Quarter 3 2019
Pump industry insight from
FOCUS ON: Utilities & wastewater
Tackling the wet wipe dilemma
Condition monitoring: The positive impact
Pump Industry News
Motors | Automation | Energy | Transmission & Distribution | Coatings
GEAR UP FOR A NEW GENERATION WEG MOTOR SCAN
The monitoring solution for Industry 4.0 - for more information visit www.weg.net/wegmotorscan/en
We present the WG20 product range extension up to 18.000 Nm WG20 is the first geared motor program to be completely developed by WEG. It consists of helical, flat and bevel-helical gearboxes offering high efficiencies throughout the large gear range. The specification and design of the robust housing is compatible with those already established on the market making the WG20 fully interchangeable with other geared motors in an existing system or production line without delays or conversions. This flexibility makes the WG20 series of products both versatile and realiable for a wide range of applications. Learn more about the WG20: www.weg.net/wg20
Transforming energy into solutions.
CONTENTS 3 Editor Chris Callander email@example.com 01732 671123 Contributing Editor Suzanne Gill firstname.lastname@example.org Publisher Andrew Castle email@example.com 07785 290034 Accounts Touchwave Media Ltd firstname.lastname@example.org Production G and C Media Ltd email@example.com
For over three-quarters of a century the British Pump Manufacturers’ Association (BPMA) has been serving the interests of UK and Irish suppliers of liquid pumps and pumping equipment.
irstly, I’d like to thank those of you who have given us your feedback on flow and how the publication is developing. It’s encouraging to get so many positive comments, but also some fabulous ideas. The magazine is for you, users of pumps and pumping systems, so what you think about flow, and what you want from it, is important to us. For our third issue, the theme is utilities and wastewater. In our main feature, we pick up on the topic of ragging, raised by Gary Wilde in the last issue. This piece looks at how the industry is helping utilities and wastewater processors to overcome the challenge. We also explore the role edge computing, the Industrial Internet of Things and cloud computing can play in monitoring systems, particularly in remote locations. Elsewhere in the issue we have an interesting article on the role condition monitoring can play in a preventative maintenance strategy, and in our Q&A we return to the often-misunderstood topic of NPSH, this time in a suction lift scenario. We also explore the challenge of developing much-needed engineering talent for the future, with a piece from Primary Engineer’s Susan Scurlock MBE, which looks at the role the industry can play. And, on the subject of developing engineering talent, the Pump Industry Awards discovers the journey an early recipient of the Young Engineer of the Year award has been on, as the awards celebrates its 20th anniversary. Add to that news from both the BPMA and the wider industry, a host of product news and updates, and a new opinion piece looking at non-compliant pumps, and you have in your hands what we hope you will agree is another excellent issue. And don’t forget, we love your feedback, comments and ideas. So please, let us know what you think by emailing the editor – firstname.lastname@example.org. Richard Harden, President, BPMA
PUMP INDUSTRY NEWS BPMA National Metalforming Centre 47 Birmingham Road West Bromwich B70 6PY www.bpma.org.uk
14 Calculate NPSH in a suction lift application
Saniflo joins BPMA New HQ for Sulzer
Twitter @bpmapumps 6
BPMA membership grows
flow is a controlled circulation journal published quarterly on behalf of the BPMA by Touchwave Media Ltd and G and C Media Ltd. For a copy of the magazine’s terms of control and to request a copy please email email@example.com The content of flow magazine does not necessarily reflect the views of the editor, publishers or the BPMA. The publishers accept no legal responsibility for loss arising from information in this publication and do not endorse any products or processes mentioned within it. No part of this publication may be reproduced or stored in a retrieval system without the publisher’s written consent. © BPMA. All rights reserved.
awards update 7
Celebrating pump excellence for 20 years
PRODUCTS 8 New products for the pump industry
SKILLS 12 Shrinking the skills gap
FEATURE 16 The positive impact of condition monitoring
Focus on utilities & wastewater 18 Tackling the wet wipe dilemma 22 Pump monitoring at the cutting edge 24 Utilities & wastewater news
OPINION 26 Action needed on non-compliant pumps Quarter 3 2019
4 INDUSTRY NEWS
WOMEN IN ENGINEERING ADVOCATE JOINS AESSEAL BOARD
echanical seal specialist, AESSEAL has appointed the former Institution of Mechanical Engineers President (IMechE), Carolyn Griffiths, to its board. Joining AESSEAL as a non-executive director, Carolyn is a senior professional from the rail industry who established and was the first Chief Inspector of the UK’s Rail Accident Investigation Branch and is vocal in her support for change within the engineering profession.
Carolyn was elected President of the Institution of Mechanical Engineers in 2017 and used the platform to focus on the need to attract more young people to the engineering profession and, in particular, to make engineering more attractive to women. She is also committed to further developing professional standards in engineering and to that end, she serves as a Board member for the Engineering Council.
SANIFLO JOINS BPMA FOLLOWING ACQUISITION
aniflo, the inventor of the macerator, has a comprehensive range of pumps and lifting stations that work in domestic and commercial sectors throughout the UK. In 2017 the company produced its first ever underground pump stations; the Sanifos range, which is designed to be sited underground where the drainage is too low for a sewer or for a surface mounted pump. With models ranging from 110 to 1300 litres, the pumps can be used to pump waste from a single dwelling, large commercial premises or multiple smaller properties, such as chalets, pods, containers or caravans. To consolidate the success of the Sanifos range and further strengthen Saniflo’s position in the global pump market, the French parent company
of Saniflo, SFA, has acquired Zehnder Pumpen GmbH of Germany. Founded in 1970 Zehnder is a specialist in pump technology for water purification, industry, home and garden and has a comprehensive portfolio of products that are globally renowned for innovation, durability and performance. The new range will immediately expand Saniflo’s pump range to 3100 litres of waste and opens up more market opportunities for the company.
ARMSTRONG FLUID TECHNOLOGY SIGNS NET ZERO CARBON BUILDINGS COMMITMENT
ARMSTRONG FLUID TECHNOLOGY has announced that it has signed the Net Zero Carbon Buildings Commitment, launched by the World Green Building Council. The commitment is unique in positioning energy efficiency as a central component to achieving decarbonisation across global portfolios. All signatories to the Net Zero Carbon Buildings Commitment pledge to reach net zero carbon operating emissions within their portfolios by 2030. To meet this commitment, Armstrong has committed to implement energy efficiency measures to lower electricity and fossil fuel consumption, generate renewable energy on-site and to procure renewable generated electricity and carbon offsets.
AXFLOW IS ON THE ACQUISITION TRAIL
xFlow Ireland has announced its acquisition of Irish Pumps & Valves Limited, a supplier of valves, actuators, pumps and ancillary equipment to the wastewater, power generation and process industries. AxFlow Ireland has a long and wellestablished presence in these industries through its pump distribution and service facilities, and by adding valves to its portfolio, it will be able to offer pump and valve packages for large scale projects. Quarter 3 2019
Announcing the acquisition, AxFlow Group CEO, Ole Weiner, said: “This acquisition will enable AxFlow Ireland to enter the valve market in the wastewater sector and thereby capitalise on Irish Pumps & Valves strong position. The strategy of adding valves to our product portfolio has already realised benefits in the food sector with the introduction of SPX products. This is a big opportunity for us to grow valve sales in sectors which AxFlow Ireland has never explored.”
