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Welcome to the first issue of Flow magazine for 2025. As I write, we are just a few short weeks away from this year’s Pump Industry Awards, a key date in the pump sector’s annual calendar.
The fact that this year’s staging of the Pump Industry Awards is its 25th outing demonstrates how important this event is in recognising and rewarding the amazing work and achievements happening – every day – in a sector that doesn’t often get the recognition I believe it deserves. Those not working in the sector often don’t realise how important pumps are to almost every facet of daily life. And it is important, then, that we come together to shine a spotlight on the many achievements made by the businesses and individuals that make up this vital industry.
There are over 40 finalists, and the winners are determined through the combined efforts of an independent judging panel and public voting, which demonstrates that the awards are truly deserved.
I’m excited to discover who this year’s winners are, selected from what I know was an extremely strong set of entries.
I’m also looking forward to catching up with friends and colleagues, old and new, during the awards event, and if you are coming, I look forward to seeing you there. If you can’t be there on the night, you can, of course, find out about the winners and finalists online and there will be a report in the next issue of Flow.
In the meantime, I hope you enjoy this issue.
Lee Tebbatt, President, BPMA
Steph Issues skills SOS
PRESENTER
AND
JOURNALIST STEPH McGovern is launching an SOS to help crack the ever-growing skills crisis faced by UK industry.
Steph on Skills, powered by Enginuity, is a new podcast that tackles many of the impediments that are endangering growth in one of the nation’s most important sectors— engineering and manufacturing.
The podcast also features some examples of best practice and innovative initiatives that are beginning to make their mark in making things better.
Steph, a fully trained engineer in her own right, is passionate about skills and has been a tireless campaigner highlighting the wealth of opportunities that await young people who crave a stimulating and rewarding career.
She said, “I don’t need to tell you how important engineering is. Practically everything is engineered; when you open the fridge, get on a plane, or even go to the loo,
it’s mind-blowing to see what’s been created by engineers, and that’s why I got into this sector.
“We need loads more people to do the same. There are so many jobs out there, paying decent money too. Let’s help inspire and guide people to get on board – and look at the issues that might be in their way.”
Ann Watson, CEO of skills charity Enginuity, who masterminded the project, believes that the long-term conundrum of closing the skills gap has become a crisis for engineering, manufacturing and the UK as a whole.
“The sector has struggled with a significant skills gap for as long as I can remember, and if we don’t act now, then we risk failing to deliver the Government’s ambitious Industrial Strategy, and that would be to the detriment of UK plc.
“We need some quick fixes and long-term strategic thought as to how to stabilise and help secure the financial future that the nation needs.
“Who better than one of our own, Steph McGovern, to kick off the campaign? She will not shy away from the questions that need asking.
“There are also some wonderful initiatives out there, which we intend to highlight and we will include some of the inspirational and uplifting personal stories that need celebrating.”
The podcast will be available in vision on the Enginuity website and on all podcast platforms.
TSURUMI PUMPS UK EXPANDS CARBON REDUCTION INITIATIVES
FOLLOWING THE SUCCESS OF its tree planting project, Tsurumi Pumps UK has introduced a brand new initiative to reduce carbon and provide shelter and habitat for marine life.
During 2024, Tsurumi Pumps planted a tree for every Tsurumi Pump purchased by customers. A total of 12,052 trees were planted both in the UK and worldwide throughout the year, smashing the original target of planting in excess of 10,000 trees.
The tree planting project is carried out in conjunction with Carma, a B Corp certified company. Trees are one of the biggest weapons in combating climate change, absorbing and storing harmful carbon dioxide (CO2) from the atmosphere and releasing clean, breathable oxygen back into the air. Trees also help prevent flooding, reduce local temperatures and provide habitats for life.
The tree planting project has proved such a success that not only is Tsurumi Pumps UK continuing to plant a tree for every pump sold in 2025, but the company has also pledged to plant a kelp plant for every Tsurumi brand pump complete with hose sold in 2025.
Kelp is a type of seaweed that locks away millions of tonnes of carbon every year, making it a crucial carbon-capture tool in the race to solve climate change. Found along one-third of the world’s
coastlines, it produces oxygen and food and provides shelter and habitat for marine life whilst increasing biodiversity.
Collectively, Tsurumi Pumps is aiming to plant in excess of 12,000 trees and kelp plants in 2025. Throughout the year, Tsurumi Pumps will measure, record and publicise how many trees and kelp plants have been planted and the carbon reductions made, with a live status report on the Tsurumi Pumps website showing progress towards the target.
Pete McMutrie, Sales Director at Tsurumi Pumps UK, said: “We want to thank all our customers for supporting our carbon reduction initiatives with their Tsurumi Pump purchases, and we hope they will continue to support our campaigns throughout 2025. We welcome customers joining us in our journey to help fight climate change, and we can even register trees or kelp plants in their name if they wish to do so following any purchase of a Tsurumi Pump or Tsurumi Pump with hose.
“Sustainability is one of our key objectives, and we’ll soon be launching our brand-new sustainability video, which highlights the journey the business has been on since 2012 when we started to implement strategies to reduce our carbon footprint,” he added.
UKWIR APPOINTS NEW CHIEF EXECUTIVE OFFICER
UK WATER INDUSTRY RESEARCH (UKWIR) has announced the appointment of Mike Rose as its new Chief Executive Officer with immediate effect.
With a career including senior positions in utilities and global consultancy organisations, Mike brings diverse experience to UKWIR. His appointment comes at a crucial time for the water sector, with challenges including climate change and resilience, improvements in river water quality and evolving customer expectations.
UKWIR is committed to enabling the industry to meet these challenges through the delivery of collaborative research. Bringing together partners with the right skills and the new leadership will be instrumental in driving this mission forward.
Commenting on the announcement, UKWIR Chair, Richard Warneford, said: “We are delighted to be able to appoint such a high calibre individual to this position. Mike Rose’s understanding and experience in multiple sectors including
water, coupled with his strategic vision and proven leadership capabilities, makes him the perfect choice to lead UKWIR as we navigate the evolving landscape and strive to deliver solutions for the sector and society in general. Mike’s experience in asset management and technology, combined with his global perspective, will be invaluable as we work to address the critical challenges facing the UK water industry and ensure a sustainable future.”
In 2024, Mike Rose founded Asset Intelligence Advisory, a professional
PARTNERSHIP DELIVERS ENHANCED DIGITAL MONITORING SOLUTIONS
DIGITAL AUTOMATION SOLUTIONS PROVIDER WEG HAS agreed a collaborative partnership with condition monitoring expert AZServ.
The move establishes AZServ as a WEG Digital Partner and authorised distributor for WEGscan, WEG’s wireless monitoring system designed to optimise machinery performance and operational reliability.
This partnership comes at a critical time when industries are increasingly turning to digital technology to drive efficiency and reduce costs. By combining WEG’s technology with AZServ’s expertise in condition monitoring, the two companies are wellpositioned to support customers across a range of sectors.
Since its founding in 2009, AZServ has steadily expanded its expertise and team, specialising in services such as vibration analysis, fluid analysis, motion amplification and thermal imaging. The addition of WEGscan to its portfolio underscores AZServ’s commitment to delivering solutions that maximise equipment uptime and efficiency.
The WEGscan advanced monitoring system utilises sensors and software to provide real-time insights into equipment performance. Optimised for motors and rotating machinery, it can help identify potential issues early, reducing unplanned downtime and extending equipment life. The remotely accessible technology is scalable, supporting varied industrial applications and budgets.
services consultancy with a strong focus on operations, asset management and sustainability across heavily regulated sectors, including water, energy and transport.
That followed a number of senior positions, including Global Sales Director and Chief Strategy Officer at Arcadis, a leading global consultancy that delivers sustainable design, engineering, and consultancy services for natural and built assets.
Mike’s earlier career included leadership roles at United Utilities, where he was Head Of Asset Management & Planning until 2016. He holds a Masters in Water, Energy and the Environment and is a Chartered Management Consultant.
“I am honoured to join UKWIR at this crucial time for the water industry,” said Mike. “The sector is at a pivotal confluence, traditional solutions and current ways of working will not enable us to meet the challenges and opportunities we and future generations face.”
Mike succeeds Steve Kaye, who served as CEO of UKWIR for six years.
2 WEEKS
WATER EQUIPMENT SHOW 2025
THE WATER EQUIPMENT SHOW returns to the International Centre Telford on Thursday, 15 May 2025.
Presented by the Pump Centre, The Water Equipment Show is the UK’s leading event for anyone involved with equipment and services for the water industry.
For 2025, the main conference theme is ‘AMP 8: Challenges and Opportunities in the Water Sector’, and the event’s breakout sessions will focus on four key themes, which include Pumps & Systems, Water Industry Equipment, Technology & Innovation and Water Industry Specifications (WIMES).
The conference, exhibition, and all the technical sessions are free to preregistered delegates, and, subject to availability, delegates will also receive a complimentary lunch bag, hot drinks, and car parking.
