Category: Prefabricated Housing

CBOC-Blog Post

Installation of the pre-fabricated boiler-house for the new Veterans Affairs Outpatient Center at Hines Veteran Administration of Joliet, measuring 47-feet long by 20-feet wide by 13-feet tall, one of Metropolitan’s largest housed system to date.

 

What started as an engineering and fabrication challenge for Metropolitan Industries, has turned into one of the largest housed systems we have produced in our 55 plus year history: A prefabricated boiler-house measuring 47-feet long by 20-feet wide by 13-feet tall and weighing almost 90,000 lbs.

Following months of arduous labor and immense preparation from the Metropolitan team, the modular central steam plant designed for the new Veterans Affairs Outpatient Center at Hines Veterans Administration of Joliet, Ill. departed our facility and was placed in its permanent home.

Designed to provide steam and water utilities to a facility purchased by the Veterans Administration and located on the Old Silver Cross Hospital Campus in Joliet, mechanical division salesman Mike Temes described the project as “fast moving” and said Metropolitan wasn’t brought in on the project until the bidding process was nearly closed.  The short time frame from bidding the project to receiving the customer’s letter of intent required extensive planning amongst the many departments of our company.

“Once we came to the realization that we were a legitimate contender to receive this project, a meeting was conducted between our engineering, electrical, fabrication and sales staff to determine whether or not we could complete such an intricate job during the allotted time,” said Temes.  “From the start everyone involved in the project was extremely eager to help and provide support. These individuals were extremely supportive in the early process of this project and it could not have gotten off the ground without them.”

With a project integrating so many complex components, Temes said that both he and project engineer Neil Vogel relied heavily upon the expertise of Metropolitan’s staff for direction, and that the sacrifices exhibited were striking.

“This entire project has been a valuable exercise in teamwork and unity,” said Temes.  “As relatively new employees, Neil and I are novices in the design of prefabricated structures and relied greatly upon our co-workers for help.  Our staff members experienced in the design of these structures went above and beyond to assist us with this project, and the sacrifices made speaks volumes about the team atmosphere present here at Metropolitan.”

Among the many challenges faced throughout the project’s development, two particular challenges were overcome during the process.

“This structure is larger than what we could accommodate when it came to erecting the building within our facility,” said Vogel.  “Fortunately Metropolitan invested in the expansion of our warehouse doors, thus allowing us to complete almost all of the fabrication and wiring of the building indoors during the harsh winter months.”

He also cited the drawing and assembly of the structure as a demanding process for our engineering staff. The final submittals were extremely intricate, which required our engineering, fabrication and electrical staffs to pay very close attention to detail throughout the project’s construction.

The steam boilers for this project had the longest lead time of any equipment on this project.  For that reason we had to wait until the steam boilers were at our facility to start the majority of the structural fabrication.

“One of the most extraordinary aspects of this project is the fact that the majority of its construction has taken place over a 10 week period,” said Temes.  “We couldn’t order materials and put torch to metal until we received the approved submittals, and studied the precise specifications that the customer required.”

Due to the sheer size and weight of the building we needed to have the base design stamped by a professional structural engineer.

“The collaboration of efforts between Metropolitan’s sales, engineering, fabrication and electrical departments, the trucking company, and the crane operator, ultimately played the most prominent role in the installation’s success,” said  Metropolitan’s project engineer Neil Vogel.  “Transporting such a large structure from one site to another is no easy feat, but we were able to achieve positive results with the right team and strategy in place.”

Ushered by police escorts and accompanied by many Metropolitan personnel, the boiler-house was moved nearly 10 miles to the job site with complete ease, and the installation process began shortly thereafter.

The entire installation went as well as we had envisioned, and no issues were encountered throughout the process. Both the police escorts and the trucking company did a fabulous job of not only ensuring that the structure arrived safely, but did so in a timely manner. The entire installation was a valuable exercise in teamwork and everyone involved should be credited for its success.

In an effort to provide a cost effective benefit, the VA was able to officially disconnect its building from the original Silver Cross Hospital central loop and is now receiving its steam from the new modular central steam plant.

Project engineer Peter Papanikolaou of KJWW Engineering Consultants was pleased Metropolitan was ultimately brought in to contribute to the project and is satisfied with the end result.

“I was very familiar with the work Metropolitan had completed in regard to housed pumping stations, and was pleased to discover that they could engineer a sophisticated steam-based system like this,” said Papanikolaou.  “It was comforting working with a local organization, which ultimately helped everyone involved with the project.  Overall, I would describe Metropolitan as extremely professional and helpful during this entire venture.”

Officially disconnected from the original Silver Cross Hospital central loop, the VA is now receiving steam and water utilities from the Joliet Modular Central Steam Plant. (Interior View)

Officially disconnected from the original Silver Cross Hospital central loop, the VA is now receiving steam and water utilities from the Joliet Modular Central Steam Plant. (Interior View)

 

 

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.

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.

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.

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.

Contact Us

(815) 886-9200 or Email Us: info@metropolitanind.com
37 Forestwood Dr., Romeoville, Il 60446

Archives