Flow Magazine: Quarter 2, 2021 - Focus on Mining, Quarrying & Construction

Quarter 2 2021

Pump industry insight from

FOCUS ON: Mining, quarrying and construction

Selecting the right dewatering pump

Reliable pumps for boiler feed duties Pump Industry News

Innovations

Applications

Expert Opinion

Motors | Automation | Energy | Transmission & Distribution | Painting

PUMP GENIUS MULTIPUMP CONTROL TWO OR MORE PUMPS WITH ONE VARIABLE SPEED DRIVE

WEG’s Pump Genius Multipump allows you to control two or more pumps in parallel using one variable speed drive. The drive selects which pumps will operate in order to control the process of the pumping system and allows you to increase or decrease supply according to demand. Pumps can be used alernately or in sequence to ensure even use and prevent excessive wear on one pump.

In addition pumps can be isolated for maintenance removing the need to shut down the system.

WEG variable speed drives all comply with EU 2019/1781 which comes into effect July 1st 2021

Transforming energy into solutions

www.weg.net

CONTENTS 3 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.

A

s the restrictions across the UK continue to ease, there are real signs that we will be getting back to business activities that we used to call normal.

For the BPMA, this means two of our annual events are due to take place later this year. The much-anticipated Pump Industry Awards ceremony, which brings the industry together to celebrate excellence across the sector, is being held on Thursday 23rd September 2021.

While the Association’s popular annual golf day is also scheduled for September, being held in Chepstow on the 2nd.

Training is also seeing a move back to physical form. While the Association has seen growth in its online courses, the practical nature of some of our training means it needs to be carried out in a live environment. To that end, we are running our Pump Repair & Maintenance course in June and our Certified Pump Systems Auditor course in September this year.

Then, of course, there are exhibitions. Despite various attempts to deliver exhibitions in a virtual format, they are fundamentally about face-to-face contact. And so, we are delighted to see that CHEMUK, of which the BPMA is a partner, is also returning in September, running at the NEC from the 15th to the 16th.

Despite the way much of the country has embraced video conferencing and other innovative ways of doing business in the last year, face-to-face contact with customers, suppliers, colleagues and peers simply cannot be fully replaced. And I believe that as more and more physical opportunities are opened up, we will see a further boost in business activity and the benefits that will bring.

However, we must take care, and we must be sensible about how we ease back into these activities to ensure we can reap the benefits and not create a third wave.

Richard Harden, President, BPMA

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

4 Bringing the UK chemical

industry back together

6 Europump welcomes new president

BPMA NEWS

Twitter @bpmapumps 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. All rights reserved.

www.bpma.org.uk

7

Membership and training growth for the BPMA

PRODUCT NEWS 8

10

Sealless pump technology improves site safety HVAC circulator pumps never miss a beat

Projects 14 South West Water seizes

energy saving opportunity

Pumping stations for Tower Vaults

Q&A 16 Rhurpumpen’s Shaun Hampson

answers readers’ questions

Features 18 Reliable pumps for

boiler feed duties 20 Reading a centrifugal

pump performance curve 22 Thermal cycle testing

of wound stator coils

Focus on Mining, Quarrying & Construction 24 Selecting the right

dewatering pump 26 Pump solutions for mining,

quarrying and construction

OPINION 30 Green industrial revolution

plan misses pump’s potential Quarter 2 2021

4 INDUSTRY NEWS

AESSEAL GOES BEYOND NET-ZERO AESSEAL PLC HAS ANNOUNCED that, in 2020, the impact of all its operations had a net beneficial impact on the environment.

Following the achievement of Net Zero for Scope 1 and 2 emissions, the company sought independent verification of its indirect Scope 3 emissions, as well as the balancing impact of the emissions avoided by the use of the company’s products in major industry.

Separate evaluations were carried out on Scope 3 emissions, including indirect emissions in the company’s value chain such as business travel, and on the emissions avoided by installing one of its leading-edge environmental systems.

Independent consultants verified that AESSEAL’s Scope 3 indirect emissions amounted to 46,300 tonnes of CO2e in 2020. It was also separately verified that the emissions avoided by the sale of AESSEAL’s Water Management Systems totalled 64,200 tonnes of CO2e.

Commenting on the news, Chris Rea, Group Managing Director, said: “We promised that reaching Net Zero for Scope 1 and 2 emissions, which cover our direct emissions and indirect emissions from electricity, heating

AESSEAL’s Rotherham HQ.

or cooling, was just the start. These independent verifications of Scope 3 emissions and emissions savings show that getting our systems adopted has a net beneficial impact on the environment. Our experts travel all over the world to persuade major industrial customers to invest in environmentallyfriendly systems. That means air miles are unavoidable.”