The news came just a matter of weeks after AxFlow Italy announced its acquisition of Generalcontrol S.p.a, a Milan-based distributor of positive displacement (PD) pumps, instruments, vacuum pumps, and compressors. Through its product mix, Generalcontrol has well-established positions in the sanitary, chemical, ceramics and automotive industries. The company is a perfect fit for AxFlow, thanks to its complementary range of products. www.bpma.org.uk
INDUSTRY NEWS 5
CONSTRUCTION STARTS ON SULZER’S NEW BIRMINGHAM SERVICE CENTRE
XYLEM SUPPORTS OPERATION TO MAKE WHALEY BRIDGE DAM SAFE
fter more than 100 years at its Camp Hill site, Sulzer has started the process to move its facilities and create a new centre of excellence for its customers. Sulzer’s brand new service centre will be located at the Birmingham Business Park, where the company will base its UK head office as well as state-ofthe-art repair and maintenance facilities. Sulzer is working with Canmoor Developments Limited to deliver this important project, which aims to provide Sulzer’s customers with best-in-class service for electromechanical repairs as well as new high voltage testing facilities. The 7,618m2 purpose-built service centre has been designed using 3D mapping technology that positions both the existing and new equipment in the most efficient layout. By optimising the floor plan, the material flow will be improved, and project repair times for customers will be minimised. The building phase is scheduled to be completed in early May 2020, after which there will be a carefully planned relocation of all the equipment, such as the copper rolling mill and coil manufacturing machinery, winding machines and the high voltage testbed.
IN A WELL-COORDINATED OPERATION TO PREVENT the collapse of the Toddbrook Reservoir dam wall in Whaley Bridge, Xylem Water Solutions worked with SLD Construction and Kier, to achieve a positive outcome. The wall of the reservoir dam was at serious risk of collapse after days of torrential rain led to what police called an ‘unprecedented, fast-moving, emergency situation’. The water technology company deployed five 55Kw 2250 Flygt submersible dewatering pumps to draw water out of the reservoir at a rate of 250 litres per second. Within a week the water levels had been reduced by more than 10 metres, and the town’s 1,500 residents were allowed to return to their homes. In total seven engineers from Xylem worked on site – often around the clock – from the beginning of the emergency on August 1. As well as installing the submersible pumps, the team set up six large diesel pumps and numerous smaller pumps. Then, as the water receded, they extended the cables and moved the pumps further into the reservoir basin. In addition, they provided aeration units and two 150ml diesel pumps with spray bars to help oxygenate the water so the resident fish could survive in the lower level of water.
ABB AbilityTM Smart Sensor for low voltage motors
less unplanned downtime
extended motor lifetime
improved energy efficiency
— Your motors are talking to you Are you listening?
6 BPMA News
BPMA MEMBERSHIP GROWS Three new members, the publication of the latest buyer’s guide, a sold-out CE Marking course and partnerships with four industry events have marked a busy few months for the BPMA.
or some months the BPMA has been campaigning for the proper CE Marking of assembled systems and machinery utilising pumps. The organisation has a mandate to ensure that the correct standards and directives are adhered to across the pump manufacturing and supply arena and is supporting organisations with the information and guidance needed to be compliant. In July the Association held its first CE Marking guidance course. The session provided the knowledge and skills required to understand the essentials of self-certification CE Marking. It also covered other related product certification and documentation issues. The sold-out course was a huge success and a second has been scheduled for October 1st. Details can be found on the associations’ website (bpma.org.uk) and it is open to members and non-members alike. July also saw the publication of the latest version of the BPMA’s Buyer’s Guide & Directory. Packed full of important pump sector news and technical specifications for all pump types, along with updates from both the BPMA and its 80+ strong membership, the guide, which provides unparalleled levels of technical and application-based information, is available free of charge by contacting Steve Smith at the association on 0121 601 6691. Another publication with invaluable information for the pump sector was published in July; the 2019-20 World Pump report, created specifically for the Pump Industry by Oxford Economics. The report is designed to provide essential insight for professionals looking to understand the economic and sectoral forces shaping the pump market. The report is made available free of charge to members of the BPMA, and non-members can purchase access to the report via the Oxford Economics website (bit.ly/2KTxHSr). The BPMA has welcomed three new members in recent weeks. The first is RuhrPumpen-Industrial, a division of the Global family-owned RuhrPumpen group. The company is responsible for manufacturing, servicing, packaging and supporting pumping equipment for use across the process & industrial markets, construction, and building services for fire protection. The second is DESMI A/S, a global manufacturer of pumps and systems for liquid handling, ballast water management and equipment for oil spill response. The third business to recognise the benefits of BPMA membership is Saniflo, which is best known for its range of domestic macerators and pumps that enable extra facilities to be installed when gravity drainage isn’t feasible. Finally, the BPMA has confirmed its attendance at several industry events scheduled for the coming months. The first is the Flood Expo which takes place at the Birmingham NEC on September 11 and 12. The next is Floodex running at the Peterborough Arena on February 26-27, 2020. Then the association will be at Fluid Sealing in Manchester from March 4-6 and then also in Manchester for ChemUK from May 13-14. Members of the team will be on hand at all these events and look forward to meeting anyone PUMP BUYERS GU IDE & DIRECTORY interested in finding out more about the Association’s work. 2019 -20
THE ENERGY MANAGEMENT SUMMIT Radisson Blu Hotel, London Stansted
October 1-3 2-3
PPMA Total Show
NEC, Birmingham www.ppmatotalshow.co.uk
Asset Integrity Management conference Aberdeen energyinst.org
utility week congress
Hilton Birmingham Metropole event.utilityweek.co.uk/congress
UK Construction Week
NEC, Birmingham www.ukconstructionweek.com
november 11 30-31
Agricultural, Adhesives, Asphalt, Automotive, Ballast, Bilge, Boilers, Cellar Drainage, Chemica l, Condensate, Cryogen ics, Desalination, Dewatering, District Energy, Domestic Water Supply, Dosing, Energy Audits, Filtration Drainage, Effluent, , Fire Fighting, Food & Beverage, Geother Hydraulic Systems, mal, General Process Industrial Water Supply, , HVAC, Inks & Paints, Irrigation Monitoring & Control, , Marine, Lubricat Oil & Gas, Pharma ion, Mining, ceutical, Polymers, Process, Pulp & Paper, Potable Water, Power Generation, Pump Stations, Radio-ac tive Liquids, Rainwat Energy, Reverse Osmosis er, Renewable , Sampling, Sewage , Separators, Solar, Slurries, Storm Water, Sludge, Transfer, Utility, Wash-d own, Water Displays & Feature s, Water Boosting, Water Treatment, Washing & Cleaning
the flood expo
NEC, Birmingham www.thefloodexpo.co.uk
Europump council meeting
NEC, Birmingham www.maintec.co.uk
CERTIFIED PUMP SYSTEM AUDITOR course West Bromwich www.bpma-cpsa.co.uk/
Build 2 perform
Olympia, London www.build2perform.co.uk/
Olympia, London www.londonbuildexpo.com/
Buy with Confiden ce from BPMA Members
Quarter 3 2019
AWARDS UPDATE 7
CELEBRATING PUMP EXCELLENCE FOR 20 YEARS 2020 heralds the 20th anniversary of the BPMA’s Pump Industry Awards – two decades of recognising and rewarding excellence throughout the pump sector.
