Blog

Today, it’s difficult to find things that aren’t connected to the internet. From vehicles and appliances to toys and TVs, everything seems to connect to something else. Sometimes, this can seem a little obnoxious or even unnecessary, but connectivity also serves an important purpose, even — or maybe even especially — in the world of water supply.

After the town of Schaghticoke, New York experienced an issue with their booster pump system and the lease line failed to provide necessary alerts, the importance of connectivity quickly surfaced. However, this unfortunate experience also presented two opportunities. First, it gave Schaghticoke a good reason to assess its water infrastructure and plan for necessary upgrades to the aging system. Second, it offered Emmons Metro the chance to demonstrate their capabilities with the MetroCloud system.

An Alarm That Failed to Sound

When a watermain issue led to low suction pressure within Schaghticoke’s triplex booster system (a Metropolitan Industries design that’s still running strong after 20 years), the pumps shut down, just like they’re designed to do. The problem was that no one was notified of the issue. The dialer failed to connect and alert the operations team, delaying their efforts to make necessary repairs. A new modem and line were added as a quick fix in the short term, which gave the municipality time to explore a modern upgrade with more reliable communication methods for receiving notifications with additional access to real-time insights.

While the Illinois-based Metropolitan is used to crossing state lines to help customers across the United States, we also know there’s value in a local presence. Local relationships go a long way, local service speaks volumes, and with Emmons Metro in Albany, New York, our definition of local has expanded to include New York state and parts of New England.

A History of Service and a Strong Local Name

Emmons Metro has been serving upstate New York and surrounding areas for over 30 years, meaning they’ve developed considerable expertise in the industry and strong relationships in the market. So, when the dialer failed in Schaghticoke, Emmons Metro got the call, and they were able to be on-site quickly to assess the issue and better understand the needed upgrades. Of course, because no two applications are exactly alike and budgets needed to be sorted before work could begin, the Schaghticoke project still required a fair amount of up-front planning before new equipment could be installed.

As the team in Schaghticoke worked to secure funds from the 2021 Infrastructure Investment and Jobs Act., Emmons Metro worked with the Metropolitan team in Illinois to design a more modern solution while also remaining in close communication with the town should any unforeseen events occur. When it was finally time to change out the drivers with more modern equipment, Metropolitan was ready to assist as needed while Emmons’ on-the-ground team was on-site and ready to work.

The project was relatively straightforward, but nothing is ever really a true one-to-one, in-and-out replacement. In this case, there were two small challenges that required workarounds:

1. First, the new control panel was larger than the old and had to be installed on the existing skid.
2. Second, the old system relied on an aftermarket flow meter that had been added to the original equipment after its initial installation. To bring that component into the new MetroCloud system, a custom program modification was necessary.

Newly installed control panel and VFDs customized to fit with the
existing booster pump system equipment.

Fortunately, these challenges were identified in the design stage, and Emmons planned for its integration. When the system was brought online for the first time, however, the value of both a local partner and a reliable, cloud-supported notification system were thrust into the spotlight.

At startup, a check valve failed and MetroCloud, quickly detecting a suction issue, alerted the system. Having just upgraded from a failing dialer, this was an obvious improvement. Thankfully, because the Emmons team is local and was on-site in Schaghticoke to ensure a smooth start, they were able to pull and clear two check valves and replace a third without needing to book flights or schedule a service call.

The entire experience left Emmons Metro fully prepared to sell, install, and service our MetroCloud platform. And, equally as important, Metropolitan as a whole officially realized what we’ve known all along: adding a Northeast arm to our growing company and expertise allows us to better serve our customers from coast to coast and everywhere in-between.

CAD drawing of customized panel components for custom-fitting with the existing booster system.