So far, the calculation of emissions avoided in 2020 covers just one of the company’s products – the water management systems.

The business also has a solid action

plan to ensure that it meets the target of Net Zero for the Global Group by 1st April 2029. Actions include creating an investment policy for electric vehicles in December 2020 and creating an innovative nature walk on its headquarters site.

As part of the ongoing attempt to create a better world, AESSEAL plc has also announced that it will provide free of charge emissions training to any organisation that adopts an Investment Policy to Prevent Global Warming. Details of the policy are available and can be downloaded from Betterworld.Solutions.

BRINGING THE UK CHEMICAL INDUSTRIES BACK TOGETHER THE CHEMUK 2021 SUPPLY-CHAIN EXPO AND SPEAKER programme returns on the 15th & 16th September 2021 at the NEC in Birmingham.

The event aims to bring together the UK’s chemicals, chemical & bio-chem processing, and chemical product formulation industries, providing a two-day supply chain sourcing, business networking, intelligence gathering, bestpractice and strategy development experience.

New for 2021 will be the ‘CHEMSOURCE’ Zone that will see an expansion of the exhibits space and speaker programme coverage relating to chemicals, ingredients & raw materials supply chain & sourcing.

The CHEMUK 2021 event will showcase the latest plant, equipment, materials and services from over 300 specialist exhibitors.

Alongside the exhibition will be a speaker programme, hosted across four open stages, which will deliver around 40+ hours of free to attend expert intelligence, case studies, best practice and technology insight presentations.

Visitors can register at www.chemicalukexpo.com Quarter 2 2021

www.bpma.org.uk

LOW PRESSURE? NO PROBLEM. AQUABOOST COLD WATER BOOSTING SYSTEMS The NEW Aquaboost iBolt and iMatic range of high flow, high head, cold water pressure and flow boosting solutions.

Designed to optimise space and provide a very quiet, simple to install solution for domestic and commercial applications.

STUART-TURNER.CO.UK

6 INDUSTRY NEWS

EUROPUMP WELCOMES NEW PRESIDENT VANNI VIGNOLI HAS BEEN ELECTED as the 30th President of Europump, the European pump industry association. In a historic first, and in keeping with other such COVID induced adaptations, the election was undertaken digitally, forming part of the association’s Virtual General Assembly.

Vanni has been an engineer in the pump sector for over 20 years and has held various positions with Italian pump manufacturer Caprari – best known for its centrifugal pumps, submersible motors, and integrated solutions for water systems. Most recently, as Caprari’s Head of Corporate Marketing, Vanni has been responsible for both strategic and product marketing activities whilst coordinating several businesses within the Caprari suite of companies.

However, as of 1st June 2021, he will hold the position of Research and Development Director.

Currently Chairman of the Marketing Commission and Second Vice-President of Assopompe, Europump’s Italian association member, Vanni has served Europump for many years. He became

Chairman of the SME Commission and a member of the Executive Council before his election as First Vice-President in 2019.

Vanni succeeds Dr Sönke Brodersen, Global Executive Officer Committees and Associations at KSB SE & Co. KGaA and Chairman of VDMA Pumps+Systems, the German pump manufacturer association.

Vanni said of his election: “I very much

look forward to continuing the work started by Sönke, notably with the settingup of our new digital working group to address data, artificial intelligence and cybersecurity issues as they affect our industry, and the continuous promotion of our Extended Product Approach, which places us at the forefront of the EU’s sustainability policy”.

PUMPS ACHIEVES POWERING THE WORLD’S LARGEST TT ALCUMUS SAFEPQQ SEAWATER DESALINATION PROJECT VERIFICATION

TECHNOLOGY FROM ABB IS BEING used to build the world’s largest desalination plant in the United Arab Emirates.

The Taweelah project will be the first reverse osmosis independent water project in Abu Dhabi which will desalinate seawater. It will also set new benchmarks for its size, efficiency and cost by utilising the lowest amount of energy per cubic meter of water produced.

The development will have the capacity to process over 900,000m³ of seawater per day and is scheduled to become fully operational in the fourth quarter of 2022. The plant will play a critical role in meeting the region’s peak water demand, which is projected to rise by 11% between 2017 and 2024.

ABB is working with SEPCOIII, the EPC contractor of the plant, to ensure power supply continuity, and to boost system Quarter 2 2021

operational efficiency and reduce maintenance costs. It is delivering 30 panels of medium-voltage switchgear and 250 panels of low-voltage switchgear with digital capabilities.

In an electric power system, switchgear is used to control, protect and isolate electrical equipment to ensure an uninterrupted power supply.