Visitors to the event will be able to meet over 120 of the UK’s major manufacturers
and suppliers and network with industry experts and key contacts from across the water industry. The latest technologies and products for the water sector will be on display, enabling delegates to keep abreast of innovative solutions throughout the event, all while using the show as part of their Continuous Professional Development (CPD).
Anyone looking to attend the 2025 staging of the Water Equipment Show can register in advance on the event’s website at bit.ly/WESUK25
CREST PUMPS CEMENTS PARTNERSHIP WITH SR SALVATORE ROBUSCHI
CREST PUMPS HAS
announced a development in its partnership with SR Salvatore Robuschi, after 12 years of successfully supplying pumps into the UK market under Crest’s own brand. Crest Pumps will now serve as the exclusive UK distributor for Salvatore Robuschi’s renowned range of industrial pumps.
This new agreement marks a shift to promoting the products exclusively as SR pumps, aligning with Crest’s commitment to transparency, quality, and customer trust.
seal options – from closed to vortex – mean a much wider range to suit all corrosive or difficult pump applications our customers face.
MAKE UK LAUNCHES NATIONAL MANUFACTURING DAY 2025
THE FOURTH NATIONAL Manufacturing Day, championed by Make UK, will see companies from across the UK host open days on Thursday 25th September to give visitors a unique behind-the scenes look at the innovative and varied jobs on offer in this highly paid sector of British industry.
From engineering to food and drink, aerospace, automotive, chemicals, renewables and pharmaceuticals, visitors will get the chance to take part in handson workshops and speak to current staff about the fast career progression and opportunities available. Last year, we saw over 250 businesses open their doors to take part in activities including building their own aeroplane, designing circuit boards from scratch, 3-D printing, virtual welding and even how lifeboats start production as simple composites.
This exclusive partnership allows Crest to provide an extensive product range designed for energy efficiency and durability, with decades of industry expertise, ensuring robust performance in challenging applications.
Complementing Crest’s historical association with thermoplastic pumps, the addition of SR metallic centrifugal pumps in materials including cast iron, stainless steel and Hastelloy and various
“We’re thrilled to take our partnership with SR Salvatore Robuschi to the next level,” said James Dashwood, Managing Director at Crest Pumps. “This change ensures complete transparency for our customers and demonstrates our commitment to offering the highest quality products from globally respected manufacturers that complement our own ranges of British Built thermoplastic pumps.”
Students and other guests will also have the opportunity to talk to current apprentices about their paid training as well as delving into the roles of the marketing, planning and research which drive the innovations of tomorrow.
Anyone who runs or works in a manufacturing business, can sign up to take part in National Manufacturing Day up at bit.ly/NMD25
MENZEL ELEKTROMOTOREN HAS delivered its largest low-voltage motor to date – it weighs a total of 19,800 kg.
The motor drives a cooling water pump in a combined heat and power plant in Venice. Previously, several motors had failed in a short time in this application, probably due to unsuitable designs.
Menzel customised its new motor specifically for the pump application and proved in load tests that it provides the required output power at the various load points. The MEBKSL-type three-phase squirrel-cage motor is designed as a vertical motor in construction type IM 3011 (IM V1) with a 710mm shaft height. It boasts 650kW rated power, 690V rated voltage and 16731Nm rated torque.
The family-run German motor manufacturer had a suitable 12-pole
LOW-VOLTAGE MOTOR AT 20 TONS
converter motor with 31-Hz star winding in stock and, therefore, could complete the order very quickly – only seven weeks passed between the first inquiry and the motor’s arrival at the installation site. The motor’s electrical data was well suited
to the application, needing only minor changes to the converter parameterisation on site. The motor’s cooling type IC 86W (water-cooled) had to be converted to IC 666 (air-cooled). Menzel built an adapter for an in-stock air cooler and modified the airflow in the motor casing. Menzel also manufactured an individual adapter flange for mounting on the pump and adapted the shaft dimensions. The pump motor features IP55 protection. In its new energy-efficient paint shop, Menzel also finished it with a special coat of paint to guard against aggressive climatic conditions.
www.menzel-motors.com
FLEXIBLE SELF-COOLED SUBMERSIBLE PUMPS PROVE EASY TO SERVICE
THE HIDROSTAL GROUP HAS introduced the Small Tuma motor line; a submersible and self-cooled design which is said to be easy to service.
The pumps comply with efficiency class IE3 and offer a robust design and high reliability for demanding applications. Thanks to Hidrostal’s modular system, the pumps can be combined with various hydraulic configurations of the unique screw centrifugal impeller.
Innovative features in the Small Tuma motors include forced cooling integrated into the outer casing with highly efficient cooling circuit impellers and patented mechanical seals.
The motors achieve efficiency class IE3, meeting the highest efficiency standards in the industry without relying on rare earth metals in their production.
The motors, which have been named after Lake Tuma, the source of the Rhine, are suited to use in a wide range of applications, both for dry and flooded installations. Their watertight design (to protection class IP68) allows continuous operation under demanding conditions. While flexible options for speeds, line voltages, insulation classes and construction materials, including a
duplex stainless-steel version for use in aggressive media such as seawater, add to the Small Tuma motor line’s versatility.
A fully cast outer shell and a patented cooling system enable reliable operation even under the most difficult conditions. Its durability and reliability are supported by components such as ball bearings with a service life of at least 50,000 hours, and mechanical seals, both of which ensure maximum quality. A comprehensive sensor system monitors the bearing condition as well as the mechanical seals and enables connection to Industry 4.0 systems – such as HidroSmart, an intelligent platform for monitoring and controlling pump systems that evaluates data in real time and enables early fault detection – ensuring maximum operational reliability. Bimetallic switches, PTC sensors and optional PT100 sensors protect the windings from overheating, and the motors are certified according to IECEx, ATEX, FM and FMc (in the certification process) for use in potentially explosive atmospheres.
Ease of servicing was a key objective in the development of the Small Tuma motor range. The motors have plugin connection cables that can be left on site for servicing. All components
are designed so that they can be replaced with a minimum of tools, and the smooth surface of the motors facilitates cleaning and maintenance. For maximum flexibility, the motors can be installed both vertically and horizontally and can be supplemented with certified suspensions or maintenance-friendly base plates.
www.hidrostal.com
UK FLOWTECHNIK EXPANDS ITS FLOW METER OFFERING
UK FLOWTECHNIK
is now the official UK and Eire distributor for Unimass Coriolis flow meters manufactured by Walsn.
A new agreement sees UK Flowtechnik extend its flow meter product range, enabling the company to provide solutions for an increased range of applications.
The Unimass meters are designed for a wide range of industries, including chemical processing, pharmaceutical manufacturing, paper industry, wastewater treatment and food and beverage production.
The Unimass series addresses a critical need in the chemical and process industries by providing high accuracy (up to 0.1%) and durability while also being able to handle
aggressive media. The meters can also cope with most temperatures ranging from cryogenic applications (-200°C) to high-temperature processes (up to 350°C). Thanks to robust design and the availability of Stainless Steel 316 and Hastelloy C22 options, the Unimass series helps to reduce maintenance costs and minimise downtime. This
HIGH-FLOW WASTEWATER PUMPS FOR MAXIMUM PERFORMANCE
CAPRARI HAS INTRODUCED THE KCD400, the latest DN400 submersible pump designed for high-flow wastewater transport and treatment. With a capacity exceeding 1,000l/s, this addition to the range ensures efficient and reliable operation even in demanding conditions.
Engineered with advanced fluid dynamics, the KCD400 features optimised hydraulic profiles, achieving efficiencies above 80% and delivering significant energy savings.
Equipped with 6- or 8-pole motors rated up to 260 kW, the KCD400 is available with an optional cooling shroud for drychamber applications.
A double mechanical seal offers maximum protection for electric components, with an alarm signal sent to the panel if the first mechanical seal fails.
Built with premium materials and offered in multiple configurations, it guarantees outstanding durability and performance in heavy-duty wastewater management.
www.caprari.com
will improve efficiency and safety for many applications, especially the chemical industry measuring corrosive substances such as aggressive acids and alkalis. The Coriolis meters can also be supplied with a built-in display that offers local real-time data on flow rate, totalised flow, temperature, and density. This enables the user to optimise their processes efficiently.
In addition to strengthening its range, UK Flowtechnik believes these Coriolis meters will provide the market with a cost-effective alternative.
www.ukflowtechnik.com
6.5 YEARS
BPMA WELCOMES LATEST NEW MEMBERS
Both of these latest two organisations to recognise the value of membership of the BPMA bring expertise, innovation, and dedication to the pump industry, further strengthening the BPMA’s commitment to promoting pump engineering excellence across the sector.
