Flow Magazine: Quarter 1, 2022 - Focus on Water & Waste Treatment

Page 1

Quarter 1 2022

Pump industry insight from

FOCUS ON: Utilities, water and waste treatment

What makes a water VSD the right choice?

Why choose a magnetic drive pump?

Pump Industry News



Expert Opinion



Editor Chris Callander chris@flowmag.co.uk 01732 671123 Contributing Editor Suzanne Gill suzanne@flowmag.co.uk Publisher Andrew Castle andrew@flowmag.co.uk 07785 290034 Accounts Touchwave Media Ltd accounts@flowmag.co.uk Production G and C Media Ltd production@flowmag.co.uk 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.

hanks to a return to its regular spring dateline, the Pump Industry Awards are set to take place once again at the end of this month (March). A record number of entries sees some 48 finalists across the eight open categories, showcasing the innovation, ingenuity and dedication the pump sector continuously delivers. In this issue, we list all the finalists, and if you’d like to join what must be the UK’s largest gathering of pump industry professionals for the gala awards dinner, you can find all the information you need on page 10. Sustainability also features in this issue of Flow. Our industry news section reports on how AES Engineering is delivering on its pledge to achieve Net Zero across its global operations – something it has achieved an incredible eight years earlier than it initially planned. We also look at the role energy audits can play in unlocking carbon and energy savings with a case study looking at how Wilo helped a student accommodation provider save nearly £6,000 and an impressive 10,383kg of carbon every year. Under our utilities, water and waste theme, we find out how the latest generation of variable speed drives are delivering features specifically suited to pump operation in the sector. ABB explains how its drives can detect and prevent cavitation, alongside how they can automatically perform cleaning functions and more. Plus, we share details of a white paper that outlines how water utilities could cut emissions by 50%, potentially at low or no cost. In addition to all of the above, we cover a new selection of projects from across the industry, including one which saw a paint manufacturer cut its maintenance costs, we introduce several new products, from booster sets to borehole pumps, and in our opinion section, the Association of Electrical and Mechanical Trades looks at the end-user’s responsibilities when Ex rated equipment, such as pumps and motors, are repaired. I hope you enjoy the issue. Richard Harden, President, BPMA

BPMA National Metalforming Centre 47 Birmingham Road West Bromwich B70 6PY www.bpma.org.uk

Twitter @bpmapumps


Net Zero target reached eight years early


Private equity deal boosts growth plans

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 circulation@flowmag.co.uk 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 Update 6





2022 Pump Industry Awards finalists revealed


PEFC Certified


New pressure booster systems for water supply applications

Awards update

© BPMA. All rights reserved.

This product is from sustainably managed forests and controlled sources

Upcoming training from the BPMA


Resolving a water storage problem

Features 16

Energy audits key to unlocking hidden carbon and energy savings

20 Why choose a magnetic drive pump? 22

Built-in safety sets the standard

Utilities, WAter & Waste Treatment 24 What makes a water VSD the right choice? 28 High efficiency pumps for Aalborg District Heating Global water utilities could cut emissions by 50%

OPINION 30 You must ask your Ex equipment repair provider the right questions? Quarter 1 2022


NET ZERO TARGET REACHED EIGHT YEARS EARLY AES ENGINEERING LTD, THE Yorkshire-based engineering group which includes AESSEAL, says it has reached Net Zero eight years earlier than it initially committed to. The group’s UK business has been Net Zero in terms of its carbon footprint since 2019. Subsequently, the Rotherham headquartered global reliability company pledged to invest £29 million to get to Net Zero and beyond for its entire operation in time for the 50th anniversary of its founding, which falls in 2029. In the latest update on its ‘29by29’ investment pledge, AES says that in just over a year it has placed orders to a value of almost £7.8 million for environmental projects, including solar panels, advanced battery systems, fleet electrification, and other energy-saving or environmental measures. The group, which produces precisionengineered mechanical seals and water management systems for global industry, says that, pending independent verification, it has already reached the Net Zero target for 2021 but is pressing on with its investment. AES Engineering Managing Director, Chris Rea, said: “Even after the noise around the COP26 climate change conference has passed, we are following up on our undertaking to report until we have invested all the money.” After preparing and internally auditing hundreds of calculations of the group’s carbon footprint, AES has calculated that its global Scope 1 and 2 emissions in 2021

were 4,799 tonnes for direct and indirect emissions. This has been compensated for by purchasing 5,000 tonnes of offsets from ‘gold standard’ schemes. The group also calculated that its global Scope 3 emissions amounted to 87,000 tonnes CO2e in the supply chain. However, as a result of the positive environmental impact of the products and services supplied, CO2e avoidance was almost five times larger at 464,000 tonnes. The figures have been passed to the independent auditors, BSI, for accreditation or confirmation, but Chris says they are confident that they hit the Net Zero target and by-passed it in 2021, eight years earlier than they committed to. The company has reported the exact financial commitments made between January 1, 2021, and January 14, 2022, including a breakdown of the main investment areas and the global regions

where the money is being spent. Chris believes that this level of detail and openness is absolutely necessary in the face of public scepticism about the real commitment that businesses have to the environment. “I realise that accusations of ‘green washing’ are out there. The best way to combat this is to be open and honest. That is why our commitments to date are calculated to the penny and reported for all the world to see.” Chris insists that the investment is good for the group, good for the planet and also good for customers as the benefits of dealing with suppliers that have Net Zero credentials becomes increasingly important. “Let’s remember, for external customers who buy from a Net Zero supplier, there is no CO2e tariff to report for the purchases,” he concluded.

ATLAS COPCO TO ACQUIRE WANGEN PUMPEN ADDING TO AN ALREADY WIDE PORTFOLIO OF BRANDS, Atlas Copco has agreed to acquire Pumpenfabrik Wangen GmbH, a German manufacturer of progressive cavity pumps used for transferring fluids mainly in the biogas and wastewater sectors. The company also manufactures twinscrew pumps used in sectors like food and beverage and cosmetics. Pumpenfabrik Wangen GmbH is based in Wangen, Germany, and has 265 employees. In 2020 it had revenues of approximately €46.4m. The company has manufacturing facilities in Germany and a global sales and service footprint. “Industrial pumps is a segment that we have identified as a strategic fit for Atlas Copco, and Wangen Pumpen has leading differentiated technology with a strong aftermarket business,” said Andrew Walker, Business Quarter 1 2022

Area President, Power Technique. “Wangen Pumpen is a strong brand known for quality in demanding industrial applications. This acquisition will create a solid foundation for further growth in new industrial pump segments. Industrial pumps play a crucial role in creating sustainable solutions for many industries and contributing to a better tomorrow.” The acquisition is expected to be completed during the second quarter of 2022 and is subject to regulatory approvals. The purchase price has not been disclosed. The acquired business will become part of the Power and Flow division within Atlas Copco’s Power Technique Business Area.