To optimise operations, the low-voltage switchgear delivered has incorporated intelligent devices with a data interface to enable remote operation monitoring and condition-based maintenance of the switchgear.

ABB has also delivered a wide range of low and medium voltage motors and variable speed drives to ensure reliable and energy-efficient pumping in the plant. The medium voltage drives match the speed and torque of the motors to the pumping demand for maximum energy savings.

TT PUMPS HAS BEEN AWARDED THE GOLD SafePQQ verification for being a safe, ethical and sustainable company.

SafePQQ is an extension of the SafeContractor accreditation already held

by TT Pumps for several years. Together, the two accreditations require businesses to demonstrate compliance and best practice across various areas, including health and safety, equal opportunities, quality and the environment. www.bpma.org.uk

BPMA NEWS 7

MEMBERSHIP AND TRAINING GROWTH FOR BPMA THE ASSOCIATION’S ‘INTRODUCTION to Pumping Technology’ e-learning training course has always enjoyed good enrolment levels, averaging between 45 and 55 students annually.

However, in the nine months since July 2020, over 100 students have signed up for this online training. This significant increase could, in part, be down to COVID-19, although the Joint Industry Board’s recommendation of this course for pump installers as a route to securing their CSCS Blue Cards will also have helped boost numbers. Additionally, the sheer number of people who are now seeing the value of this important training course and what it offers to both the individuals and their employers is a key factor.

The Association’s membership has also seen further growth in recent weeks, with six new companies signing up.

Super Drain installs and maintains pumps, oil interceptors and below ground drainage in the Republic of Ireland.

NT Cloke Pumps & Water specialises in the installation, service repair and maintenance of booster sets, pressurisation systems, tanks and vessels.

Pump distributor, Michael Smith Engineers, supplies a range of larger pumps to the chemical, petrochemical, pharmaceutical and process sectors, whilst meeting the requirements of laboratories, research and development institutions and OEMs with a broad range of smaller pumps.

Combined Pumps serves the chemical injection, pressure testing and fluid transfer markets, offering pumping solutions through

its range of specially designed, engineered, and manufactured pump systems.

Oxford-based Impact Pumps is behind the Impact Pump SLX-40, described as a submersible pump with a difference. It allows surface pumps to lift water from beyond the suction limit – up to 25 metres, with instantaneous flow rates up to 2000 litres per hour.

Dynamic balancing technology specialists, Cemb Hofmann UK, manufactures a wide range of dynamic balancing machines.

As well as supplying new machinery, the company can carry out balancing machine upgrades, plus a wide range of calibration and site services for balancing and vibration monitoring applications.

And finally, with restrictions continuing to ease, the Association’s popular annual golf day is still very much scheduled to take place on September 2nd at the St.Pierre Marriott Hotel & Country Club in Chepstow.

There are still places available, with further details available on the BPMA website www.bpma.org.uk.

Sponsored article

MEGATOR CELEBRATES 75 YEARS MEGATOR WAS FOUNDED IN 1946

by Fredrick Walter McCombie to develop and market his invention, the sliding-shoe positive displacement pump.

The company initially concentrated on developing its product range and expanding its markets both at home and overseas whilst utilising the manufacturing facilities of Blackburn Aircraft to manufacture the pump.

Megator quickly became well established in the United Kingdom and exported the product throughout the world through a network of agents. As early as its first year of operation in 1947, the company had sales in Australia, India, South Africa, Rhodesia, and most of Western Europe. This tradition of exporting has always figured prominently in Megator’s achievements, and today 75% of all sales are for export.

Due to the company’s steady growth, it was decided that the manufacture of the Megator pump should be inhouse. So a factory and office complex was constructed in Sunderland, where production commenced in 1962. The www.bpma.org.uk

management, design and sales functions continued to operate from the head office in London. Eventually, over a number of years and after a detailed study of every aspect of the company’s activities, the decision was finally made to transfer the London operation to the Sunderland Factory in 1985. For the first time, all departments were together under the same roof.

Since its inception, Megator has developed its product range, resulting in the production and marketing of several product lines such as: • Dolphin floating strainers • Oily water skimmers • Dispersant spray systems • Packaged hydrophore systems • Floating containment booms Megator’s worldwide reputation has led to long term partnerships with other company’s and has allowed it to increase its product range to include: • Pumps 2000 diaphragm pump • Mycelx filtration systems • Hydroflo oily water separators

75 Megator has always strived to produce high-quality products and in 1994 achieved certification to BSEN ISO 9001; this commitment is ongoing, and the company currently holds BSEN ISO 9001:2015 certification.

Megator’s involvement in pollution control motivated the company also to achieve ISO 14001:2015, which as well as benefitting the company, has helped Megator limit its environmental impact.