uring the last 20 years, the Pump Industry Awards has acknowledged and celebrated some incredible innovations, challenging applications, impressive skills development, engineering acumen and great business achievement. It has rewarded companies, products, people and projects, all of which have contributed to making the pump industry the success that it is today. Tirelessly supported by the industry’s trade organisation, the BPMA, along with various partners and sponsors, the Gala Awards Dinner has established itself as a highly regarded and well-respected industry event. What is most encouraging is to see the journey that previous winners have been on. One such example is John Hollins of SPP Pumps, who was the proud recipient of an award back in 2007. “The pump industry awards have had a big impact on my career to date,” explained John. “In 2007, I won the Young Pump Engineer of the Year award. On the way to the awards, I clearly remember Steve Wright on the radio announcing the Pump Industry Awards and wishing the pump industry all the best! “Since 2007 a lot has changed for me, SPP and of course the wider pump industry. I have held various roles at SPP, including SPP’s Product Development Manager, Chief Engineer, and currently, I’m responsible for SPP’s pre-engineered product ranges. Some career highlights are working on the largest Fire Pump ever approved by UL and the Fire Pumps that protect the tallest building in the UK, the Shard. “Outside of SPP, I have the honour of representing the pump industry as
Chairman for the BSI Pump Committee (MCE/6) and the BPMA Technical Committee. “As well as my involvement in SPP’s product development, I’m proud of the fact that the company’s Graduate Training Program has produced several finalists in the Engineer of the Year category since 2007,” concluded John. In recognition of the importance excellent engineering talent plays in the success of the industry, the 2020 awards programme will include two brand new categories. The Contribution to Skills & Training Award will be presented to the company, organisation, or individual(s) that can demonstrate a consistent contribution to the delivery of professional training and skills development within the pump industry. The Rising Star Award will be presented to an employee who has been within the industry for no more
than six years and who has made a significant contribution to a company or the industry, as demonstrated by the individual’s merits, successes, impact on the company, and who has a colleague or customer endorsement. In total there are nine awards up for grabs, and the call for nominations is now open, with online entry forms being available for completion until 5.00pm on Monday 6th January 2020, providing ample time in which to prepare and submit an entry. Entries, which are free of charge, are sought for any company, product, application, service or individual within the pump industry that is worthy of recognition and reward. Nominations are not restricted to BPMA members, and applicants can put forward as many entries as they like including multiple entries in any given category. pumpindustryawards.com
WE DON’T JUST SELL PUMPS, WE ENGINEER SOLUTIONS.
Find yours at tri-ark.com
8 PRODUCT NEWS
MATCH HOSE MATERIAL TO PUMPED FLUIDS HIGH-FLOW ATEX FIVE NEW HOSE MATERIAL immersion sample packs are available to Bredel and APEX pump users. Watson-Marlow Fluid Technology Group (WMFTG) is offering the packs as a way of matching Bredel hose material to the fluid being pumped, which, if completed correctly, is proven to reduce costs. In tough fluid-handling applications, optimised pump life and efficiency depends on selecting the right hose material. Matching the peristaltic hose material to the pumped fluid can reduce downtime, cut production costs and save energy in pumping operations that involve viscous and abrasive fluids. Each Bredel hose features a precisionmachined natural rubber outer, with intermediate compound layers, bonded by multiple nylon cord reinforcements to add strength and flexibility. However, it is the critical inner hose material that must be selected to match the fluid as each Bredel hose bore material has specific attributes for abrasion resistance, along with differing
suitability for oils and greases, acids, alcohols, strong oxidising products and many other substances. The sample packs carry complete hose material data, including temperature resistance, as well as instructions for immersion tests.
THE NEW PIUSI EX100 AND EX140 pumps with ATEX and UL certification, which are available from Bell Flow Systems, have been developed to meet the requirements of various fuel transfer markets. The maximum safety has been applied to these pumps when dealing with potentially explosive atmospheres or flammable fluids. Both the EX100 and EX140 are sturdy and versatile, mainly developed for the heavy-duty transfer of kerosene, petrol and diesel fuel. They are simple to use, as well as compact and versatile. Their adaptability means the pumps can be used for their chosen applications in most working conditions. Offering high and constant flow rates, even in complicated delivery systems, they are high performing pumps that can work without interruption because of their capability to operate continuously.
EFFICIENT SELF-PRIMING PUMPS FOR IMPROVED PERFORMANCE THE HYGIENIC, SELF-PRIMING, LKH Prime 40 pump from Alfa Laval not only offers high energy efficiency and versatility, but it also allows for significantly reduced noise levels and easy maintenance. Performance has been increased, allowing the pump to reach a flowrate up to 110 m3/hr and head of 115m. These results have been achieved thanks to a combination of advanced air-screw technology and optimised impeller and casing geometry. The pump shares common parts with the Alfa Laval LKH range and is EHEDG certified and authorised to carry the 3-A symbol. It has been designed for cleaning-in-place (CIP) duties containing entrained air, and can also pump product, potentially reducing the capital investment when designing process systems â€“ whatever the industry. www.alfalaval.com Quarter 3 2019
LICENCE TO BUILD
READY FOR ANYTHING The Sanifos lifting station opens up new possibilities, as it enables residential or industrial waste water to be pumped along or up to a mains sewer, septic tank or waste treatment plant. Sited underground, it is armed with load balancing pumps and a choice of vortex or high-performance macerating systems, ensuring efficient waste water disposalâ€Ś whatever the project.
Anythingâ€™s possible. Visit saniflo.co.uk to see how.
10 PRODUCT NEWS
MECHANICAL SEALS GAIN IECEX APPROVAL AESSEAL has achieved a world’s first with the recent introduction of its IECEx compliant short canister mixer seal (SCMS) range of mechanical seals.
SINCE THE ORIGINAL INTRODUCTION of the SCMS mechanical seal range it has evolved from being available only as a double seal to being configurable as either a single or double seal.The range has also, literally, grown in size, from the original offering for shaft diameters of up to 220mm, in both liquid lubricated or dry contacting versions. The mechanical seals find applications in a broad range of mixer, agitator and reactor applications and are suitable for side entry (flooded) or top entry (running in vapour) mounting. The original SCMS was ATEX Zone 0 certified for use on systems in explosive atmospheres, but of course this certification is only applicable within the EU. However, in 2016, the global IECEx certification was expanded beyond its original remit for electrical goods to include non-electrical products. AESSEAL responded quickly to this change and, early in 2017, the company began work to have the SCMS verified as meeting the IECEx standard. Working alongside CML, an independent notified body, over an 18-month period detailed design documents were scrutinised. The seals were tested under arduous operational conditions and risk assessment procedures verified. The result of this work is that AESSEAL is now able to offer what it believes to be
the world’s only mechanical seal that is both ATEX and IECEx certified. This affirms the AESSEAL SCMS range as suitable for use in hazardous locations around the world where flammable liquids, vapours, gases or combustible dusts have the potential to cause a fire or explosion. Traditionally, it has been the responsibility of customers to carry out the IECEx verification process themselves, so the availability of pre-certified seals can offer significant savings in time and investment for customers as they no longer need to do this. Luke Farmer, Technical Manager for AESSEAL, said: “AESSEAL’s professional identity and pride is rooted in investment, innovation and customer service, combined with a strong commitment to responsible manufacturing and environmental sustainability. This ethos informed our SW2/3 water management seal support systems – which recycle flush water rather than discard it – a product which can lead to a potential saving of 6.3 million litres of water, per pump, per year. “It also led to our F-range of mechanical seals – developed in direct
response to EU regulations governing food contact materials (FCMs), which require full traceability of raw materials. These ensure that customers in the food and drink and pharmaceutical sectors can be confident that their mechanical seals comply with Regulation (EC) 1935/2004 on FCMs and pose no risk of contamination on production lines. The ATEX and IECEx verified SCMS range is another important step in our innovation journey.” www.aesseal.co.uk
WIRELESS CONDITION MONITORING SULZER HAS ANNOUNCED THE introduction of Sulzer Sense, a wireless IoT condition monitoring system. The solution includes wireless sensors that can be attached to a pump, agitator, motor or any rotating equipment. The sensors measure temperature and vibration and send the data to the cloud. This means that the operating status of the equipment can be remotely monitored 24 hours a day, seven days a week. Sulzer Sense devices are battery-powered, and they operate in a wireless mesh network, making them easy and cost-efficient to deploy and operate. The condition monitoring feature identifies changes in condition parameters and indicates potential faults at an early stage. The new Quarter 3 2019
devices will detect possible imbalance, misalignment, looseness and bearing wear. This supports predictive maintenance and helps to avoid sudden pump failure and eventual downtime. Data captured by the system is sent to the cloud and can be monitored on a mobile, tablet, laptop, etc. through the company’s online service – virtually anywhere and anytime. Users of the system can set an alert value and
will automatically be notified if this value is exceeded without the need for manual measurement. www.sulzer.com
THE HEART OF YOUR BUILDING NOW HAS A BRAIN Mechanical equipment, cloud-based analytics and digital controls perfectly integrated for reliability and efficiency that no other company can match.
