsius) and below, the control system will run the condensing boiler. The savings are maximized in temperate climates where winters are cold and summers are warm.

When the system uses the condensing boiler, the amount of usable, sensible heat that is generated is significantly larger than that of a conventional boiler system–creating true system efficiency.

Why not just use condensing boilers?

It may seem as if the perfect boiler system would simply use condensing technology. But if return water temperatures are too high, the condensing boiler will be only as efficient as a conventional type boiler. In a condensing boiler, when the temperature of the return water is too high and the air temperature is too cold, it will not allow a condensing boiler to operate in condensing mode. Initial capital costs can be reduced with a hybrid system by combining a lower cost conventional boiler with a premium efficiency condensing boiler.

Due to Iowa Wesleyan’s upgrades, carbon emissions are expected to reduce, which will translate into savings in total energy costs.

Every customer’s needs are unique and Metropolitan can tailor the solutions to meet your needs.

“What’s nice about these systems is that they’re completely customized to the client’s needs,” said Brickey. “Metropolitan Industries can configure the piping, boilers and system components in any manner to ease the installation process for a new or retrofit application.”

In the case of Iowa Wesleyan College, the savings are significant.

For more information regarding HVAC products, please contact Matt Brickey at 815-886-9200, ext. 266 or sales@metropolitanind.com.

At Metropolitan, we can supply all equipment needed to keep your pump station functioning as efficiently as possible.  Our adaptability and knowledge of new technologies give us the ability to supply the most cutting-edge equipment, which can extend the life of a system and save end users funds.

Metropolitan was recently chosen to supply all equipment associated with the upgrade of the existing stormwater and sanitary lift stations for the Joe Orr Road lift stations of Chicago Heights, IL.  The new lift stations include a number of up to date accessories and were housed in a large prefabricated concrete building.

The equipment supplied by Metropolitan was housed in a large prefabricated concrete building that included both a control room and a generator room.

Metropolitan’s Keith Girup said a number of factors contributed to the customer’s decision to make the upgrades.

“The project was done to replace an existing dry-pit type sanitary lift station that was over 30 years old,” said Girup.  “The design was chosen to eliminate the confined space environment as well as improve the operational efficiency, thus improving safety and reducing cost of daily operations.”

The stormwater lift station contains two Hydromatic model S4N300 submersible non-clog pumps, each with a capacity of 150 GPM at 20’ TDH.  Each motor is rated at 3 HP, 1750 RPM, 230 volts and 60 Hz.  One submersible level controller and five level switches to control on, off, override and alarm levels were also provided with the stormwater station.

The sanitary lift station contains two Hydromatic model S4MVX750 submersible non-clog vortex explosion pumps, each with a capacity of 375 GPM at 28.5’ TDH.  Each motor is rated at 7.5 HP, 1750 RPM, 230 volts, 60 Hz and are explosion proof at Class I, Division I, Group C and/or Group D locations.  One submersible level controller and five level switches to control on, off, override and alarm levels were also provided with the sanitary station.

The equipment supplied gave the customer the ability to operate both stations, creating a cost-effective solution for lift stations upgrades.

The prefabricated concrete building measures at 20’ L x 8’ W x 9’ H (outside dimensions).  The building is comprised of a 36” x 84” single door for the control room and a 72” x 84” double door for the generator room.  A Caterpillar 55 kW generator was also included.

Girup said the way in which the total system operates makes the application distinctive and efficient.

“This project is unique because the controls and generator are capable of operating the sanitary lift station as well as the nearby stormwater lift station,” said Girup. “By discussing the options and costs associated with also upgrading the stormwater lift station simultaneously with the sanitary lift station, the owner and engineer were able to make an educated decision to upgrade both lift stations and reap the benefits of twice the improved technology more cost effectively.”

Girup said Metropolitan’s involvement in the project can be attributed to a long standing relationship with the City of Chicago Heights, IL and project engineer.

“Metropolitan has been a trusted partner for the owner and engineer for many years and we were contacted at this projects’ inception,” said Girup. “We were instrumental in assisting with the design which included budget number preparation used for grant funding acquisition.”-

For more information please contact Keith Girup at 815-886-9200, ext. 264 or sales@metropolitanind.com.

Metropolitan Industries supplied a large air-gap break tank system that isolates processes from the source water feed for the Hanford Site near Richland, Washington.

By Joseph Sanchez

The Manhattan Project was the effort, led by the United States with participation from the United Kingdom and Canada, which resulted in the development of the first atomic bomb during World War II according to the U.S. Department of Energy.

The Hanford Site near Richland, Washington, was one of the main locations for the project due to its isolation and its proximity near the Columbia River, which could supply sufficient water to cool the nuclear reactors that produced plutonium during World War II.

