Efficient and reliable transportation infrastructure is crucial for moving people, goods and services. Well-maintained roads and highways enhance the economy and quality of life for citizens.
Calumet Avenue, a major highway in Northwest Indiana, frequently experiences heavy stop-and-go traffic, especially at its intersections with East and West 45th Street and the national railroad. In the town of Munster, the situation is worsened by railroad crossings and frequent freight trains, leading to daily gridlock.
Addressing the Problem From Beneath
To alleviate this long-standing issue, the Indiana Department of Transportation (INDOT) proposed an underpass at nearby 45th Street. This would allow vehicles to travel beneath the railroad tracks, reducing reliance on Calumet Avenue.
Ensuring the new underpass would not flood during rainfall was crucial. A complete system solution was designed to prevent flooding. The project included a lift station built with highly durable materials to transport collected stormwater to an adjacent retention pond. Calculations, pump selection, electrical and controls design, standby power generator sizing, equipment specifications and drawings were all provided by a specialized engineering team.
and generator
Selecting the Right Materials
Another consideration was INDOT’s commitment to enhancing infrastructure while managing assets throughout their life cycle. The recommended material for the wet well structure was fiber-reinforced polymer (FRP), known for its durability and cost-effectiveness. Since stormwater stations, especially those with a viaduct, face aggressive conditions due to road salt, FRP was chosen specifically for its ability to withstand corrosive contaminants in rainwater, including gasoline, diesel and road salt.
Stainless steel was used for piping and accessories inside the station, and proper pump cables were selected to withstand various chemicals. Water quality was also taken into consideration, as pumps, base elbows and piping would be sitting in water for extended periods between rain events.
Assembly & Completion
The lift station was assembled in a Romeoville, Illinois, facility, where prefabrications are completed in-house, and a construction company of Highland, Indiana, installed the equipment on-site. With less to do in the field, there were fewer chances for delays and rising costs.
In the end, the triplex, variable speed, submersible stormwater pump system included:
- Prefabricated FRP wet well structure measuring 12 feet in diameter x 39 feet deep with all internal stainless-steel piping and pump removal components, including hatches with safety grates, installed before delivery
- 12-feet submersible pumps capable of approximately 10,000 gallons per minute (gpm) with all three pumps operating simultaneously when needed at full speed
- Prefabricated control building measuring 8 feet wide x 12 feet long x 8 feet inside height housing all power distribution and control equipment, including ultra-low harmonic variable frequency drives
- 150 kilowatt (kW) natural gas-fueled standby power generator with sound-attenuated enclosure
The lift station startup was completed in late 2020, with service technicians on-site to verify all equipment was functioning properly. Personnel were trained on the systems, and everyone was satisfied with the operations.
Monitoring & Security
Aligning with the other existing potable and stormwater pump stations within the town, the addition of a level management system controller was an obvious choice for the newly installed lift station. The controls were integrated into a cloud-based supervisory control and data acquisition (SCADA) monitoring platform, providing access to system operations and alarm notifications from users’ mobile devices while also generating the necessary reports needed for governing agencies.
Operators have benefited significantly from the security measures, encryption and backend updates provided by the cloud-based SCADA system. These features ensure sensitive operational data is protected from cyber threats, while automatic updates keep the system running smoothly with the latest security patches and enhancements. This integration has not only improved the reliability and efficiency of the lift station but also aligns with the town’s commitment to leveraging advanced technology for better infrastructure management.
The new underpass solves the current gridlock problems and creates opportunities for new economic development due to improved traffic flow. Continued growth is expected throughout Northwest Indiana, especially as new transportation infrastructure opportunities develop.
