Posts Tagged ‘Booster Pump System’

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

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.

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.

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.

The Merchandise Mart located in Chicago.

By: Joseph Sanchez

When the world-renowned Merchandise Mart in Chicago began the task of obtaining LEED-EB certification, it was just the fifth building in Chicago to go “Green”. Adhering to standards set forth by the LEED Green Building Rating System, a voluntary, consensus-based national standard for developing high-performance, sustainable buildings. The Merchandise Mart focused on five key areas of green building strategy: sustainable sites, water efficiency, energy efficiency, materials/resources and indoor environmental quality as set forth by LEED. Such on-going improvements involved reevaluation of capital programs for replacement of windows, roofs, controls, plumbing fixtures, utility meters and lighting.

To better target energy efficiency, just one of the many strategies directed by Merchandise Mart’s Vice President of Engineering Mark J Bettin, P.E. was replacing an outdated domestic water supply system that was a large consumer of energy and an inefficient supplier of water.

Original System

The original system consisted of five pumps ranging in size from 40 hp to 75 hp.  The pumps ran at a constant speed intended for the highest demands even during low-flow periods such as during the middle of the night. The system was designed to deliver over 1250 gpm, churned at 290psig, and incorporated pressure reducing valves on the discharge of each pump to maintain a system pressure at 200psig. The five original pumps were oversized by 35HP each, totaling 175 unnecessary horses.

“With recent restroom renovations complete, the water consumption and demand reduced annually by over 35%, resulting in an oversized, inefficient pumping system.

It required large amounts of energy to run and replacing it would help in the buildings’ on going energy reduction efforts and contribute in maintaining the standards of LEED certification,” Bettin said.

According to Merchandise Mart’s Plumbing Foreman, John Geiss, prior to the retro-fit and during heavy usage the domestic water system would see momentary swings in the system as much as 40-PSI at the top end of the system, resulting in noticeable fluctuations at the fixtures and excessive pipe movement.

The Merchandise Mart is the world’s largest commercial building, largest wholesale design center and one of Chicago’s premier international busine

Back View of the Energy-Saving Pump System

ss locations. Encompassing 4.2 million gross square feet, The Mart spans two city blocks and stands 25 stories high. Today, The Merchandise Mart welcomes more than three million visitors each year to its retail shops, boutiques, 11 floors of permanent showrooms for gift, residential, casual and contract furnishings, 10 floors of office space, dozens of trade shows and a myriad of special educational, community and consumer events.

During peak flows, which typically are during a large tradeshow event or during the workweek, demand can reach 750 gallons a minute when up to 20,000 people populate the building during major exhibitions. However, during low flows, as witnessed during the early morning hours, demand can slow to a few gallons a minute. With such a wide range of flows and given the Merchandise Mart’s demanding show schedule where water consumption constantly changes, the new domestic water system would need to match not only extremely high flow demands but also the low flow demands using the least amount of energy necessary.

During the bidding process, quality, service and experience were the criteria important to Bettin when choosing the companies to complete the work.

“We pre-qualified the companies such as engineer KGWW, Metropolitan Industries, Inc., Great Lakes Plumbing and Blaze Electric based on their experience and reputation,” he said.

Chicago-based Great Lakes Plumbing was awarded the design/build contract based on the proposal they submitted. Great Lakes’ Bob DeGuiseppe, project manager, served as the general plumbing contractor and pump and control system manufacturer Metropolitan Industries, Inc. of Romeoville, Ill., designed the new system and pressure reducing zone stations while Blaze Electric of Broadview, Ill. served as the installing electrical contractor and KJWW of Chicago served as Engineer during the project.

The New “Green” System

Metropolitan’s design of the pump system and pressure reducing zone stations was based on two specific goals that included reducing energy costs on day one of start-up; and ensuring enough redundancy to prevent loss of service in the future due to power or mechanical issues.

Working closely with DeGuiseppe, Metropolitan Chicago Sales Manger, Mike Ponx suggested installing a variable-speed system that would reduce energy costs by half due to the system’s ability to precisely match demand using only the minimal amount of energy necessary.

During low flow periods where little or no demand exists, a variable speed system shuts down entirely saving energy and money while four bladder tanks located in two separate locations help maintain pressure, while the system is in shutdown / low flow mode

Front view of the Energy-Saving Pump System

The system supplied was a variable speed, quadraplex booster system using vertical, multi-stage pumps, total system rated at 1000GPM at 200 PSI. The Merchandise Mart’s peak flows are 750 gallons/minute so in a condition where any single pump fails, the system will still be able to handle the load without shut down. To add to the redundancy, there are two separate power feeds divided between the system. Feed A runs three pumps and Feed B runs two pumps. If either feed A or feed B is lost, the building will still have one electrical feed to supply water to the building without interruption or system shutdown. The electrical control system and plumbing design was also configured to one existing pump to operate as a manual stand-by pump to further add redundancy to the building.

The building is divided into four zones to stabilize pressure. At each zone, pressure reducing valves were downsized to maintain each of the zone’s pressure requirements and the four bladder tanks were installed on the 6’’ cold water express risers to sustain pressure when the system shuts off during low flow periods.

Using bladder tanks at the top of the express riser, pressure is stored 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.

During installation of the pumps and controls, interruption of service did not occur to the building said DeGuiseppe. “Since the existing booster system had two independent electrical feeds and the building could not be without water at any time, the electrical controls were built into two sections, which would be mated together during the second phase, he said. DeGuiseppe spilt the new control panel into two sections, Blaze Electric installed the main control section first after disconnecting the first electrical feed, than installed the first two of four pumps using the new controls. Once the first two new pumps were online Blaze Electric removed the old panel and installed the second half of the new control panel, which was designed to mate up to the first section. After that, the remaining two pumps were installed.

Green Savings

The energy savings realized using a variable speed booster system are tremendous. In order to commission the system and measure the savings, meters were installed to measure flow and energy consumption.

Results appeared quickly with the installation of the first two pumps.  Energy reductions in the first week were 34%.  With completion of all the pumps, the bladder tanks came on line and the system was set for commissioning.  Utilizing a system by-pass and real-time flow meter, various loads were created to allow for fine tuning of the drives and staging of  pumps.  With the removal of the top zone PRV, the system pressure was successfully lowered from 200 to 185.   Taking advantage of the bladder tanks, the night-time mode was enabled resulting in the cycling of pumps.  Week after week evaluation has shown a reduction in energy by up to 50% with an anticipated annual energy reduction of over 125,000 kwh.

Within a decade, the system will pay for itself entirely on energy-savings and the expected life of this system is over 25-30 years so eventually the system will not only pay the end-user for the cost of the system but it will also pay the costs to replace itself in its lifetime!

Conclusion

According to Geiss, the completion of the retro-fit work improved the overall performance of the system by lowering working pressure and reducing fluctuations throughout the system.

“For the first time we have experienced the most even flow and the best overall PSI performance at the top of the 10th, 18th and 25th floor zones,” he said.

This was accomplished by reducing the size of the valves in the respective zones to “tighten,” up the flow in conjunction to the smooth operation of the variable speed booster system and bladder tanks that feed and assist the entire system as a whole.

“Overall Metropolitan and all parties involved came through with the promise and commitment to a 2-4 psi swing, and an energy savings that will match the Merchandise Mart’s committed effort to LEED providing for a GREENER tomorrow,” said Geiss.

Contact Us

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

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