October 1, 2021
By Martin Hawrysko & Susan Gnirke
Emmons Metro LLC

Within the sparsely populated area of the Mohawk Valley in Upstate New York are Gloversville and Johnstown. The two communities have historically been closely connected by location, resources and industry since the 1700’s. By the early 20th century, the area had become the country’s center for glove manufacturing and was known as the glove capital of the world, thus earning the nickname “Glove Cities.” While glove manufacturing in the area has since dropped off, the remaining glove industry businesses serve as a reminder of the area’s proud manufacturing history.

In 1992, the Town of Johnstown acquired over six acres of land that housed a water source shed and pump system used by the “Glove Cities” municipalities and the local fire district. In 1996, Kim Emmons and his team at then Emmons Pump & Control of Albany, N.Y. became involved with supplying a municipal booster system on Wesskum Woods Road, a residential street shared by the two communities. To ensure that the project proceeded as planned, Emmons turned to his then system design and manufacturing partner, Metropolitan Industries of Romeoville, Ill.

The collaboration in planning, engineering, meticulous attention to detail, and coordination every step of the way resulted in a successful development and installation of the booster system. The Wesskum Woods Road project was one of several that demonstrated the positive working relationship between the two companies, which paved the way for a natural transition in 2019 following Metropolitan Industries’ acquisition of Emmons Pump & Control. Today, both Metropolitan Industries and now Emmons Metro, work in tandem to manufacture and supply various system-based water pumping and control solutions throughout North America.

Going on 25 years since the original install, Emmons, now the general manager of Emmons Metro, knew that the Wesskum Woods Road booster system was nearing its end of life. “We had been servicing this system since it was originally installed,” said Emmons. “Due to the amount of maintenance required keeping the system operational, we had strongly been recommending an upgrade over the last couple of years.” Following a public bid for the replacement skid, the contractor who secured the project turned to Emmons Metro. And just as Emmons did 25 years ago, he called upon Metropolitan Industries to assist.

While the new system matched the footprint of the original, the change in technology over the last 25 years provided an opportunity to seize a far more energy efficient solution according to Emmons. “We recommended that the system be upgraded to current control technology along with vertical multi-stage pumps for the normal domestic load and a high capacity pump for hydrant flows.”

Angled picture of the booster system prior to arriving at the job site emphasizing the high capacity hydrant flow pump.

The upgrade to variable speed meant replacing all of the existing controls and pressure regulating valves, which had required regular maintenance. “Variable speed allows for the system to only use the energy absolutely needed to make the work happen,” said Mike Tierney, sales and technical consultant at Metropolitan Industries. The result is better electrical efficiencies and less wear and tear on the equipment.

To further capitalize on minimizing wear and tear, the two domestic water pumps were vertical multi-stage, as opposed to end suction. The 3:1 turn down ratio of end suction pumps is relatively small according to Tierney, compared to 10:1 ratio of vertical multi-stage pumps, which offers a steeper curve profile.

“That pump can operate all day and every day at a lower flow rate without any concern over potential radial loading,” said Tierney. “The pump won’t object to the lower gallons-per-minute.” Tierney attributes the use of a diffuser housing in place of a traditional pump volute casing as the difference maker. Tierney emphasized that with people now more conscious of their water use, domestic flows on average have trended lower.

“With the water conservation taking place, the net result is when we put in a pump, we typically operate it at way low capacities,” said Tierney. “Vertical multi-stage pumps make great sense from that perspective. In most scenarios, it will perform at its lower capabilities and there is no harm in doing that. And when it is necessary to utilize its full capabilities, it will keep up. As soon as the hydrant opens, the bigger pump comes on, allowing the system to go from 50 gallons-per-minute up to 500 gallons-per-minute without a hitch.”

The single skid configuration of the two domestic vertical multi-stage pumps and the high capacity pump for hydrant flows personifies the customization possibilities routinely offered by Metropolitan Industries and Emmons Metro. With the design, manufacturing, and overall project management all taking place in-house, we can output complete customizable systems that adhere to the unique specifications of a given application.