The Hanford Site is now the focus of cleanup efforts which is the mission of Prime Contractor CH2M HILL Plateau Remediation Company. They are tasked with cleaning up waste sites and treating contaminated groundwater to ensure a healthy future for the Columbia River. To accomplish this goal, CH2M HILL is currently working on groundwater treatment and remediation efforts under way through Hanford’s 100 area and Central Plateau, which includes a total of 11 groundwater operable units.

The task of this project is enormous with on-going efforts to remediate 39 waste sites and more than 250,000 tons of soil left behind by operations on the Hanford Site; installing 327 wells across the site that will extract, monitor, and remediate contaminated groundwater; and treating 625 million gallons of contaminated groundwater to slow further migration toward the Columbia River.

Metropolitan Industries, Inc. participated in the remediation process by supplying a large air-gap break tank system that isolates processes from the source water feed for the 200 W Pump & Treat facility at Hanford.

Working together with Project Engineer CH2M Hill located in Englewood, Co., University Mechanical Contractors located in Mukilteo, Wa., and Metropolitan Representative PumpTech, Inc located in Moses Lake, Wa., Metropolitan Industries supplied a custom-designed triplex, pressure booster system with air gap protection for the potable water supply, a 2,100 gallon tank with a system capacity rated for 580 gallons per minute.

“This is a large air gap system,” says Mike Tierney, national sales manager who oversaw design and production of this project. “We are always asked if we can build large air-gap systems and this is evidence that we can,” he said. According to Tierney, air-gap systems typically range anywhere from 100-200 gallons per minute. This system is triple that capacity at 580 gallons per minute.

Other features of the system include a U.L. listed control panel with intuitive operator interface and touch screen control. Metropolitan Industries is one of the few pump system manufactures with a U.L. control panel shop in-house. This capability reduces costs while increasing quality.

Prior to shipping, Metropolitan verified the system in their test lab to ensure precise operation in the field. With the added value of system testing, the contractor simply had to make their connections, which dramatically reduced their startup time.

Shipment of the large system occurred early second quarter of 2011. Metropolitan was pleased to be part of such an important environmental project. For more information about air-gap break tank systems, please contact Mike Tierney at 815-886-9200 ext 234.

by Joseph Sanchez

The Encarta Dictionary of North America defines the word “feat” as a remarkable act or achievement involving skill and determination. When describing the plumbing renovations conducted in the east and west towers of Hyatt Regency Chicago, a feat is the only word that best describes this project.

Hyatt Regency Chicago is the largest hotel in Chicago and the largest Hyatt in the world. It is situated just off the world famous Magnificent Mile and within walking distance of the city’s most exciting shopping, dining and nightlife. Amenities include 228,000 square feet of flexible functional meeting space that includes four ballrooms, 63 meeting rooms and a 70,000 square foot exhibit floor.

The hotel recently underwent a massive $90 million renovation that focused on both the west and east towers. Renovations included redesigning the water supply system, re-piping 40 levels of each building and modernizing 2,019 rooms, while reducing consumption demands on water and electricity. The significance of the work lies with the speed in which it was accomplished. Both tower renovations began in a fourth quarter and were completed by the end of the following first quarter. Again, feats only accomplished by skill and determination.

East Tower

The east tower of Hyatt Regency Chicago sits across the street from the west tower and was the second phase of a two-phase project. The west tower completed during the first phase in 2010.

The 36-year-old existing water system in the east tower never worked efficiently according to Dennis Sartain, project executive and vice president of Abbott Industries, headquartered in Bensenville, IL. Sartain oversaw the project from design throughout construction and was a main factor in its 12-week completion.

“There were many deficiencies in the existing system that reduced the efficiency of the building,” said Sartain.

Those deficiencies included unequal hot and cold water to room fixtures and waiting for hot water to arrive to a fixture, which was related to the original zone design that had three zones spread over 40 floors, requiring a reconfiguration of three zones.

According to Sartain, the problem was the mid-zone because its water supply pressures (Hot and Cold) could not stay balanced. The hot and cold water pressure reducing valves were located at opposite ends of the supply risers and had a significant pressure differential between the hot and cold supply pressure to that zone.

To understand the magnitude of the situation one needs to look at the numbers. There are over 1,053 rooms spread over 31 floors in the east tower. Assuming that each room has three fixtures, that would be a minimum of 3,159 fixtures not including the ballrooms, kitchens, service areas, etc. Water consumption is an enormous budget line item for a hotel this large and prestigious. When each hotel guest lets the tap run for only a few minutes waiting for hot water to arrive, the hotel will spend substantial dollars on wasted water and energy.

Enormous Challenge

This was a total renovation of en existing building’s domestic water pump system, PRV stations and express risers, local risers and branch piping, without the guests ever knowing. Typically this is a task that teeters on the impossible, but with an intricate plan the impossible was realized.

So how does one re-pipe 40 levels of building, replace a domestic water pump system and PRV stations without ever terminating existing water service and without inconveniencing hotel guests?