The Megator team is proud to be part of the company’s 75-year history and is looking forward to helping the company achieve the next milestone – 100 years. www.megator.com Quarter 2 2021

8 Product News

BALLAST WATER MANAGEMENT SYSTEMS OPTIMISED FOR IMO WATERS DESMI HAS DEVELOPED TWO NEW Ballast Water Management Systems (BWMS) covering bulker solutions, and ships sailing in International Maritime Organization (IMO) waters only or primarily.

The CompactClean Bulker and CompactClean OptIMO systems join the DESMI portfolio of BWMS alongside its CompactClean BWMS. Not all ships are engaged in global trade but rather in regional or domestic trade, and as such, a significant part of the world fleet will never, or only rarely, enter US waters.

Such vessels can benefit from a BWMS solution optimised to IMO requirements and not US Coast Guard requirements, and this is how DESMI has developed its new CompactClean OptIMO BWMS.

This BWMS has lower power consumption and fewer UV lamps, so it provides both CAPEX and OPEX savings and a small footprint. Moreover, it meets the USCG requirements and can be operated in a US compliance mode when needed.

The CompactClean OptIMO BWMS DESMI provides customers with an opportunity to select a BWMS that is optimised to the vessel’s needs and operation.

If max flowrate treatment is required globally, including US waters, then the CompactClean BWMS, the only UV system available that does not employ special flow

reduction when operated in US compliance mode, is the right choice. desmioceanguard.com

SEALLESS PUMP TECHNOLOGY IMPROVES SITE SAFETY THE CONTAINMENT SHELL OF A MAGNETIC DRIVE PUMP provides a complete mechanical barrier, preventing leaks, escapes and emissions of the product being handled. There is no reliance on any internal or external seal system or method of prevention.

When it comes to applications that involve toxic, fine, corrosive, aggressive and valuable liquids, HMD’s new CSA (ASME) / CSI (ISO) magnetic drive pumps for chemical and industrial processes deliver ultra-safe and reliable performance.

In challenging applications, compliance with stringent

standards calls for a secondary control or containment option to be available to eliminate any possibility of a leak of pumped product, in the highly unlikely event of a containment shell failure.

With its CSA / CSI product line, HMD has taken the secondary control/containment options further by ensuring both options are available on separately mounted pumps and close-coupled units. It is believed that this is unique to the HMD Kontro CSA (ASME) / CSI (ISO) sealless pump range. hmdkontro.com

EXTENDED RANGE OF PACKAGE PUMPING STATIONS THE PLANET RANGE OF package pumping stations from TT Pumps has been upgraded to meet the demand for robust and reliable sewage/drainage pumping solutions.

Upgrades to the Venus and Mercury models include a new style access cover to meet the requirements of the world and European markets. In addition, a new extension neck is available for both the Venus and Mercury pumping stations, allowing them to be installed at least 1m deeper below surface level without impairment to the structural Quarter 2 2021

strength of the pumping chamber.

Fully approved by the BBA, the Planet Range of package pumping stations includes several different models suitable

for small and large applications across domestic, commercial and industrial environments.

The Mercury single/dual pump is suited for smaller flows where excavation depth is limited, while the Venus model is suited to use in single dwellings, toilet blocks and small office applications. Larger Saturn and Jupiter dual pumps are also available, along with larger capacities available to order.

The range also offers ease of installation and is fully recyclable. www.ttpumps.com www.bpma.org.uk

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.

Contact us at: T: +44 (0)1484 557200 E: sales@brookcrompton.com

Product News 10 NEWS 10

COMPACT SUBMERSIBLE GREY WATER PUMPS THE KSB GROUP HAS LAUNCHED a new generation of its time-tested submersible grey water pumps.

The AmaDrainer 3 type series is available in four sizes and is the company’s response to customer requests for a design that is more compact and easy to handle.

The compact pumps feature an integrated float switch and a maximum diameter of 155mm, making them suitable for narrow spaces such as light wells. The maximum head is 11.3m. All four sizes are designed for continuous duty at a fluid temperature of up to 70°C and for very short periods, even up to 90°C. A new feature is the integrated low water level intake. The two smaller pump sizes can achieve residual water levels as low as 2mm by removing the suction strainer. The larger pump sizes are characterised by free passages of up to 35mm, so they can also transport coarse matter contained in the wastewater. For aggressive wastewater

and other fluids handled, a special variant is available for all sizes.

All four pump sets feature a highquality plastic casing, making them lightweight and corrosion-resistant. A jacket-cooled motor permits operation even when the motor is not submerged.

In addition, AmaDrainer 3 comes with integrated motor protection. Fitted with a 10m power cable as standard, the pump set allows for more flexible handling.