PRIVATE EQUITY DEAL BOOSTS GROWTH PLANS STUART TURNER GROUP HAS announced the completion of a secondary management buyout with top-decile private equity firm Epiris, providing fresh investment to pursue its growth plans. The deal delivers an exit for leading mid-market private equity firm LDC. LDC first backed Stuart Turner in September 2017 and supported the company in making three complementary acquisitions to expand its range of products and services. These included the acquisition of the UK’s leading mains-powered pressurisation unit and heating systems provider, Mikrofill Systems, in March 2021. This followed the additions of Fluid Water Solutions in 2019 and GAH Heating in 2018 and, alongside a strong focus on new product development, these acquisitions have helped Stuart Turner become a complete solutions provider in the pressurisation and hot water generation market across the domestic, commercial and industrial sectors.

Stuart Turner has grown its revenues by over 66%, from £24m in 2017 to more than £40m this financial year, and the company’s headcount has increased to more than 125. Epiris will support the company as it looks to further broaden its product and geographic offering. “We’re determined to become a full water-boosting solutions provider, not only in the UK, but expanding into international markets too. Our excellent reputation in the residential boosting market forms the foundation for our ambition within the commercial sector. Our HVAC and commercial building services offering continues to grow at pace and is already gaining traction within the market,” said Richard Harden, CEO of Stuart Turner.

“Stuart Turner is a strong platform with a tremendous opportunity ahead, not only to become the leading provider of water-boosting solutions in the UK, but also to take this expertise into international markets. We look forward to working with Richard and his team to build on Stuart Turner’s rich heritage of product innovation and manufacturing excellence,” added Charles Elkington, Partner at Epiris.

Pumps to support flood control in Paraguay AT THE END OF 2021, THE KSB Group was awarded a contract to deliver 14 large submersible motor pumps for flood control in Paraguay. The pumps are intended for equipping several pumping stations belonging to the “Costanera de Pilar y control de inundaciones” project. The pumps are to be used to prevent future flooding during the high-water season along the tributaries of the Río Paraguay. The city of Pilar is located some 230 km southwest of the capital Asunción, on the border to Argentina. Each of the submersible motor pumps of the Amacan type series weighs six tonnes and is driven by a 370kW, 380V motor. The maximum flow rate of each axial-flow pump set is about 18,000 cubic metres per hour. Delivery of the pump sets is expected to be completed by the end of 2022.



Quarter 1 2022


6 BPMA Update

BPMA’S E-LEARNING – THE FIRST AND STILL THE BEST Some years ago, as part of its support for the UK and Irish suppliers of liquid pumps and their customers, the British Pump Manufacturers’ Association (BPMA) launched an initiative in e-learning for the pump industry. It was the first suite of truly independent pumping technology training, which is still revered today. Independently accredited and quality-controlled by the NOCN, the courses are offered in accordance with Ofqual (The Office of Qualifications and Examination’s Regulation). It is thought to be the first such accreditation for the pump sector globally, and the initiative also forms part of the UK government’s educational framework. WHO ARE THE NOCN? NOCN is a market-leading international Awarding Organisation (AO) and Government-approved End Point Assessment Organisation (EPAO) that has created opportunities for 30 years. NOCN Group includes NOCN, NOCN India Skills Foundation, C Skills Awards and One Awards. More information can be found at www.nocn.org.uk. Key features of the BPMA’s e-learning portfolio include: • Industry recognised courses

• Professionally voiced, easy to follow • Accessed from anywhere through a web browser • Easy registration and secure payment Overall, the training on offer provides a comprehensive foundation in all aspects of pumps and pumping technology which allows a wider range of learners to obtain the qualifications they need, in a way that suits them. Those passing the final tests can take forward the credits they earn into apprenticeships, continuing professional development (CPD), and further education such as university entrance, enhancing CVs and aiding career progression. There is a suite of two industrially and nationally recognised courses designed to raise the knowledge and awareness of technical pumping issues. NOCN certificates are awarded upon successful course completion, and to address the wider issues covered by the courses, the BPMA also awards its own graded certificate where a successful candidate can pass with a credit or distinction. For more information, please visit the BPMA website at www.bpma.org.uk


Course title

Duration Location

16-19 May 2022

Certified Pump Systems Auditor (CPSA)

4 days

West Bromwich

23-24 May 2022

Virtual Pumping Testing

2 x half day


23-24 May 2022

Virtual Pump Fundamentals

2 x half day


25-27 May 2022

City & Guilds Basic Competency – Electrical

3 days

West Bromwich

3 days

West Bromwich

14-15 September 2022 BPMA Pump Repair & Maintenance

For more information or to book any of the courses listed please visit www.bpma.org.uk/lectures *All classroom-based training is scheduled subject to the COVID-19 restrictions in place at the time.

Quarter 1 2022


Product news 11


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8 Product News

NEW PRESSURE BOOSTER SYSTEMS FOR WATER SUPPLY APPLICATIONS KSB HAS INTRODUCED NEW ready-to-connect pressure booster systems, the Delta Macro type series, designed for large flow rates. The maximum flow rate per system is 960m3/ hr, and the maximum pump head is 160m as standard. The ready-to-connect units operate fully automatically and are equipped with between two and six Movitec high-efficiency centrifugal pumps. The system’s microprocessor control unit (Booster Command Pro+) starts and stops the pumps in line with demand using either cascade control (F variant) or a frequency inverter for speed control (VC and SVP). LEDs on the control panel indicate the system’s current operating status. A Modbus RTU interface, provided as standard, facilitates connection to external communication devices. For transmitting warnings or alerts to a higher-level control station, the standard configuration has two volt-free contacts on terminals in addition to other optional signal terminals. The pressure booster systems can be connected to the KSB Delta FlowManager app using a Bluetooth LE interface. The app shows the current status of the pumps, the pressures on the suction and discharge side, and the programmed

parameters. It also allows users to control and operate the system directly and change the settings. The SVP version is fitted with highefficiency IE5 synchronous reluctance motors from the Supreme type series and the PumpDrive variable speed system. The F and VC variants are equipped with IE3 motors. The first pump is started by a pressure drop in the piping on the opening of a consumer installation. While the pressure booster system is in operation, the microprocessor control unit starts and stops the pumps in line with demand.

