Quarter 3 2020
Pump industry insight from
FOCUS ON: Building services
Improving energy and water usage in data centres
Managing changes in water demand Pump Industry News
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.
CONTENTS 3 Editor Chris Callander firstname.lastname@example.org 01732 671123 Contributing Editor Suzanne Gill email@example.com Publisher Andrew Castle firstname.lastname@example.org 07785 290034 Accounts Touchwave Media Ltd email@example.com Production G and C Media Ltd firstname.lastname@example.org
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.
hile many organisations have seen business fall away over recent months, one sector that has seen a huge surge in demand is data centres. This has, of course, been fuelled by a massive increase in internet use for tasks such as teaching, business meetings, catching up with friends and family and pub quizzing. Running data centres consumes significant amounts of energy. While the apparent reason for that might seem to be powering banks of servers, a substantial proportion of the energy is used to maintain a suitable atmosphere within the data centre – largely for cooling. With many data centre cooling systems relying on motor-driven pumps, and significant pressure being placed on the sector to reduce energy usage, making the right choices are key. As part of this issue’s building services theme, we have a feature looking at precisely this, and in particular how technology developments are making a style of chilled water-cooling system, that had fallen out of favour, a more viable solution today. Also in our theme section we explain how a mains boosting system has been able to quadruple a property’s water pressure, and we explore how using pumps as turbines can tackle pressure reduction challenges while providing a renewable energy source. Elsewhere in this issue, we look at the problems that can be solved by degassing, outline how water companies can manage changing water demands and cover the latest news and product developments. And in BPMA news, we report on the pressure the association is placing on the UK Government to clarify the requirements that will apply to products supplied into the UK after the transition period ends. Plus, we share details of three new members, whose addition has brought the BPMA to a record level of membership. I would, of course, like to welcome them and to thank all our members for their ongoing support. I hope you enjoy the issue. Richard Harden, President, BPMA
PUMP INDUSTRY NEWS BPMA National Metalforming Centre 47 Birmingham Road West Bromwich B70 6PY www.bpma.org.uk
AESSEAL gains cybersecurity certification Global Pump Report Call for water professionals to join crisis response register
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. Cover image courtesy of Wilo
Record membership and Make UK partenrship
awards update 10 New date for Pump Industry Awards
PRODUCT NEWS 12 Compact flow sensors Marking solution makes things clear 13 Piston pump offers more fluid handling solutions
Compliance 14 How to plan for a no-deal scenario
features 18 Degassing: futureproofing, or eliminating installation issues? 20 Rapid manufacturing 22 Managing changes in water demand
Focus on building services 24 Improving energy and water usage in data centres 26 System boosts incoming mains flow by a factor of four 28 Building services sector news and updates
OPINION 30 Policymakers must look to the future Quarter 3 2020
As an original innovator of electric motors, Brook Crompton offers over a century of technical and design expertise. With an extensive stock we can also modify to suit specific customer needs, with technical support from the company’s knowledgeable team readily available to ensure the correct selection of motors for any application.
Shaping the future of electric motors, Brook Crompton is focused on the development of new products that improve energy efficiency, offer lower cost of ownership throughout the motor lifetime and reduce environmental impact.
Ex d range
The Brook Crompton W motor range is avaliable in aluminium (63-180) or cast iron (80-355) with outputs from 0.07 kW to 22 kW in frame sizes 63S to 355L. (56 to 587 NEMA).
Brook Crompton’s flameproof motors are designated Ex db flameproof and are designed for operation in Zone 1 hazardous areas. Outputs range from 0.37 kW to 200 kW with smaller or larger outputs on request.
Special build options: • Multi speed • Brake / brake kit friendly (63-132) • Encoder • Force ventilated (IC416) • Special shaft / special flange dims • Special paint • Special voltage • Low starting torque • Marine • Hoist / crane duty • Plus many more
Special build options: • Ex db eb IIB or IIC • Group I mining • Special shaft dimensions • Special voltage • Low starting torque • Offshore • Roller bearing • plus many more
Keeping industry turning Series 10 range
Medium / high voltage
The Brook Crompton Series 10 aluminium range is a high quality standard range of electric motors with a specification suitable for most industrial applications. It covers outputs from 0.06 kW up to 900 kW in frame sizes 56 to 160 (aluminium). 80 to 450 kW (cast iron).
Brook Crompton’s range of medium and high voltage motors are available in cast-iron and fabricated steel frames, with die cast aluminium and copper bar rotors to suit the requirements of a wide range of applications and are available in outputs from 90 kW to 130 MW in induction and synchronous designs.
Stock modifications include: • B14, B34, B35 mounting options • IP56, IP65 ingress protection • Cable entry position change • Anti condensation heaters • Restamp for inverter rating • Roller bearing
Special build options: • Special shaft dimensions • Special voltage • Low starting torque • Offshore • Roller bearing • plus many more
Contact us at: T: +44 (0)1484 557200 E: firstname.lastname@example.org
6 INDUSTRY NEWS
AESSEAL GAINS INDUSTRIAL CYBERSECURITY CERTIFICATION
EXTENDED GUARANTEE SCHEME
AESSEAL HAS ACHIEVED certification for Information Security Management System (ISMS) ISO 27001, one of the most widely recognised international standards for industrial supply chain security. This certification demonstrates the company’s ability to ensure the secure management of the information, business processes, information systems and facilities that support its products and services. Commenting on the announcement, Stuart Welsh, IT director at AESSEAL, said: “As a business
GRUNDFOS HAS LAUNCHED A NEW extended guarantee scheme which offers a five-year manufacturer’s guarantee, at no extra charge, on its ranges of intelligent MAGNA3, TPE3, NBE and NKE pump models purchased after 1st May 2020. This guarantee provides added security – directly from commissioning. To take full advantage, purchasers simply need to register the pump, which can be done at the point of commissioning, and complete and submit a GRUNDFOS GO report’. The guarantee can then be accessed via a simple on-line registration process. The pump product line-up included in the scheme will be under constant review. Visit www.grundfos.co.uk/ggg to learn more and to access the most upto-date information on the products covered by the guarantee.
which is committed to evidencing best practice, continuous improvement and outstanding customer service, achieving ISO 27001 certification is an important accomplishment. It sends a clear message to our customers that we take ensuring the security of their data extremely seriously. We are extremely grateful for the professionalism of our colleagues who helped us to complete the external audit successfully despite the challenges we faced with operating remotely.”
GUIDE TO EC NO 640/2009 REQUIREMENTS A VISUAL GUIDE HAS BEEN created by WEG to explain the impending stricter requirements for motor ecodesign, which have been approved by the European Commission (EC). Previously, the requirements for electric motors only applied to 3-phase motors ranging from 0.75 kW to 375 kW. It specified IE3 class efficiency as the minimum requirement with IE2 class allowed when used with a variable speed drive. Electric motors outside of this power range were excluded from the regulation, with exemptions for hazardous area motors amongst others. This is set to change from July 2021. The updated regulation will require that all new 2-, 4-, 6- and 8-pole electric motors in the 0.75 to 1000 kW power range meet the IE3 classification, regardless of whether or not they are combined with a VSD. The ruling will also apply to electric motors for hazardous environments. Additionally, VSDs will be held to energy efficiency standards and expected to meet their own IE2 classification. “We realise that the coming Quarter 3 2020
regulation changes have left people with a number of questions and that is why we have released a new guide – to help explain the changes and provide some clarity,” said Marek Lukaszczyk, European and Middle East marketing manager at WEG. One reason for the stricter EC No 640/2009 regulation is that is has become increasingly hard to regulate IE2 motors combined with VSDs. Some users choose not to use a VSD at all. “We understand the confusion from motor users, particularly
surrounding the classification of VSDs,” continued Marek. “Interestingly, the IE2 rating of a VSD isn’t equivalent to an IE2 rating of an electric motor – they are measured differently.” WEG’s guide is designed to highlight the benefits that are available if businesses adhere to the updated EC No 640/2009 standard. For more information on the stricter ecodesign regulations for motors, download WEG’s guide. bit.ly/WEG640 www.bpma.org.uk
INDUSTRY NEWS 7
ANGLIAN WATER SIGNS A NEW FRAMEWORK AGREEMENT FOR SMART ACTUATORS ROTORK HAS BEEN AWARDED A new framework agreement for the supply of its products and services to Anglian Water which manages over 112,000 km of water and sewer pipes to supply and transport water and wastewater to and from 1,257 water and water recycling treatment works. The agreement will see Rotork providing Anglian Water with intelligent electric IQ actuators and modular electric CK actuators.