The versatile pump range can be used for draining shafts and cellar rooms and extracting water from reservoirs and rivers. In emergency situations, the pumps can be used for applications such as draining external basement stairwells and underground passages. The pump sets are supplied ready to be plugged in, enabling fast installation and commissioning. www.ksb.com

HVAC circulator pumps never miss a beat STUART TURNER HAS INTRODUCED a new range of commercial circulators for HVAC applications. The Pulse range features high-efficiency ErP compliant pumps in various sizes with both single and twin-head options for Rp1½ to DN80. The range also contains brass secondary hot water circulators.

The pumps are driven by highefficiency permanent magnet motors with EEI ratings as low as <0.20 and can self-modulate to only deliver what flow is required based on demand. This

operating mode offers energy savings of up to 90% compared to old-style fixed speed pumps.

The range uses industry-standard port-to-port connections, meaning that Pulse can act as a quick and easy replacement with no pipework modification required in most cases.

They feature a simple to install electrical connection with no need to remove any terminal box. www.stuart-turner.co.uk

DRIVING VERTICAL LOW-SPEED CENTRIFUGAL PUMPS W60 VERTICAL LINE MOTORS FROM WEG are said to offer robust design and excellent performance in a wide variety of operating conditions.

The range offers the flexibility of electromagnetic and mechanical design, complying with several applications and segment requirements, such as solutions that demand motors to withstand external Quarter 2 2021

axial loads, which are suitable to operate in severe conditions and aggressive environments and allow different cooling configurations.

The optimised design of the motors qualifies them for applications in power generation, water and wastewater, oil and gas and other segments. www.weg.net www.bpma.org.uk

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12 Industry awards

PUMP INDUSTRY CELEBRATION SET FOR SEPTEMBER

A

s the UK charts its course out of COVID lockdown, the BPMA looks forward to once again recognising and rewarding excellence in the pump sector.

Having been one of the first industry events to be postponed due to the Coronavirus pandemic, the 20th Annual Pump Industry Awards ceremony was moved from its original March 2020 dateline to the new date of Thursday 23rd September 2021. Commenting on the rescheduling, Event Director Andrew Castle said: “Although the decision to postpone the awards dinner was essentially out of our hands, the complex nature of such an event and the amount of time, work and effort spent on its delivery demanded that we found the best possible alternative date. I am therefore delighted that in conjunction with our sponsors and partners, and with the full support of our excellent venue, we have been able to secure this September 2021 date.”

He continued: “Not only does this allow as much time as possible for the virus to be adequately managed, as determined by the Government’s roadmap to the lifting of restrictions, it also positions our celebration to follow the successful nationwide rollout of the vaccination programme, whereby all adults across the UK will have received both doses, and social confidence will have returned.”

Steve Schofield, CEO, at the British Pump Manufacturers Association, added: “No-one could have foreseen the disruption caused by the pandemic, and the pump sector has not been immune to its impact.

However, despite the many challenges, or maybe because of them, business

and professional excellence still deserves to be acknowledged and celebrated. The Pump Industry Awards will do just that, and at a time when I am sure we will all be ready for a good night out.”

The Gala Awards Dinner will be staged at the Chesford Grange Hotel in Kenilworth, as originally planned. All sponsorships, table bookings and overnight accommodation will be honoured for this new date and carried forward accordingly.

Nine awards will be presented to their rightful winners: • Product of the Year Sponsored by Process Engineering • Project of the Year Sponsored by Stuart Turner • Environmental Contribution of the Year Sponsored by SPP Pumps • Manufacturer of the Year Sponsored by WEG UK • Distributor of the Year Sponsored by EMIR Software • Supplier of the Year Sponsored by Wilo • Contribution to Skills & Training Sponsored by Tomlinson Hall • Rising Star Award Sponsored by World Pumps • Lifetime Contribution Sponsored by BPMA The complete list of finalists can be found on the dedicated awards website.

This year’s awards programme celebrates its 20th Anniversary. So despite the postponement, we can still look forward to a wonderful evening of reward and celebration, when hopefully the current health crisis will be drawing to an end. In the meantime, should you have questions regarding any aspect of the Pump Industry Awards ceremony, the organisers can be reached via the event’s website. www.pumpindustryawards.com Allowing for a return to its usual March timeline, the 2022 Pump Industry Awards ceremony has been scheduled for the evening of Thursday 24th March 2022.

The call for nominations, which will cover activities in the two years up to December 2021, will open on Monday 27th September this year – directly after the 2020/21 awards presentation.