Based in the UK, H20 Pumping Solutions Ltd specialises in supplying, installing, maintaining, and repairing pumps and pumping systems across various industries. Known for its tailored approach, the company provides bespoke solutions to meet the diverse needs of its customers, ensuring efficient and reliable performance in critical applications. With a strong focus on customer satisfaction, H20 Pumping Solutions has established itself as a trusted partner in the pump industry. Visit its website for more information at www.h20pumpingsolutions.co.uk
Vulcan Seals is one of the world’s
leading manufacturers and suppliers of mechanical seals, offering a comprehensive range of sealing solutions to a global customer base. With a commitment to innovation, quality, and customer service, Vulcan Seals supports the pump industry with products that enhance efficiency, reliability, and sustainability. From standard designs to custom-engineered solutions, its expertise helps businesses tackle even the most demanding sealing challenges. More details are available on the company’s website at vulcanseals. com
Commenting on these latest members, Director and CEO of the BPMA, Wayne Rose, said: “We are thrilled to welcome H20 Pumping Solutions and Vulcan Seals to the BPMA. Both companies have demonstrated exceptional dedication to advancing the pump industry through innovative products and services. Their membership reinforces our mission to
UPCOMING TRAINING
support and represent the UK’s pump sector, and we look forward to working closely with them to achieve mutual success.”
JOIN THE BPMA COMMUNITY
The BPMA continues to provide its members with unparalleled opportunities for collaboration, knowledge sharing, and market promotion. From technical support and training programs to marketing initiatives and industry advocacy, BPMA membership offers valuable resources to help businesses thrive in today’s competitive environment.
For more information on the commercial and promotional benefits of becoming a BPMA member, please visit the Association’s website
INDUSTRY-LEADING PUMP TRAINING COURSES
THE BRITISH PUMP MANUFACTURERS Association (BPMA) offers a comprehensive range of high-quality training courses designed for professionals involved in the selection, installation, operation, maintenance, and repair of pumps and pump-related equipment.
The courses from the BPMA are tailored to meet the specific needs of industry professionals and provide the skills and knowledge required to excel in a highly technical and vital sector.
For seasoned engineers, maintenance technicians, or newcomers to the pump industry, BPMA’s training programmes offer unparalleled insights and practical expertise. Delivered by industry experts, the courses cover essential topics and best practices to help participants improve efficiency, reduce downtime, and optimise performance in pump systems.
Some of the most popular topics include:
• Pump systems fundamentals: A perfect starting point for individuals new to the industry or those seeking a refresher.
• Energy efficiency in pumping systems:
Learn how to optimise pump performance while reducing energy consumption and operating costs.
• Pump maintenance and repair: Develop the skills to identify and resolve common issues, ensuring pumps operate reliably and efficiently.
• Hydraulic design and pump selection: Gain a deeper understanding of pump design considerations and how to choose the right equipment for your application.
• Mechanical seals and seal systems: Explore the principles of seal design, installation, and troubleshooting to minimise failures.
A full schedule of upcoming courses is detailed on the BPMA website at www.bpma.org.uk/lectures, where visitors can explore the complete list of options and
find the perfect course.
Courses are available both online and in person, offering flexible, convenient learning options to suit busy schedules.
While participants gain hands-on knowledge and real-world insights, making the training immediately applicable in the workplace.
A detailed overview of the training opportunities available, can be found in the BPMA Training Guide, which is available to download on the BPMA website. This comprehensive resource provides everything prospective delegates need to know about the courses, including objectives, schedules, and how to register.
The Pump Industry Awards celebrates 25 years
The Pump Industry Awards finalists for 2025 showcase the best in innovation, performance, and contribution across the pump sector. The winners will be celebrated at the gala dinner on Thursday, 13 March, at the Hilton Hotel, St. Georges Park in Burton on Trent.
The finalists for the 2025 Pump Industry Awards will find out if they have succeeded just days after this issue of Flow magazine is published.
To help deliver the 25th anniversary of this key industry awards ceremony, the evening will feature Perry McCarthy, ex-Formula 1 driver and the original secret racing driver from BBC1’s Top Gear, The Stig. With over 1,500 speaking appearances to date, Perry combines his famous sense of humour with experiences of rising to the top of motorsport against the odds to entertain audiences the world over with hilarious after-dinner speeches.
The award categories for this year’s event have seen some changes as the organisers work to ensure the awards remain current and relevant. One of these changes sees the introduction of the Award for Sustainable Contribution to a Better World. This category will recognise a business, operation, or project that has made a significant
contribution to improved sustainability and helping to create a better world. Those in attendance at the sold-out event will discover who the winner of this new category is and will hear about all of the other great achievements.
The Distributor of the Year category has been split into two turnover bands – under and over £3m – to ensure the contribution of distributors of all sizes can be acknowledged.
The finalists by category are as follows:
PRODUCT OF THE YEAR
Sponsored by DFA Media Group
• ABB: IE5 SynRM Liquid-Cooled Motors
• HIGRA INDUSTRIAL: EDAM
• INNOMOTICS MOTORS AND LARGE
DRIVES: GH180 VSD Gen 5
• SALAMANDER PUMPS: AquaScan
• SANIFLO: Sanisub 800 Rainkit
• SELWOOD: SelTank
• WATSON-MARLOW FLUID
TECHNOLOGY SOLUTIONS: WMArchitect
PROJECT OF THE YEAR
Sponsored by World Pumps
• BAKER HUGHES: Water Injection Systems for Efficient FPSO Operations
• INNOMOTICS MOTORS AND LARGE DRIVES: CCGT Power Station – Main Cooling Water Pumps VSD Retrofit
• IOI EDIBLE OILS: Optimizing the Water Pumping System for Enhanced Efficiency in Palm Oil Refinery Vacuum Operations
• SELWOOD: Complex Overpump during STW Repairs and Maintenance Works for Northumbrian Water Group
• SELWOOD: Prioritising Training and Skill Development to Drive Employee Engagement
• SPP PUMPS: Future Cell
• TOMLINSON HALL / MIDDLESBROUGH COLLEGE: Pump Centre of Excellence
RISING STAR AWARD
Sponsored by Innomotics
• Patrick Worth, ANGLO PUMPS
• Joe Smith, DECKPRO PUMPS
• Ismael Nicholas Schröer, HIGRA INDUSTRIAL
• Charlotte Bell, SALAMANDER PUMPS
• Noel Pemberton, SALAMANDER PUMPS
• David Higgins, SULZER PUMPS WASTEWATER UK
SUSTAINABLE CONTRIBUTION FOR A BETTER WORLD
Sponsored by AESSEAL
• ANGLO PUMPS part of the METCOR GROUP
• APEX PUMPS
• WILO: Water Security and Optimisation Project
Those in attendance are set for a fantastic evening once again, and we will be sharing details of the winners in the next issue of flow magazine.
www.pumpindustryawards.com
Patterson Pump Ireland is a complete pump manufacturer, offering our customers some of the most reliable pumping solutions available. Our fire pumps stand over life and property throughout the world.
Reduce on-site labor time, engineering and installation time and associated costs. Choose a system that arrives on-site in a fully enclosed ready for use pump house. This pre-engineered pumping system saves time and money for our customers.
The UK expo for process engineers returns this may
The Process & Chemical Engineering Show, running as part of the CHEMUK 2025 Group of Events, will return to the NEC in Birmingham on 21 & 22 May, presenting hundreds of exhibitors and a full programme of expert speaker sessions over two packed days.
The Process & Chemical Engineering Show will showcase the latest technology and specialist services to attending process, plant, and control engineering professionals across the chemical, food & beverage, pharmaceutical, oil & gas, water & waste, and energy sectors.
RECORD NUMBERS OF NEW EXHIBITORS
The 2025 event will see over 60 brand new exhibitors for visitors to meet with, including BPMA members Ambic Equipment, Innomotics and Sulzer Pumps Wastewater, with returning members including ABB, Apex Pumps, Axflow, Crest Pumps, Grundfos Pumps, UK Flowtechnik and Vogelsang.
The BPMA is also exhibiting once again, and visitors are welcome to pop along to Stand F66 to discuss the work of the Association and its membership.
ICHEME AND IMECHE TO HEADLINE
The Process & Chemical Engineering Show speaker programme is an unmissable opportunity to hear from the heads of industry and academia as they discuss the challenges, opportunities, and innovations affecting the process engineering industries.
The IChemE and IMechE will be presenting a series of expert panel discussions, keynotes, and technical clinics at the show. Their respective membership teams will also be exhibiting, ready to meet with current and potential members and companies to see how they can support their personal and business development.
The full speaker programme will be published in March 2025. Please see the website for full details.
THE BIG EDUCATION DEBATE
This feature session, running on Thursday, 22 May, will invite senior panel leaders from across academia and industry to discuss the UK’s educational framework and commitment to supporting its science skills and science base requirements. This critical debate comes in response to the recent pressures facing higher education chemistry departments across the UK.
INNOVATION ECOSYSTEM
CHEMUK 2025 will present several of the UK’s primary innovation support organisations, giving startups and spinouts the opportunity to receive the support they need to continue their development journey towards full-scale commercialisation.