Following a successful installation and start-up of the new system, the water supply alongside Wesskum Woods Road is set for the long haul. The new system more than meets the needs of today while going a long way to reduce energy consumption. Just the same as 25 years ago, the engineered and designed materials used in the manufacturing remain solid through and through while the people to be trusted and products provided are dependable, reliable, and ready for today and well into the future.

Installation of the booster pump skid on Wesskum Woods Rd.

Booster system skid installed on Wesskum Woods Rd. in the Glove Cities.

New underpass located at 45th St and Calumet Ave. Lift Station Generator and Control Building can be seen upper right.

August 16, 2021
By Martin Hawrysko, Metropolitan Industries, Inc.

Efficient and reliable transportation infrastructure is more than about moving people, goods, and services from one point to another. Well-maintained roads and highways that are accessible and keep traffic moving create a healthy economy and help enhance the quality of life for citizens.

In the case of Calumet Ave., a prominent Northwest Indiana highway that intersects with a major interstate, heavy stop-and-go traffic was considered normal. In the Town of Munster, railroad crossings and frequent freight trains made the problem far worse, resulting in nightmare gridlock for vehicles each day.

Addressing the Problem from Beneath

As a long source of frustration for residents and commuters, the Indiana Department of Transportation (INDOT) came up with a solution to circumvent the railroad delays. The enhancement plan included an underpass at nearby 45th St. which would allow vehicles to travel beneath the railroad tracks, therefore relieving some of the reliance on Calumet Ave.

Ensuring that the new underpass would not flood during each rainfall was paramount. Metropolitan Industries, the parent company of Emmons Metro, was brought in to provide a complete system solution that would ensure flooding would not become a problem. The project called for a lift station built with highly durable materials capable of transporting collected stormwater to the adjacent retention pond. Metropolitan provided calculations, pump selection, electrical and controls design, standby power generator sizing, equipment specifications, and drawings.

Immediate Cost Savings Without Short-Changing the Future

Another consideration while proposing a solution to INDOT was their commitment to enhancing infrastructure while allowing for better management of assets throughout the lifecycle. To support that endeavor, the recommended choice of material for the wet well structure was fiber reinforced polymer, a highly durable material known to stand up to external factors such as extreme environmental conditions. Fiber reinforced polymer (often identified in the field as fiberglass) is praised for its cost-effectiveness compared to other materials used for these types of structures.

“Stormwater stations, especially like this one with a viaduct, have a lot of road salt, which is pretty aggressive,” said Keith Girup, municipal sales representative at Metropolitan. “That was a key part of why we went with the fiber reinforced polymer; because it could withstand the corrosive contaminants that would be in rainwater, including gasoline, diesel, road salt, etc.”

“Piping and accessories inside the station are stainless steel,” added Girup. “There was careful consideration when selecting the proper pump cables so they could withstand whichever chemicals they might be subjected to. We have to think about what we are going to be pumping. There’s always three to four feet at the bottom of the wet well, so you have your pumps, your base elbows, and your piping sitting in whatever this water quality is for an extended period of time until another rain event occurs.”

Stormwater control building interior.

With the choice of fiber reinforced polymer, the lift station was assembled at Metropolitan’s Romeoville, Ill. facility, where prefabrications are completed in-house. Girup emphasized that the prefabrication approach for lift stations ends up being much more efficient, both in terms of time and costs, for the end user.

“With prefab, it’s a one-day shot,” said Girup. “There is no contractor building it in the field for several weeks, at which it’s definitely going to rain at some point. So, they have to put contingency costs for bypass pumping and dewatering. All of those contingency costs and efforts are eliminated with prefab.”

Grimmer Construction Company of Highland, Indiana was on-site to install equipment. With less to do in the field, the less chance there are for delays and rising costs according to Girup. “Excavation, installation, powering, and backfilling are all completed rapidly. Get in, get out, and be done with reduced circumstances and time span playing out.”