environmental contribution of the year
energy efficient innovation
Shrinking the skills gap Our industry knows the skills issue well – but what are we doing to change the future? And how can today’s engineers support and encourage the engineers of tomorrow? Susan Scurlock, Founder of Primary Engineer, shares details of some of the work that is making a difference, and explains how the engineering community can help.
f one thing stands out from our experience at Primary Engineer, it’s that kids don’t need to be ‘turned on’ to the problem finding and solving skills that underpin everything in engineering. They need to be tuned in. We need to provide the ways and means that enable them, their teachers, parents and industry to identify and work together to retain the passion and mindset for creating and improving things. The career and life opportunities that this continual development can offer will be paid back in spades to all the parties involved – everyone wins. The role of the teacher in this process cannot be overstated. So, when we consider programmes that incubate the engineering thinkers of the future, equal consideration must be given to providing the support that teachers need to feel comfortable delivering the relevant STEM content. So training is not just for future engineers but also for the schools and teachers. Without their enthusiasm and their penchant for identifying latent skills in budding designers, we won’t be able to capture engineers in the making, and we can’t nurture the next generation and support them through their educational journey. Keeping and nurturing children’s attention is harder than ever in a world obsessed with celebrity, which is nowadays seen as a career choice by many. We must give boys and girls the tools to think outside of the box. That’s one of the reasons we created the competition: ‘If you were an engineer, what would you do?’. This is the question we’ve posed to schools across the country for the past five years and last year we received over 49,000 responses. Each one showcased individual thinking on a grand (and often extravagant) scale! The competition is the result of joined-up thinking and working between teachers, children and engineers that sets free a creativity unbounded by perceived limitations of what is possible. The teachers engage with the programme, the children interview engineers then answer the one simple question, responding with their annotated design. The engineers then review and grade each design; it’s simple. The cherry on the cake? University students on engineering courses choose a design to build working closely with the pupil and then sharing the process publicly. We know this works. We’ve seen it snowball and are party-to, along with industry, its continued growth. We’ve seen isolated projects grow into ecosystems – truly astonishing and inspiring results from teachers, children, engineers and universities working together. It’s an approach that highlights how to bring about a fundamental change in engineering skills development on a huge scale.
Our vision for our programmes is that they are end-toend and that any industrial company can be involved. And that is where you, today’s engineer, can help us to support tomorrow’s engineer. Each industrial sector should be taking an active role in the future of their workforce, and we’re starting to see how creating this environment is gathering momentum – so we’re focused on continuing to build on that. We’re continuing to join up the community, the programmes and, importantly, the infrastructure, so that kids don’t unlearn their innate problem solving skills, they all have the opportunity to continue to build the skills that underpin the practical application of them. It’s not merely a case of introducing kids to engineering careers, though that is a good start, it’s a matter of introducing them and lighting an attainable, consistent and progressive path, all the way to a rewarding career. Everyone is welcome in engineering the future, and it’s down to all of us to build that future. If you want to know how you or your company can be involved, get in touch via our website. And if you have an idea about how we can do more, tell us. chevron-circle-right www.primaryengineer.com
Maisie Crook from Surrey was just six years old when she designed the Bicycle Sucker to suck water up from a well using the mechanics of the bike as power.
For details of the full range of training available from the BPMA download the FREE training guide at:
bit.ly/BPMAtraining BPMA TR AINING
Quarter 3 2019
CE THROUGH INDEPEND
ENT PUM P TRAINING
i-ALERT Solution T Monitoring i-ALERT
• Monitor your machine from your phone with the free mobile app Monitoring Solution
Sensor | App e right from your phone| Ai
• Monitor all your i-ALERT sensors from a simple web interface
• Monitor tri-axial vibration temperature and run hours www.ittproservices.com
form Sensor | App | Ai Platform
our i-ALERT sensors from a
Product & Services
• Sensor&- Monitor tri-axial vibration temperature, Product Services and run hours. • Sensor - Monitor tri-axial vibration temperature, ibration temperature, run hours. your machine right from your phone App - Monitor • and with -the free mobile app. right from your phone Monitor your machine • App e right from your phone the free mobile app. all your i-ALERT sensors from a Ai Platform - Monitor • with Platform - Monitor all your i-ALERT sensors from a • Ai simple web your i-ALERT sensors from a interface
simple web interface Benefits Available on Apple and Android devices.
lligence the equipmentto health of any Go toMonitor www.i-alert.ai learn more about
elligence the i-ALERT Monitoring Solution and
Monitor the equipment health of any such as pumps,motors, fans, and more. ne such as pumps,motors, fans, and more.
® Smart wireless connectionthe allows monitoring download app eAce.Bluetooth A Bluetooth® Smart wireless connection allows monitoring
Quickly machinesatatonce once and cover Quicklyscan scanmultiple multiple machines and cover with less timefor foranalysis analysis t with lessresources, resources, freeing freeing time andand Available on Apple and Android devices. g.
to www.i-alert.ai to learnofmore aboutuser. Use machine monitoring monitoring ininthe thethe everyday e PutPutGo machine thehands hands of everyday user. the i-ALERT Monitoring Solution and ection Unplanned machine failures can cost 10 times more download the app ction Unplanned machine failures can cost 10 times more
Available on and Apple and Android Available on Apple Android devices. devices.
to www.i-alert.ai learn more about Go toGo www.i-alert.ai to learnto more about the i-ALERT Monitoring SolutionSolution and the i-ALERT Monitoring and download the app the app download
oblems Advanced vibration diagnostic tools are available to
blems Advanced diagnostic tools are available to n use a smart phone or vibration tablet.
use a smart phone or tablet.
ITT Goulds Pumps |
Tel +44(0) 1256 311904
FOR WHERE IT REALLY MATTERS
FIRE PROTECTION SHARD, LONDON
FLOOD DEFENCE PRAGUE 30
SPP PUMPS LIMITED, 1420 LAKEVIEW, ARLINGTON BUSINESS PARK, THEALE, READING, RG7 4SA TEL: +44 (0) 1189 32 31 23 • EMAIL: ENQUIRIES@SPPPUMPS.COM
Calculate NPSH for a suction lift application In this issue of flow we return to the topic of Net Positive Suction Head and specifically calculating it accurately in a high suction lift application. Pav Vatani, Regional Sales Manager for UK & Ireland at Varisco, gave us his explanation of the steps involved in the calculation. flow: What are the considerations when calculating Net Positive Suction Head (NPSH) in a high suction lift application? Pav Vatani: One of the first fascinating facts I ever learnt about pump related physics is that the term ‘suction’ is rather misleading. When I discovered that a pump must create an area of low pressure at the inlet to allow the atmospheric pressure to ‘push’ the liquid to the pump, it changed everything I thought I understood about physics. This explains why it is so important to ensure that there is enough NPSH available in the pump system to push a liquid to the inlet of the pump, without dropping below the required NPSH of the pump. If the NPSHa (available) drops below the NPSHr (required) value of the pump, then cavitation will occur. Most engineers are aware of the risks of cavitation due to high flow, or high-pressure conditions, which is why we always try to make a pump selection at the BEP (Best Efficiency Point) on a pump’s curve. And, one would be forgiven for overlooking the fact that cavitation can be induced due to insufficient NPSHa. However, in my opinion, although a selection can be made mid-curve, the NPSHr can easily exceed the NPSHa in a high suction lift application. For instance, if a suction lift of 6m is required at a given flow rate, it would be conceivable that although relatively mid-point in the pump’s performance curve, the NPSHr of the pump could be 5m. Even before you consider vapour pressure, density and friction losses, you would already exceed the available atmospheric pressure of 10.33m. The pump would still produce a flow rate and head, but would sound very noisy and would likely experience a drop in performance. If allowed to run for an extended period in such a condition, it would likely suffer premature wear and potential failure, the most common of course being a leaking mechanical seal.