UPCOMING TRAINING FROM THE BPMA Date

Course title

Duration Format

16-17 June 2021

Pump Fundamentals (AM) & Pump Systems (PM) 3.5 hours

Online

23-24 June 2021

BPMA Pump Repair & Maintenance

2 days

West Bromwich*

14-17 September 2021

Certified Pump Systems Auditor (CPSA)

4 days

West Bromwich*

For more information or to book any of the couses 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 2 2021

www.bpma.org.uk

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14 Projects

SOUTH WEST WATER SEIZES ENERGY SAVING OPPORTUNITY

W

hen South West Water (SWW) identified an energy-saving opportunity at its Restormel Water Treatment Works near Lostwithiel in Cornwall, it called in ABB and one of its Value Providers, APDS. The plant uses eight variable speed drives (VSDs) to control the motors used to run the reservoir pumps, altering the speed of the motors to meet the actual pumping demand. The drives operated their cooling fans constantly, even when the drive was not being used for pumping.

The fans are used to maintain various parts of the drive enclosure at temperatures within the drive’s operating range. The fans involved were the door fan, the main drive fan and the fan used to cool the LCL harmonic filters.

An ABB timer circuit was added to the internal 115V supply to switch the fans off via a relay, half an hour after the drive is shut down. The resultant savings in energy costs amount to around £1000 for each of the eight drives. With the retrofitted solution costing £1000, the

payback time for each drive is only 12 months. www.abb.com

PROJECT TO UPGRADE WASTEWATER PUMPING STATION

B

razil’s SAMAE - Municipal Autonomous Water and Sewage Service - started a project to upgrade and improve a raw water pumping station. Improvements were needed to modernise the system, which had relied on some unreliable and obsolete equipment which was becoming increasingly difficult to maintain.

In addition to modernising the installed machinery, the project also aimed to increase the power of the motors and increase the efficiency, capacity and availability of the station. WEG was able to help achieve this goal by providing three W60 line motors and frequency inverters for use on the station’s motor pumps, to help achieve more accurate and precise control of raw water flow.

In addition, WEG also provided start-up and commissioning services for some of the motors. www.weg.net

FOUL AND SURFACE WATER PUMPING STATIONS FOR TOWER VAULTS

T

T Pumps was asked to supply replacement foul and surface water pumping stations at Tower Vaults, an underground retail mall adjacent to the Tower of London.

TT Pumps received an enquiry for a 400 volt 3-phase set using self-priming pumps and operated by float switches, with a control panel including volt free contacts.

Specification requirements included gate valves and non-return valves on the discharge of each pump, along with a 1.4m suction head and discharge run.

The project also required a Surface Mounted Sewage Set to pump foul water

Quarter 2 2021

from toilets and restaurant units. This needed a 5m static head, 20m run, volt free contacts, and a 3,500l capacity.

A key project challenge was the severely restricted access to the basement. The

pumping stations and components would need to overcome these issues and be easy to install and maintain.

TT Pumps supplied a Triple Pump Set, consisting of a self-priming surface mounted pump.

It also supplied an Above Ground Packaged Pumping Station with a 3500L polyethene chamber housing and pneumatic level control with LCD display for foul waste from toilets and restaurant units. A manual hand pump, and emergency surface mounted generator socket were also provided. www.ttpumps.com www.bpma.org.uk

Projects 15

Intelligent pump monitoring solution for chocolate factory An investment in Armstrong Technology’s Design Envelope pumps has paid for itself in just seven months, achieving energy cost savings of 90% within 90 days.

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.

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rmstrong Fluid Technology’s Design Envelope pump technology was specified for a cooling system energy upgrade at La Ronda Chocolate Factory in Dubai.

Following a walk-through, Armstrong suggested using its Design Envelope 4200h end-suction pumps with integrated intelligent sensorless control, which are said to be able to offer savings of up to 90% compared to traditional constant speed systems.

The integrated inverters in the Design Envelope 4200h pumps save the added cost and technical complexity of installing variable frequency drives. At La Ronda, these pumps are connected to the global Pump Manager database, allowing Armstrong to support the local team through performance tracking, and alerts to any smart device, anywhere. Pump Manager is a cloud-based application that uses Armstrong Design Envelope pumps’ embedded intelligence and connectivity to provide performance reports to system operators.

With this information, operators can make changes and address issues to optimise HVAC performance.

Online trending and analysis across multiple parameters on single pumps, or on an aggregated basis for multiple pumps, assists in identifying performance degradation and facilitates a predictive and proactive approach. Pump Manager will, for example, report issues such as excessive vibration, pump in hand, risk of cavitation or a dead head, should they start to occur.

In the three months after the installation, the plant was able to save 118,355 kWh of energy.