Sartain had a plan that was clever and unique. While looking at the original drawings for the Hyatt’s east tower he noticed an existing garbage chute that was not being utilized. After further investigation he realized that he could use the abandoned chute to run his express risers, eliminating the need to tear the hotel apart. Once the plan was formed, officials at Hyatt Regency Chicago agreed to move forward on the total renovation, knowing the inconvenience would be minimal.

“This was a once in a generation opportunity to fix a problem once and for all that plagued the property for 36 years,” said Sartain.

So while work was being done on the west tower the plan for the east tower was formulated. The day the west tower was completed, work seamlessly began on the east tower. Working together with Metropolitan Industries of Romeoville who served as the equipment supplier; Tom Feilen, senior director of engineering for Hyatt Regency Chicago; Electrical Contractor Steve Wierema of Continental Electric; and Scott Stalcup of Babco Construction, Sartain and his team, which included Eric Evans, project manager, Terry Davis, project superintendent, implemented the plan.

Domestic Water Pump System

While the express risers were being installed through access hatches located on various floors of the building, the domestic water pump system was addressed. The new triplex booster system, variable speed control system and the pressure reducing zone valves were all supplied by Metropolitan Industries and replaced the 36-year-old original constant speed system that had been field modified with Variable frequency drives but used out-dated technology.

The new variable-speed, triplex domestic water booster system consisted of three 50-HP vertical multi-staged pumps, each rated 300 gallons a minute (GPM) at 428’ of total dynamic head and a system pressure of 200 PSI with a total system capacity of 900 GPM. The new booster system uses 1/3 less power than the constant speed system saving the building owners money on energy costs while reducing maintenance costs. Two 119-gallon bladder tanks were installed as well in the top floor mechanical room for low flow shut-down and stabilization of building pressure.

The new booster system is controlled with Metropolitan’s patented variable speed controller known as the Metro-Tech II. The Metro-Tech II integrates all pump operation and displays information on its color user interface. Operators can change set points, view real-time operating conditions, view integrated help screens and view alarms using its color touch screen interface.

The building is divided into three zones to stabilize pressure. There is a commercial level zone, a mid level zone and high level zone. At each zone, pressure reducing valve stations maintain each of the zone’s pressure requirements and the two 119-gallon bladder tanks installed in the top floor mechanical room help to sustain constant pressure to all zone’s regardless of building flow demands.

Using bladder tanks at the top of the express riser stores pressure so the system can shut off during low flow periods. As flow is consumed the pump system will activate and supply water to the building at the desired pressure. Once the demand for water is reduced to a low flow period, the system will shut off once again. Significant energy savings is realized during low flow periods when using variable speed drives and bladder tanks in combination.

Water Savings Astounding

With the installation of new plumbing risers, properly designed PRV stations, the new variable speed domestic booster system and water efficient fixtures, Hyatt Regency Chicago has seen a reduction in 2010’s water consumption of 16.5 %, a savings of 17 million gallons of water when compared to 2009. Once the east tower comes fully online with the already renovated west tower in first quarter 2011, the water savings should double.

By: Joseph Sanchez

A Supervisory, Control and Data Acquisition system (SCADA) is vital to any municipal application by providing users need to know information in real time critical to water and wastewater pumping installations. Having this information available allows for the efficient allocation of staff, reduces wasteful spending and most importantly allows for faster troubleshooting and minimizing the downtime of an installation. Many owners also rely on SCADA to help with preventable maintenance and can be pro-active in fine-tuning their systems for maximum efficiency.

Sycamore, Ill., Water Superintendant Mike Swedberg demonstrates how he can control and monitor vital pumping operations from the comforts of his office using the SCADA master computer.

Since SCADA’s inception back in the 1980s, Metropolitan Industries has played an integral role in the development, deployment and advancement of these systems in communities throughout the country. These systems allow operators to monitor, control, archive, receive alerts through a personal computer, cell phone, pager and land line phones.

Metropolitan is currently working on new SCADA systems for The City of Macomb, Ill., The City of Sycamore, Ill., The City of Hickory Hills, Ill., and The Village of Thornton, Ill. This article will demonstrate the unique steps each customer is taking to upgrade their systems. As you will see not all installations are cookie cutter and customization is key when incorporating a SCADA any system.

City of Sycamore, Ill.

The City of Sycamore is located 58 miles west of Chicago and encompasses about 5.57 square miles. Sycamore pumps water to over 15,000 residents through 108 miles of water main currently using four deep wells.

The City of Sycamore has experienced growth over the last decade and realized demand for the addition of new 1.5 million gallon water tower and one new deep well brining the city’s well total to five.

Given the size of the water tower, thermal wearing can become an issue and the installation of a recirculation pump is necessary. This pump is responsible for taking water from the bottom of the water tower and pumping it to the top to keep it fresh and moving.