Dirty Rain Water
Viscosity 1cP Density 1000 kg/m3 pH Assumed neutral Liquid Temp.
Solids 10mm Flow Rate 20m3/hr Suction Lift
Suction Friction Losses 1m Discharge Static Head 6m Discharge Friction Losses 4m Total Dynamic Head
Atex Safe Area
((101,325 – 2,337) / (1000 x 9.81)) – 4m – 1m (98,988 / 9,810) – 4m – 1m 10.09m – 4m – 1m = 5m NPSHa Using a Varisco J2-120 pump in this example, figure 1 shows that, to prevent cavitation, it requires 3m NPSH at the given duty point. This is a function of the pump. Above we calculated that there would be 5m NPSHa in the proposed pump system. So, the proposed duty point would be a good selection for this size of pump on this application. chevron-circle-right www.varisco.it
System duty point
flow: How do you ensure you are making the right calculation? PV: In order to understand how we accurately calculate the NPSHa of a pump system it is important to understand the formula. For a systems’ NPSHa, expressed in metres, the formula is: (Atmospheric Pressure – Vapour Pressure) – Suction Lift – Friction Loss = NPSHa
(Density x Gravity)
First, we need to take the atmospheric pressure in Pascals minus the vapour pressure of the liquid, also in Pascals. This figure is then divided by the density of the liquid in Kg/m3 multiplied by the acceleration of gravity (9.81m/s2). From the resulting figure we minus the suction lift height in metres, and then minus the suction friction losses, which is also expressed in metres Using the following sample application data, let us work through the formula. Quarter 3 2019
Figure 1: J2-J120 performance curve NOTE: Always allow 0.5m margin between NPSHa and NPSHr. 1 Atm = 1.01 Bar = 101,325 Pascals = 101Kpa = 10.33m Column of Water at sea level. Vapour Pressure of Water is 2337 Pascals at 20oC at sea level. Density of Water is 1000kg/m3 (This is also the reference point when referring to relative density) It will be necessary to calculate the friction losses in the suction pipework prior to using this formula.
At AESSEAL® we pride ourselves on exceeding customer expectations for over 40 years.
AESSEAL® develops, manufactures, and sells mechanical sealing and reliability focused engineering solutions, to major blue chip customers around the world. Since establishing in 1979, UK based AESSEAL® has quickly grown to be the fourth largest mechanical seal manufacturer in the world, employing over 1,800 employees, with operations in more than 100 countries.
The world’s deep-drawing expert of high volume and precision components
Tel: +44 (0) 1254 582233 firstname.lastname@example.org www.htindustrial.com
The positive impact of condition monitoring When rotating equipment such as pumps and motors are running smoothly, it is easy to overlook common maintenance tasks and justify that it is not worth the time to regularly inspect and replace parts. Houghton International explains why it is vital to ensure that such equipment has a programme of maintenance.
y adopting a maintenance programme for a critical pump, a business can prevent costly downtime and improve performance. A good maintenance programme will help identify a problem in its infancy, allowing users to put a plan in place to carry out repairs during a shutdown period. It also lets users maintain pumping capacity to ensure a pump is running as efficiently as possible and reduce future costs by prolonging its life. Routine preventative maintenance practices should include the monitoring of bearing temperature, vibration, bearing lubrication, amps (power) readings, suction and delivery pressures. By comparing them to the test and commissioning data, users can set a predetermined level of internal wear, which is acceptable to the process and the pump, to use as the basis of a maintenance plan. It is also worth noting that during an annual assessment of a pumpâ€™s performance, any changes in the benchmarks can be recorded and used to determine the level of maintenance that may be required to get a pump back to operating at its Best Efficiency Point (BEP). When planning the maintenance of a pump as part of a predictive maintenance programme, it is worth considering condition monitoring. Condition monitoring is performed to show a pump decreasing in performance, as opposed to predefined scheduled intervals. It is a maintenance approach that monitors the actual condition of a pump to decide what maintenance needs to be carried out on specific pump components when a set level is reached. Another benefit of adopting this maintenance approach is that it is performed while a pump is running, which reduces the disruption to normal operations and reduces the cost of pump failures, increasing reliability and minimising the overall time spent on maintenance compared to a reactive approach. Also, this method will identify when the pump is running left of the BEP and therefore running less efficiently. Another advantage of ongoing condition monitoring is that data readings can be digitally stored, reducing the need for manual input. Techniques such as vibration analysis can help detect many serious problems at an early stage, allowing maintenance engineers to undertake remedial work at a time that suits. All rotating electromechanical equipment exhibits a varying degree of vibration, but by utilising a vibration sensor, you can detect how excessive the vibration is. Quarter 3 2019
Vibration can be measured in three basic quantities: displacement, velocity, and acceleration and should be measured when the pump is at its normal steady-state operating condition. It is a nonintrusive, fast response, preventative maintenance solution, designed to locate a potential problem and rectify it before it causes further damage to the machinery. Laser alignment is another key part of the overall condition monitoring process and gives users a firm printed report, which is unchangeable. As with vibration analysis, laser alignment detects the smallest deviations in the shaft to provide accurate warning of possible breakdowns. Oil and lubrication analysis, on the other hand, is one of the easiest and most effective condition monitoring methods to identify the condition of a machine. Trending particle counts can be an early sign of bearing and seal wear long before vibration analysis can be effective. There are, however, a few points to consider when planning to implement condition-based monitoring as part of your maintenance programme. The initial investment cost of the measuring equipment and sensors, as well as the subsequent installation, needs to be taken into consideration and even then, particularly on older equipment, users might have to make modifications to allow monitoring equipment to be retrofitted correctly. There is also the time and money investment in up-skilling maintenance staff to ensure that they can use the condition-based monitoring equipment correctly and safely. All things considered, the benefits of adopting a predictive maintenance system such as conditionbased monitoring have become well accepted and can help prevent costly downtimes, ensure pump efficiency and reduce overhead costs. chevron-circle-right www.houghton-international.com www.bpma.org.uk
Solutions for systems of all types and sizes
â†’ Learn more about our products: visit www.reflex.de/en or contact email@example.com
18 utilities & Wastewater
Tackling the wet wipe dilemma
Suzanne Gill finds out how pump system providers are helping the utility and wastewater industries to overcome the challenges posed by the increasing quantity of wet wipes and other solid products in systems and networks.