HORIZONTAL SPLIT CASE (HSC)

16 technical solutions

Q&A

In this issue of flow, Shaun Hampson, Vice President of RuhrpPumpen Industrial Europa, answers readers’ pump related questions.

QUESTION: With today’s modern technology, am I best moving to seal-less magnetic drive technology instead of mechanical seals?

SHAUN HAMPSON: A simple answer would be ‘yes’ because of the benefits of safeguarding leakage and emissions with a magnetic drive. When it is important to safeguard the escape of toxic/corrosive/ explosive media, then sealless technology removes the risks of leakage associated with mechanical seal failure and vapour/gas passing the seal faces to the environment.

As with single mechanically sealed pumps, magnetic drive machines also need to be protected from dry running and entrained solids controlled. Compared with simple mechanically sealed pumps, the sealless magnetic drive option is generally more expensive.

However, costs are balanced firstly when double mechanically sealed Plan 52/53 systems are being employed and secondly when the environmental impact cost would be high. Higher-end magnetic drive pumps also offer ‘double containment’ that seeks to prevent escape even in the event of sealing failure.

QUESTION: What is the simplest way to improve pump efficiency in an old(er) existing continuous process-production facility?

SHAUN HAMPSON: First of all, you should check that the pump is running at its best efficiency point. If the pump duty is to the left of its best efficiency point, because the process requires less flow, then consider trimming the impeller to match the flow & head demand. If the duty is to the right of its best efficiency point, then the pump manufacturer may have a larger impeller to fit with the existing machine and motor. If these options are not possible, or the process is batch/ fluctuating production, then maybe best to install a variable frequency drive. This will, at least, get the best match and power absorbed.

QUESTION: What is the best way to minimise escape of VOC’s to the atmosphere when being pumped?.

SHAUN HAMPSON: Other than opting for gravity feed systems, the main three solutions are: 1. Install seal-less pump technology like a magnetic drive pump with optional secondary control. The secondary control offers protection in the event of containment shell failure.

2. Install canned-motor pump technology.

3. Use double-acting mechanical seals and associated thermosyphon systems.

Generally, the first and second options would be used for cleaner liquids, while the third, with a Plan 53 system, offers protection while pumping liquids with entrained solids.

To pose your questions, or to see more technical solutions to pump user’s challenges and engage in the discussion, head over to the BPMA’s new online technical forum.

Go to forum.bpma.org.uk or scan the QR code



For details of the full range of training available from the BPMA, scan the QR code to access a digital version of the new and updated training guide.

Or for a copy in the post, email your name and address to: training@bpma.org.uk

Quarter 2 2021

www.bpma.org.uk

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18 boiler feed pumps

Reliable pumps for boiler feed duties The reliable operation of industrial boilers is critical across many industry sectors, where downtime brings with it potentially significant cost implications. Flow magazine found out how Byworth Boilers is working with KSB UK to ensure its customers can count on the reliability of its boiler range.

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eading steam and hot water boiler service provider, Byworth Boilers, offers several ranges of large and medium-sized boilers to industry sectors which include food and beverage production, health services, pharmaceuticals, paper and board making. The company recognises that, for its customers, buying a boiler is a long-term investment, so it is important that it is as efficient as possible and extremely easy to maintain in order to maximise the investment and product lifecycle. It also recognises that the readily available supply of steam and hot water are crucial to its customers’ production requirements.

For its boiler systems, Byworth manufactures and fabricates a considerable number of components inhouse; however, there are always certain components that have to be outsourced. One such component is the boiler feed pump, a highly specialised precision piece of equipment, as Jason Atkinson, Byworth’s Head of Technical and Product Development, explained: “Pumps are integral to how the boilers work because the pumps are used to feed the water into the boiler. Without a constant supply of water at the correct pressure and flow rate, the boiler simply does not work.”

BOILER FEED PUMPS In its quest to find a reliable pump that it can employ across its range of boilers, in 2012 Byworth opened discussions with KSB UK. Since the companies began working together some eight years ago, KSB UK has sold over 400 Movitec pumps to Byworth.

Keeley O’Neill, OEM Area Sales Manager at KSB UK, took up the story: “We approached Byworth Boilers in 2012 with an offer of a free trial of a Movitec VCF4-14 pump on its own boiler system, also used for training, to test its reliability and suitability for the company’s systems. This turned out to be a great success, and subsequently, Byworth started officially placing orders in 2013. They have gradually increased their spend with KSB year-on-year to a point where we now have in place pricing agreements and a rebate scheme.”

In addition to its boiler sales, Byworth was the first company in the UK to recognise the potential need for a mobile boiler hire service, and in 2019 Byworth Hire decided to install Movitec pumps on its boiler hire units as well. “The decision to expand its six-year Quarter 2 2021

KSB’s Movitec pumps deliver a constant supply of water at the correct pressure and flow rate.

relationship with KSB was taken largely on the issues of fast delivery, reliability and cost,” added Keeley.