This agreement brings with it the prospect of potentially hundreds of applications for Rotork’s products, encompassing the flow of effluent, clean water, steam and chemicals. Meanwhile, Rotork Site Services will also be working closely with Anglian Water to provide preventative maintenance advice, product testing, repairs and upgrades, helping to ensure reliable and efficient operation at their sites.
CALL FOR WATER PROFESSIONALS TO JOIN CRISIS RESPONSE REGISTER A NEW CENTRALLY HELD REGISTER of water professionals, who are able to contribute to disaster efforts, has been launched by the Water Action Platform. Initially The Crisis Response Register was set up as a response to the explosion in the port of Beirut, Lebanon on 4 August. Now it is intended that it is a permanent record. Dr Piers Clark, chairman of Isle Utilities, which hosts the Water Action Platform, said: “My thoughts turned to the water and sanitation challenges that this accident has created in a country which already had unsatisfactory infrastructure. Ensuring that there is no cholera outbreak and protecting them from Covid-19 are going to be particular challenges. “We are launching the Crisis Response Register for water
GLOBAL PUMP REPORT PUBLISHED
professionals who feel they may have something they could contribute. Whether you work within a water utility directly, or are part of the supply chain – contractor, consultant, tech company – your input, and perhaps that of your organisation, could make a difference. There are many highly capable and wellequipped organisations and charities who are working hard to address the immediate needs,” continued Piers. “What we are creating here is a register of water professionals who can be called up to support these organisations.” Industry professionals wishing to join the Crisis Response Register can watch Dr Clark’s personal appeal and register at: bit.ly/WAPCRR20
FORECASTING AND QUANTITATIVE analysis specialist, Oxford Economics, has released the latest edition of its annual report, the Global Pump Market Outlook. Available free of charge to BPMA members, this 100-page analytic report is aimed at professionals looking to understand the economic and sectoral forces that are shaping the pump market and its outlook. It is an invaluable tool for professionals looking to benchmark company performance, identify new business opportunities and understand the key risks facing the sector looking ahead. Commissioned by Europump, the report includes forecasts and analysis of 71 countries including a macro – economic overview of each country. A total of 16 end use sectors are covered, including agriculture, basic metals, chemicals, construction, food & beverages, mechanical engineering, mining, oil & gas, pulp & paper, pharmaceuticals and utilities. In addition to the sectors, five pump types are analysed, including centrifugal pumps, rotary pumps, pump parts, reciprocating pumps and other pump varieties. The report is underpinned by Oxford Economics’ proven integrated suite of global macroeconomic and sector models – as well as its staff of more than 200 economists – to ensure a coherent and consistent view of the pump outlook at a global, regional and national level. bit.ly/OEPR2020
Quarter 3 2020
8 BPMA News
RECORD MEMBERSHIP AND PRESSURE ON THE GOVERNMENT AT A TIME WHEN COMPANIES IN ALL SECTORS ARE recognising the value membership of a trade body can bring, the BPMA has seen its membership grow to a record number of 98 companies. The most recent member is Hertford based, non-metallic material and component failure specialist, Polymeric Material Failure Consultants (PMFC). PMFC provides an independent failure investigation to offer a reliable root cause failure analysis service. Another company to appreciate the opportunities afforded by membership is Megator, a company with a reputation for manufacturing innovative and unique positive displacement pumps and pollution control solutions for some of the harshest environments. M.J.B Engineering Precision, a sub-contract engineering company manufacturing precision parts for a wide range of clients within the engineering, packaging, printing & food processing industries, has also signed up to be a full member. The association has also published the 2020/21 edition of its annual Pump Buyers’ Guide and directory. Invaluable for users of pumping systems, the guide includes a range of technical articles, resources to aid pump selection, standards updates and much more. Copies can be requested via email@example.com. The BPMA has also been actively engaged in discussions with The Department for Business, Energy and Industrial Strategy, calling for clarity around placing goods on the UK market after December 31st. Alongside this and with 14 other trade bodies, the association has co-signed a letter to Michael Gove expressing deep concern over the lack of detail around the requirements with just weeks remaining. Finally, the first student ever to get 100% in the BPMA’s Essentials E-Learning course, Shane Bates from KSB, has been awarded a free place on the association’s Certified Pump Systems Auditor (CPSA) course between 13-16 October 2020, including three nights’ accommodation. The four-day course is being held in Birmingham following strict Covid-19 guidelines, and anyone who would like more details should contact firstname.lastname@example.org.
BPMA PARTNERS WITH MAKE UK THE BRITISH PUMP Manufacturers’ Association (BPMA) has recently partnered with Make UK, the manufacturers’ organisation. Make UK is the largest force backing UK manufacturing and has been helping the sector to compete, innovate and grow for more than 120 years. As part of the agreement, BPMA representatives will be in regular contact with Make UK’s policy and lobbying teams and will be helping them to understand the pump sector and the specific challenges it faces. The partnership also entitles all BPMA member companies to Affiliate Membership of Make UK, providing a range of benefits to complement the existing BPMA membership. In these quite extraordinary times, Make UK is in regular contact with the Government and is working hard to support all areas of the manufacturing sector. The latest COVID-19 related updates and resources, including some very useful FAQs, are available at: www.makeuk.org/coronavirus. Quarter 3 2020
BPMA Golf Day
Belton Woods, Lincs bit.ly/bpmagolf
EUROPEAN WASTE WATER MANAGEMENTCONFERENCE Online event ewwmconference.com
CERTIFIED PUMP SYSTEMS AUDITOR (CPSA) course
NEC, Birmingham www.thefloodexpo.co.uk
pump industry awards
2021 january 25-27
drives & Controls 2021 NEC, Birmingham www.drives-expo.com
NEC, Birmingham www.machexhibition.com
NEC, Birmingham www.chemicalukexpo.com
Utility Week Live
NEC, Birmingham www.utilityweeklive.co.uk
Hillhead Quarry, Buxton www.hillhead.com www.bpma.org.uk
ABB Abilityâ„˘ Smart Sensor for low voltage motors Up to
less unplanned downtime
extended motor lifetime
reduction in operating costs
higher system efficiency
70% 30% 30% 10% â€” Your motors are talking to you Are you listening?
ALWAYS KNOWS HOW TO DEAL WITH PRESSURE.