very year UK utilities spend around £100 million clearing an estimated 300,000 fatbergs from the sewerage system. These blockages are made up of congealed fats, oils and grease (FOG), mixed with ever-increasing quantities of solid waste that has been deposited into the network, such as wet wipes. Although promoted as flushable, single-use wipes do not break down in the same way and in the same timeframe as toilet paper and handling these ‘disposable’ products is becoming a serious problem for utilities and wastewater systems. Indeed, wet wipes are believed to be responsible for 80% of blockages in sewer systems today. System failure due to blockages can require costly manual attendance – often in confined spaces. It can lead to the need for emergency tankering, equipment removal, and cleaning, in addition to strip down and repair of the pump. Attempts to combat the problem can include the installation of macerators and choppers in the system. However, over time, the cutting action of these solutions can become less effective as the wearing parts become blunt and so regular maintenance is often still a necessity. “We believe the answer to the majority of blockages is free passage,” said Paul Walthew, Business Development Manager – Site Services at Caprari. “In our three and four-inch adoptable sewage pumping stations we endeavour to install, where possible, vortex and channel impeller pumps matched to the pipework size to enable what enters the pump to be passed through the pumping station pipework.” The Caprari KCW range has a large free passage – 80mm & 100mm on 3in and 4in branch sizes respectively. “We have teamed these with other technologies, such as fibre cutting and back impeller cleaning, to ensure that the pump is efficient and fights against blockages effectively. We have also installed telemetry units on pumping stations to monitor performance and combined with regular maintenance, we have seen reactive callout intervals now being measured in months – and in some cases years!” CUTTING-EDGE DESIGN NOV, formally Mono Pumps, has been providing heavy-duty wastewater grinders for over 30 years and its Muncher range of twin shaft, slow speed,
Quarter 3 2019
high torque grinders are used by all the major UK water companies, along with many private operations such as airports, hospitals, hotels, shopping centres and leisure facilities. “In recognition of the increasing use of wet wipes and other one-use disposable products, NOV conducted several operational performance trials to measure the effectiveness of grinding this fibrous product to an acceptable and handleable particle size to significantly reduce pump station blockages,” said Ian Hallows, Business Development Manager at NOV. “Our Muncher grinders are fitted with ETOS cutters which offer positive and effective solids maceration and which have been designed specifically for the effective processing of products such as wet wipes.” The ETOS cutters provide effective maceration with the cutter shafts operating at differential speeds to exert a tearing action on the solids. The off-set tooth design of the cutter reduces impact load and power. The saw-tooth profile of the ETOS cutters offers greater strength, while its close machining tolerances offer less clearance and ‘chatter’ on the shaft. The design includes a serrated tooth profile to snag and hold textiles, and a large circumference gives less clearance and better grinding.
The asymmetrical blade arrangement of the KSB F-M impeller allows solids of different sizes to pass easily.
Established in 2006 TEC Electric motors is now considered to be the largest independent electric motor supplier within the UK & Ireland. From humble beginnings 12 years ago, TEC has consistently grown at a rate of £1.5 million pounds per annum. Sales of £20 million GBP are expected in 2019. TEC's policy of re-investment in the business has resulted in a move to a new modern 90,000 square foot facility on Europe's largest industrial estate. The stock holding of £12 million GBP and approximately 150,000 units is the largest in the UK. All Backed by 24/7 365 day call out; "Exceptional customer service" is at the core of company beliefs. Facilities to modify motors to customer requirements on short lead-times; in particular to"WIMES" specifications and non-standard paint finishes (ISO12944/C5M) makes TEC the preferred supplier of choice to many industries in particular the pump sector. TEC continues its pursuit of continuous improvement with a recently re designed website which allows customers to access electrical data sheets and drawings in 2D & 3D formats instantly. However TEC is not just a local supplier, forming part of a global organisation with TECHTOP's partners in America, Australia, France, Germany, Spain, Greece, Holland and Italy to name but a few. This allows access to an additional stock holding of over £50 million offering global support to your business. If you are looking for an electric motor supplier with a dedicated team, integrity and reliability, we are sure you will not be disappointed.
otal ngineering ommitment
Year formed: 2006 Number of staff: 47 HQ location: Worcestershire Turnover: £19 million Markets: HVAC, Conveyor, Pump, Hydraulic, Offshore, Distribution. Website: www.tecmotors.co.uk
• 0.09kW-8MW • 2/4/6/8/10/12 Pole • 56-630 frame • Multi mount 56-200 Aluminium • Multi mount 80-280 Cast Iron • Fixed feet 315-630 Cast Iron • High Voltage: 3.3, 6, 6.6, 10, 13.8kV • TEFC, CACA/CACW • IE1, IE2, IE3, IE4 Efficiency motors • IE3 motors ECA approved • Increased output IE1, IE2, IE3 • 1ph motors 56-112 frame 1ph motors 230v/110v • 60hz 1ph motors also available • ATEX Exde Zone 1 71-355 frame • ATEX Zone 2/22 56-355 frame • ATEX Zone 21 & ATEX 1ph • Brake motors, retro brake fitting • Special voltage, special shaft • Vector encoder motors • Forced ventilated motors • In-line gearboxes • Right angle worm boxes • • • • •
Mechanical speed variators TECDrive Inverters - IP66 and IP20 Double reduction units Helical in-lines Slipring Motors on request
20 utilities & Wastewater IMPELLER DESIGN previously only reached by single-channel Centrifugal pumps employed in the wastewater impellers. When rotating, the impeller keeps solids treatment industry are characterised by their in suspension and reduces the risk of clogging. design features – specifically impeller type, the Since the radial forces and vibrations created by direction of flow and type of installation. If the the new impeller are usually lower than those of pump runs too slowly with a heavy load there can single-channel impellers, the service life of shaft be a problem with suction becoming blocked; if the seals and rolling element bearings is increased.” pump runs at intermediate speeds with a partial load, then the gap between the impeller and the DESIGN AND SMART CONTROL pumping case may become blocked as suspended Sulzer has taken a multifaceted approach to solids settle out and collect in the pump inlet; it is solving pump blockages using both robust and also possible that the gap between the impeller optimised design coupled with smart pumping wear ring and casing wear ring becomes blocked. control and monitoring. Over a decade ago, Sulzer “These factors make pump selection, and more Pumps established a test method – based on site importantly impeller selection, vital because the surveys, material examination and usage analysis impeller must match the nature of the fluids to – to study samples taken from a site and to decide be pumped and the operating environment,” said upon a representative Christoph P. Pauly of KSB. test material. This According to Pauly, the most important helped the company consideration in impeller selection is its operating in the redesign of its reliability, and this can only be obtained by the Contrablock Plus pump size of the free passage. “While free-flow or ‘open’ impeller system. impellers enable suspended solids in wastewater In addition to its to pass more easily through the pump than optimised impeller closed single-channel or multi-channel impellers, design, recent advances they do not compare favourably when it comes in smart pumping have to performance. It is for these reasons that KSB also helped in the battle has focused on designing an open impeller that to overcome blockage can achieve and even exceed the efficiency issues. A recent field levels associated with single-channel impellers,” trial of the latest continued Pauly. “The first stage in finding a Sulzer control and monitoring solution, coupled solution to clogging is to differentiate between with Contrablock Plus, has resulted in improved rigid and non-rigid solids. Rigid solids need to reliability and reduced downtimes. Smart sensing have sufficient space in the pump chamber for of the electrical supply coupled with custom start/ them to pass through the pump. When it comes stop cleaning cycles has ensured that any spike to non-rigid solids, it is necessary to ensure that in load on the pump results in removal of the the presence of wet tissues and similar fibrous potential blockage. “Issues which had once been materials do not form a mass.” reported on a test site in the UK every three months, KSB has addressed these issues with the have since disappeared and the site has run without development of the Amarex-KRT F-Max impeller intervention for eight months. This pilot project – a which incorporates varying distances between joint venture between Anglian Water, Sulzer Pumps, its blades, arranged in groups with two small and Vega Controls and ABB – was awarded Project of the two large distances. This asymmetrical blade Year 2019 by The Pump Centre,” concluded Robert arrangement offers wide, free passages ensuring Connolly, Hydraulic Design Engineer at Sulzer. chevron-circle-right that even larger rigid solids pass easily through the pump. Improved hydraulic system and motor performance are delivered through the design of a new vortex impeller and a motor that offers efficiencies currently calculated according to the same IEC 60034-2 measurement method as that used for motors of dry-installed pumps. “Blockages involving soft materials start at the hub or ‘eye’ of the impeller, and there is a physical reason for this,” explained Pauly. “The revolving motion of the impeller introduces velocity and the greater the distance from the centre of the impeller is where the velocity is greatest. If there is material at the centre of the impeller and there is insufficient speed to eject the material, this means that a swirl has to be created to remove the material. The swirl motion through a slightly convex profile at the hub of Image courtesy of Caprari Pumps the F-max impeller achieves efficiencies
“Blockages involving soft materials start at the hub or ‘eye’ of the impeller, and there is a physical reason for this.”