Participating partners include the Henry Royce Institute, Innovate UK Business Connect, CPI, Aston University, RSC Changemakers, Materials Innovation Factory, and the Biorenewables
Development Centre.
Visitors this year will be able to see the hydrogen-powered Le Mans Prototype class 3 car, fuelled by sewage, in a project entitled Waste2Race. The engineering team behind the project from the University of Warwick will be at the show to explain the technology that is creating green hydrogen from wastewater.
Attendees will also be invited to a full UK Government programme. HSE and DEFRA will be providing industry briefings on Wednesday, 21 May.
The UK Export Academy team will also be exhibiting at the show, ready to meet with visitors who are looking to develop international trade opportunities, with a one-hour panel session on Thursday, 22 May, outlining the international trade landscape.Entry is free, and tickets can be requested on the event website. chevron-circle-right
21st & 22nd May 2025 The NEC, Birmingham, UK
2 Packed Days
Hundreds of Exhibitors
Panel Sessions
Plant & Process Intensification
Control & Instrumentation
CHEMICAL 4.0
Automation / Digitisation
Plant Management
Flow & Thermal Solutions
Thousands of Specialist Products... plus
WEG SUPPLIES INTEGRATED DRIVES FOR MAJOR SUSTAINABILITY PROJECT
MOTOR, DRIVE AND GEARBOX manufacturer, WEG, is supporting a major UAE oil and gas organisation in reducing its onshore operations’ environmental footprint. WEG’s integrated drive solutions, including electric motors, variable speed drives (VSDs) and transformers, will help maximise efficiency, reliability and safety in critical water injection operations.
The $2.4 billion project will create a state-of-the-art seawater treatment facility and transportation network to enable more sustainable water injection operations. Water injection is a common procedure in upstream oil and gas applications — used to maintain pressure or to drive oil towards the well to increase production.
The new infrastructure will replace the existing high-salinity, deep aquifer water system, reducing energy consumption by up to 30% during water injection procedures. Entirely powered by renewable energy, the project will deliver more than 110 million imperial gallons per day of nano-filtered seawater. The system operates through 75km of transportation and over 230 kilometres of distribution pipelines and two pumping stations.
WEG’s solutions will drive the water
injection pumps at the heart of the project. The company will supply 21 integrated drive packages, including WEG M-Line (Master Line) 6.6kV medium voltage motors with power ratings between 6.63MW and 11.97MW, medium voltage MVW01 VSDs
and Oil Type phase-shifting transformers.
One of the highlights of WEG’s integrated solutions is an entirely new arc-resistant VSD developed specifically for this project. The drive is designed to absorb explosions caused by sudden electric arcs, protecting pump operators and maintenance personnel working on site. Other notable features include a touchscreen HMI for easy programming and access to key parameters.
The motors are made to withstand the Arabian desert’s harsh environmental conditions, including extreme heat of up to 55°C. In addition, the motors are IP55-certified against dust and water. The robust carbon steel frame delivers superior structural rigidity and low vibration levels for optimal reliability. In addition, high-quality materials combined with design optimisations minimise losses and maximise energy efficiency.
WEG expects to deliver the drive packages by September 2025.
www.weg.net
POTATO PLANT RELIES ON DEGASSING PROCESS PUMPS
THE LYCKEBY POTATO STARCH plant in Mjällby, Southern Sweden, produces native and speciality starches and valuable by-products such as fibres, proteins, and biofertilisers for the global food and paper industries.
In 2022, the factory underwent modernisation, expanding production to 40,000 tons of commercial starch annually, with a focus on energy savings for enhanced sustainability.
Sulzer pumps were chosen to handle the toughest liquid pumping applications. Twenty-eight new AHLSTAR and SNS pump units are now working on site, complementing the older installed Sulzer pumps that have operated for decades. Producing potato starch involves technical challenges, from raw material washing and rasping to fibre and fruit juice separation, and final starch washing and drying.
Pumping liquids prone to foaming is a significant issue. This special feature arises partly because of the protein content of
liquids and partly because the different raw material components are separated mechanically. The fibre pulp separation stage is particularly critical, as the liquids pumped can contain over 40% air.
Conventional centrifugal pumps cannot operate with such high gas content as capacity is reduced dramatically and pumping becomes unstable.
After rasping, the slurry mixture of pulp, starch, and potato juice passes through rotating conical sieves for pulp fibre separation. Sulzer provided seven AHLSTAR A-LM pumping units for transferring or recirculating starch, fruit juice, fibres and water.
The pumps, with LM-integrated liquid ring pump degassing units, are designed to handle foamy suspensions effectively and reliably, ensuring trouble-free operation and a steady process.
Even for viscous slurries, the A-LM pumps with a built-in vacuum system can separate most of the air from the liquids, maintaining a constant flow.
The internal degassing device in the A-LM pump removes most air bubbles from the impeller eye, significantly increasing pump efficiency, which saves energy and benefits the environment. Reduced air in the system also enhances the efficiency of other process devices, and the use of expensive antifoam agents is greatly minimised.
www.sulzer.com
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Customer Services provides industry-leading services and digitalization to ensure the productivity, availability, and reliability of our customers’ assets.
With a trusted legacy of more than 150 years of engineering expertise, we are and have always been the backbone of reliable motion for industries and infrastructure worldwide. We are now about to take this to the next level. Our mission is to support you, our customers in the mining and minerals sector, on the road to the future - sustainable, digital, reliable. Redefining reliable motion for a better tomorrow.
MECHANICAL SEAL RUNS FOR 17 YEARS WITHOUT PROBLEMS
SOUTH AFRICAN SUGAR PRODUCER,
Tongaat Hullett Sugar was unhappy with the amount of maintenance required on the sealing of one of its pumps.
The pumps on site were all sealed with gland packing, and the mean time between failure for this particular pump was just two weeks. When the pump failed, the plant had to stop operations for four hours at a cost of ZAR 300,000 (around £13,000) per hour as there was no backup pump. Unhappy with this situation, the customer turned to AESSEAL for assistance.
AESSEAL recommended replacing
FISH WASTE BECOMES FUEL
A BORGER MULTICRUSHER HAS BEEN installed at a cement manufacturing plant to chop up fish remains that are used as fuel for furnaces.
The Multicrusher’s interconnecting cutting blades (set on a hexagonal carrier shaft) handle the 20% dissolved solids material to ensure that the fish remains (predominantly bones) are chopped efficiently so that they can be incinerated effectively.
Based on the principle of the Borger Rotary Lobe Pump, the Multicrusher has blades (instead of rotating lobes) configured for optimum chopping yields that continuously macerate fish waste that would otherwise be economically unviable.
Using basic tools, maintenance staff at the plant can easily service the Multicrusher without dismantling any pipe or drive systems. Designed with a quick-release cover to access worn parts, the Multicrusher benefits from maintenance-in-place design.
the gland packing with a Convertor II cartridge mechanical seal. The new seal was installed in July 2004 and ran without problems for 17 years before it failed in May 2021. This solution was the first time a mechanical seal had been used to seal a pump on this site and saved the sugar producer approximately ZAR 1,200,000 ( over £50,000) per year.
www.aesseal.com
NON-RETURN VALVES FOR CRITICAL RESERVOIR REPAIR
IN 2019 A DERBYSHIRE TOWN WAS faced with a severe flood warning that posed a threat to life and major structural damage.
A 300-million-gallon reservoir upstream from the town was at risk of bursting due to two consecutive storms and the intense rainfall they brought with them. This led to damage and erosion of the reservoir’s auxiliary spillway and prompted fear of a dam breach.
Over 1500 people were evacuated from the town in a huge emergency effort while a stream diversion and pumping works were implemented to drain the reservoir in order for repair works to begin.
configure and function test flap valves within the works schedule.
The supplied flap valves were chosen for their industry-proven design, featuring a maximum seating pressure of 6m water column for reliable backflow prevention. Consistent sealing performance is further guaranteed by the valves’ durable elastomeric seat, flexible double hinge profile and corrosionresistant stainless-steel hinge and antitamper pins.
www.boerger.com
Nearly three years later, in 2022, the monumental repair effort began with a predicted completion date of late 2024, with T-T Flow being called upon to supply essential flap valves to the project.
T-T’s engineers worked to stringent end-user specifications to assemble,
Their ductile iron body offers a good strength-to-weight ratio, while a robust fusion-bonded epoxy coating provides corrosion resistance for long-term operation, which is essential due to the critical nature of the repair works.
www.ttpumps.com
TOUGH OUTSIDE. SMART INSIDE.
Good things made even better: our new submersible motor pump, the AmaRex Pro, can do more, but needs less. Thanks to self-cleaning, smart functions and IE-5 motors, maintenance costs and energy consumption are reduced, making it both smarter and more economical.
Find out more at www.ksb.co.uk - 01509 231872 - sales@ksb.com
We supply a large range of high precision horizontal, vertical and automated hard bearing dynamic balancing machines suitable for all industries.
