Posts Tagged ‘Green Pumping Solutions’

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.

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.

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.

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.

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.

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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