Major Lift Station Renovation for O’Hara Woods Includes Increased Pumping Capacity, Upgraded Controls and Prefabricated Concrete Structure
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.”
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.
“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.
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 firstname.lastname@example.org.