When water consumption stops, all pumps are ramped down sequentially once the stop pressure has been reached. This ensures that the individual pumps operate only in line with actual demand. If a pump has not been operated for over 24 hours, the microprocessor control unit initiates a test run for the pump. Should a lack of water occur in the inlet, the system stops automatically to prevent damage caused by dry running. www.ksb.com


THE HOMOGENIZER WATER RECYCLING SYSTEM (HWRS) from SPX FLOW is designed to recycle up to 97% of the water used by homogenisers. Traditionally, a continual flow of water gets supplied to homogenisers to cool the transmission oil and lubricate the plungers. The HWRS technology recaptures that water, sanitises and chills it, then returns it to the homogeniser. The amount of water saved depends on the homogeniser, but the HWRS can save up to 2 million gallons each year (7,500m3). For context, it takes almost three seconds for that much water to flow over Niagara Falls. “Water recycling has become increasingly urgent as the cost of water and sewer bills rise and the availability of water shrinks,” said Con O’Driscoll, SPX FLOW’s Global Product Manager of Dispersion Products. “We believe sustainability is paramount, and we are continually developing innovative processes and solutions to help our customers reach their goals. The HWRS is a great example.” The HWRS can be used with both new and existing homogenisers made by any manufacturer. It’s compact Quarter 1 2022

– only 533.4 x 812.8mm – and if any problems emerge, the HWRS has its own control system, including fail-safe features that would default to fresh water without causing downtime. www.spxflow.com. www.bpma.org.uk

Product News 9

BOREHOLE PUMP RANGE EXPANDED WITH TWO NEW SERIES CAPRARI HAS EXPANDED ITS product range with two new launches. The new E6KX series offers the first 6in stainless steel borehole pumps in the EASYWELL family, said to be ideal for professional agriculture, the water sector, and domestic and industrial applications alike. The E6KX borehole pumps offer a compact design, long-term fuel-efficient performance, high levels of reliability and a low environmental impact thanks to a careful and efficient manufacturing process. Among other defining characteristics, the attachment between the hydraulic element and the motor can be NEMA 4 or 6, making the pumps compatible with all readily available standard motors. Moreover, the impellers and diffusers are made from stainless steel, and the suction support is in precision-cast stainless steel to offer durability and a long lifespan overall.

The valve body is also made from precision cast stainless steel with an integrated clapet, eliminating the need to install an additional valve, allowing customers to save money while ensuring maximum protection against water hammer. The E6KX pumps perform even in the presence of sand, thanks to their waterlubricated radial bearings. A booster can also be installed, with a cooling mantle (for the motor) in either a horizontal or vertical position, allowing flexibility of use. Also joining the EASYWELL family of pumps is the new compact E5MX monobloc series available in ten models and two sizes. The E5MX series is ideal for domestic, civil and industrial applications, the supply and transport of water from wells and tanks, and irrigation systems. The EASYWELL E5MX series features a stainless steel compact structure for

corrosion resistance, technopolymer impellers and diffusers to ensure reliability even in the presence of sand and an electric motor protected by a double mechanical seal for durability. www.caprari.com

App calculates drive efficiency AUTOMATION SOLUTIONS MANUFACTURER, WEG, has developed a new app called EcoDrive which allows engineers to calculate the efficiency of their system — be it a variable speed drive (VSD), motor or a combination. WEG EcoDrive is free to download from the Apple App Store or Google Play. Last year the European Union changed its ecodesign legislation for electric motors. From July 1, 2021, it became mandatory to meet the minimum IE3 energy efficiency levels for three-phase electric motors (from 0.75kW to 1000 kW), and VSDs having their own efficiency levels of IE2. In light of this, WEG has developed the app to ensure engineers are in line with the new legislation. It automatically calculates the eight operating points of the VSD and of the system and provides the ability to check the efficiency class of the motor. “Our app helps to demonstrate the efficiency and losses of WEG inverters and motors in accordance with IEC618009-1 and IEC 61800-9-2,” said Marek Lukaszczyk, Marketing Manager for Europe and the Middle East at WEG. “Avoiding energy waste is crucial for sustainable consumption. “The regulations regulate the efficiency of VSDs by subjecting them to information requirements such as energy efficiency at different load points in terms of speed and torque. WEG has a complete line of VSDs that exceed the requirements established by the new directive.” www.weg.net Quarter 1 2022


10 Awards Update

2022 PUMP INDUSTRY AWARDS FINALISTS REVEALED The finalists in the 2022 Pump Industry Awards have been determined following yet another comprehensive and robust judging session.


rom the record number of entries and nominations received, the judges shortlisted 48 finalists across the eight award categories to go through to the public vote. Those that were fortunate enough to be selected are as follows: PRODUCT OF THE YEAR Sponsored by Process Engineering • CDR Pumps • Crest Pumps • DAB Pumps • ITT • John Crane • Stuart Turner • Vyoda • Watson-Marlow • WEG • Wilo PROJECT OF THE YEAR Sponsored by Stuart Turner • Baker Hughes • Bedford Pumps • Campion Pumps • Crest Pumps • DPS Drilling & Pumping Supplies • SPP Pumps • Sulzer ENVIRONMENTAL CONTRIBUTION OF THE YEAR Sponsored by SPP Pumps • Bedford Pumps • CDR Pumps • Crest Pumps • HMD Kontro • Stuart Turner • Wilo MANUFACTURER OF THE YEAR Sponsored by WEG UK • Apex Pumps • Atlas Copco Power Technique • Crest Pumps • Salamander Pumps • Stuart Turner • Wilo UK Quarter 1 2022

DISTRIBUTOR OF THE YEAR Sponsored by Particle • • • •

Campion Pumps Flowtech Water Solutions Seal & Pump Engineering Tomlinson Hall & Co

SUPPLIER OF THE YEAR Sponsored by Wilo • ABB • Amcanu • Atlas Copco Power Technique • John Crane • WEG CONTRIBUTION TO SKILLS & TRAINING Sponsored by Crest Pumps • ABB • CDR Pumps • EKKI Pumps • EMiR • Salamander Pumps • Sulzer RISING STAR AWARD Sponsored by World Pumps • Liam Blackshaw, ABB • Colm Scott, Campion Pumps • Kanishka Arumugam, EKKI Pumps • Jack Sheard, Fluid Water Solutions

Details of all the finalists are now available to view on the dedicated awards website – www.pumpindustryawards.com/finalists. JOIN THE CELEBRATION Places are still available at the Gala Awards Dinner on 31st March at the Chesford Grange Hotel in Kenilworth. Whether you take a table to host customers or book a few seats for you and your team, don’t miss this fantastic opportunity. You and your guests will enjoy a wonderful evening of great food, fine wine, amazing entertainment and all-important networking until the early hours when the now infamous survivors’ breakfast will be served. To help deliver the 21st staging of this key industry awards programme, the presentation ceremony will be hosted by Andrea Byrne, the much-loved broadcaster and television presenter. Andrea presented our 2018 awards ceremony, and we are delighted to welcome her back. As for the evening’s entertainment, you will be treated to the mind-blowing double act that is DNA. Places can be booked online at www.pumpindustryawards.com and with a record number of tables booked already, it’s set to be a great event. chevron-circle-right www.bpma.org.uk

ENERGY REVOLUTION STARTS AT HOME. Hassle-free installation, operation and maintenance: The Calio S circulator pump replaces most models without the need to change the connector. For more information, contact KSB UK. 01509 231872 - www.ksb.co.uk