Given this is a new addition to the water infrastructure of the city, it needed to be integrated with the existing SCADA system provided by Metropolitan. The entire system communicates via 468 MHz licensed radio frequency and is responsible for monitoring and reporting trends, alarms, process, etc. from each station. Licensed radio fit well given the rural location of the City.

“It monitors all production process of the water and all systems within,” according to Mike Swedburg, water superintendent for the City of Sycamore.

Working together with the City, Metropolitan Sales Engineer Dan Howorth suggested controlling well operation using a variable speed frequency drive and level management control to the tower using a SCADA PLC controller that integrates in seamlessly with the existing SCADA system.

City of Macomb, Ill.

Located in rural western Illinois, Macomb boasts a peaceful, laid-back feel, with plenty of pioneer history. Farms and historic barns dot the country-side and original brick buildings still make up a large portion of the city. College athletics are a source of local pride, as Macomb is home to Western Illinois University and its teams, known as The Fighting Leathernecks.

The wastewater treatment plant in town was due for a technology upgrade. It had no way to monitor or collect data electronically from the plant other than public works officials manually doing it themselves with paper, pen and a clip board.

Working together with city officials, Metropolitan surveyed the site and suggested a system that communicates via spread spectrum radio at separate frequencies of 900 MHz and 2.4 MHz. The reason two frequencies were necessary is because the clarifier and sand filters use digital I/O transmitters while the other 6 station use trio radios.

Spread Spectrum Radios can connect systems wirelessly without monthly fees or reliance upon an outside broadcasting station. They split up serial data and send it over multiple frequencies where the receiver radio merges the pieces and passes it along to the intended node. With line-of-sight communication, this option can be a secure way of linking together sites that could be many miles apart.

Sycamore, Ill., Water Superintendant Mike Swedburg shows the inside of a SCADA control panel located in Sycamore's well house reponsible for transmitting vital information to the master computer.

Information from all 8 stations will route to a main admin building where the operator can control all mechanical components using the Internet.

Village of Thornton, Ill.,

The Village of Thornton is a quiet community located in Chicago’s south suburbs. It offers the unique combination of a true small-town charm, while being only located only 25 miles from downtown Chicago.

The Village operates two water pumping stations and one wastewater lift station. The existing “tone-style” telemetry system that monitored all three stations began to show its age and needed replacement. It communicated via hard-wired telephone lines known for frequent downtime due to lighting strikes and/or accidental cutting by construction crews.

Working with Robinson Engineering Ltd., and Contractor Gaskill and Walton Construction Company, Metropolitan Sales Engineer Keith Girup recommended upgrading to a SCADA system with cellular communication.

Fast becoming the first choice of clients wanting dependability and 99.9% uptime, Cellular communication is the easiest way to integrate remote sites in to a SCADA system. If cellular service is available in your area, a cellular modem can bring DSL-like speeds to any site for just a small monthly fee.

All information is transmitted to a master computer located in an administration building. By working one on one with client, Metropolitan was able to program the master computer to print out Environmental Protection Agency reports by the click of a mouse. These reports are specific in nature and the programming in the computer converts all information into a format the EPA demands.

Hickory Hills, Ill.

The City of Hickory Hills is a southwest suburb of Chicago and home to around 15,000 residents and encompasses around 3 square miles. There SCADA project is a great example of how you can “phase-in” upgrades overtime without losing any communication during the process.

The City operates two pumping stations and one sanitary lift station using an existing SCADA system that communicates via hard-wired telephone lines but will soon upgrade to licensed radio. When the existing system began to show its age, Metropolitan suggested upgrading to the licensed radio.

Phase one of the project will involve the supplying and installation of a new SCADA master computer in the administration building. This will allow the user to get up to minute status reports of all three stations in the field from the comforts of the office.

Future phases will involve upgrading the communication from hard-wired telephone lines to licensed radio. During the transition, no communication will be lost and the system will operate as a hybrid until all three stations are upgraded to the new communication medium. This allows the City to slowly upgrade their SCADA equipment according to their timetable and budget.

HVAC Sales Engineer Matt Brickey operates the new boiler system during start-up of the system.

By: Joseph Sanchez

The life blood of any commercial building is the mechanical systems running behind the scenes that include domestic water booster systems, fire suppression pump systems and HVAC systems.

Of the three mechanical components, HVAC is by far the largest consumer of energy due to the sheer nature of how they are specified and designed. The school of thought in the HVAC community is size everything for peak demand without considering demand fluctuates, especially during warmer months when demand is at the lowest.

The biggest misconception when specifying a boiler system is, “If I specify a boiler at 90% efficiency then the plant will operate at 90% efficiency.” This is false because during light load conditions, such as during warm months, boiler efficiency becomes random which results in poor overall, “cycle” efficiency. In other words, “Seasonal Efficiency,” is only 50-80% of measured efficiency resulting in no realized energy savings during the warm months when your boiler runs less.