All machines are supplied with guarding meeting the requirements of Machinery Directive 2006/42/CE.
For further information contact us: T: 0161 872 3122 E: sales@cembhofmann.co.uk
HIGH LIFT PUMP REPAIR AND UPGRADE ENHANCES EFFICIENCY FOR WATER UTILITY
UTILISING ITS LARGE-CAPACITY
handling capabilities, which allow the company to manage and refurbish substantial infrastructure components efficiently, Hayley 247 DEXIS was recently tasked with the full inspection, repair, and upgrade of an 8-tonne high lift pump, a critical component in water distribution across London. The goal was to maximise efficiency, extend the pump’s lifespan, and reduce the total cost of ownership through comprehensive refurbishment and upgrades.
As part of the inspection, repair, and upgrade of the high lift pump, Belzona 1341 ceramic efficiency coating was
applied to all internal water passageways, enhancing the pump’s efficiency and reducing operational costs. Running clearances were reinstated in accordance
with water industry mechanical and electrical specifications to optimise performance. The mechanical seal arrangement was also upgraded in collaboration with sealing technology specialist, Eagle Burgmann.
Hayley 247 DEXIS was able to utilise its in-house services, including grit blasting, coating, dynamic balancing, and machining, to ensure full control over the repair process.
www.hayley247.co.uk
CUSTOM SEAL SOLUTION REDUCES DOWNTIME FOR CHALLENGING PUMPING APPLICATION
VULCAN SEALS HAS PROVIDED A solution for a global manufacturer facing severe slurry substance challenges on positive displacement pumps. This innovation significantly reduced clogging, pump downtime, and maintenance costs while enhancing overall system reliability.
A multinational manufacturer faced persistent issues with traditional cartridge mechanical seal designs that employed multi-spring technology on positive displacement pumps. The application involved a challenging slurry substance of fine, soft, sticky particles interspersed with cellulose-based fibres. These conditions caused the mechanical seals’ moving parts to become quickly clogged, preventing the seal faces from correctly adjusting. As a result, leakage occurred shortly after installation. The result was frequent pump downtime with extended operating hours being interrupted by the need for unscheduled maintenance. Due to the cartridge mechanical seal’s short lifecycle (replacement needed after 72 hours), regular pump strip-downs and seal repairs and replacements significantly raised operating expenses.
Vulcan Seals introduced the Vulcassette custom solution design, a
product that completely removed the springs used to energise the primary seal surfaces.
Removing springs meant there were fewer surfaces and mechanisms for slurry particles to accumulate, thereby reducing clogging.
The design simplified the energisation method and integrated carefully selected sealing materials to overcome chemical incompatibility and inadequate wear resistance, key issues that led to failures with traditional mechanical seal technology.
The new design also allowed the seal faces to re-adjust automatically, even after minor impacts or blockages.
And, although on this occasion, the manufacturer did not utilise the builtin seal cleaning system, the option to circulate cleaning water around the sealing face area further improves performance by preventing particle deposition.
The introduction of the Vulcassette enabled extended run times with the pumps operating for much longer periods between maintenance strip-downs, reducing process downtime. With less frequent seal replacements and repairs, overall operating expenses were substantially lowered.
The self-adjusting capability ensured that minor leakages caused by oversize contaminants or impaction were promptly corrected without manual intervention.
While the Vulcassette design now allows adjustments to be made when the equipment is not rotating, eliminating the need for complete removal from the shaft during planned maintenance.
www.vulcanseals.com
Boost Your Efficiency with WEG
We offer a wide range of solutions to improve performance, efficiency and reliability for your pump applications.
• WEG Sync+ Ultra, with an anticipated IE6 efficiency rating, this is the most efficient industrial motor on the market.
• Pump Genius, a customisable feature of WEG drives that enables your standard VSD to become dedicated for pumping systems ensuring accurate pressure / flow control throughout the process
• Motion Fleet Management, scans and monitors the performance of assets using cloud based technology for preventative and predictive maintenance.
• WEG SEE +, new efficiency calculator enables you to calculate energy savings, return on investment and ultimately reduce GHG emissions.
Learn more at www.weg.net
Secure Your Water Infrastructure: Top Cybersecurity Tips for Digital Transformation
Dr Kenneth Crowther, Xylem’s Applied Water Product Security Leader (PSL), outlines five ways to help ensure that water and wastewater infrastructure can benefit from the opportunities digitalisation offers while maintaining robust cybersecurity.
Digital transformation in the water and wastewater infrastructure space offers incredible value in the face of increasing challenges – from ageing infrastructure to stretched resources. Moving to the cloud and using new platforms to integrate and leverage data shouldn't feel scary. In fact, when implemented thoughtfully, digital solutions can help bolster data and infrastructure security. Here are five tips to help you navigate the digital landscape securely.
UNDERSTAND
CYBERSECURITY
STANDARDS AND RISKS
Knowledge is power – and water infrastructure cybersecurity is no
exception. First, it pays to keep up to date with local and global regulations around cybersecurity standards for utilities. While it may seem overwhelming, most local standards are derived from international standards like ISO 27001 and IEC 62443, so familiarising yourself with those is a good place to start. The US Cybersecurity and Infrastructure Security Agency (CISA) recently published a helpful tool titled "Secure by Demand". Developed in collaboration
with over a dozen international government organisations, it provides tips to help organisations implementing water technologies or other operational technology (OT).
Knowledge is power –and water infrastructure cybersecurity is no exception.
Equally important is staying up to date with threat activity. Understanding bad actors' latest techniques and activities can help you stay one step ahead. Organisations like the Water Information Sharing & Analysis Center (WaterISAC) and the Dragos Community Defense Program (CDP) are bringing utilities together to bolster security and
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www.crestpumps.co.uk
T: 01425 627700
E: info@crestpumps.co.uk
Cybersecurity
share knowledge.
Both organisations allow utilities to report incidents (anonymously, if preferred) so that the full water infrastructure community can be aware of recent activity. Users of these platforms can also get free resources and training. In fact, Dragos provides utilities with under $100 million in annual revenue free access to cybersecurity training and toolkits, and both AWWA and NRWA provide free training and resources.
SYSTEM VISIBILITY ENABLES SECURITY AWARENESS
Cyberattacks are increasing as more utilities embrace cloud-based systems. But there's another side to that coin: without sophisticated digital monitoring and control technologies, it may be difficult to detect attacks or suspicious activity until it's too late. Data is often siloed – even in organisations that have embraced digital technology. This makes it harder for operators to fully understand what's happening in their system. But the right digital applications can remove silos and create a holistic, streamlined view of the entire operation.
MAKE SURE CYBERSECURITY IS BUILT INTO YOUR TECH
Each element of your tech stack has the potential to strengthen your security – or be the weak link vulnerable to attack. This is why water infrastructure cybersecurity shouldn't be an add-on to existing and new digital implementations; instead, it must be built into the core of your chosen technologies.
It is also important to implement additional layers of security – what experts call the 'security onion' or the 'security layered cake' approach. This involves considering security at multiple levels, from the physical environment to the network, host systems and applications themselves. No single measure is undefeatable, but creating security in layers maximises protection.
HAVE A RESPONSE PLAN
Even with the best preventive measures in place, cyberattacks can occur. That's why it's crucial to have
a robust incident response plan. With thorough training and a good plan, utilities may be able to stop hackers and suspicious activity in their tracks or at least mitigate the damage. EPA and CISA programs have free tools and resources to help you create and implement these plans, but it also pays to build your response into your digital platforms. Ask each vendor how they will support you in the event of suspicious activity or attacks. Then, you can work together to formulate a process specific to their systems.
providers with technology and water expertise is vital.
Many cyberattacks are still a result of phishing – a testament to human vulnerability rather than that of digital systems.
Remember, the most effective response begins long before an incident occurs. Many cyberattacks are still a result of phishing – a testament to human vulnerability rather than that of digital systems. That's why it's crucial to train employees regularly on how to avoid cyberattacks and how to respond to suspicious activity.
SELECT EXPERT PARTNERS
Cybersecurity is an ongoing joint effort between an organisation's internal team and technology partners. Since many utilities operate without large IT and cybersecurity teams, identifying the most competent solution
www.xylem.com
For example, Xylem Vue is a digital solution built to help utilities bolster operational efficiency and cost savings, all with best-in-class security protocols in place. The Xylem Vue team stays updated with evolving water infrastructure cybersecurity standards and updates the platform accordingly. This includes regular security testing to ensure all existing and new deployments are completely secure. What's more, utilities using this platform get a built-in product security incident response team, and every cloud service is monitored around the clock for real-time threat detection.
Digital transformation offers immense opportunities for water utilities to optimise operations, reduce costs and improve service. By following these tips and partnering with the right experts, you can embrace these opportunities while maintaining robust cybersecurity. chevron-circle-right
TOUGH PUMPS, POWERFUL PERFORMANCE
In everything we do, we never lose sight of what it‘s all about for you: economical work and easy handling.