Here is the new design. Don't let this be yourAny enquires should be sent to: sean.austen@ksb.com last copy of flow! 01278 458 686 To make sure you continue to receive your free copy of flow register online at: flowmag.co.uk Choose flow, in print or digital format, and stay up to date with the latest products, technical insights, news and innovations, for the design, specification, installation and management of pumps in: z Manufacturing z Construction z HVAC z Building services FOCUS ON: Utilities, wate z Mining r waste treatm and ent z Utilities Quarter 1 2022

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NEWS 12 Projects

PAINT MANUFACTURER CUTS MAINTENANCE AND CLEANING COSTS fluid is completely contained in a long-life hose, which is the only wear part and this can be changed quickly and easily. Cleaning costs are also far less. Not only are modern acrylic or latexbased paints easier to clean using just water, but Bredel pumps have no valves or seals to clog, while cleaning the hose is simple using sponge/ foam balls (pigs). At the German paint manufacturer, Bredel hose pumps transfer mixed paint to a filling station. Here, 10-20 litre containers await paint, which has a viscosity of about 5,000 mPas. Pump duty is intermittent, running for approximately 20 minutes to complete each batch, depending on paint stock/order demand. The Bredel pumps operate at a flow rate of around 3,000 l/hr and ensure there is no paint colour contamination.

A WELL-KNOWN PAINT manufacturer in Germany is using Bredel hose pumps from WatsonMarlow Fluid Technology Group (WMFTG) to produce its interior and exterior emulsion paints. The company previously used progressive cavity pumps in the production of the paints, but the costs associated with cleaning, maintenance and repair were unacceptably high. Even tiny traces of colour could spoil the next batch of paint. Additionally, the TiO2 (titanium dioxide) and pigment dyes are extremely abrasive and caused excessive wear to the PC pumps. Unlike progressive cavity pumps, Bredel hose pumps have no moving parts that come into contact with the product. Instead, the pumped


RESOLVING A WATER STORAGE PROBLEM T-T PUMPS WAS ASKED TO SUPPLY A COMBINED 10,500l tank and T-T-manufactured DAS VX10-9 Hi-Dro Booster Set to Aviator Park, a residential development in Surrey. Aviator Park is a new development close to Addlestone in Surrey and within a short walking distance of the Addlestone One Shopping Centre. The site is also close to Addlestone station, providing direct National Rail access to London Waterloo. Planning permission has been submitted for the conversion and repurposing of an existing office building to create 92 residential units and an additional two stories to create a further 62 apartments. As part of the development works, there was a requirement for a combination unit consisting of a 10,500l tank and booster set within the same structure. After receiving an enquiry in June 2021, a combination unit was supplied by Decca tanks with T-T manufacturing a DAS VX10-9 set from its Hi-Dro Boost range and carrying out the fitting of the set, including electrics, at the company’s works. Space restrictions meant that it was impossible to install the tank and booster set within a designated plant room, therefore the combination tank option was selected and relocated to a nearby car park area. Quarter 1 2022

The Hi-Dro Boost range is a comprehensive range of fixed and variable speed multiple clean water booster sets, designed and manufactured to provide both the required flow and water pressure for the application. Designed for transfer and pressure boosting of hot and cold water systems, it maintains and regulates constant water pressure throughout an application during varying flow rate demand. www.ttpumps.com www.bpma.org.uk

NEW for 2022

Join us at Drives & Controls from the 5th to the 7th April stand E110, to learn more about the new products we have available for 2022. The CFW900 variable speed drive is a high tech solution for driving and controlling three-phase induction and permanent magnet motors. It offers excellent static and dynamic performance and highly precise torque, speed and position control. It can be used across a wide range of applications due to its high overload capacity. The WEG Motion Fleet Management system is the ideal solution for monitoring and increasing the uptime of your industrial drive fleet. Based on cloud computing technology, the performance of assets can be monitored at any time from any part of the world.


14 Projects

HYGIENIC PUMPS FOR ALCOHOL TRANSFER AS AN EXISTING CUSTOMER, A long‐established distillery based in Dundalk, Ireland, contacted DPS Pumps as it had a new application and wanted advice on potential options for the new process. The request required high specification units with specific requirements, while keeping pricing economical. The client had two parts to the application, one requirement for a transfer rate of just over 20m3/hr and another running at approximately twice the flow. With a wide portfolio to choose from, DPS offered several solutions from several manufacturers to suit the client’s needs. In the end, the client opted to proceed with the recently introduced KSB range of Vitachrom hygienic pumps. Meeting requests for a hygienic pump with the correct approvals, including ATEX motors, DPS offered two different sizes from the Vitachrom range for the two different flows. The Vitachrom series offered options to cover both flow rates and meet all the specific requests while keeping costs

down by using a rolled stainless‐steel construction. Some other key features for the Vitachrom series included a zero dead volume casing design with excellent surface grades thanks to electropolishing. The pumps are gentle with the fluid thanks to the polished surfaces, open impeller with wide free passage and smooth edges.

The design is also available with numerous sealing options, including flushing making it suitable for clean-inplace (CIP) applications. The pumps are supplied using a separate shaft design that allows the use of motors from various manufacturers and can accommodate KSB’s new range of premium efficiency SuPremE motors. www.dps-ni.com

CHEMICAL AND WATER PUMPS SUPPORT NICKEL EXTRACTION PROJECT MINING OPERATIONS CREATE A considerable amount of crude waste streams from their extraction operations. If purified, those streams can yield valuable minerals. Built to take advantage of the opportunity, the Thakadu Nickel Purification Plant produces 2,500 tons per month of high-purity, battery-grade nickel sulphate from a crude nickel sulphate stream. The plant utilises a process called nickel crystallisation. A crude nickel sulfate stream is pumped to the purification plant, where it is heated and evaporated into a vacuum, forming nickel sulfate crystals for harvesting. Quarter 1 2022

Such purification is a highly intensive and precise process requiring the careful balancing of components and energy requirements to accomplish the purification safely and profitably. To help enable the plant’s vision, Xylem provided 102 pumps from different brands within its stable along with pump selection and engineering services to align the right choices. Though the initial focus was on pumps for the water process, that scope expanded to include pumps for the plant’s chemical processes. Xylem’s in-house application engineers collaborated with the project’s leaders to consider numerous variables that influence selecting pumps for

the site. These included severe space constraints, limited power restrictions, appropriate pricing to ensure the project’s profitability, and managing liquids in various aggressive states. The pumps chosen for the project included 42 Lowara Vogel LSB SS316 block pumps suited to moving high volumes of slightly contaminated fluids, 12 Lowara ESHS centrifugal end-suction pumps, a single impeller centrifugal pump made in AISI 316 stainless steel, which is ideal for moving water and aggressive liquids, 39 Lowara e-SV stainless steel vertical multistage pumps – highly reliable and technologically advanced multipurpose pumps – and nine Lowara DOC7 submersible pumps which are corrosion-resistant and compact, suited to pumping clean and dirty water. xylem.com www.bpma.org.uk