Metropolitan Industries, Inc., located in Romeoville, Ill., has a solution that reduces boiler fuel consumption by 20-50% using a patented procedure that addresses seasonal efficiency, which increases cycle efficiency therefore reducing fuel consumption dramatically.

Case Study – Multi Occupancy Condominium

A great example of this technology was demonstrated by the work done at a 139 unit Condominium located in Will County, Ill. At the request of the owner, the building name and location of the project is to remain confidential.

To address the leaking heating pumps located in the ceiling, Metropolitan had the contractor move them to floor level for easier inspection and service.

The existing system had two problems the first being the plant ran inefficiently due to the boilers being the sole heat source for the domestic water. Due to this, they operated all year round, even during the summer months. The inefficient design operated by pumping city water and boiler water through a shell and tube heat exchanger mounted near the ceiling. Since there was no way to prevent gravity flow of hot water through the heating system return lines, the radiation caused the building to stay warm all year, even in the dog days of summer. This resulted in increased fuel consumption and increased electrical consumption as well because air conditioners witnessed an additional load imposed by the uncontrolled flow of unwanted heat from the boiler plant and needed to run overtime.

The second problem was the existing heating pumps were leaking and had been since day one. There were eight zone pumps serving four zones. Three zones were for space heating and the other zone for domestic hot water heating. The reason why they leak was because they were mounted near the ceiling without the proper supports. This made it difficult to service the pumps given a technician need to perform the work on a ladder.

Green Performance Solution

To solve the inefficient operation of the plant, Metropolitan Industries installed a “summer boiler,” sized to the requirements of the domestic hot water heating system. This allows the owner to turn off the boiler completely when a heating load is non-existent. The result is energy savings up to 50% because the new boiler system handles the small summer loads efficiently and eliminates short cycling and cycle losses.

The summer boiler is so efficient that the owner can run it year round for more efficient domestic water heating meaning the building can now be heated with only one boiler in all but the most severe weather promotes more efficient boiler loading for improved energy performance.

Green Distribution Solution

To address the issue of the leaky heating pumps, Metropolitan moved the domestic water heat exchanger and blending valve to floor level for easier inspection and

Pictured is the variable-speed, duplex domestic water booster system with total system capacity of 220 GPM at a system pressure of 95 PSI.

service Workers no longer needed to climb on ladders when servicing the heat exchanger or blending valves. This not only improves staff and contractor safety but reduced maintenance costs overall due to the easier and less expensive service.

One of the biggest benefits is the control over domestic hot water temperatures. No longer will they have spikes or drifts of temperature irregardless of no load or light load conditions. The elimination of spikes in temperature was important given residents were at risk for being injured.

There were benefits as well with the relocation of the heat exchanger and blending valves to the floor. For one, it reduced the safety hazards associated with working on ladders when servicing the heat exchanger or blending valves improving contractor safety.  Also with the new pumps, the constant leaking was eliminated.

Realized Energy Savings

With the installation of the “summer boiler”, new heat exchanger and blending valve, the building owner realizes a 20-50% reduction in fuel consumption on any given day depending on load conditions. The entire package combines indirect water heating, condensing water heating and the blending valve function all into one complete system. Metropolitan Industries is the only company currently providing this technology. For more information, contact Matt Brickey at 815-886-9200 ext. 266 for a complete analysis of your system.

The Ion Digital Level Controller that contains no moving parts that fail 98% of the time.

Mechanical pump switch’s days are numbered thanks to a new product called the Ion Digital Level Control launched by Romeoville, Ill.,-based Metropolitan Industries that replaces mechanical switch operation with intelligent microprocessor technology.

Under development for several years, the patent-pending Ion Digital Level Controller eliminates moving parts, which are the detriment of most mechanical switches and replaces it with solid-state sensing technology resulting in over 1.5 million cycles which is approximately triple the life of a mechanical switch.

“The problem was never the pump because they are generally built to last. The problem has always been the switch responsible for the critical task of turning the pump on and off,” says John Kochan, Jr., Metropolitan Industries President who developed the idea for the new product by utilizing solid state components and applying them to switch technology.

While mechanical switches are useful and function properly over a period of time, they are always subject to failure. “Mechanical switches use moving parts and wear and tear in a sump pit environment will always break those components down over time,” says Kochan, Jr.

Switch failures translate into non-running pumps, which can result in flooded commercial, industrial and residential locations.

With the demand for reliable switches evident with recent recalls put forth by some of the largest pump manufacturers during the last decade, Metropolitan began work over a period of three years to develop a product that can outperform mechanical switches in longevity and dependability.