Whether chemical substances, oils or media for the food industry, it is important to fill or empty quickly and precisely. Due to the reversible conveying direction, both processes can be carried out with just one pump.
As a result of their compact yet powerful construction, Vogelsang rotary lobe pumps are among the most frequently ordered pumps in many UK industries. They transport highly viscous or aggressive media of all kinds and even pump liquids with rough solids without blocking.
VOGELSANG – LEADING IN TECHNOLOGY
For more information: sales.uk@vogelsang.info | 01270 216 600 vogelsang.co.uk
Advanced materials help mechanical seals transform the efficiency and sustainability of pumping equipment
Phillip Charlton, Chairman of the European Sealing Association’s Mechanical Seal Division, explores how carbon-graphite and silicon carbide seal ring wear faces contribute to the energy transition and boost the efficiency of pumps across various industries.
The global energy transition towards sustainable and renewable energy sources requires significant advancements in technology and materials to improve efficiency and reduce waste. In this context, carbon-graphite and silicon carbide (SiC) seal ring wear faces have emerged as critical components in pumping equipment, playing a vital role in enhancing performance, longevity, and energy efficiency.
Pumping equipment is essential to various industrial processes, including oil and gas, chemical processing, water treatment, and renewable energy. Efficient pumps are crucial for reducing energy consumption and ensuring the smooth operation of these systems. Mechanical seals, especially those using carbongraphite and silicon carbide wear faces, are key to maintaining pump reliability, minimising leaks, and reducing energy losses.
HOW CARBON-GRAPHITE AND SILICON CARBIDE MATERIALS WORK
Seal rings can be subjected to extreme conditions, such as high temperatures, corrosive environments, and mechanical stress. The choice of materials for these components significantly impacts their durability and efficiency. Carbon graphite and silicon carbide are preferred in modern mechanical seals for the following reasons.
CARBON-GRAPHITE WEAR FACES
• Self-lubricating properties: Carbon graphite has excellent self-lubricating characteristics, which reduce friction between the seal faces. This property
is essential in preventing wear and extending the life of the mechanical seal, especially in applications where lubrication is limited or unavailable.
• Thermal stability: It can withstand high temperatures without losing its mechanical properties, making it ideal for harsh operating conditions in industries like power generation and chemical processing.
• Chemical resistance: Carbon graphite is highly resistant to chemicals, ensuring it remains effective even in corrosive environments commonly found in the oil and gas and chemical industries.
SILICON CARBIDE WEAR FACES
• High hardness and durability: Silicon carbide is one of the hardest materials available, providing exceptional wear resistance and durability. This property significantly extends the lifespan of the seal, reducing the need for frequent replacements and downtime.
• Low friction coefficient: The smooth surface of silicon carbide reduces friction between the seal faces, contributing to lower energy consumption in pumping systems. This efficiency is critical for renewable energy and water treatment applications, where energy savings are a priority.
• Thermal conductivity: Silicon carbide’s high thermal conductivity helps dissipate heat effectively, preventing overheating and maintaining stable operation under extreme conditions.
ENHANCING EFFICIENCY AND SUSTAINABILITY IN PUMPING SYSTEMS
The use of carbon-graphite and silicon carbide wear faces in mechanical seals directly impacts the energy efficiency and sustainability of pumping systems in several ways.
• Reducing energy consumption: The low
friction properties of carbon-graphite and silicon carbide seal faces reduce the energy required to operate pumps. Lower friction means less power is needed to overcome the resistance within the system, leading to significant energy savings over the lifetime of the equipment.
• Extending equipment life: The durability and wear resistance of these materials lead to longer-lasting seals, reducing maintenance needs and the frequency of seal replacements. This extension of equipment life minimises the use of raw materials and energy resources in manufacturing new parts, aligning with the principles of a circular economy.
• Minimising emissions and leakages: Effective mechanical seals made with carbon-graphite and silicon carbide help prevent leaks of fluids and gases. In industries like oil and gas, where preventing fugitive emissions is crucial, these seals play a critical role in reducing environmental impact. They ensure that harmful chemicals or greenhouse gases do not escape into the atmosphere, supporting global efforts to lower carbon footprints.
• Supporting renewable energy applications: In renewable energy sectors, such as wind, solar, and hydropower, pumps equipped with efficient seals are essential for optimal performance. The reliability and energy efficiency provided by carbon-graphite and silicon carbide seals contribute to making renewable energy systems more cost-effective and competitive with traditional energy sources.
CONCLUSION
The use of carbon-graphite and silicon carbide seal ring wear faces in mechanical seals is transforming the efficiency and sustainability of pumping equipment across various industries. Their unique properties of low friction, high durability, thermal stability, and chemical resistance make them ideal for supporting the energy transition towards more sustainable practices. By enhancing pump efficiency, extending equipment life, and reducing emissions, these advanced materials play a crucial role in optimising industrial processes and contributing to a greener, more energy-efficient future. chevron-circle-right
www.europeansealing.com
Chopper pump drives farm’s diversification
Hendwr Farm’s biogas plant is helping third-generation farmer Phil Hughes to continue his farm’s diversification journey – with a Landia chopper pump as its beating heart.
Hendwr Farm, a traditional hill farm in North Wales that produces lamb and beef began life in 1902 when it was purchased by Cadwalader Jones Hughes.
Today, diversification is a big buzzword in farming, but John Hughes (Cadwalader’s son) saw the benefits of it back in the late 1960s when he began offering camping at the farm, which then evolved into the thriving Hendwr Caravan Holiday Park. Income from the serenly-set medium-sized static caravan holiday park was and continues to be a success, but its growth meant plenty of electricity consumption, so as the third generation of the Hughes family brought its influence to bear, Phil Hughes (in 2011) went ahead with the introduction of ground-mounted solar panels.
“We wanted to limit external inputs into the farm,” explained Phil, “and when we saw the benefits of this first venture into renewable energy, we started looking at how else we could expand it.”
Producing a modest amount of manure from 120 Angus calves, a plan emerged to combine this with waste, corn and chaff to feed a biogas plant that would not only produce energy but fertiliser too, which, especially given the rising costs, the farm didn’t want to have to buy any more. The key ingredient, though, would be to use chicken litter, which has proved to be a very fast and efficient feedstock.
“I would say that when we started building our biogas plant in 2015, we were gloriously ignorant,” added Phil. “It was a thousand times harder than we thought it would be – but when you look at the value of farm produce
compared to the value of anaerobic digestion (AD), there’s a strong financial case for making this source of renewable energy work and work well. Food is so undervalued. We’re incentivised as farmers to produce food as cheaply as possible rather than look at the whole food cost and the effect on land and our wider society.
“We have almost 100 control signals on our biogas process, so if something isn’t right and an alarm goes off, you have to deal with it straight away if you want to keep the plant up at its target performance levels, which, for us, is a minimum of 95%. We have a 200kW
“We have almost 100 control signals on our biogas process, so if something isn’t right an alarm goes off.”
engine, and a digester that very much fits our farm size. I’ll admit that we’re obsessive about maintenance, but we have to hit high numbers to be profitable, and you just can’t neglect the biological process. It’s not like a light that you switch straight on. It takes time to come back to full production, so time is money. To keep our system running at its optimum levels, we’re always absolutely on it. We take regular samples and, over the years, have learned what good biology is so we know what to do and what not to do.”
For its 90m3 reception tank,
Hendwr Farm spans almost 1,000 acres of lush green grazing fields in North Wales.
Renewable Energy 30
Hendwr invested in a chopper pump and a mixer from Landia to blend the incoming feedstock into a very homogenous mix.
“The only problem we had,” continued Phil, “is that after six years of continuous use, we eventually killed the pump. It was cast iron and was basically being asked to do something that it wasn’t designed for. The low pH, running at 3.8, had over time, made everything corrode. We very much wanted to stay with Landia, but upgrading to stainless steel meant a short wait, so they kindly helped us out with a temporary replacement so that we could keep producing gas. The Landia chopper pump is very effective and reliable, continuously reducing particle sizes, ready for the liquid to go through into our milling and micronising lines.”
During lockdown, when some of us put on far too much weight and drank far too much, Hendwr far more wisely relieved the boredom by learning how to dewater, digestate and slurry to get not only a dry, stackable solid but a polished water that’s dischargeable into water courses. This has resulted in the development of Ekogea, whose BioComplex product maximises biogas outputs and improves commercial viability, as well as reducing waste digestate by up to 80% by volume. It also treats wastewater to Environment Agency permitted discharge standards. The product range helps with sustainable and profitable slurry management, provides natural fertiliser for crops and soil regeneration, and improves the health and profitability of livestock.
Phil Hughes continued: “We’ve found a way of concentrating solids so that we can now dewater very efficiently. As hill farmers, it allows us to take that digestate as valuable fertiliser safely up onto the banks, whereas slurry tankers would be dangerous with all that weight sloshing around. It’s a big advantage because we can deliver nutrients much further through the farm, which has increased our productivity. When spreading onto our land, it’s going into the plant instead of going up into the air, which is why we’re
growing so much more grass on the farm, because the nitrogen isn’t being lost to the atmosphere.