Quarter 3 2019
LIVES FOR HARD ROCK. Safe, solid, strong. Find out more - www.ksb.co.uk - 01509 231872
Pumps Valves Service
Here is the new design. Any enquires should be sent to: firstname.lastname@example.org 01278 458 686
22 utilities & Wastewater
Pump monitoring at the cutting edge With demand for water and wastewater treatment on the rise, operators tasked with keeping it all flowing face numerous challenges. Industrial Internet of Things technologies, including edge computing, may provide the answer, as Stratus Technologies explains.
t the top of the priority list for most pumping systems is the need to increase efficiency and reliability. Reducing energy consumption is a critical focus for both municipal and commercial operations. This requirement is driving the continuing movement away from singlespeed pumps towards the adoption of variable-speed pumps that can satisfy flow requirements while using significantly less energy. However, while they offer attractive advantages, variable-speed pumps are more sensitive and require more monitoring than traditional single-speed pumps. Further, as operators also face expanding regulations governing water quality and effluent safety, in some cases, continuous monitoring is required to ensure regulations are met and avoid costly fines. ENTER THE INTELLIGENT EDGE To meet these challenges, forward-looking water and wastewater system operators are turning to Industrial Internet of Things (IIoT) technologies, including distributed sensors and edge computing systems that bring intelligence right to the pumps and controllers doing the work. Edge systems provide the computing necessary to perform sophisticated monitoring and control of sensitive pumping systems that need to run 24x7x365, often located in remote and unstaffed locations. Gathering and analysing data from a host of sensors on critical pumping components in real-time, edge computing systems can perform a wide range of highvalue applications. If critical performance parameters, such as temperature or vibration, are found to be out of range by the edge system in that location, the pump could be automatically shut down to prevent damage, with the system sending a real-time alert back to the central control facility. Even more valuable is the ability to continuously gather data on pump performance and perform analytics to proactively determine when periodic maintenance is required. This predictive maintenance analysis can significantly reduce unplanned downtime while extending the lifespan of costly pumps and components. LIMITLESS POSSIBILITIES Given the flexibility of edge computing platforms, the possibilities for optimising operations are endless. Chemical treatment of water or wastewater can be automated with edge systems that analyse the chemical makeup of water or effluent in real-time, minimising the need for human intervention while maintaining optimal quality. Leak detection is another application where IIoT sensors and edge computing systems can play an invaluable role. Edge systems can continuously analyse flow data and pinpoint problem areas with unprecedented speed. In fact, edge computing has a role to play at source locations and distribution points
Quarter 3 2019
throughout the infrastructure, wherever data can be gathered, analysed and acted upon to reduce energy use, minimise human interaction and maximise efficiency and uptime. EVOLUTION, NOT REVOLUTION In the real world of water and wastewater operations, realising the intelligent edge will be an evolutionary process. The plan is often to start small and build on success. Users must clearly understand what they are trying to achieve â€“ to understand how success will be defined. Then a limited pilot program with clear objectives is an excellent place to start. For example, an edge system might be deployed at a remote pumping station to collect sensor data over time and perform simple analytics on pump performance. Periodically, a technician could visit the site and connect to the edge system using a tablet or mobile phone and review pump performance â€“ without the complexity or expense of sending the data up to the cloud for analysis. When a user is ready to scale up their intelligent edge infrastructure, this pilot approach can be replicated at critical locations as budget realities permit. This enables users to localise computing without having to invest in a lot of costly infrastructure. Ultimately, this can evolve into a hybrid cloud approach where local edge systems perform real-time monitoring and control functions, sending data relevant to longer-term planning up to the cloud for more in-depth historical analysis. MAKING THE CASE The business case for IIoT and edge computing is already well established in process industries. In the oil and gas industry, edge systems are used to monitor far-flung pipeline pumping and compressor stations, identifying potential performance problems before they interrupt the flow of product or cause an environmental disaster. For industries where the performance of pumps and other critical components impacts the bottom line, the decision to deploy IIoT sensors and intelligent edge systems is an easy case to make. For water and wastewater system operators, the case for an incremental approach to edge computing that targets crucial points of potential efficiency gains and/or component failure is just as strong. chevron-circle-right www.stratus.com www.bpma.org.uk
24 Utilities & Wastewater news
WATER DISTRIBUTION INSIGHTS GRUNDFOS’ ISOLUTIONS HUB has been developed to offer water professionals an integrated approach that will allow them to look at the entire system in order to ensure optimised operations. The iSolutions approach integrates intelligent pumps, cloud connectivity and digital services to help users reach a new level of system control, optimisation and predictability. A dedicated section for water utility applications on the hub includes video content and case studies that demonstrate water saving and energy efficiency, as well as how maintenance costs can be reduced. There is also access
to dedicated training content on the Grundfos Ecademy, plus a whitepaper exploring pressure management and a detailed water distribution manual are available for download.
CONDITION MONITORING PREVENTS UNPLANNED DOWNTIME AT TREATMENT PLANT
MODULE PROTECTS WATER AND WASTEWATER APPLICATIONS NEW FROM KSB, THE AMACONTROL III offers protection and monitoring functions for pumps and submersible mixers. The device monitors phase-sequence and detects phase failures; it can also track any overvoltage/undervoltage or voltage asymmetry that may occur. Temperature sensors can also be monitored as can two conductance sensors for leakage monitoring and a 4-20 mA vibration signal. In addition, the frequency of starts and the number of operating hours can be logged while the failure of any connected sensors can also be detected. A fault relay and a warning relay ensure that attached units are reliably stopped or, if required, a warning can be emitted.
An integrated diagnosis function provides operating data, fault lists, a fault counter, information on operating periods, start/stop cycles, current measurement values and detailed fault analysis for the most recent fault. This makes it possible to control the monitored units via an app on a smartphone or tablet.
aeration system is responsible for between 30 and 70% of a wastewater plant’s overall energy demand, this can impact the plant’s bottom line. To maximise membrane life while avoiding disruption, Xylem recommends the use of a weekly air bump cycle which involves over-inflating the diffuser membranes for a short period of time to shear off any membrane fouling. This will result in retained SOTE and minimises back pressure increase. However, at a certain point within the life of the aeration system – typically seven to ten years after installation – the completion of recommended routine maintenance will not provide sufficient performance retention and it becomes cost-effective to replace the membranes. This investment will be recouped through lower power consumption.
A DRINKING WATER TREATMENT company in Asia is preventing unplanned downtime of critical equipment across its pumping stations following the successful installation of a condition monitoring solution from Schaeffler. The customer operates a drinking water treatment facility where each day, 200 million litres of water can be treated. As the operator is responsible for ensuring a reliable supply of high-quality drinking water for the region, protecting the relevant facilities against failure is a key priority. The customer was looking for an intelligent condition monitoring (CM) system to reliably prevent failures in its pumping stations. The solution comprises a custom designed CM system based on SmartCheck sensors. In total, 84 SmartChecks are fully integrated into the customer’s infrastructure via a PLC (programmable logic controller), monitoring the critical items of equipment across 15 pumping stations. Equipment monitored includes bearings on pumps and motors, as well as pump vanes/impellers. The SmartChecks monitor vibration, temperature and speed, as well as shaft alignment and balancing. The data can be viewed individually at each pumping station or centrally in the control room. The system also allows the implementation of automated routines such as the triggering of alarms and the emergency shut-off of equipment.