“And the quality, you know what you’re getting up front,” said Girup in reference to the lift station being built at Metropolitan. “Built in a controlled environment, not in the field. It’s all been tested prior to delivery. There are no surprises afterward.”

Installation of reinforced polymer wet well.

From Our Roof to the Job Site and Beyond

In the end, the triplex, variable speed, submersible stormwater pump system equipment provided by Metropolitan included:

• Prefabricated fiber reinforced polymer wet well structure measuring 12’ diameter x 39’ deep with all internal stainless steel piping and pump removal components, including hatches with safety grates, installed before delivery.
• 12″ submersible pumps capable of approximate 10,000 GPM with all three pumps operating simultaneously when needed
  at full speed.
• Prefabricated control building measuring 8’ wide x 12’ long x 8’ inside height house all power distribution and control equipment including ultra-low harmonic variable frequency drives.
• 150 kW natural gas fueled standby power generator with sound attenuated enclosure.

Aligning with the other existing potable and stormwater pump stations within the town, the addition of Metropolitan’s LMS II controller was an obvious choice for the newly installed lift station. Integrated with the LMS II was MetroCloud, our cloud-based SCADA monitoring platform, providing access to system operations and alarm notifications from users’ mobile devices while also seamlessly generating the necessary reports needed for governing agencies.

The lift station start-up was completed in late 2020, with Metropolitan service technicians on-site to verify that all Metropolitan provided equipment was indeed functioning properly. All personnel were trained on the systems, and everybody was satisfied with system operations. From project conceptualization through installation, Metropolitan was involved in every step of the way.

The new underpass solves the current gridlock problems and creates the opportunity for new economic development because of the better traffic flow.

We look forward to the continued growth that is poised to occur throughout Northwest Indiana, especially as new transportation infrastructure opportunities develop. And if another unique water collecting challenge arises for any of those infrastructure opportunities, Metropolitan will be on call to take the incoming call.

Prefabricated control building & generator.

The manufacturing and engineering capabilities of Metropolitan Industries are readibly available via Emmons Metro, including the integration of the MetroCloud SCADA platform. Whether your project calls for a new lift station or the retrofitting of MetroCloud into an existing application, our collective resources provide robust solutions to the most dynamic water and wastewater challenges. To learn more or to get your free quote process started, send us a message or give us a call at (518) 694-0404.

Completed upgraded potable water pump station at W. Averell Harriman State Office Building Campus.

The surge of office campuses began in the 1950’s. Post World War II era, many people were fleeing what was considered the overly populated and polluted city to find solace in the suburbs. In an effort to follow the white collar employees that companies were searching for, corporate campuses were born.

One such visionary to follow suit in New York was Governor W. Averell Harriman. His vision included a campus that would be more accessible for the state employees that were increasing by number as well as provide more space for parking. The campus eventually included the State University of New York at Albany (SUNYA) and now boasts over three million square feet of office space for over 7,000 state employees and 13,000 students of the university.

As one can imagine, the critical potable water and wastewater management needs and designs have changed dramatically from over 60 years ago. Keeping up with the demands is costly, ongoing, and crucial. But progress is fluid, always moving, just like the water.

Emmons Metro, a division of Metropolitan Industries, was first approached by MJ Engineering and Land Surveying, P.C. in 2016 about upgrading the campus’ potable water pump station. Based on conversations between Emmons and MJ Engineering and an understanding of the preliminary specifications, a pump selection along with the custom control panel theory of operation was made and brought to bid in 2018.

Unfortunately, issues with the building specified to house the equipment were identified and all bids were rejected. After a bigger building was selected, the job went back out to bid in June 2019 which brought with it new challenges.

Crew and Subs responsible for making this project a success.