Projects 15 Sponsored article


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WHEN A CUSTOMER IN THE CHEMICAL INDUSTRY sent SPP Pumps a 50-plus-year-old 5 ton Blair horizontal split case pump for refurbishment, it was soon evident that it would be uneconomical to repair. The pump was received in a very poor condition and, needed to be replaced. However, the pump’s manufacturer was no longer in business, and original parts were long since unavailable. In addition, due to the surrounding plant layout, it was not possible to install a new type of pump without significant piping, civil and structural modifications. SPP had to find an alternative solution and took on the task of reverseengineering the obsolete pump and manufacturing an identical replacement. The company’s engineers scanned the top and bottom casings with a 3D laser scanner and captured the existing pump surface data in a mesh form. Using this information and elements of original drawings held by the pump’s user, dimensional drawings and 3D models of the pump’s components were produced. From this data, SPP was able to cast new casings from an NI Resist iron which suited the pump’s application, produce a new impeller and machine the other parts, including shafts and sleeves. The ‘new’ pump was then assembled before being delivered to site for installation in time for a planned shutdown. The pump was fitted into the existing footprint and connecting pipework without issue, and upon commissioning, was found to run smoothly, capable of delivering the required process flow of 22,000 GPM at 20ft head. Re-engineering the pump cost SPP’s customer less than half of the cost of a new alternative – maybe a quarter had the civil and structural engineering changes been needed on site. And in addition, the customer now has full drawings and data to enable the production of new parts should they be needed in the future.

FEATUREEfficiency Dewatering 16 Energy

ENERGY AUDITS KEY TO UNLOCKING HIDDEN CARBON AND ENERGY SAVINGS Water pumps and pump systems manufacturer, Wilo UK, highlights the importance of energy-saving audits in helping companies get closer to their net zero goals in line with government climate change targets.


ith the government pledging to reach net zero emissions by 2050, there is pressure on companies to set out detailed plans for how they will move to a low-carbon future, including retrofitting buildings with upgraded energy-efficient equipment. With sustainability at the forefront of its product innovation, Wilo is helping clients meet their net zero goals through the use of its energy-saving audits. By carrying out detailed site surveys, Wilo is able to demonstrate how clients can significantly reduce energy usage and carbon emissions, as well as costs – something that was proven during the company’s recent work with a leading student accommodation provider at its Bristol residence. Wilo is currently working on multiple sites with the student accommodation provider, helping the company to get closer to its 2030 net zero carbon target. When Wilo put forward a proposal to replace the existing, inefficient booster set with an energy-efficient upgrade, the company was keen to understand the impact this would have on its energy and carbon savings. Jason Cox, Wilo’s National Business Development Manager, said: “We have a planned preventative maintenance contract in place for all of the company’s student accommodation buildings across the UK. But we recognised an opportunity for the company to benefit even more from our expertise – by showing how it could move closer to its sustainability goals. Major energy and carbon savings could be made by replacing Quarter 1 2022

the company’s existing, inefficient, fixed-speed booster set with a highly efficient alternative from Wilo. “For this project, we carried out a detailed site survey, which resulted in an energy solutions report. This provided evidence of how the capital cost required to upgrade the booster set would be offset against energy savings over a specific timeframe. Jason Cox, National Business Development Manager at Wilo. We also demonstrated significant carbon savings alongside the return on straightforward as replacing old investment.” booster sets or HVAC pumping Wilo’s energy-saving audit for the equipment can make a vital student accommodation residence difference. In addition to these revealed the provider could save at savings, the project also provides least £5,868 every year on energy the customer with additional peace expenses through straightforward of mind, through an extended improvements to its pump warranty, whilst ensuring the installations. This meant the project company meets its sustainability would pay for goals.” itself in just over Jason three years, and concluded: this return on “Pumps across investment could the world use be achieved even about 10% of the sooner, given the global energy current rise in consumption, energy prices. On and around top of this, the equipment upgrade 90% of today’s installed pumps would result in an impressive are outdated and inefficient, so carbon saving of 10,383 kg per it’s important to demonstrate just annum. how simple it can be to make Wilo also carried out a full test very worthwhile changes. The and verification plan to validate both government’s net zero pledge will be the cost and energy savings that the at the forefront of many operators’ customer would achieve. minds, and if they can reduce Jason added: “These calculations carbon emissions and energy show the hidden carbon- and expenses while gaining a return on energy-saving opportunities most investment, it’s a win-win.” chevron-circle-right building owner/operators have within their grasp. Something as bit.ly/WiloES

Around 90% of today’s installed pumps are outdated and inefficient.


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18 Compliance

Sustainability and Decarbonisation:

how can EU policy support industry’s efforts? Ahead of its annual meetings and joint conference with CEIR and Pneurop in Brussels this coming May, Vanni Vignoli, President of Europump, the European Pump Association, looks at the EU’s roadmap for industrial support.


ollowing its announcements of 5 May 2021, updating the New Industrial Strategy proposed in 2020, the European Commission has further indicated that it will rely quite heavily on industry to deliver on the major challenges faced by our economies and societies in Europe. This is particularly the case in relation to sustainability, digital transformation, and global competitiveness, as well as the need to overcome the crisis provoked by the COVID-19 pandemic. The EU Recovery and Resilience Plan, launched in Spring 2021, is largely building on the capability of European industry to design and produce the building blocks of the twin green and digital transitions. At the same time, the EU is shaping a dense regulatory framework that does not always support the freedom and flexibility needed for companies to grow and compete globally. The European technology industries, particularly our pumps, compressors, taps and valves sectors, have for a long time considered the enhancement of their global competitiveness within the challenges of societal and environmental challenges, notably by contributing to the preparation of energy efficiency and ecolabel regulations. In parallel, digitalisation has provided increased opportunities and brought new challenges, including debates on the appropriate regulatory level (sharing of industrial data, artificial intelligence, cybersecurity, etc). Amidst ever more fierce international competition, these developments require public authorities and industry in the EU to work increasingly more closely to design and deploy strategies that reinforce our competitiveness and our contribution to the United Nations Sustainable Development Goals (SDGs). This will be the subject of the initial debate kicking off our Joint EU Policy Conference, which will bring together key policymakers from the three EU policy institutions in charge of the Industrial Strategy and three executives representing and illustrating the achievements enjoyed, and challenges still

Quarter 1 2022

Vanni Vignoli, President of Europump.

