Posts Tagged ‘Variable Speed Controls’

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.

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.

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.

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.

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.

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

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