The KSB Delta Pressure Boosting Sets have many unique features. Such as, their rotatable handed manifolds, patented hygenic tees, and clever O ring connections. They are also WRAS and ACS approved. More unique selling points can be found on our LinkedIn Page: www.linkedin.com/company/ksbuk-ltd Find out more. www.ksb.co.uk - 01509 231872 Pumps Valves Service
10 Awards Update
PUMP INDUSTRY CELEBRATION SET FOR DECEMBER As the UK charts its course out of COVID lockdown, with schools and universities reopening to the nations young people, and UK businesses, large and small, forging ahead towards some semblance of normality, the BPMA looks forward to once again recognising and rewarding pump sector excellence.
aving been one of the first industry events to be postponed due to the Coronavirus pandemic, the 20th Annual Pump Industry Awards Ceremony was moved from its original March dateline to the new date of Monday 7th December. Commenting on the rescheduling, Event Director, Andrew Castle said: “Although the decision to postpone the awards dinner was essentially out of our hands, the complex nature of such an event and the amount of time, work and effort spent on its delivery, demanded that we found the best possible alternative date. I am therefore delighted that in conjunction with our sponsors and partners, and with the full support of our excellent venue, we were able to secure this December date.” He continued: “Not only does this allow as much time as possible for the virus to be adequately managed, but it also positions our celebration at the outset of the festive season; a time when spirits are already high and goodwill abounds.” Steve Schofield, CEO, British Pump Manufacturers Association added: “Noone could have foreseen the disruption caused by the pandemic, and the pump sector has not been immune to its impact, however, despite the many challenges this year, or maybe because of them, business and professional excellence still deserves to be acknowledged and celebrated. The Pump Industry Awards will do just that, and at a time when I am sure we will all be ready for a good night out.” The Gala Awards Dinner will be staged on the evening of the first Monday in December at the Chesford Grange Hotel in Kenilworth, and on the same basis as
originally planned. All sponsorships, table bookings and overnight accommodation will be honoured for this new date and will be carried forward accordingly. The following nine awards will be presented to their rightful winners: Product of the Year Sponsored by Process Engineering Project of the Year Sponsored by Stuart Turner Environmental Contribution of the Year Sponsored by SPP Pumps Manufacturer of the Year Sponsored by WEG UK Distributor of the Year Sponsored by EMIR Software Supplier of the Year Sponsored by Wilo Contribution to Skills & Training Sponsored by Tomlinson Hall Rising Star Award Sponsored by World Pumps Lifetime Contribution Sponsored by BPMA
From the record number of nominations received, the judges shortlisted 37 finalists across the full complement of categories to go through to the public vote. That online voting process has now closed, and the winners will be announced during the charged atmosphere of the awards ceremony in December. The full list of finalists can be found on the dedicated awards website. This year’s awards programme celebrates its 20th Anniversary. So despite the postponement, we can still look forward to a wonderful evening of reward and celebration, when hopefully the current health crisis will be drawing-to-an-end. In the meantime, should you have questions regarding any aspect of the Pump Industry Awards Dinner, please do not hesitate to contact the organisers directly or via the website. chevron-circle-right www.pumpindustryawards.com
WE DON’T JUST SELL PUMPS, WE ENGINEER SOLUTIONS.
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Product news 12 FEATURE 12
COMPACT FLOW SENSORS FLOW SENSORS IN THE NEW SM range from ifm electronic feature a slim design that allows them to be used side-by-side in the outlets from standard manifold boxes. With compact construction, and no straight length requirements, they can be accommodated in installations where space is limited. A further benefit is that they use a measuring system that minimises pressure drop; in many applications, this allows pump output to be reduced, helping to save energy. The sensors can also monitor
temperature and total quantity of flow which reduces cost and complexity by eliminating the need to use separate sensors to provide this functionality. The sensors also incorporate an IO-Link output, which means that all of the measured values can be accessed via a single connection. They also provide analogue and pulse outputs to enhance compatibility with legacy automation systems, and they have two useradjustable switching set points. www.ifm.com
MARKING SOLUTION MAKES THINGS CLEAR SCHREINER PROTECH OFFERS A solution to ensure marking labels of components remain clearly visible following the painting process. Its product portfolio includes a label with a paint mask attached to the marking label. Following inscription of the 2D code, the folding paint mask is applied by means of its folding mechanism. This solution has, for example, been used by InLine Hydraulik. Traditionally the company used metal nameplates to mark components at the end of the production process, which precluded automated integration of digital information and storage or tracing. The folding paint mask label from Schreiner ProTech is now imprinted with a 2D code on-site and manually applied to pumps and regulators at an early stage of the production process. After painting, the
paint mask is peeled off. This has made it possible to introduce 2D code marking and automated traceability is ensured at any time. Schreiner ProTechâ€™s paint mask solution offers the additional option of combining a removable paint mask label with durable overlamination for
permanent protection of the nameplate underneath against mechanical stress. After the drying process of the coats of paint, the protection label is peeled off using a starter tab. This ensures easy handling even when working with gloves. The paint mask itself is a little smaller than the marking label. As a result, the label will remain embedded in the paint after removal of the paint mask film so is permanently protected. www.schreiner-protech.com
SEALLESS PUMPS TAKE A SAFE MODULAR APPROACH THE CSA AND CSI FRAME 1 GROUPS of sealless pumps, from HMD Kontro Sealless Pumps, are said to take a modular approach to combining performance with durability and versatility while ensuring industry and regulatory safety compliance to ASME, ISO and IECEx standards. Designed for maximum part interchangeability, to reduce inventory, ease of onsite servicing and upgrade, the pumps are available on short lead times. Meeting the challenge of safely transferring high volumes of hazardous chemicals and other liquids the CSA and Quarter 3 2020
CSI ranges offer total containment, eliminating the risk of product leakage. The containment shell can be provided either in metal or as HMD Kontroâ€™s ZeroLoss format, which increases resistance against system upsets and saves energy. A fully contained casing gasket also eliminates the risk of blowouts. The new range conforms to the latest
IECEx standard and assures compliance with ASME B73.3 and ISO2858/15783 for the CSA and CSI respectively. www.hmdkontro.com www.bpma.org.uk
Product news 13
PISTON PUMP OFFERS MORE FLUID HANDLING OPTIONS MASTERFLEX (A COLE-PARMER BRAND) HAS INTRODUCED a new Reglo piston pump to enable more fluid handling options. The Ismatec Reglo digital piston pump drive range, with MasterflexLive, is said to offer accurate performance and precise digital control. A 12.7cm user-friendly touch screen with a wide viewing angle helps simplify pump operation. It also enables commonly used dispense programs to be quickly and easily saved and retrieved; while anti-drip and speed ramping functions, in the volume dispense mode, help ensure accuracy and minimise sample loss. The low maintenance valveless piston pump head is said to
have fewer piston seizures or clogs. It features just one single moving part for less drift over time. Finally, Masterflex Cloudenabled drives, featuring MasterflexLive, allow for real-time remote pump control and monitoring. It is possible to monitor and adjust critical processes without the need for onsite personnel. ColeParmer.co.uk
ENCLOSURES ENSURE HIGH VACCUM PUMP HYGIENE STANDARDS TO ENSURE THAT VACUUM PUMPS are protected from the aggressive cleaning media required in food production environments, Leybold has developed a range of Hygienic Enclosures. In the food industry vacuum pumps are often placed alongside the processing and packaging lines to ensure high vacuum performance. However, this results in them being directly exposed to aggressive cleaning media during the rinsing processes. Over time, this leads to
WRAS AND MID APPROVED UTILITY WATER METER RANGE
corroded vacuum pumps, shorter life cycles, higher costs and ultimately even food contamination. The stainless-steel housings are available in seven different sizes, to match Leybold vacuum pumps. Encased by these enclosures, the pumps can be positioned near machines and systems without any problems. www.leybold.com/uk/en/
POLYMERIC MATERIAL FAILURE CONSULTANTS
RESOLVE FLUID LEAKAGE CAUSED BY SEAL FAILURE SPECIALIST INVESTIGATORS OF POLYMERIC AND ELASTOMERIC COMPONENT FAILURE IN FLUID CONTAINING HARDWARE
O-RINGS GASKETS SEALS HOSES
Material identification and condition assessment Damage documentation and characterisation Forensic information gathering Evidence based root cause analysis
THE VUAQUA FAMILY IS A BUDGET RANGE OF MECHANICAL water meters from Bell Flow Systems, available in sizes from 1/2in to 20in, with pulse output options. The range is suited to a variety of potable water metering applications, including secondary domestic billing, light industrial use and bulk water measurement. This entire range is WRAS approved for compliance with UK drinking water regulations and MID (Measuring instruments directive 2004/22/EC) approved for compliance with EU regulations related to accurate measurement and billing. www.bellflowsystems.co.uk www.bpma.org.uk
07851 086922 01992 509470
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14 FEATURE 14 Compliance
How to plan for a No-Deal scenario
EURIS is an advisory body for the potential impacts of the changing relationship between the UK and EU, with 13 trade association members, including the British Pump Manufacturers’ Association. The taskforce recently issued advice to members to allow for early planning for the undesired outcome of a no-deal Brexit.