faced by these three key sectors of industry. SPECIFIC TECHNICAL AND POLICY ISSUES As the regulatory landscape across Europe, and the whole World, becomes ever more complex, the burden on industry only increases. It, therefore, falls to sector-specific trade organisations, such as Europump, CEIR and Pneurop, to identify and advise on those technical and policy issues most relevant to their respective sectors. In our particular arena, that relates, of course, to the manufacture, distribution and use of pumps and all pump related equipment – a huge and important subset of industry, given the width and breadth of pump applications. Against this backdrop, one of the main considerations when determining the core themes for the joint conference was to maintain a direct reference to the United Nations Sustainable Development Goals (UN SDGs). Within this focus, the three associations intend to highlight how, together with the importance for companies to address technical aspects impacting their daily business operations, they consider the positive role of industry in addressing societal challenges. Indeed, all the sessions will have a technical theme matching at least one of the 17 UN SDGs. The conference will be reflective of

the current legislative terrain, as it relates to pumps and pumping systems in the following key areas: 1. Circular Economy & Eco-design (Relevant UN Sustainable Development Goal no. 12: Responsible Consumption and Production) 2. Industry’s Digital Transformation and Innovation (Relevant UN Sustainable Development Goal no. 9: Industry, Innovation, and Infrastructure) 3. The restriction of use of materials and substances of concern (Relevant UN Sustainable Development Goal no. 6: Clean Water and Sanitation) By engaging with those trade organisations that represent your best interests, you can keep abreast of all the compliance developments as they affect your business and the areas in which you operate. Europump’s 2022 Annual Meeting & Joint Conference takes place in Brussels on 09-11 May 2022 at the NH Collection Grand Sablon, Rue Bodenbroek - Bodenbroekstraat, 2, B-1000 Brussels Belgium. The full programme and registration process can be found by visiting the dedicated event website: chevron-circle-right www.2022jointconference.be www.bpma.org.uk

Pioneering for You

When it comes to reliability, you can count on Wilo. We understand how important reliability is to your projects, and that’s why we manufacture quality products that won’t let you down. You can also count on our expert teams to support you with maintenance and service, technical advice and energy saving solutions that help you to meet your sustainability goals.

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20 Sealless Pumps

Why choose a magnetic drive pump? Liquids that are corrosive, explosive, flammable, toxic, ultrapure or expensive require a pumping solution that offers complete containment. Pump specialist, March May, outlines some of the features and advantages of sealless magnetic drive pumps, which are particularly suited to these applications.


ith a magnetic drive or mag-drive pump, instead of a shaft that passes through the body of the pump, which requires a dynamic seal, the pump has one assembly of external magnets attached to the shaft of the motor and a second assembly of internal magnets attached to the impeller inside the pump body. When the motor rotates, the magnetic field generated between the two magnets means that the impeller turns in the pump body. Therefore, the liquid to be pumped is contained within the hermetically sealed pump housing without the risk of any leaks from the shaft seal. This means that there is no direct or indirect path through which any fluids or gases can escape and pose a risk to operators and the environment. The term magnetic drive applies to the coupling mechanism and the nature of construction, so magnetic drive options are not just restricted to centrifugal pumps, but can be gear pumps, rotary vane pumps or screw pumps, for example. Available in close-coupled and long-coupled (base frame mounted) configurations, mag-drive pumps are made from many different metallic and non-metallic materials, giving a wide choice for excellent chemical compatibility and scope to handle these difficult liquids. They can be configured for applications with low and high temperatures and high system pressures and are available with ATEX certification, a self-priming ability, and with air motor drives. In close-coupled design systems, many mag-drive pumps offer a back pull-out design allowing pipework and the associated pumped fluid to be kept in-situ. This allows the motor to be easily removed for maintenance without draining down the system. In addition to the low risk of fluid emissions, mag-drive pumps offer several other advantages. The lack of seals means less maintenance and no requirement for potentially expensive seal support systems. The magnetic coupling means the motor should not Quarter 1 2022

be damaged if the pump is jammed and motor alignment issues are eliminated. While together, these advantages can lower the total cost of ownership of the pumping solution. Indeed, this should be assessed when specifying a pumping solution, as the initial cost of the pumping system is typically a relatively small proportion of the total lifecycle cost. There are other factors to take into consideration, however. Mag-drive pumps are generally not suited to liquids with solids or metallic particles in suspension, and they can be damaged if operated incorrectly. They also have a limited torque transmission capacity due to the strength of their magnets and typically require higher motor power than mechanically sealed pumps for the same duty. Plus, they will have minimum flow requirements; a stable minimum flow rate to ensure the pump operates reliably, and a thermal minimum flow rate to ensure heat generated in the driven magnet/bearing section is dissipated. An important factor with mag-drive pumps is to monitor for evidence that the pump is running dry. This is when the impeller/gear/rotor of a pump

rotates without any lubrication between it and the shaft that it runs on. A lack of lubrication results in excessive heat being generated on the surfaces of the mating bearing sections. This heat will damage the shaft and the bearing element and will eventually cause the pump to seize and fail. However, as science and technology progress, modern material options are continuously evolving and improving the life span of mag-drive pumps. The latest sleeve bearings offer very low coefficients of friction.

In addition to the low risk of fluid emissions, mag-drive pumps offer several other advantages.

CONCLUSION It is important to understand that magdrive pumps are not a cure for all difficult liquid applications. Improper selection will cause more problems than they were intended to solve and will cost a plant dearly. But there are many applications where a mag-drive pump offers significant benefits. Pump users are advised to use the technical expertise of the pump manufacturers and their appointed sales distributors. chevron-circle-right marchmay.co.uk www.bpma.org.uk


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22 Machine Safety

Built-in safety sets the standard Marek Lukaszczyk, European and Middle East Marketing Manager at electric motors, drives and gearboxes manufacturer, WEG, explains the use and importance of safety certifications for variable speed drives.


n the pursuit of quality and productivity, machines and production systems progressively become more sophisticated. Following this evolution, the demand for equipment safety in industrial processes also grows. Functional safety is a reality, and its presence in the machinery sector has become a legal requirement in many countries. For example, variable speed drives (VSDs) need to have their safety features certified. This is done by an unbiased third-party body that follows the applicable safety standards for VSDs and machine safety, approving them for different safety levels. But what is the meaning of functional safety, its rules, acronyms and terms quoted by those who sell, apply, certify and use this type of equipment? And how are VSDs related to machine safety? INTEGRATED SAFETY FUNCTIONALITIES Built-in safety functions for VSDs ensure safe cleaning and maintenance of processing machinery. For example, according to IEC 61800-5-2, the safe torque off (STO) safety function prevents force-producing power from being provided to the motor, corresponding to an uncontrolled stop in accordance with stop category zero of EN/IEC 60204-1. This means that once triggered, this safety function will virtually eliminate any possibility of electromagnetic torque production on the motor shaft. Therefore, if a motor is rotating, it will coast to a stop after the STO activation. The main application of this safety function is to prevent unexpected start-up of a machine or equipment when Quarter 1 2022

an engineer needs to come into direct contact with dangerous moving parts during either commissioning, operation or maintenance. Another safety function – safe stop one (SS1-t) – is described in EN/IEC 61800-5-2 as a function that initiates the motor deceleration and performs the STO function after a specific time delay. This corresponds to a controlled stop in accordance with stop category one of EN/IEC 60204-1. Differently from the plain STO, this safety function will wait a predefined delay time in which the VSD imposes a deceleration ramp to the motor before the torquegenerating energy cuts off. SS1-t is especially useful in applications where inertial loads need to be quickly decelerated, before removing torque from the motor. With the SS1-t safety function integrated into the VSD, the use of an external safety relay is no longer necessary to perform the controlled stop in accordance with stop category 1 of EN/IEC 60204-1. This lowers costs in the design of a machine or equipment and reduces the occupied area within the panel. WEG’s VSDs are recognised for their ease of use, reliability and updated safety functions –