The volume of water that was being calculated for the new pump system was very high, even at resting hours. The original vertical in-line pumps that Emmons specified for the low flow service were discontinued due to new hydraulic efficiency standards by the Department of Energy. Unfortunately, the new replacement pumps from the same manufacturer met all criteria except for the minimum continuous stable flow (MCSF) requirement. Replacement pumps at a price level that was acceptable to all parties needed to be found.

With Emmons Metro’s commitment to continuous collaboration with the engineers to identify what is needed for each project and the manufacturers to make it happen, Grundfos Paco VL series vertical in-line pumps were approved and furnished for this project.

Another challenge according to Hal Bayly with Kingsley Arms Inc, the general contractor, was the pilings. The estimated depth for the project was 100’ but for other projects on the campus, they had to go deeper. Luckily, the specifications were met and the 5,000 feet of pipe was laid efficiently.

When asking Hal what his most valuable resource on the project was, he noted “the crews and the subs” without missing a beat.

Despite harsh winters, geological unknowns, Department of Energy changes, and a pandemic, the project was a success and finished ahead of schedule.

Team leader Kim Emmons next to one of the newly installed pumps.

At Emmons Metro, we know the key for successful projects is found in the planning and the collaboration between all project partners. Kim Emmons, general manager of Emmons Metro, adds that one of our most valuable attributes is the ability to overcome and adapt. This mantra has served Emmons Metro and the rest of the Metropolitan Industries family well during our time in the industry. Project partners and end-users will benefit greatly from Emmons Metro’s years of experience.

To provide the best hydraulic solution to the various challenges that each project presents, we review several pump manufacturers’ offerings to ensure the most state-of-the-art mechanical equipment, i.e., pumps and motors, is being used. Customers will also have the added benefit of a well-versed controls provider and expert design team with Emmons’ parent company, Metropolitan Industries.

System owners will have peace of mind knowing the years of experience and the 24/7 field service capabilities of Emmons Metro were ingrained from the project’s very beginnings for their water, wastewater, and stormwater pumping needs.

And while equipment and technology will no doubt change again, the potable water is now flowing without issue and ready for the SUNYA campus to fill up again as well as the New York State office buildings.

New six-pump variable speed control panel with double door enclosure.

Water management professionals are never really off the clock. After all, the systems and processes that they maintain and monitor need to be fully operational at all times. So even if they’re not on-site or it’s after hours, these individuals need to have the ability to make sure operations are maintaining as expected.

Non-municipal water systems, like mobile home communities, can be tricky though. More often than not, they have restricted financial resources and limited manpower. These entities may rely on contractors to provide water management services which can also have its limitations. And what happens when phantom alarms or minor issues arise that end up costing these budget restricted entities unnecessary service bills? It leads to short-term fixes but no long-term solutions.

That’s where our cloud-based SCADA solution, MetroCloud, comes in.

In this most recent case study, MetroCloud examines how their state-of-the-art SCADA solution helped Black Hawk Estates, a mobile home community in Illinois, save money while also creating more efficiencies between onsite management and their water management contractor.

Learn how the MetroCloud-ready LMS II Level Control System brings intuitive and affordable remote lift station monitoring to just about any application.

Shandaken, N.Y., an area critical to the water supply of New York City.

January 22, 2021
By Susan Gnirke & Martin Hawrysko

During normal times, New York City is filled with a surplus of people, movement, and activity. Millions of people come and go while going about their business, with hardly any thought towards the many behind the scenes services and processes that allow it to run as it does – at least until something goes wrong.

Of all the processes that New York City is dependent on, one of the most important is its water supply. Any disruption to that availability would without a doubt be catastrophic. As it turns out, such a scenario wasn’t far off from occurring.

The problem began 125 miles north in Shandaken, N.Y. a small rural community compiled of 12 hamlets. Thanks to a 2018 environmental impact study, it was discovered that the septic water systems in Shandaken as well as many other communities were on the brink of failure. Collectively, these areas are an integral part of the New York City Catskill-Delaware Watershed, which is responsible for supplying New York City’s water.