uch of the advice issued by EURIS will still be useful, and some necessary, under most free-trade agreement scenarios. As such, the task force is advising its members’ companies to review its checklist and act on the recommendations. MAP AND AUDIT SUPPLY CHAINS Supply chain mapping is an essential early step in Brexit planning. Knowing where inputs come from, and what product category they fall into can help assess the possible tariffs that might apply. Even if a company is ready for Brexit, it will be disrupted if a supplier is not prepared and cannot meet its contracts. Recommendation: Discuss Brexit readiness with critical trading partners and ensure they have contingency plans in place. It is also worth considering alternative transit arrangements in case existing transport routes become blocked or bottlenecked. CONSIDER AUTHORISED ECONOMIC OPERATOR (AEO) STATUS This status allows faster clearance at borders if a company’s procedures are deemed as compliant by authorities in both countries. Recommendation: Consider applying for AEO status, which entitles simplified customs procedures and faster clearance at borders. The process, which involves filling out a complex form takes a long time, so this should be an urgent priority. KNOW YOUR EMPLOYEES’ NATIONALITIES While existing employees who are EU nationals can be expected to receive the necessary residency status, it is important to plan for cut-off dates and any differential status that might apply to new arrivals to the UK. Recommendation: Consider upgrading your IT system to be able to track the nationality status of employees. ENSURE ADEQUATE CASH FLOW FOR ADDITIONAL INVENTORY Brexit poses a cash flow problem for trading companies because more complex port procedures could mean businesses need to be prepared to carry out more inventory, tying up additional working capital. Recommendation: Consider whether you will need to hold more inventory to buffer against potential delays at Quarter 3 2020
the border. Small businesses should consider whether to apply for a government-backed loan as these are interest-free for the first 12 months. ESTABLISH YOUR CORPORATE CUSTOMS INFRASTRUCTURE HM Revenue & Customs estimates the number of customs declarations will rise from 55m to 255m annually. British companies will need to fill in customs declarations for all goods crossing the EU border when the UK leaves the single market. On 13 July 2020, the Government published the plans for the UK-EU Border for Import & Export of Goods from January 2021. Recommendation: If you are not yet familiar with them, prepare to use Import/Export Declarations for trade within Europe. In a no-deal scenario, the Single Administrative Document is likely to be applied to all trade between the UK and the EU. Also, review your customs internal infrastructure and consider how to increase its capacity and understand whether you have time-sensitive deliveries that could be impacted by additional customs procedures and plan for what you might do to mitigate this. ASSESS WHETHER YOU ARE AFFECTED BY EU FREE-TRADE AGREEMENTS Using a bilateral trade agreement can save costs on tariffs but will increase bureaucracy because businesses must prove each good is sufficiently British to qualify for zero rates. With the trade-weighted EU average tariff of only 2.3% for non-agricultural goods, some exporters will decide to pay rather than face compliance costs, so www.bpma.org.uk
compliance 15 companies will need to take a strategic decision after auditing their processes. Recommendation: Understand the EU’s Rules Of Origin (for ‘third nations’ outside of a trade deal) and how they would apply to your products,
says European patents will still apply in the UK but, according to the website, the UK is ‘exploring options’ in other IP areas, such as trademarks and designs, because in many cases these will lapse after Brexit. Recommendation: Understand whether your IP rights might change after Brexit and take protective steps.
“Understand whether your IP rights might change after Brexit.”
AUDIT ALL INTERNATIONAL CONTRACTS, RENEGOTIATE SOME The legal provisions for importing and exporting that define who is responsible for shipping goods across borders is important and has significant tax implications. It is particularly important that contracts adequately clarify the terms for trade across EU borders, including how VAT is dealt with. In the event of no deal, you will need to ensure that contracts and International Terms and Conditions of Service reflect that they are now an international exporter or importer. Recommendation: Audit all your international contracts and consider whether any need renegotiation.
CHECK YOUR CE MARKING STATUS In a no-deal scenario, the testing and certification applied by your UK Notified/Approved Body may not be recognised by the EU as validating a CE mark on your product. For all CE marked products, anticipate that you will also need to apply UKCA marking either immediately post-transition or at some point afterwards. For products traded into, from or through Northern Ireland, UK (NI) marking may also be required if a UK Notified/Approved Body has issued mandatory third-party certification. Recommendation: Your UK Notified Body may have opened an EU27 operation and made arrangements to transfer and re-issue this certification to ensure EU-validity, but check this. chevron-circle-right
UNDERSTAND YOUR INTELLECTUAL PROPERTY RIGHTS Intellectual property protection, including patents, trademarks, registered designs, and copyright could all change after Brexit. The British Government’s Brexit IP website seeks to reassure companies that such protections will still apply in the EU, but it says it cannot give the same assurances for the UK. The Government
Pioneering for You
Wilo-Yonos MAXO Range, Now available with Wilo-Connect Module.
Wilo-Yonos MAXO D:
The Wilo-Connect Module Expanding the Wilo-Yonos MAXO Capabilities
The Wilo-Connect module is a retrofittable plug-in module for Wilo-Yonos MAXO Range of pumps, that significantly expands the pumps functionality. The Connect Module is installed on the electronic module of the pump at the position of the Wilo plug. With functions like EXT. OFF, SBM and dual pump management the Yonos-MAXO and its competitive pricing make this pump a stand-alone contender within the marketplace. Utilisation of the Wilo-Connect module dispenses with external contactors and other switchgears as well as the associated installation workload. The load of customer-side switchgears (relays) due to high starting currents is reduced to a minimum by the Connect module.
Features & Benefits:
Run signal display
SSM collective fault signal as potential-free NC contact
SBM collective run signal as potential-free NO contact
Overriding Off control input (External Off)
Integrated dual pump management with the functions:
Main/standby operation with runtime-dependent (24 h) switchover from main to standby pump
Fault-sensitive switchover to operational standby pump
*We understand a smart-pump as a new category of pumps, which goes far beyond our high-efficiency pumps or pumps with pump intelligence. Onlythe 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 For more information please contact 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.
T: 01283 523000 | E: firstname.lastname@example.org www.wilo.com/gb/en
our sales team.
16 COMPLIANCE CALENDAR
ur compliance calendar outlines legislation that manufacturers and end users of pumps need to be aware of. Each piece of legislation includes far more detail than we are able to share here. If you would like further guidance on any of the information below, contact the author at email@example.com.
31 October 2019
1 July 2019
1 July 2021
WEEE 2012/19/EU In the UK, since August 2018, pumps have been included in the scope of the WEEE regulations and companies that produce and sell pumps need to be registered with the Environment Agency and with a recognised collection scheme.
ATEX (EXPLOSIVE ATMOSPHERES) 2014/34/EU IEC standards 80079-36 & 37 were published in 2016 and include major changes to the marking and documentation of non-electrical goods such as pumps. Pump manufacturers should all be working to these two new standards which became a legal requirement on 31 October 2019.
