Ways that smart pump systems add value

Powering the Wastewater Renaissance, a research report commissioned by Xylem, finds that adopting energy-efficient wastewater management technologies can cut electricity-related greenhouse gas emissions by almost half. Such advantages are very timely for pump operations under pressure, says Chetan Mistry, strategy and marketing manager, Xylem Africa.

As the market faces pressure from rising energy costs and growing urbanisation, pump sites need to make the most of what they've got, as well as invest smartly in new pump innovations. They need to improve ageing infrastructure with retrofitted improvements and new designs that take less space at existing sites,” Mistry explains.

“The savings come from improved operations, reduced maintenance and fewer breakdowns due to dry running and clogging. Then there is the massive leap provided by variable-speed motors that adapt to changing conditions. This is a fantastic time to leverage smart pump innovations,” Mistry continues.

Seven good reasons

The following seven examples demonstrate how switching to smart pumps helps to drive down costs and optimise budgets:

1Retrofit existing infrastructure Replacing older pumps is a daunting expense and a primary reason why sites avoid upgrades. Yet innovations in control systems bring new life to established pumping infrastructure. Sites can retrofit modern control systems to existing pumps, opening the door to features such as performance monitoring, emergency shutdowns and variable-speed controls. 2 Reduce energy consumption Modern pumps offer energy savings of up to 70% (versus fixed-speed drives). New models of inverters and variable-speed drives manage usage to ensure optimal performance. Unlike traditional pumps that operate on a set level regardless of the conditions, smart pumps adjust accordingly. Some pumps adapt along a kilowatt field rather than a static curve – thus, one pump can act in various capacities that previously required several pumps.

3Lower wear and tear Variable conditions can radically reduce a pump’s lifespan or maintenance intervals. Snoring and dry running are two examples of how prolonged exposure damages a pump, taking years off its lifespan. Smart pumps manage their speed based on inflow conditions, using modern sensors. Sensors and controls can also be fitted on to established pumps to manage inflow conditions.

4Improved maintenance Smart pumps facilitate improved modular maintenance and repair conditions, reducing downtime and maintenance costs by as much as 50%. New pump designs often require fewer components, further lessening the chance of parts failure, and reducing spares inventory requirements. 5 Improved continued operations Shutting down pumps can be very disruptive and stop-start conditions can create unwanted pressure peaks and dreaded water hammers. New features such as adaptive modes enable smart pumps to run continuously as they adapt to factors such as inflow and variable particle sizes. Control systems and sensors enable smart pumps to turn off when not needed but stay online when operations require it.

6Integrated monitoring and planning Smart pump infrastructure brings several benefits to operations planning while simplifying the environment. Smart motors can operate multipump environments, negating the need for external control panels or programmable logic controllers. Sensor data can be integrated into existing operations centres or sent to tablets and mobile phone apps for remote monitoring and control.

7Lower space utilisation Traditional pumps are bulky and take up a lot of space. Modern smart pumps offer smaller profiles, which means there is more room for other equipment or additional pumps. Multipump controllers further reduce the space required for control boxes while providing additional features to both new and traditional pumps.

Leading the smart pump revolution

Xylem invests in the research and development of new smart pump technologies and control systems via a range of class-leading brands that include Flygt and Godwin. Prime examples of innovation include: - The Xylem Smart Motor, an ‘ultra-premium’

IE5 permanent magnet motor with built-in pump protection controls and monitoring, which can optimise pump operations and increase energy savings up to 70%. - Flygt Biboα dewatering pumps, which adapt automatically and only operate when needed, delivering energy savings of up to 60% compared to traditional dewatering pumps. - Godwin’s NC150S Dri-Prime dewatering pump, which features Xylem’s unique, self-cleaning, Flygt N-Technology nonclog impeller and Godwin’s Field Smart

Technology for remote management even in rugged environments. - Flygt’s SmartRun intelligent control, which combines the advanced functionality of a VFD/drive with a simple and intuitive controller. SmartRun takes care of pump, pipe and sump cleaning, as well as water hammer reduction by intelligent soft starts and stops.

Chetan Mistry, strategy and marketing manager, Xylem Africa

“Whether the goal is to acquire new equipment or increase the value of existing systems, study the choices available and make a smart investment today that will deliver value for decades,” Mistry concludes.