How it works

The ION Digital Level Controller is a technologically advanced device that senses water level/pressure through the use of a proprietary sensor and microprocessor driven digital control. The microprocessor within the digital float sensor samples analog data from proprietary sensor, which electro-mechanically converts the water pressure to an electrical resistance. Because water pressure is directly proportional to the water height, the electrical resistance of the proprietary sensor is also proportional to the water height. The resistance of the proprietary sensor is measured by means of a resistive bridge network before passing into the microprocessors analog to digital converter.

Metropolitan Industries Presdient John Kochan, Jr., holds the Ion Digital Level Controller that has been tested over 1.5 million cycles and counting.

Traditionally, sump and sewage pumps often have been started by means of a mechanical switch. The mechanical switch design often uses a set of electrical contacts which close under a given water height scenario, thereby activating the sump pump. Due to the alternating nature of the electrical voltage source from the utility, large voltage differentials could possibly be present across the mechanical switch contacts prior to turning on a pump. When a pump is suddenly turned on under these conditions, large transient current surges could be expected as the motor begins to rotate. These transient surges often cause heating of the electrical contacts which, over time, effectively reduce the lifetime of the switch. This condition is further amplified when a mechanical switch attempts to open and turn off the pump.

When a mechanical switch suddenly opens an inductive motor load, the time rate of change of the current flow can be very large. This value, multiplied by the motors internal inductance, induces a large voltage transient across the mechanical switch contacts. This transient often causes arcing of the contacts which, over time, can cause the switch to wear and ultimately fail. It is well known in the sump pump industry that the cause of most pumping failures occurs when the pumps switch fails.

The embodiments of the ION Switch effectively eliminate the problem of switching transients and contact arcing by incorporating both a solid state switching device in parallel with an electrical relay. When a pump is called for, the turn on cycle begins by enabling the solid state device, or triac. The nature of the triac in our design is to switch on a load under low voltage conditions. By starting the pump motor from a low voltage potential, both radiated and conducted electrical noise have been dramatically reduced.

The Ion Digital Level Control is universal and can be used in almost any pumping application dependent of level control as well as effluent sump and sewage. To customize operation, the Ion Digital Level Control has standard differential heights of 6 inches for standard sump applications and 10 inches for sewage applications and is inverter rated for use with most battery back up systems. The Ion can be programmed for custom applications as well.

“We feel the Ion Digital Level Controller will transform the plumbing industry much the way battery back up systems did in the 1980s because we figured the way to eliminate the moving parts associated  with most switch failures,” says Kochan, Jr.

“As wholesalers and plumbers realize there is a product available that can eliminate the problems associated with mechanical switches, it will only be a matter of time until mechanical switches are replaced entirely,” he added.

For further information about the Ion Digital Level Controller visit www.IonNation.us.

As a system supplier of wind, solar, water harvesting and gray water recycling sytems, Metropolitan Industries has taken a leadership role by educating and helping contractors, plumbers, engineers and inspectors navigate their way through this new frontier of opportunity.

Company raises Green awareness

By: Joseph Sanchez
As energy prices rise and our limited resources such as water continue to dwindle, our Federal and State governments are considering many new technologies to reduce consumption such as rain water harvesting, gray water recycling and solar domestic hot water heating.

According to an article on Forbes.com, Treasury Secretary Timothy Geithner on July 9 announced rules that will finally allow developers of wind, solar and other green energy projects to apply for a total of $3 billion in federal grants to cover upfront project costs. The article states that under Treasury Department guidelines, the Department of Energy will disburse cash grants worth 30% of upfront costs for projects that start construction by the end of 2010. This funding is part of the American Recovery and Reinvestment Act and will be critical to boosting the demand for these technologies.

As a system supplier of wind, solar, water harvesting and gray water recycling systems, Metropolitan Industries has taken a leadership role by educating and helping contractors, plumbers, engineers and inspectors navigate their way through this new frontier of opportunity.

This proactive stance inspired the company to construct a 2000 sq. ft. working indoor/outdoor “green” display facility in 2008, known as Metro-Green, that allows association groups, universities, government leaders, decision makers and others the chance to witness all green technologies available and installed under one roof. It takes theory to a whole new level by actually applying it in the field for all to see.

Touring Metro-Green is one aspect of an intensive seminar conducted by the company at their headquarters once a month. The purpose of the seminar is to educate contractors, facility managers, architects, engineers and inspectors about the available types of green systems, how they work, best installation practices, available tax credits and/or rebates for green installations, and various plumbing codes related to green systems or the lack thereof.

A recent visit by memebers of the Illinois Plumbing Inspectors Association recently was a unique opportunity to address and inform inspectors of the need to adopt and legislate an enforcable set of codes related to green pumping applications.

A recent visit by members of the Illinois Plumbing Association this summer was a unique opportunity to address and inform inspectors of the need to adopt and legislate an enforceable set of codes. Of course, it is up to each individual state, not the inspectors, to adopt a code but the spread of awareness is effective, given the fact that technology is outpacing regulation. Currently, only four states have published guidelines regarding  water harvesting and gray water recycling. Those states are Virginia, Texas, Oregon and Hawaii.