STO and SS1-t. For example, WEG’s CFW500 series uses safety integrated level (SIL) three and performance level (PL) rating, according to EN/IEC 61508 and EN ISO 13849-1 – the highest levels of reliability for industrial VSDs. Using a VSD with safety features makes it possible to reduce the number of safety devices needed to comply with the required PL or SIL. Built-in safety features in VSDs, like these, make it easier to achieve safe operation of processes and protect maintenance staff working on motor-driven machinery. And, by temporarily cutting the voltage to the motor, there is no need to shut down the drive so processes can resume safely. chevron-circle-right

This safety function will virtually eliminate any possibility of electromagnetic torque production on the motor shaft.

www.weg.net www.bpma.org.uk


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FEATURE WAter & Waste Treatment 24 Utilities,

What makes a water VSD the right choice? Pumping applications in the water industry present some unique challenges. Clayton Mead, UK Water Industry Manager for ABB, explains how the latest generation of variable speed drives contain features designed specifically for use in the water industry, helping to achieve resilience and reliability while also improving operational sustainability.


hen discussing the benefits of using variable speed drives (VSDs), the focus is often on energy saving. Indeed, in variable torque applications such as pumps, they can reduce energy costs by up to 60% by varying a motor’s speed in accordance with actual demand. This can help to significantly cut costs and reduce carbon footprint – particularly important against the backdrop of the ongoing push towards net-zero. However, a VSD, and more specifically a VSD designed specifically for the water industry, has much more to offer beyond energy efficiency. ABB’s ACQ range of VSDs, also known as water drives, has been engineered with additional features and functions on top of those typically found in general-purpose or industrial VSDs. These are designed to help tackle some of the many challenges encountered in the operation and maintenance of water industry pumping applications. CAVITATION Cavitation is generally bad news for any pumping system, and its effects can have a severe impact on the performance and lifetime of pumps and pump components. It is caused by pump impeller blades creating a vacuum on the suction side/inlet of a pump – the vacuum results in tiny steam bubbles, which collapse to produce a shockwave. Over time, enough of these shockwaves will gradually erode the impellers and, if left unchecked, can cause the pump to catastrophically fail. Quarter 1 2022

ACQ VSDs can detect and prevent cavitation in real-time. The VSD monitors a pump’s speed and torque directly from the motor shaft, allowing any potential flow issues to be picked up immediately with zero latency and no need for additional sensors or other equipment. The VSD contains integrated anticavitation software, which uses patented algorithms to look for specific patterns in the motor and VSD operating data. It can then preemptively and automatically reduce pump speed to prevent cavitation before it occurs, helping to increase the pump’s lifetime significantly. PUMP CLEANING Obstructions to the impeller are a major cause of pump system downtime and are a common occurrence in wastewater treatment. A VSD’s pump cleaning (also known as anti-jam or anti-ragging) function uses a programmable sequence of forward and reverse rotations of the pump to shake off any build-up on the impeller. This reduces the need for manual cleaning. The VSD can automatically trigger a cleaning cycle by monitoring the pump load for an under-load or over-load curve, or cycles can be scheduled for set intervals, on-demand, or through a fieldbus command. If the drive is cleaning more frequently than usual, this can suggest that it will take more than cleaning cycles to

Clayton Mead, UK Water Industry Manager at ABB

clear the obstruction. In this case, the VSD can trigger a warning to indicate that the pump may require additional attention, or even manual intervention, to prevent the situation from worsening. HARMONIC MITIGATION Harmonics can affect system efficiency and cause electrical equipment to run erratically. They can affect power quality, and in some cases lead to unreliable operation and trips on critical equipment such as generators, which are vital in the water industry. Traditionally harmonics are mitigated by adding additional equipment such as filters, multi-pulse transformers, or by over-sizing equipment. ABB’s

Integrated anti-cavitation software uses patented algorithms to look for specific patterns in the motor and VSD operating data.


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26 Utilities, WAter & Waste Treatment

Ultra-Low Harmonic (ULH) drives have harmonic mitigation built-in, including an active supply unit and integrated low harmonic line filter. In practice, this can reduce harmonic content by up to around 90% compared to a conventional VSD. This is particularly useful when installing VSDs with generators, in hydro installations, or at facilities in remote areas where power quality is an issue. MULTI-PUMP CONTROL Many water treatment facilities use multi-pump configurations. With each pump requiring its own drive, a multi-pump configuration allows for the daisy-chaining of up to eight ACQ580 drives, thus creating an intelligent multi-pump control system that makes it easier to maintain a stable water flow whilst accounting for varying water pressures and variances in pump speeds. Most importantly, this is achieved without the need for an external logic controller. The built-in multi-pump functions also provide backup redundancy to provide stability and ensure continuous operations – balancing the load across all pumps for Quarter 1 2022

greater efficiency should one of the pumps fail and the multi-pump configuration break down or require maintenance. Multi-pump control can also work well in combination with another feature known as pump auto change, which balances the operating time of pumps in a parallel pump system, helping to reduce strain on pumps both individually and collectively. More complex operations can also be programmed, for instance to favour the most efficient pump in a series. A sleep/boost feature reduces equipment wear in such a configuration even further by increasing pressure just before shutting a pump down to allow for extended sleep periods.

build-up of pressure in empty pipes. This avoids pressure peaks in, for example, irrigation systems, where pipes are momentarily empty and controlled pipe filling is required, reducing overpressure and water hammer. As a result, this helps to avoid excess stress to sprinkler heads and pipe joints as the pipe is filled.

Built-in multi-pump functions also provide backup redundancy to provide stability and ensure continuous operations.