ECO Design requirements for electric motors – repealing of Commission Regulation (EC) No 640/2009 (EU) 2019/1781 Motors • IE2 level applies to three-phase induction motors rated at 0.12kW to 0.75kW with 2, 4, 6 or 8 poles (Exception Ex eb). • IE 3 level applies to three-phase induction motors rated at 0.75kW to 1,000kW with 2, 4, 6 or 8 poles, TEAO motors new in scope, (exception Ex eb and mining motors).
ECO Design requirements for electric motors – repealing of Commission Regulation (EC) No 640/2009 (EU) 2019/1781
Motors • IE 2 level applies to the following products: • Three-phase induction motors rated at 0.12kW to 0.75kW 2, 4, 6 & 8 poles • IE 3 level applies to the following products: • Three-phase induction motors rated at 375kW to 1,000kW with 2, 4, 6 & 8 poles • ATEX (excl. Ex eb)/non-integrated brake motors rated at 0.75kW to 1,000kW • Variable speed drives (VSDs) • IE 2 level applies to variable speed drives rated for operating with motors with a rated output at or between 0.75kW to 1,000kW. • The following drive technologies are excluded: • Regenerative drives (AFE, active front end). • Drives with sinusoidal input current (THD <10%).
Revisions To Water Pumps regulation 547/2012 The following thresholds still require ratification and an impact assessment. This regulation is expected to be in force by 2023. • EEIv (variable) for single stage pumps up to 45kW pump input power and booster sets up to 150kW pump input power. • EEIv threshold value of EEIv <0.62 for single stage pumps. • EEIv threshold value of EEIv <0.50 for booster sets. • Two tier approach: 1st product information, 2nd threshold. • EEIc (constant) or MEI for all other pumps in scope. • EEIc threshold value EEIc <1.00. • MEI threshold value MEI <0.40.
ECO Design requirements for electric motors – repealing of Commission Regulation (EC) No 640/2009 (EU) 2019/1781 1 July 2023
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Motors • IE 2 level applies to the following products: • Single-phase induction motors rated at above 0.12kW • Increased safety motors (Ex-eb) rated at 0.12kW to 1,000kW with 2, 4, 6 & 8 poles • IE 4 level applies to the following • Three phase motors from 75 kW to 200 kW with 2, 4 & 6 poles
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Degassing: futureproofing, or eliminating installation problems? Dave Cannon, Technical Manager, UK, for Reflex Winkelmann, points out some of the issues that can be solved by degassing in a pumping system, and offers some advice for selecting a suitable solution.
any within our industry would think of the installation of degassers, in both atmospheric and vacuum formats, as being methods by which issues such as air locking were cleared. Other than that, they are seen as a long-term solution to corrosion issues. We have all probably seen these problems encountered by both installers and manufacturers, but over the years we’ve gained an understanding of those issues, and the solution. With experience, our views on these issues have probably changed significantly. Some years ago, when most pumps had a fixed speed drive, it was my experience that service engineers would often be called to sites to be told ‘your pumps are down on duty’. This caused delays in practical completion, as systems could not be signed off. After a while, a pattern tended to emerge. Generally, the flow was down to 80-90% of duty, and it was often on chilled water circuits. In each case, it would be found that the pumped medium was highly micro-bubbled, compromising the hydraulic performance. Had a vacuum degasser been installed, the system would have been clear of any air/gas and the pumps’ performance would have followed the published performance curve. In each case, the project experienced unnecessary and often costly delays. These days, variable speed drives are the norm, but under fixed speed conditions, where a pump selection would have been made with an envisaged operating frequency of 40Hz, it was found that the pumps needed to run at nearer 50Hz to achieve the required duty. It’s worth remembering that because the hydraulic properties of the pumped medium are compromised, the efficiency of devices across the system will be severely reduced. By simply restoring the hydraulic properties to the correct values, the energy savings across the entire system can be considerable. Let’s look at a real-life example at Heathrow Terminal 2. It’s a chilled water system, with a content of some 1.3 million litres. I had spent some considerable time on site, wiring and setting up a dual Reflex Giga system and had always attributed the shaking of the building’s structure to sympathetic vibration, generated by the jets outside. Although ten years ago, I can still remember on a Monday morning, the commissioning manager asking how long it would be before the equipment would be operational, and how long it would take to degas
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the pumped medium atmospherically. He went on to explain, they were unable to balance the system hydraulically, and it was proving impossible to achieve repeatable readings across the metering stations. I gave an estimate of about seven days, before I went off to complete the commissioning, Dave Cannon, Technical Manager, UK, and set the units up to Reflex Winkelmann. operate in a continuous degassing mode. It was only four days later when I returned to site that the commissioning manager was delighted to tell me that the system readings were now stable; however, that was not what impressed me the most about this installation. With the now smooth, laminar flow through the pump volutes and impellers, the structure of the building was no longer shaking, and the plant rooms were now relatively quiet. The vibration had been due to the 200kW pumps shuddering as small pockets of air entered the impeller vanes. The mechanical stresses on the pump shaft bearings must have been considerable. It is these conditions under which you will see spreading of the impeller keyways, rolling of the key steels and in extreme cases, failure of the impeller hubs. At that time, it also occurred to me that the amount of energy being dissipated must be huge to shake a structure of that size. Both from the manufacturers and installers points of view, one of the biggest issues is the repeated failure of mechanical seals on some of the larger pumps. Not only can this ruin the finish on an otherwise pristine plant room floor, but the installer will also ask if substandard seals are being used. An engineer will attend site, remove the mechanical seal, see that the rotating assembly is covered in deposits of material, the rotating and stationary seats are scored and conclude that the system has not been fully cleaned.
“The energy savings across the entire system can be considerable.”
Degassing 19 Not only does this cause delay to a project, understandably it leads to disputes between all parties, including the water treatment engineers. They will produce samples of system content that are usually described as ‘bright and of a light straw colour’. The water engineers are right, but they are relying on a sample that may have been out of the system for many hours, possibly even days. You need to be looking at a sample of water drawn off from the discharge side of a running pump. Initially, it can look almost as white as milk, but it will slowly clear from the bottom to become the liquid described by the water treatment engineers. You must realise that the condition of the pumped medium when decanted is the same as seen by the pump impeller and mechanical seal. A good indication of the presence of entrained gases is the rapid oscillation of the pump discharge pressure gauge needle. A mechanical seal, by design, must leak but in a very controlled manner. When the pump is stationary, the rotating and fixed faces of the seal are pushed together with a combination of spring and hydraulic pressure. When the pump is running a film of water, only microns thick, holds the faces apart. However, if the pumped medium is highly micro-bubbled, the hydraulic properties of the lubricating film are compromised and the two seal faces will touch. This can be witnessed in quiet plant rooms, by a ‘chippering’ noise coming from the pumps. That is the noise of the seal faces, ‘kissing’ each other. As the seal faces touch, friction can elevate the temperature at the seal faces to over 200ºC at the point of contact, even on a chilled water circuit. It follows that the water content flashes off to steam. What it leaves behind are the solids in suspension. In some cases this will be sodium nitrates and other materials from the water treatment, although we have seen an instance where the material was residue from glycol in a cooling system. Over a relatively short period the materials form an abrasive slurry which can damage the seal faces, creating a leakage path. When an engineer changes the seal, based on his observation that the seal components are contaminated, he may conclude that the pumped medium is not clean. Glandless or canned rotor pumps use a film to lubricate the motor shaft’s carbon or ceramic bearings. If the hydraulic properties of the pumped medium are compromised, deposits of the former solids in suspension are left on both the shaft and the bearing bores. This is not an issue when the pumps are running, but when they are stopped, ‘heat soak’ causes the material to form a bond between the two components. When the pump is restarted the motor cannot produce enough break-out torque and this can result in a ‘locked rotor’ burn out. There is another problem that took some lateral thinking to establish the cause. A pump that had run without issue for a month was stopped, and its counterpart put online. Some twenty-four hours after stopping system water pressurised to 3.0 bar started to gush out from the mechanical seal housing. Some twenty seconds later it stopped. The pump was on a system with known micro-bubble issues and there had been a formation of slurry in between the faces, but it was not enough to prevent closure. In the warm www.bpma.org.uk
plant room the sodium content of the slurry had dried and started to crystallise. This action lifted the seal faces apart causing a significant leakage path. The resultant flush of water across the seal faces then washed away the crystals, and the seal closed. It would seem fair to estimate that 90% of circulating pumps that have the issues addressed relate to micro-bubbled systems. In all cases the introduction of a vacuum degasser proved to offer a satisfactory solution. However, I would advocate caution when selecting the right unit to address these issues. Most of these units are produced outside of the UK where the water treatment regimens are very different from the ones utilised here in the UK. To that end, solenoid valves are used for the regulation of flow. These devices are extremely susceptible to any solids in suspension and will often be seen discarded in plant rooms. It makes sense to try to select units that do not employ a combination of solenoid and pressure reducing valves. Units that use selfcleaning motorised valves, with automatic hydraulic optimisation, are a far more viable option. chevron-circle-right
“A good indication of the presence of entrained gases is the rapid oscillation of the discharge pressure gauge needle.”