Engineers, Architects and Contractors working in the United States without official code to regulate gray water reuse and water harvesting/reuse only have informal guidelines to guide them as published in the Uniform Plumbing Code of 2009, International Plumbing Code of 2009, The American Water Works Association for reclaimed water and the American Society of Plumbing Engineers in regards to gray water reuse systems.

As these water re-use applications gain more and more popularity, the states will eventually catch up with some type of code to regulate their installations. Metropolitan Industries will continue to be an advocate for education and awareness and encourages all who are interested to visit www.MetroGreen.US or www.greenwatersystems.us. The company hopes that their working exhibit can help set an example as a possible standard moving forward. To schedule a private tour of our Metro Green Energy and Water Independent facility visit the www.MetroGreen.US or call Joe Sanchez at 815-886-9200 ext. 260.

Pictured above is a packaged pump station that water districts use to pressurize water that supplies household plumbing devices as well as provide water for cooling, industrial needs and also fire protection.

Applications and Best Practices

By: Joseph Sanchez

Introduction

Packaged pumping systems are popular these days due to the benefits associated with them, which include the ease of installation, single source responsibility and streamlining of the manufacturing process.

Packaged systems simplify the installation process. Installation of these systems typically involves lifting it off the delivery truck, setting into place and connecting the piping and power to prepare it for operation.

Single source responsibility simply means there is one company to call if there is a service issue. Issues are solved quickly and end-users eliminate the need to consult with multiple vendors in an attempt to determine which company to call. This ultimately reduces service downtime and eliminates the need to deal with multiple vendors.

“One manufacturer means one number to call anytime technical support is needed,” says Municipal Sales Engineer Bob Wedell of Metropolitan Industries who oversees the design and manufacturing of packaged systems for the municipal, industrial and commercial markets.

Finally, packaged systems are manufactured in a controlled environment which allows for testing of a system prior to jobsite delivery and a reduction of fabrication timelines. This controlled approach minimizes start-up problems in the field and allows for system testing.

Packaged pump systems satisfy the demands of many pump industry applications including municipal distribution systems, industrial process systems, non potable and water reuse systems and domestic water booster systems in high-rise buildings. This article will discuss each and share design concepts, common mistakes and best practices.

Municipal Water Distribution Systems

Municipalities rely on water mains to bring treated and disinfected water from the source to our homes, through a distribution network using pump stations as this one pictured above for the Village of Plainfield, Ill.

For years, municipalities have relied on water mains to bring treated and disinfected water from the source to our homes, through a distribution network. This network may be comprised of reservoirs, pump stations, water towers and storage facilities. In order to ensure there is clean, drinkable water at an adequate pressure to keep the supply system working properly, water districts employ pump stations that pressurize water to run our household plumbing devices (toilets, sinks, showers, etc) as well as provide water for cooling, industrial needs and also fire protection.

These pump stations can be packaged and delivered as a complete unit. Typical designs include a large steel base with pump and control components pre-installed. Base and components are eventually housed in any material of the customer’s choosing.  Organizations such as the American Water Works Association help to create standards that are used when designing the various components in such a system.

When sizing a packaged pump station for a distribution network, flow and pressure are the two main elements, but there are also many other variables that factor into how a pump system is designed and ultimately operated. The size required varies directly with the number of users or volume of water required and designers will engineer these systems for the total “peak demand” for that segment of the community. For instance, factors such as usage (flow) will affect pump & piping sizing; topography will affect the pressure required; a water tower will also affect pressures and how much water is needed to be stored in order to be able to fight a fire.  Monitoring requirements may vary from system to system, but the dynamic nature of the system will make it very important to monitor these changes conditions to react appropriately and to prevent these changes from causing water hammer and wide pressure swings which often result in water main breaks.

Whether the system is pumping from a reservoir or directly boosting the pressure “in-line” within the piping network, there is a need for pressure and flow monitoring instrumentation required locally and remotely.  Motor and valve controls needed at the pump station and level monitoring of towers and reservoirs also directly interface with the pump system.  Often times SCADA systems are utilized to collect data and automatically make system adjustments to keep the water pressure constant.  They also serve as a means to allow operators to be more proactive in the regular maintenance of the equipment throughout their systems.

The bottom line is that whether the system is 50 gallons per minute (GPM) or 25,000 GPM, it is possible to pre-fabricate or package these elements, discussed above, to provide the end-user with a product designed with “complete system responsibility” in mind.

Processed Industrial Systems

Factory prefabricated pumping packages can be applied in many different types of industrial process water applications. Water transfer, level control, recirculation and pressure boosting are just a few examples. Typical skid mounted packages include pumps, motors, valves, package piping, and a factory pre-wired and integrated control system. Specifiers may also consider systems with complete factory prefabricated buildings to protect the equipment and provide a controlled environment in which to perform maintenance and service.