Both the New York City Department of Environmental Protection (NYC-DEP) and Catskill Watershed Corporation, agencies responsible for protecting the water quality in New York City’s Watershed West of the Hudson River, recognized the necessity to work proactively to keep clean water flowing through the watersheds.

After thorough examination, it was decided that the most practical and efficient approach to solving the problem was by adding a secondary treatment system. Evergreen Mountain Contracting was awarded the job, designed by Lamont Engineers based in Cobleskill, N.Y. Their recommendation was to supplement the septic systems with Anua Puraflo systems, which provide an advanced secondary treatment process that purifies septic tank effluent to an extremely high degree before final dispersal.

Based on previous work experience with the Anua Puraflo systems, Evergreen Mountain Contracting knew that Emmons Metro, a division of Metropolitan Industries, had the experience needed to solve the problem in Shandaken.

Kim Emmons, general manager of Emmons Metro, became involved with the Anua Puraflo systems 17 years earlier when it was first introduced as a new process to supplement septic systems. Following a thorough vetting with the manufacturer, researching the science, and examining the capability of its components, Emmons saw the potential in the green-friendly system, and recognized that it would be an efficient, effective, and nature-based solution to protect the integrity of drinking water, especially in New York’s rural areas.

Anua Puraflo system that Emmons Metro provided, being installed in Shandaken, N.Y

The Anua Puraflo system utilizes a peat fiber as a biofilter to purify septic tanks. This environmentally friendly process uses little to no energy, resulting in clean water at a lowered cost. In addition to being simple to use, its unique peat fiber with high lignin content provides for a longer media life.

The filtered septic tank effluent collects under gravity in the pump tank. A timed dosing system is activated by a programmable timer, which pumps the effluent through a flow splitting inlet manifold located at the base of the treatment modules. An orifice plate located inside the top of each inlet manifold allows the flows to be split equally and fed simultaneously to each biofilter module.

The inlet manifold is connected to the base of the biofilter module and is fed upwards to a rectangular distribution grid located 6 inches below the top of the lid. The effluent percolates laterally and vertically through the depth of the peat fiber treatment media and emerges as a clear, innocuous liquid from the base of the system. The treated effluent is then collected and dispersed. To ensure long-term safety, Puraflo systems are inspected annually to test the water quality coming out and going in.

The integration of the Anua Puralfo systems for the Shandaken project was recently completed, sparing New York City from a disruption to the quality of its water supply. As a result, the millions of people who live, work, and play within New York City can continue going about their business without a second thought to its water supply process.

To this day, Emmons Metro continues to promote the Anua Puraflo systems for the various watersheds of the NYC-DEP, the Lake George Region, the Adirondacks, and Western New York.

The most recent success in Shandaken further fuels Emmons Metro’s enthusiastic advocating of the system. As a result, New Yorkers have cleaner water and more effective septic solutions that make the application viable for all communities, large and small.

A successful installation of the Anua Puraflo system in Shandaken, N.Y

Trident Manufacturing headquarters in Pingree Grove, Ill.

2020 was a memorable year. It required a level of resilience, flexibility, and collaboration like we’ve never seen before.

So when Metropolitan Industries, our parent company, was asked how fast they could complete a sanitary lift station project for a Chicago-based medical manufacturing facility wanting to open earlier in order to support COVID-19 relief efforts, Metropolitan let them know the project would be ready in less than a month.

Turnaround times like that are unheard of in our industry. But as a single-source supplier, Metropolitan Industries was able to save time with component sourcing while also building, testing, and programming everything in their facility for a seamless installation. All while also keeping the safety of their employees and customers top of mind.

It’s fair to say that no one wants to tackle rush jobs, but as a company, we strive to be prepared for the unpredictable so our customers know they have someone they could rely on.

To learn more, please continue with the full Trident Manufacturing project story via the Metropolitan Industries website.