20 rapid manufacturing
Innovative production process brings customer benefits Apex Pumps has developed a rapid manufacturing design, development and production system utilising the patternless Replicast process, which removes the need for fixed tool patterns. As a result, the design, development and modification of parts can be completed by the companyâ€™s in-house design engineering team using 3D CAD modelling and simulation technology.
significant barrier to product development, particularly where pumps are concerned, is the need for investment in costly tooling that can render many projects uneconomical. Replicast negates the need for tooling with replicas (a positive of the component) being made from rapid machined foam, printed SLA components or tooled for blown polystyrene volume production. Use of a rapid casting process has many benefits including lighter casting, less requirement for feed metal, high as-cast integrity and less waste. It also allows for the use of inert ceramic moulds which are more compatible with special steel alloys. Additionally, thanks to the process, end-users benefit from having the ability to specify any number of bespoke alterations to standard pump designs which, as they are manufactured in-house, reduces the productsâ€™ carbon footprint and shortens leadtimes. The uses of a sacrificial replica in the Replicast procedure eliminates the need for features such as draft angles and the need for allowances for core float and dimensional inaccuracy, all of which increase the weight of standard sand casting. Replicast does not require these increased tolerances, and weight can be reduced from the raw casting as a result. The shape and form of a finished component are considered from a casting perspective during the design phase, in some instances removing the need for dedicated feed material in areas of the casting. The versatility of the casting process reduces restrictions on component casting orientation. Also, it allows for the casting method to be iteratively developed without the need to modify any fixed tooling. Porosity within castings is the nemesis of any pump manufacturer and targeted calculated feed metal focussed on specific areas of a casting will improve integrity. Improved casting accuracy also enables near net-shape design, reducing required machining allowances and therefore reducing machining times or the need for machining at all on some features. The process is used as standard on Apex Pumpsâ€™ API610 11th edition OH2 range, where customer requirements can vary, and the quality and integrity of the parts are vital. The end-to-end production of these pumps on-site allows the company to offer fast lead times where less time is lost with components waiting in a sub-contractors queue Quarter 3 2020
or simply a reduction of transportation between foundries, inspection facilities and machines shops. The process can also be used on some of the more unique customer requirements, including adding safety features such as ribbing, which can be added where pressure or temperature may be an issue. However, it is not possible to increase the overall wall thickness. Specific bosses for the ever-increasing number of sensors attached to pumps can also be added without effecting overall integrity. An excellent example of the benefits of this flexibility with customisation was for a brewery with limited head height. Apex produced ISO pumps with a side discharge enabling the brewery to increase capacity within the same footprint. By combining the process with its in-house micro foundry facility, Apex has been able to reduce its reliance on external suppliers. This provided its customers with an unexpected benefit during the height of the recent lockdown period. Enabling the majority of its production operations to be conducted on-site meant customers, many with critical processes that needed to be maintained, were not held to delays while supply chains were shut down. chevron-circle-right www.apexpumps.com www.bpma.org.uk
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22 Water Supply
managing changes in water demand Marek Lukaszczyk, European and Middle East Marketing Manager at motor and drive manufacturer, WEG, explores three equipment upgrades that water companies can make to increase their agility and efficiency.
n July 2020, the Met Office reported that most UK water companies had seen an increase in average water consumption during lockdown, especially those operating in suburban areas. This sudden surge sits alongside a six-fold increase in global water usage over the past 100 years, as reported by the United Nations World Water Development Report 2020. Climate change is undoubtedly a longstanding consideration for water management, but low rainfall, high population density and intensive agricultural or industrial activity may also result in sustainability issues – without throwing a global pandemic into the mix. Faced with these challenges and ageing infrastructure, the European water industry is focussing on rejuvenating its existing assets, building resilient systems, and improving operational and energy efficiency. So, where should a water company start in implementing system upgrades? THE TOTEX BASED APPROACH Firstly, it’s important to build an effective strategy. The totex (total expenditure) approach continues to reshape the water industry. This framework considers total cost throughout the lifecycle of a project, allowing water companies to be assessed against long-term outcome measures. In addition to cutting costs, the framework looks to provide better value to consumers, and to achieve better efficiency management and operational efficiency. Predictability is therefore high on the optimisation agenda, through close integration and collaboration with manufacturers at the design stage. CUTTING DOWN WASTAGE Waste, in the form of unnecessary energy usage or pipe leaks, can be a real problem, affecting a water company’s maximum output. According to the International Energy Agency, a quarter of the electricity consumed by the water sector is for wastewater collection and treatment. For this reason, companies operating in this space must consider investing in energy-efficient technologies. Reducing energy wastage not only offers environmental and cost-saving benefits, but also allows businesses to commit more resources to meet changing demands. Opting for an energy-efficient motor that conforms to IE4 and IE5 standards is a good place to start, but it is also important to ensure the motor is matched to the load. For example, at a water pump station in Surrey, WEG supplied three 900kW W50 IE4 super premium efficiency motors with IP55 protection, operating at 96.9% efficiency. With new pump impellers, gearboxes, drives and the WEG motors, the facility was upgraded from its existing 400 megalitres per day capacity to 750 megalitres per day, with an efficiency increase from 80 to 86%.
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CONDITION MONITORING To ensure that motors are running optimally, water plant managers can retrofit sensors. By using smart technology such as Industrial Internet of Things (IIoT) data, water companies can monitor their assets and processes in real-time, allowing them to ensure that their systems are performing optimally and to respond quickly to unexpected events. Key metrics such as vibration and temperature changes can be early indicators of more serious system faults. This predictive maintenance approach reduces the risk of downtime and consumer disruption.
“Key metrics such as vibration and temperature changes can be early indicators of more serious system faults.”