It must be noted that there are many important variables to be considered when selecting equipment that’s best suited for these types of applications. Reliability and efficient operation are keys to making the right choices. The properties of the source water and demands of the process must be taken into account when selecting the materials of construction for the pumps, valves and piping. It is imperative that all wetted parts be researched for compatibility and doing so will assure safe and reliable operation. In addition, these types of centrifugal pump applications can often times take advantage of variable speed control strategies. Simplicity, precise process control and maximum efficiency will be realized when variable speed control is specified.

Pictured is a packaged domestic water pressure booster system for Chicago’s McCormick Convention Center that increases the pressure provided by the City’s water system and satisfies the potential peak flow demands of the facility.

Domestic Water Pressure Booster Systems

When the water pressure provided by any given municipal water system is not sufficient to satisfy the demands of end-users at higher elevations such as mid-rise or high-rise buildings, it is often necessary for these facilities to have equipment within the structure designed to increase the pressure provided by the municipal water systems that are ‘horizontal’ in nature. These types of prefabricated systems are engineered to satisfy the potential peak flow demands of the facility and are often provided with multiple pumps on a single structural steel fabrication with electronic controls, wiring, piping, valves, and multiple safety-devices. These packaged systems are typically designed based on the calculated increase in pressure required to deliver pressurized water to the highest or furthest point-of-use in the facility. Many times multiple electronic sensors are installed at remote locations within the facility. These sensors allow the controls to optimize the operation of the system, and also enhance the energy-efficiency of the equipment. In certain regions of the country, the design requirements of these types of systems are regulated by local, national, or international code requirements.

Conclusion

This article discusses the benefits associated with packaged pump systems which are ease of installation, single source responsibility and streamlining of the manufacturing process. This can be applied to the municipal, industrial, non-potable, water reuse and domestic water booster system markets. For further information regarding designs, applications and best practices contact Metropolitan Industries at 815-886-9200 or visit www.metropolitanind.com.

By: Joseph Sanchez

As energy prices continue to rise at an alarming pace, consumers are turning their attention to alternative forms of energy to power their homes. A front-runner in the alternative energy market is solar power, which is gaining popularity thanks in most part to the energy crisis gripping the country. Solar power is finding its way into homes across America tasked with reducing the costs for everyday things such as heating our homes and water.

According to the U.S. Department of Energy (DOE), heating your home accounts for about 56 percent of your utility bill making it the largest expense for most homes. Water heating is the third largest energy expense and can account for about 14-25 percent of the utility bill.

A recent addition to the Metropolitan Industries product line are solar powered systems manufactured by Viessmann for domestic hot water, radiant floor heating and air conditioning systems for residential and commercial applications.

The advantages of using solar power for domestic hot water, radiant flooring and air conditioning are significant given the cost of energy, its continued rise and its limited supply. The DOE says a solar system can provide up to 80 percent of the heating needs required for a home or business at zero cost to the consumer after initial equipment and installation costs. Given solar energy is free, a system will pay back the purchaser in just under a couple years in energy savings and will continue to pay dividends in energy savings and consumption for years to come.

Other benefits include tax incentives from Federal and State governments in forms of rebates, grants and exemptions that help offset installation and equipment costs making the technology feasible for many businesses and families.

For example, the State of Illinois offers a property tax exemption for passive solar space heat, solar water heat and solar space heat for residential, commercial and industrial properties according to website dsire.org, a database of State Incentives for Renewable & Efficiency funded by the U.S. Department of Energy. A residential solar tax credit is offered by the Federal Government that that offers a maximum incentive of $2000 for a solar water heating system installation. An incentive offered by the United States Department of Agriculture is in the form of a grant upwards to 25 percent of project costs. For renewable energy systems, the minimum grant is $2,500 and the maximum is $500,000. For energy efficiency improvements, the minimum grant is $1,500 and the maximum is $250,000.
With solar power gaining popularity in the U.S., Viessmann Manufacturing Company of Germany is ready for the increased demand based on the more than 2 million solar collector installations over the last 30 years installed in just Germany alone.
Viessmann solar hot water heating systems, marketed as the Vitosol, collect and absorb solar radiation through either solar vacuum tubes (Vitosol 300) or solar panels (Vitosol 200) and transfers the solar heat directly to a storage system, from which the heat is distributed.
Viessmann solar collectors are specifically designed for northern climates and can produce as much as 70 percent of the annual hot water requirements of an average family household. The average lifespan of any Viessmann solar product is 20 years or more.
The Viessmann product line is only available in Illinois at Metropolitan Industries, Inc. located in Romeoville. For more information, contact Mark Brickey at 815-886-9200.