SOFT PIPE FILLING Water VSDs also incorporate features for very specific pumping applications and scenarios. Soft pipe filling provides a pump with soft-start, enabling a smooth

IN SUMMARY VSDs are widely known for their energy-saving capabilities, but they also have a lot more to offer. ABB’s ACQ series provides a wide range of features tailored specifically to meet the challenges that pumping applications can present. In addition to the features outlined above, ABB VSDs also incorporate coated boards, and an enclosure class up to IP55 to protect against the harsh conditions commonly found in the water industry. chevron-circle-right bit.ly/ABB_ACQ www.bpma.org.uk



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28 Utilities, WAter & Waste Treatment

HIGH EFFICIENCY PUMPS FOR AALBORG DISTRICT HEATING AT THE RECENTLY ESTABLISHED Stigsborg Bygade pumping station in Nørresundby, Denmark, four new DESMI centrifugal pumps were installed to supply district heating for some 7-8,000 residents. DESMI was selected for the project based on three key factors: efficiency, price and compliance with noise level restrictions. A stringent maximum noise level of 35 decibels was placed on the project, but the DESMI pumps were able to meet this requirement using noise-reducing motors. Commenting on the project, Thomas Andreasen from Aalborg District Heating said: “Alongside the ability to meet the project’s noise level requirements, DESMI’s solution was selected based on the total cost of ownership. The efficiency of the

pumps is high, and the performance is excellent”. In addition, the pumps are perfect for the low temperatures at which this district heating pumping station is operating. The circulation of the 60°C hot water is ensured by the pumps, which is a

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GLOBAL WATER UTILITIES COULD CUT EMISSIONS BY 50%, AT LOW TO NO COST WATER UTILITIES COULD CUT their emissions dramatically and quickly, according to a paper from water technology company Xylem Inc titled Water Utilities: Moving Fast Toward A Zero-Carbon Future. The document outlines the sector’s opportunity to reduce emissions quickly and affordably, with current, high-efficiency technologies. “Water operators have long been stewards of such an essential resource. Water infrastructure is a cornerstone of every community and local economy around the world,” said Patrick Decker, Xylem’s President and CEO. “But today’s water systems are also major sources of global greenhouse gas (GHG) emissions – which is why a growing number of utility operators are showing leadership by committing to net-zero emissions targets. “Readily available technologies are an important and affordable part of the roadmap in utilities’ race to zero,” continued Patrick. “Combined with changes in process, policy and practice, Quarter 1 2022

these solutions can get utilities well on their way to net-zero emissions.” Xylem’s initial study of wastewater infrastructure, Powering the Wastewater Renaissance, found that 50% of electricity-related emissions from the wastewater sector can be abated with existing technologies, such as intelligent wastewater pumping systems, adaptive mixers with variable speed drives, and real-time decision support systems. Around 95% of this impact is achievable at zero or negative cost. Likewise, in clean water, further analysis by Xylem indicates that readily deployable high-efficiency technologies

such as advanced metering infrastructure (AMI) also have a material impact on emissions. In the UK alone, utilities could save up to 10 million tons of GHG by reaching net zero in 2030. The paper emphasises that deploying available high-efficiency technologies is one of several key steps leading utilities are taking as part of their wider strategies to reduce emissions. Others highlighted in the paper include making commitments to reduce emissions by joining the water sector’s Race to Zero and defining the supporting processes, policies, and practices needed to get to net zero, supported by Water UK’s Net Zero 2030 Routemap. bit.ly/Xylem_ZCF www.bpma.org.uk

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FEATURE 30 Opinion

You must ask your Ex equipment repair provider the right questions? When it comes to repairing or overhauling Ex rated equipment, the competency of the repair provider is critical to end-users maintaining the safety of their sites and staff, says Karl Metcalfe, Technical Support at the Association of Electrical and Mechanical Trades.


f you are an end-user looking to repair Ex rated equipment for use in hazardous areas, you should ask your repair provider if it follows the international repair standard, BS EN IEC 60079-19:2019. The answer should, of course, be yes. As the user, when you send hazardous area equipment away for repair, overhaul, or reclamation, it is essential that you understand your responsibilities, as it is your equipment, and you will be re-fitting it into a hazardous area on its return. The definition of a “user” is written within the international standard, which states that they are “primarily responsible for the repair”. If the repairer does not use the international Ex repair standard or follow its guidelines, the user is primarily responsible for this. So, end-users should understand this standard, be able to ask the correct questions of a repairer, know what documentation to expect, and be confident the Ex equipment has been returned fit for purpose. It is also important to ask the repair provider who their responsible person is. The responsible person at a repair facility is the person that checks the operatives’ work, creates the paperwork and obtains the correct standards for the equipment in question. They also issue the documentation for the enduser to agree on the work to be carried out and are responsible for ensuring it is carried out to the correct specification. The responsible person and the end-user should be in close contact throughout the time the equipment is in the repair facility, and so it is important for the repair provider to identify a competent, responsible person. If you are the end-user, you should also ask a repair provider what quality management systems they use. A quality management system is part of many workplaces, but traceability is vital when looking at Ex equipment repair. The international

Quarter 1 2022

repair standard requires repairers to keep documentation on all Ex repairs for a minimum of ten years. If you had an incident at your plant, would you be confident that you could produce the documentation for a repair? If not, could you be confident that the repair facility you used could issue it for a repair conducted eight years ago? If the repair facility uses a recognised quality management system, this will give the confidence that the documentation will be available if needed. It is also important to establish whether staff training certificates are still valid? The international Ex repair standard states that staff involved with Ex repairs should undergo training and assessment at intervals not exceeding three years. To comply with this requirement, AEMT members trained in repairing Ex equipment have their training certificates refreshed every three years. Finally, it is crucial to establish whether the repair facility’s measuring equipment is traceable and adequately calibrated? It is important to have complete confidence, backed by documentation, that the repairer only uses calibrated measuring equipment – for both electrical and mechanical measurements. Not only should the equipment be calibrated, but the repairer should be sure that the equipment was measuring correctly at the time of use. There should also be a record of which vernier, micrometre, surge tester etc., was used to measure the enduser’s equipment. As mentioned earlier,

Karl Metcalfe, Technical Support at the Association of Electrical and Mechanical Trades (AEMT).

traceability is a vital part of any repair, but when the equipment can cause a major incident, traceability and responsibility become a necessity. The surest way to ensure a repair facility is competent in the repair of Ex rated equipment, meets the international standard, and gives the correct answers to the questions outlined above, is to choose a repairer from the AEMT’s Ex register. All companies listed on the register have been trained in Ex equipment repair to the International and European standards BS EN IEC 60079-19 and assessed as competent. chevron-circle-right

“It is essential that you understand your responsibilities, as it is your equipment, and you will be re-fitting it into a hazardous area on its return.”

bit.ly/ExRegister www.bpma.org.uk


Join us once again at the pump industry’s biggest and best celebration! Since launching over two decades ago, the Pump Industry Awards have grown into one of the leading industrial awards programmes, recognising and rewarding the achievements delivered by this important and far reaching sector. The Gala Awards Dinner is a highlight in the pump industry’s social calendar, celebrating the successes of both companies and individuals, as finalists and winners are awarded in the charged atmosphere of the presentation ceremony. Whether it’s taking a table to host customers or booking a few seats for you and your team, don’t miss this fantastic opportunity to enjoy a wonderful evening of great food, fantastic entertainment and networking into the early hours. It’s your chance to celebrate with colleagues, re-connect with peers and be part of the pump industry’s largest gathering. Just visit the website www.pumpindustryawards.com and complete the simple online booking form to secure your places at this must-attend event, which takes place on Thursday 31st March at the Chesford Grange Hotel, Warwickshire.

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