USING A VARIABLE SPEED DRIVE Pumps consume a large proportion of the energy usage of electric motors. Upgrading to a variable speed drive (VSD) instead of using a fixed speed motor allows companies to account for varying process load. A VSD can automatically control the speed of the motor and rapidly respond to the required demand. This also allows for more efficient operation, instead of continually operating at a water flow designed for the maximum demand of the system. Going one step further, companies can invest in sophisticated process control software, such as WEG’s Pump Genius. This built-in VSD software enables engineers to increase their process accuracy and protection while offering system monitoring. The software allows one VSD to control up to five pumps, monitoring the operating hours and adding and subtracting pumps as demand changes. Automatic broken pipe detection in the VSD can also identify fluid leakage and adjusts motor performance accordingly. By implementing the totex framework, intelligent design decision making can be achieved, which will give water companies of all types, added flexibility, better performance and superior cost savings. chevron-circle-right www.weg.net www.bpma.org.uk
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24 Building Services
improving energy and water usage in data centres With the growth in demand being placed on UK data centres, electrical usage is a continuing focus in efforts to mitigate climate change. Working alongside data centre specialist, Ian Bitterlin, water pump manufacturer, Wilo UK, has identified how chilled water pumps are key to improving energy and water usage.
he Covid-19 pandemic has caused a surge in demand at data centres in the recent months, with more adults currently working from home and families streaming more content during the day. The implementation of 5G technology and streaming video is also rapidly driving data growth. With users unlikely to reduce their usage, actions such as lowering cooling losses at data centres are important, with better pumps and more efficient controls a key enabler in facilitating this. There is increasing pressure from the EU for data centres to be powered by renewable energy; however, the first step is to reduce the power consumed by the data centre infrastructure. The Green Grid, the innovator of the Power Usage Effectiveness (PUE) metric, has recently proposed the introduction of a new data-centre metric, Water Usage Factor (WUF). As PUE expectations drive lower, data centres are now being judged for water consumption as well as electrical energy use. The majority, 80%, of all data centres utilise chilledwater systems for cooling, 15% use direct-expansion refrigeration systems, and just 5% use air-based evaporative or adiabatic cooling systems. Consulting Engineer, Ian Bitterlin, commented: “Chilled-water systems (the dominant technology used to date) have continued to evolve technically, with better controls, heat-exchanger technology, variable Quarter 3 2020
speed compressors, fans and pumps. They have also developed operationally, with flow water temperatures rising from the legacy 6°C to 18°C (and higher), enabling high percentages of free cooling in suitable climates. Because of this change, an older technology has recently proved more popular – that of evaporative or adiabatic cooling. “In pursuit of achieving an ever lower PUE, the advent of free cooling solutions brought along with it adiabatic cooling solutions, where water is used to take advantage of the wet-bulb ambient temperature and crucially humidification of high volumes of fresh air. Perhaps for the first time in Europe, water consumption in data-centres is a growing issue.” Evaporative and adiabatic cooling technology – which dates back to before Roman times in high-status dwellings – use water to increase the humidity of warm, dry air and reduce its temperature from the dry-bulb to the wet-bulb value. For example, in the UK when the external ambient is near the record high of 35°C drybulb, the addition of water vapour can get the air-stream temperature down to 23°C wet-bulb and this can then be used to cool the data centre. Evaporative and adiabatic cooling systems can save 20-30% of a data centre’s energy (compared to chilled water systems) and do not use pumps. However, they have not proven to be universally popular as they need a lot of space and use a lot of water. www.bpma.org.uk
Building Services 25 Ian continued: “Despite the potential energy saving of evaporative and adiabatic cooling systems, chilled-water systems are, in my opinion, the way forward as they use hardly any water compared to ‘modern’ evaporative cooling technology. The performance of chilled water systems is much improved by high-quality variablespeed pumps and chillers fitted with evaporative or adiabatic cooling offering total control of internal air temperature and humidity. “The majority of enterprise and colocation data centres have a partial load, typically <50% at maturity, rarely high and never 100% – this means that for energy-saving reasons the chilled water pumps must be designed for variable speed drives and optimised for operation at 40-50%. “A pump designed for 100% flow, but only having 30% load, uses 100% power, while the same pump running at 30% flow rate only consumes 2.7% of the energy.” David Williamson, Director of Wilo UK, commented: “Cooling data centre plants with pumps provides an opportunity to improve on past performance with partial load and variable speed pumping, and offers a high level of control to meet a wide range of systems. “Through analysis of the hydraulic system and measurement of the power performance of existing and legacy cooling systems, we can select replacement pumps that can achieve the desired system performance while reducing energy use. Often such upgrades further increase data centre resilience and availability.” The Wilo GIGA range of pumps covers all applications within the data centre environment. The
Atmos GIGA Series has recently been upgraded to provide greater efficiency, and the Stratos GIGA delivers performance greater than IE5 through EC motor technology up to 22kW. Far from the perception that evaporative or adiabatic modules are taking over the market, the sales of chilled-water systems have proven to be increasingly resilient, aided considerably by an offshoot of the adiabatic technology; the air-cooled chiller enabled with adiabatic sprayed free cooling coils. If engineered correctly, chilled water cooling can no longer be considered as wasteful of energy, achieving an overall PUE at full load, with all the other systems included, of 1.2 in northern European city centres. The final piece of the puzzle is to cater for the endemic partial load and here is where the chilled water pump, allied to variable speed pumps and electronic proportional valves, come into their own. The product that, along with the chiller, was most threatened by air-based direct and indirect adiabatic or evaporative cooling can look forward to a successful future in the data centre industry on which we have come to rely. chevron-circle-right
“Cooling data centre plants with pumps provides an opportunity to improve on past performance.”
PUMPS AS TURBINES - HARNESSING WATER POWER TO ITS FULL POTENTIAL
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26 Building Services
System boosts incoming mains flow by a factor of four A mains water boosting system supplied by Stuart Turner has increased a Norfolk-based property’s mains water pressure by 50% and quadrupled the flow rate as flow magazine found out.
or many homes in the UK, particularly those in rural and semi-rural areas, one of the key issues day-to-day is the mains water pressure available to the property. Getting the local water company to increase the pressure is virtually impossible, so to achieve higher pressure mains water and a better flow of water in the home requires the installation of a dedicated water boosting solution. One home that has recently taken advantage of such a system is a large residential property on the Norfolk coast which has installed a Mainsboost 450 SV-2-22 system from pump and water boosting solutions provider Stuart Turner. This has transformed the mains supply to this five-bedroom, five-bathroom property. The installation company on this project was Norwich-based Art Renewables Ltd. Before the installation of the Mainsboost system, the property had an incoming mains water pressure of 2 bar at a flow of 20 litres per minute – not a bad pressure direct from the mains, but given the number of bathrooms and size of the house, insufficient to run the house comfortably. After the installation of the system the new pressure was measured at 3 bar, but at a flow of over 80 litres per minute; a considerable increase in flow in particular. The system comprised of a wall-mounted direct on mains pump and two 450 litre stored water vessels, both with insulation jackets, installed in the garage. The owner of the property is delighted with
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the outcome of the installation: “I am so happy that my plumber suggested we install the Mainsboost System. I can finally enjoy a powerful shower, and it makes a huge difference to the water pressure. I would happily recommend a similar installation to anyone needing better water pressure in their home.” All the pipework has been insulated with Armaflex tube pipe insulation lagging black foam Nitrile class 0. The installation has built-in anti-microbial protection which reduces mould and bacteria growth, and a built-in vapour barrier prevents condensation. The combination of measures to insulate the system reduces energy losses by up to 87%. Installer Konstantinos Asvestas from Art Renewables Plumbing and Heating said: “As a plumber and heating engineer, it’s so important to be able to suggest system improvements for my customers. The Mainsboost system improves the water pressure significantly – it does exactly what it says it will do, delivering more powerful showers for my customers to enjoy.” chevron-circle-right
“The combination of measures to insulate the system reduces energy losses by up to 87%.”
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28 Building services NEWS
A NEW COOLING SOLUTION FOR MISSION CRITICAL PROJECTS ARMSTRONG FLUID TECHNOLOGY has launched Design Envelope EVERCOOL, a new solution for rapid deployment in mission-critical cooling applications. Design Envelope EVERCOOL is an automation platform for mission-critical cooling systems. The EVERCOOL platform offers pre-engineered, featurerich options that can be configured on-site. The platform meets the stringent requirements of the Uptime Institute for Tier III data centres, while avoiding the traditional requirements of extensive site programming and customisation. The platform integrates with all brands of chillers, pumps, and automation systems and installs directly with chiller plant equipment. If preferred, the solution can work with any data centre information management (DCIM) system or central building automation system (BAS).