“We’re actually reducing the volumes of liquids and slurries we’re dealing with by a factor of almost ten, reusing the water to wet the dry chicken litter at the front end of our system for a much cheaper, more efficient process. When trying to dewater, covering our lagoon (5m deep) was one of the best things I ever did. We have no shortage of rain in North Wales. Dewatering offers numerous options because it makes product so much easier to transport. It is a very exciting piece of technology, which in addition to farming, can be used at factory sites, even if they already have a DAF treatment process. We can collapse the COD, BOD and nitrogen levels that they get charged for by the water companies.”
“At the heart of our biogas process, good mixing and pumping are crucial for all important homogenisation.”
Phil continued: “At the heart of our biogas process, good mixing and pumping are crucial for all important homogenisation. When the Landia team turn up to carry out maintenance, they are armed with good client data. We could be made to feel that we’re just a small customer out of thousands, but they know our names, know exactly what they are doing and provide very attentive, enthusiastic service. They’re good lads. Hitting our performance target means having the right machines, the right service, and the right after-sales, which we’ve always had from Landia.” chevron-circle-right
The biogas process at Hendwr helps provide natural fertiliser for crops and soil regeneration.
www.brookcrompton.com
Keeping industry turning every second... every day...every
year
With over 110 years of technical and design expertise, Brook Crompton offers leading edge energy efficient electric motors across global markets. As the original innovator in electric motor development, Brook Crompton are trusted to power limitless industrial processes and its robust motor design drives fans, pumps, compressors, conveyors and more.
Driven by technology and innovation, Brook Crompton has one of the widest available ranges of electric motors for operation in safe areas, hazardous atmospheres and hostile environments.
The extensive range of stock can be quickly modified to suit customers’ needs and with a high level of technical support from our knowledgeable team we ensure the correct selection of motors is provided for your application.
Brook Crompton’s focus on product and service development ensures we continue to move forward to improve efficiency, offer lower cost of ownership throughout their lifecycle and to reduce environmental impact.
Reduce energy consumption in pumping systems with advanced drive technology
According to a European Commission report, pumping systems account for nearly 22% of the energy consumed by electric motors worldwide and consume approximately 8.7% of global electricity. However, by implementing variable speed drives in pump applications, energy savings of up to 50% can be achieved – depending on the system and its demand profile. David Strain, Technical Director at industrial water equipment supplier Technidrive, explains how VSDs enhance pump energy efficiency and performance.
Pump systems move fluids in various industries, from water treatment and HVAC to manufacturing and chemical processing. They are, by nature, energy-intensive, especially when conventional control methods like throttling valves or on-off systems are used. These older methods typically force pumps to operate at full capacity, regardless of the actual demand, wasting significant energy when the flow requirement is lower.
REDUCING WEAR ON MECHANICAL COMPONENTS
Additionally, on-off pumps, with their limited two-speed maximum or stopped functionality, contribute to mechanical wear. This can lead to premature failure and increased maintenance costs. Variable speed drives (VSDs) offer critical protection and maintenance benefits by reducing wear on pipes and valves and minimising excessive stress on the motor’s windings. VSDs slowly ramp up and
gradually stop the pump mechanism, minimising the risk of mechanical shocks or sudden pressure surges that can damage pipes, joints and seals. Additionally, they can be combined with pressure sensors to maintain a consistent pressure level across the system, regardless of demand fluctuations. This ability to regulate pressure automatically helps prevent both physical damage to components and short-term overloading of the electrical supply with each pump start.
INCREASED ENERGY EFFICIENCY
Unlike traditional fixed-speed pumps, VSDs provide precise control over pump speed, adjusting energy input to match the system’s actual demand. Instead of forcing the pump to operate at its maximum capacity, a VSD allows gradual, optimised control, ensuring the pump runs only as fast as necessary. VSDs also offer significant efficiency improvements compared to throttling valves, which are commonly used to regulate
flow and pressure in industrial systems. By using VSDs, companies can eliminate throttling valves and associated pipework, enhancing system efficiency. You may even opt for a lower-power, cheaper pump without compromising performance. Throttling valves restrict flow, increasing pressure and causing energy loss. In contrast, VSDs control pump speed directly, eliminating the need for such restrictions and preventing energy waste. For example, when flow or pressure requirements decrease, the VSD slows the pump’s speed, cutting energy consumption. Over time, these savings add up to significant operational cost reductions and less frequent maintenance requirements. The adoption of VSDs has helped a wide range of industries make huge strides toward their sustainability goals by reducing energy usage, carbon emissions and environmental impact. However, to fully unlock the potential of this technology, pump systems also need intelligent control software to monitor and manage their operation.
INTELLIGENT VSDS FOR PUMPING OPERATIONS
Beyond slowing down or speeding up the pump, modern VSDs like those integrated with intelligent control systems — such as WEG’s Pump Genius — offer even more sophisticated energy management features. These systems continuously monitor and adjust the pump’s operation based on real-time data, such as flow rate, pressure and fluid levels. This ensures optimal energy usage and improves system reliability by preventing issues like cavitation, overheating, or unnecessary wear on the pump.
Pump Genius is a highly advanced solution for systems that use multiple pumps, capable of controlling up to six pumps in a coordinated system. This software balances wear and tear by rotating pumps in and out of operation and adjusting their speeds to meet system needs. It also provides real-time alerts of potential issues, such as overpressure or low flow, helping operators address
problems before inefficiencies or unplanned downtime occur.
Modern VSD systems offer the advantage of integrating intelligent motion controllers, which handle complex tasks that previously required programmable logic controllers (PLCs). This integration simplifies system design and improves performance by enabling each pump to operate autonomously within the overall network, reducing the need for high-performance communication systems.
The adoption of VSDs has helped a wide range of industries make huge strides toward their sustainability goals.
pressure, prompting the VSD to adjust the flow rate or shut down the pump altogether if necessary. This proactive control not only extends the pump’s lifespan but also safeguards the entire pumping system from operational disruptions.
In conditions where the water level drops or there isn’t enough water to meet the throughput demand, VSDs provide dry-run protection to prevent costly damage to the pump. The system’s sensor network can detect a drop in water level or
technidrive.co.uk
Sustainability in industrial processes doesn’t have to come at the cost of efficiency or performance. With advanced drive technology and intelligent control systems, businesses can have the best of both worlds — optimising their pump systems to reduce energy usage while maintaining reliable and effective operations. chevron-circle-right
Unlock efficiencies in the driven component
With electric motors creeping upwards in terms of efficiency, the savings to be made by moving between IE classifications are becoming relatively small. However, if we focus on the driven component – such as pumps – as opposed to the driving component, there are still large efficiencies and improvements to be had. BPMA member and pump maintenance and repair specialist, ERIKS, assesses how to get the best out of pumps and pumping systems.
With a major focus currently on sustainability and environmental best practice, much of ERIKS’ focus is about returning to first principles when performance testing a pump. To create the data necessary to assess the pump curve, you need to understand the flow rates, pressures it delivers, and the power consumption measured at the motor
or from the control panel. Modern technology makes it possible to test the performance of pumps in a non-intrusive way – for example ultrasonic flow meters that clip to the outside of a pipe, pressure transducers that measure the suction and discharge pressure and power measuring equipment. Testing pumps in-situ is important as there’s a recognition that if you test a pump in the
factory, it’s efficient to the curve but not necessarily the application. When a pump is tested in situ, if it’s found to be a bad fit, then there are a host of actions that can be taken to rectify the problem, from adding a new controller to trimming or changing the impeller.
The ability to change a pumping system is important because, as we have seen in the water industry, the network has changed and
has not kept up with the demand placed upon it and therefore the pumps that are in the network are not operating as efficiently as they could be. The potential energy savings in this example are significant – 10 to 15% or, in some extreme cases, as much as 20 or 30%. This thinking is true across a whole range of industries, from steelworks to chemical plants. Essentially, if the infrastructure has changed, either by expanding or decreasing, then the pumps need to be reviewed for optimisation, and while there’s a fine line where VSDs come into their own, in many cases, the solution might be more extreme, perhaps to install multiple pumps with one running permanently and one only operating at peak demand, for example.
THE BATTLE WITH OBSOLESCENCE
Obsolescence is an issue that has to be dealt with on a recurring basis. It can be linked to changes in a process or a network, but also where businesses are running older legacy equipment, and therefore, access to spares is challenging (as OEMs may no longer exist or support the equipment being used). It is possible to create a strategy to combat obsolescence with solutions ranging from the condition monitoring of pumps to ensure their condition is known to the scanning of an impeller for re-manufacture to extend the life of the pump.
Today, organisations like ERIKS have the knowledge to re-engineer and re-scope OEM equipment, either when the condition monitoring indicates or perhaps working to a timed plan of once every five years.