THE HIDDEN ENERGY COSTS OF MEMBRANE DISC DIFFUSERS XYLEM IS HIGHLIGHTING THE BENEFITS of fitting new membrane disc diffusers. Installed on the floor of aeration tanks membrane disc diffusers produce air bubbles that allow for the substantial and effective mass transfer of oxygen into the water and are crucial in encouraging the biological treatment process. Unfortunately, over time the oxygen transfer efficiency of diffusers will slowly deteriorate and the dynamic wet pressure (DWP) rises due to the rubber being ‘fouled’ by organic matter and attacked by chemicals. A combination of declining standard oxygen transfer efficiency (SOTE) and rising DWP means that more air is required to provide the same amount of oxygen, coupled with higher pressure; this results in an increased power draw. Faced with a need for additional air flow and increased pressure many operators resort to using energy-hungry temporary blowers. However, considering that an Quarter 2 2019
With over 40 years’ experience you can depend on our reputation for quality, reliability and industry expertise. Offering exceptional service since 1971 O Rings are now the supplier of choice for probably the most
ORINGS O L
comprehensive range of sealing solutions available.
You’ll also have your own dedicated customer advisor so why not give us a call on 01243 787817 or email email@example.com to discuss your requirements with our skilled & knowledgeable staff.
ISO 9001:2015 accredited we are able to offer: O O O O O O
Rapid delivery & call off opportunities A vast range of seals in a wide range of materials in stock Bespoke kits and individual labelling & bagging Sample identification & backward engineering if required No tooling limitations Partner Distributor to Trelleborg Sealing Solutions
We also supply genuine Trelleborg DOWTY Bonded Seals
As an approved UK distributor of leading global pump brands, we are proud to be a supplier of GENUINE pump spares.
Doing the job the right way.
We supply for major brands including:
We are also manufacture our very own innovative liquid ring vacuum pump
LIQUIVAC – DEVELOPED BY TOMLINSON HALL
I +44 (0)1642 379500
Liquivac is Tomlinson Hall’s own liquid ring vacuum pump, the product of decades of engineering expertise - and it’s manufactured at our site in Billingham, UK. Liquivac pumps can handle combinations of liquids, gases and fine solids and can perform a huge range of operations. They are widely used by utilities
FEATURE 26 Opinion
Action on non-compliant pumps is long overdue Gary Wilde, BPMA Technical Services Officer, argues for urgent action to be taken to stop the sale of imported non-complaint pumps.
stablished pump manufacturers go to great lengths and costs to produce the most energy-efficient circulator pumps – meeting, and sometimes exceeding the current EU regulations. The presence of illegal pump imports entering the UK from other countries is a significant concern, and it would appear that several online marketplaces and online pump sellers are allowing the sale of products that do not comply with the mandated EU Energy Efficient Index (EEI). The voluntary A-G scheme was replaced on the 1 January 2013 with the Energy Using Products directive, (Commission Regulation EU 622/2012) and this regulation specifies that an EEI must be achieved on each circulator. The figure in January 2013 was EEI 0.27, and this was reduced in 2015 to EEI 0.23. The EEI rating system requires that the correct information is indicated on the pump name plate, packaging and technical documentation. Also, the circulator is defined as part of product CE marking. Some pumps bear the Chinese export logo; This CE mark means ‘China Export’ and simply means that the pump was manufactured in China. For re-sellers of these products selling non-compliant pumps can result in imprisonment or a fine. It is now over six years since this came to the attention of the BPMA, yet to our knowledge, only one enforcement action has taken place which breached regulation 14(1) of the Eco design for energy-related products regulation 2010. The pump in question had no declared EEI value and, when tested, the EEI was 0.82, which is far more than the current 0.23 limit. I am sure that if the vast number of domestic circulators from the selling sites that I have mentioned were tested, we would see the same outcome, and this is unacceptable. The Office for Product Safety and Standards (OPSS) is responsible for coordinating market surveillance activity (MSA) in the UK. It is part of the Department for Business, Energy and Industrial Strategy and was established in January 2018 to provide additional national capacity for product safety activity and it will continue to have this remit after the UK’s exit from the EU. If we do leave the EU, I do wonder whether the UK will become the next dumping ground for inferior products. Quarter 3 2019
In my opinion, one enforcement in six years is not good enough, and more should be done to protect the public. The Health and Safety Executive has enforcing authority responsibility for product supply and safety matters, but its market surveillance activity is intelligence-based and reactive. The BPMA urges these departments to go online to see for themselves the vast problem of noncompliant and non-CE marked products being sold in the UK. These products will also have a detrimental effect on the UK achieving its environmental goals as associated running costs over the lifetime of these noncompliant products could be ten times more expensive than a ‘legal’ compliant version. We need to be collectively vigilant about illegally imported pump products to protect the safety of the consumer and the environment. The BPMA looks forward to the UK Government departments taking action as we believe the problem has been going on far too long, not just with the issue raised here, but also relating to the non-CE marking of pumping equipment built by set builders in the UK which has already been highlighted by the BPMA, with no action being taken so far for any company. The BPMA’s door is always open to assist any Government department to eradicate the substandard products entering the market place by whichever selling channels. chevron-circle-right
“We need to be collectively vigilant about illegally imported pump products to protect the safety of the consumer and the environment.”
REWARDING PUMP EXCELLENCE FOR THE PAST 20 YEARS The Pump Industry Awards have grown into one of the leading industrial awards programmes, celebrating the achievements of pump businesses, large and small. If you or your company have something to shout about these awards provide the perfect platform. We believe the best way to celebrate excellence is by bringing people together at live events, so the annual gala presentation dinner caps off the awards programme in style. As always there will be excellent networking opportunities, great food and superb entertainment. It’s your chance to celebrate with colleagues, connect with peers and be part of the pump industry’s biggest and best celebration; put the 19th March 2020 in your diary now. The Call for Nominations opens on the 2nd September, so be sure to visit the Pump Industry Awards website to review the award categories and decide which ones you will be entering! We have introduced two brand new categories, the ‘Rising Star Award’ and the ‘Contribution to Skills & Training Award’ which will bring an added and important dimension to the 2020 awards programme.
PUMP INDU ST AWARDS 20 RY 20
2nd September 2019
6th January 2020
19th March 2020
at the Chesford Grange Hotel, Warwickshire
“The 2019 Pump Industry Awards was another huge success and once again provided an excellent forum through which to acknowledge and celebrate business and professional excellence. I very much look forward to building on that success with the 2020 awards programme and would encourage all those operating in this wonderful sector of ours to put forward a nomination.” – Richard Harden, BPMA President
Award Programme Partners www.pumpindustryawards.com
on behalf of
NOW. PUMP TECHNOLOGY OF THE FUTURE. WILO-STRATOS MAXO: THE WORLDâ€™S FIRST INTUITIVE SMART-PUMP*.
Your new partner is the most flexible pump: the Wilo-Stratos MAXO is the perfect fit for any application and ensures optimal system efficiency thanks to its intelligent control mode. Furthermore, the pump can be integrated into all relevant systems due to diverse interfaces. And with optimised and innovative energy-saving features the Wilo-Stratos MAXO meets the changing requirements superbly. No other pump on the market offers you more efficiency, connectivity and convenience. This is how already today we are making your life easier with the innovations of tomorrow.
WILO BRINGS THE FUTURE. Discover the future of pump technology:www.wilo.co.uk/future
*We understand a smart-pump as a new category of pumps, which goes far beyond our high-efficiency pumps or pumps with pump intelligence. Only the combination of the latest sensor technology and innovative control functions (e.g. Dynamic Adapt plus and Multi-Flow Adaptation), bidirectional connectivity (e.g. Bluetooth, integrated analogue inputs, binary inputs and outputs, Wilo Net interface), software updates and excellent usability (e.g. thanks to the Setup Guide, the preview principle for predictive navigation and the tried and tested Green Button Technology) make this pump a smart-pump.