EVERCOOL is said to reduce site commissioning time by up to 30% and reduces overall energy consumption, coordinating cooling system operation to reduce energy costs by as much as 40%. EVERCOOL uses an innovative design with internal redundancy and a hot-standby controller for continuous uptime. This design approach ensures seamless transfer (in less than 200 milliseconds) between controllers in the event of a failure. Peter Thomsen, Director, Building Systems Solutions with Armstrong comments, “EVERCOOL is a great approach to accelerate project deployment and reduce project costs on any mission-critical project, including Tier 1, 2, 3 or 4 data centres.”
boosting equipment to phase one of the development. When it is fully completed in 2022, the £120m project will see Lauriston Place sensitively restored, extended and upgraded. Not only will it be ready to face the next 300 years but, with the help of many forward-thinking partners such as Grundfos Pumps, it will carry the momentum that it has become famous for, to forge new quests.
IT HAS LONG BEEN UNDERSTOOD that small-scale hydro-electric power production can provide a convenient, cost-effective source of renewable energy. This is something that has been explored by the water and wastewater treatment sector for some time. But more recently, the opportunity to harness unused pressure in the potable water pipelines of larger buildings is also being seen as a route to energy savings. A centrifugal pump, fitted with an impeller of the correct geometry, can operate in reverse rotation mode as a turbine. It works on the same principle as a Francis Turbine. The energy is recovered from the pressure differential (head) while the water flow is passed back into the existing system. A Pump as Turbine (PaT) can be used to generate electricity to the grid network or be directed for local supply. Or, it can be used to drive additional rotating equipment directly. SPP Pumps has found that, in water supply applications, the technique can help to dampen excess pressure, balance pressure in supply lines or tanks at different elevations, control pressure in closed-loop systems and extract excess pressure at the outlet of a water supply line. Supported by many years of advanced turbine engineering experience, SPP Pumps has developed a range of field-proven, affordable, low maintenance products based on simple, readily-available components and spares. The company can supply, install and commission split case, end suction and multistage pumps for vertical or horizontal mounting. And it says that, compared with other renewable energy options, the return on investment can be relatively short.
HEALTHY OUTLOOK FOR HOSPITAL SITE
THE FORMER ROYAL INFIRMARY site in Edinburgh’s Lauriston Place is entering a new era as home to the Edinburgh Futures Institute (EFI). Grundfos Pumps, in association with Balfour Beatty Kilpatrick, has taken up the M&E challenge to ensure that this historic location will continue to encourage yet more ground-breaking achievements. Grundfos is delighted to have been selected as the pump supplier and has already supplied a range of pumps, pressurisation units and packaged Quarter 3 2020
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WA S T E F L O
30 Opinion FEATURE 30
Policymakers must look to the future The BPMA has recently signed a partnership with the manufacturer’s organisation, Make UK. Stephen Phipson, the association’s CEO, explains how he believes that UK manufacturing’s response to the Covid-19 pandemic demonstrates our nation’s ability to lead future global economic growth; if the Government puts the right policies in place.
veryone knows that the Industrial Revolution began in Britain, but what is less widely known is that the origins of modern economic growth started during the Black Death.Like Covid-19, the plague was first detected in China before spreading to Europe where Venetian officials in the city of Ragusa kept newly arrived sailors in isolation for 40 days, known as a quarantino, until they could prove they were not sick. The economic argument goes that repeated outbreaks of the disease caused the old system of feudalism to break down. Workers responded by renegotiating contracts which increased their wages and the movement of labour between employers, helping to finance new inventions and spread new ideas. Cottage industries consequently developed and ultimately evolved into factories. Manufacturing has been at the heart of our economy ever since and, if anything, the current crisis has underlined the importance of our industrial base to maintaining our national prosperity and wellbeing. UK manufacturers have been at the forefront of the national effort with automotive companies switching to building ventilators, clothing and textile companies re-purposing to make PPE, and food and drink factories making hand sanitizers and ensuring our household supplies continue. And manufacturing is operating at the cutting edge of science and technology: whether through 3D printing techniques to produce critical components for medical equipment or working at speed to produce the medicines and vaccine we urgently need. We live in a global economy and have embraced the many benefits of this, with a wide variety of goods from around the world at affordable prices. Yet the Coronavirus has also highlighted how important our home industries are and the need to maintain and develop our domestic manufacturing base. After all, the UK remains the world’s 9th largest industrial nation. Industry is crucial to our economy and our international trade, but it is also crucial to our sense of self as a nation. An ambition for a thriving, modern and green UK manufacturing sector is therefore not just a question of economics. The task for politicians once this virus has passed Quarter 3 2020
will be to shape an economic future in which every part of the country can participate. Manufacturing must be a big part of that. The Coronavirus has brought massive changes to how the world operates. Yet even before the outbreak, we were living in a time of major change. Developments in industry from robotics, to 3D printing, nanotechnology, biotechnology, materials science and energy storage are all enabling innovative new products, but they are also creating new business practices. Throughout the crisis, firms have explored new ways to keep their workers safe while ensuring goods can still get to their customers. Though we are very much now in the eye of the storm, when the dust settles from this tragedy, policymakers must look to the future, to the new world of work that is emerging built on new digital technologies. Manufacturers have worked with the government on the national Covid-19 response, and they stand ready to continue working with government: to improve our education system to equip existing employees and a new generation with the skills they need to thrive in the fourth industrial revolution; to increase UK exports and drive our global trade; to drive forward a comprehensive industrial strategy that delivers the levelling-up that our regions desperately need; to create the right tax and regulatory conditions for industry to grow; and to invest in innovation so that we can help ensure Britain remains the best place in the world to do business. This is not the first global pandemic nor, unfortunately, will it be the last and just as with previous outbreaks, Covid-19 is proving a catalyst for transforming how our economy functions. The adaptability, innovation, and resilience demonstrated by businesses across the country shows that with the right policies and practices, UK manufacturing can be at the heart of the next industrial revolution to come. chevron-circle-right
“Industry is crucial to our economy and our international trade, but it is also crucial to our sense of self as a nation.”
PUMP INDUSTRY AWARDS 2020
th 0 2 Anniversa r y Eve nt
Will you be joining us at the pump industry’s biggest celebration? It’s your chance to network and party with the industry’s best & brightest at this special 20th anniversary event. The PI Awards Gala Dinner is the highlight of the pump industry’s social calendar, celebrating the achievements of both companies and individuals, as finalists and winners are awarded in the charged atmosphere of the presentation ceremony. 2020 heralds the 20th anniversary and two decades of recognising and rewarding excellence throughout the pump sector. Whether it’s taking a table to host customers or booking a few seats for you, your team and partners, don’t miss this fantastic opportunity to enjoy a wonderful evening of great food, fantastic entertainment and networking until the early hours. Just visit the website www.pumpindustryawards.com and complete the simple online booking form to secure your places at this must-attend event, taking place on Monday 7th December at the Chesford Grange Hotel, Warwickshire.
Date & Venue Monday 7th December 2020 Chesford Grange Hotel, Kenilworth
tHe tiMinGs 7.00pm - Drinks Reception
7.45pm - Pump Industry Awards Banquet
9.30pm - Pump Industry Awards Ceremony 10.15pm - Entertainment and Charity Raffle held on behalf of Wateraid 11.00pm - Fun Money Casino and Networking 12.30am - The Survivor’s Breakfast
2020 Award Programme Partners
on behalf of
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