Alongside the ability to reengineer pumps, coatings are also available that can, in many cases, bring pumps back from the brink to a point where they are serviceable and working within the expected range. The coatings can improve the efficiency of the unit or enable the pumps to handle abrasive material or certain chemicals, for example.
MAKING BIG GAINS
Pumps, by the nature of their application, are open to upgrades, which, in a world where flexibility is key, is important. Efficiency and material improvements can be made, including the use of composite materials that improve efficiency and help reduce MTBR (Mean Time Between Repairs).
The geometry of impellers and, in some instances the casing, can be made to be more efficient; the coupling arrangement can also be altered to eliminate historical factors such as misalignment to reduce high vibration. There’s huge scope for making a pump fit a system due to the variability in the system in which it is used, from the cleanliness of the product it is pumping
to control technology. When ERIKS looks at things from the customer’s point of view, like the maintenance or energy manager, they would mostly focus on the driven component rather than the driving component. Motors are already efficient, but due to system changes and incorrect pump sizing, there is a lot of headroom for improvement.
With the current focus of businesses on energy efficiency and to be more environmentally friendly and sustainable, pump assets represent an opportunity to make great strides. chevron-circle-right
FRESHWATER PUMP IMPROVES EFFICIENCY IN BOAT AND RECREATIONAL VEHICLE APPLICATIONS
XYLEM HAS ANNOUNCED THE launch of the Jabsco Sensor-Max II, a new variable-speed pump specifically designed to make freshwater systems more efficient in boat and recreational vehicle applications. Capable of handling flow rates of up to 5 gallons per minute (GPM), the new pump delivers consistent water pressure on demand to support a steady flow without the need for an accumulator tank.
Powered by a variable speed drive, the pump’s motor speed increases in instances where more flow is required and decreases where less flow is required. An integrated pressure transducer that converts pressure into an electrical signal, combined with a built-in sensor controller, adjusts the speed of the motor to ensure optimal flow rates. As the speed of the motor can adjust as needed, the Jabsco Sensor-
Max II reduces energy consumption for improved efficiency while delivering an at-home like experience for boat and recreational vehicle owners.
As the pump eliminates the need for a separate accumulator tank to be fitted within the water system, installation is easy. Equipped with snap port fittings, the self-priming pump can also support up to five outlets at any one time and can run dry without any damage.
“Xylem’s new Jabsco Sensor-Max II has set the standard for more efficient pumping in freshwater systems. The integrated pressure transducer, when combined with the built-in programming, supports optimised system performance for a smooth and steady flow every time,” said Young Baeg, Associate Product Manager, Jabsco, Flojet, Rule at Xylem. “As the speed of the motor is controlled, and constant pressure is delivered on demand, users don’t need to worry about rapid cycling or water hammer while the pump is in operation. The pump also uses less energy when compared to traditional solutions, making it a more sustainable choice for consumers.”
www.xylem.com/jabsco
Kiwa UK Regulation 4 (KUKreg4)
The Kiwa UK Regulation 4 Product Approval Scheme (KUKreg4)a robust method for demonstrating compliance with the Water Supply (Water Fittings) Regulations 1999.
The BPMA Member Directory
Full members of the British Pump Manufacturers Association (BPMA) include manufacturers, contractors, distributors, importers, and repairers of industrial pumps, with operations in the UK and Republic of Ireland. Membership is also available to suppliers of pump-specific equipment to pump companies. Associate Membership is available to companies and individuals who work with or supply services to BPMA members,
such as industry journals, technology centres, or consultants. BPMA members have agreed to a code of conduct which states that they must demonstrate the highest degree of professionalism, expertise and ethical standards in every aspect of their operations.
Further information about the association’s members can be found on the BPMA website at www.bpma.org.uk/members.
Standards are an essential driver of safety, efficiency, and sustainability
Wayne Rose, CEO of the British Pump Manufacturers Association (BPMA), shares his perspective on the critical role of international standards in shaping a safer, more efficient, and sustainable future for the pump industry.
In today’s global landscape, where safety, reliability, energy efficiency, and sustainability are priorities, international collaboration on standards is crucial. Pumps are vital to industrial processes, utilities, and building services, making stringent and harmonised regulations essential for safety, performance and reduced environmental impact.
ENSURING SAFETY AND RELIABILITY
Pumps are essential for seamless operations in many manufacturing environments. Whether transporting hazardous materials or regulating temperature-sensitive processes, pump performance affects system safety and efficiency. This highlights the need for globally recognised standards that establish best pump design, installation, and maintenance practices.
Standards form the backbone of industrial safety and reliability. By adhering to global regulations, the pump industry ensures optimal performance across sectors, protecting people and processes.
ENHANCING ENERGY EFFICIENCY
With increasing emphasis on reducing energy consumption and carbon emissions, the pump sector offers significant opportunities for efficiency gains. Pumps account for around 20% of global electricity consumption, and inefficient systems contribute to substantial energy waste. Strict energy efficiency standards are vital in lowering industrial energy demand and supporting the transition to a greener economy.
Standardised testing and labelling allow businesses to make informed decisions, adopting the most energy-efficient technologies while reducing costs and environmental impact.
Through its involvement with Europump, the BPMA has helped shape and enforce energy efficiency standards. Working with industry stakeholders, it ensures that policies like the EU’s Eco-Design Directive align with
industry needs, helping businesses cut operational costs and improve sustainability.
DRIVING SUSTAINABILITY
Sustainability is now an essential consideration for industries worldwide. Clear environmental performance standards help the pump industry lead the shift toward greener operations.
Standards provide a structured framework for reducing resource use, emissions, and waste. As industries move towards sustainable operations, harmonised regulations ensure sustainability remains a core manufacturing priority.
The BPMA and Europump actively define life-cycle assessments for pumps, embedding sustainability principles throughout a product’s lifespan – from raw material sourcing to end-of-life disposal. These efforts support a circular economy and promote responsible manufacturing practices.
FOSTERING INNOVATION
International standards also encourage innovation. By setting clear performance benchmarks, they drive the development of advanced pump technologies that enhance efficiency and sustainability while ensuring fair competition.
Standards help foster technological advancements and maintain a level playing
field for manufacturers worldwide. They ensure that companies continue to innovate while upholding the highest safety and quality standards.
ENCOURAGING GLOBAL COLLABORATION
The BPMA, in collaboration with Europump, urges governments, regulatory bodies, and industry associations to work together to harmonise pump standards globally. While Europe has made significant progress, broader international adoption of best practices is key to achieving universal safety, efficiency, and sustainability.
Regional borders should not confine standards. Global collaboration is essential to ensuring ongoing industry progress. Harmonised regulations allow manufacturers to meet diverse market needs while delivering consistent benefits in safety and sustainability.
Europump and the BPMA work closely with international organisations such as ISO (International Organization for Standardization) and IEC (International Electrotechnical Commission) to promote global alignment of pump standards. This ensures that regardless of where a pump is manufactured or used, it meets the same rigorous quality, safety, and environmental criteria.
BUILDING A STRONGER FUTURE
As industries evolve, the need for robust international standards has never been greater. Safety, efficiency, and sustainability are not just industry goals, but global imperatives and strong regulations provide the foundation for achieving them.
The future of the pump industry depends on continued commitment to internationally recognised standards. By championing best practices, the industry can build a safer, more efficient, and more sustainable world. chevron-circle-right
www.bpma.org.uk
The BPMA’s Pump Industry Awards Dinner has become the highlight of the pump industry’s social calendar, celebrating the industry’s best and brightest with the added bonus of excellent networking opportunities and great entertainment.
This year’s event will take place on Thursday 13th March at the Hilton at St. George’s Parkthe training ground for all 28 English national football teams - which is recognised the World over as the Home of English Football. Sporting excellence is synonymous with this venue, and in March it will once again become the location for heralding engineering excellence across the pump sector.
And in keeping with the sporting theme of recent years, the evening will be hosted by Perry McCarthy, ex Formula One driver, bestselling author and the original secret racing driver from BBC’s Top Gear - ‘The Stig’.
Whether it’s taking a table to host customers or booking a few seats for you, your team and partners it’s a fantastic opportunity to enjoy a wonderful evening of great food, fantastic live 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.
Hilton at St George’s Park, Burton upon Trent
Date: Thursday 13th March 2025
Award Programme Partners
MORE THAN 20.000 MOTORS AVAILABLE FROM STOCK!
Motors up to 25 MW and 13.8 kV
• Low voltage slip-ring and squirrel cage motors up to 3,000 kW
• Medium voltage slip-ring and squirrel cage motors up to 15,000 kW
• Direct current motors up to 2,000 kW
• Frequency converter-proof drives
• In-house load test facility up to 13.800 V, 2.300 kVA, 120 Hz
Customized special designs
• Custom designs for special applications and operating conditions
• Optimized motor design for higher efficiency
• Mechanically and electrically interchangeable motors