THE MOVITEC PUMP KSB’s Movitec pump series is a multistage vertical high-pressure centrifugal pump in ring-section design with suction and discharge nozzles of identical nominal diameters arranged opposite each other (in-line design) and close-coupled. Designed with hot water and cooling water recirculation, boiler feed, fire-fighting and pressure booster systems in mind, it offers users a range of energy-saving and high-performance features that deliver demand-driven operation.

With lower NPSH values, it provides dependable pump operation and a high level of operating reliability capable of delivering pressure up to 40 bar and flow rates of 190m³/hr. Occupying only a small footprint, so ideal for incorporation into plant systems, the Movitec is easy to maintain. Seals are easy to replace, and EasyAccess or cartridge seals can even be replaced without the need to remove the motor.

“Without a constant supply of water at the correct pressure and flow rate, the boiler simply does not work.”

www.bpma.org.uk

boiler feed pumps 19 The KSB Movitec plays an important role in saving energy at the component level due to its high-performance hydraulic system and maximum efficiencies. In addition, KSB has available drive and automation solutions for the efficient operation of the pump sets. The pumps are equipped with economical IE3 motors as standard, and optimum energy savings can be achieved in combination with the KSB SuPremE IE5 motor. Pump sets, fitted with the PumpDrive speed control system and the PumpMeter monitoring, are recommended for fluctuating flow requirements and varying intake pressures.

The latest Movitec models have the option of an impeller design that improves the pumps’ suction characteristics (NPSH value). Significantly, the impeller can be used with several Movitec variants without the need for modifications to the outer pump casing.

This impeller features a modified inlet diameter, vanes allowing a slightly diagonal through-flow and a newly designed stage casing, all of which serve to improve the pump’s NPSH curve substantially. This proves its worth in applications with critical inlet conditions (e.g. boiler feed applications) and applications in which the pump is required to take in water from low-lying tanks or at higher temperatures. Under these conditions, a pressure drop in the intake area may cause cavitation in the first pump stage. This can result in excessive wear of pump parts or motor bearings and reduced pump service life due to

damaged parts and an unbalanced hydraulic system.

The Movitec pump series is fully supported globally by KSB Group companies and distributors. For Byworth, which has a global demand for its boilers, this network is of great importance. It means that, should a problem occur or if pump maintenance is required, the boiler user has speedy access to replacement components and professional engineering support.

The latest Movitec models have the option of an impeller design that significantly improves the pumps’ suction characteristics.

MUTUAL OBJECTIVES Byworth’s aim to be the preferred partner in providing efficient heat solutions sits easily alongside KSB’s philosophy. Both companies are dedicated to providing their customers with solutions that satisfy their aspirations and requirements. In an era where optimising energy and operating efficiency combine to deliver the maximum return on investment, both Byworth and its advanced technology boilers and KSB with its intelligent pumps pursue parallel paths. chevron-circle-right www.ksb.co.uk

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and innovative control functions (e.g. Dynamic Adapt plus and Multi-Flow Adaptation), bidirectional connectivity (e.g. Bluetooth, integrated analogue inputs, binary inputs and outputs, Wilo Net Scan the QR code interface), software updates and excellent usability (e.g. thanks to the Setup Guide, the preview principle for predictive navigation and the tried and tested Green Button Technology) make this pump a to find out more: smart-pump.

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20 Pump Curves

Reading a centrifugal pump performance curve

Knowing how to read a centrifugal pump performance curve is an essential skill when selecting a centrifugal pump. To help users interpret a typical curve chart, Tony Dashwood, Technical Director at Crest Pumps, explained what the different elements referenced are.

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or each of their products, pump manufacturers will supply a performance curve detailing information, which includes flow, head, power absorbed, efficiency and NPSH required. Some essential information will be shown on all curves, such as the pump model, speed and suction, and discharge sizes.

6 2 1

1. DUTY POINT The duty point is where a centrifugal pump operates at maximum efficiency. It is determined by the flow rate and the total head at the respective pump speed – both of which will be defined by the application the pump is required for. Shown as the red lines in our example (figure 1), flow can be read from the horizontal (X) axis, and head is read from the vertical (Y) axis. In our case, the duty point required is 170m³/hr at a head of 36m.

3

2. IMPELLER TRIM Impeller trim refers to variances in impeller diameter.

In this case, three impeller trims are shown – 210mm, 200mm and 190mm diameters.

3. EFFICIENCY We can see in our example that the duty point sits very nicely at the BEP (Best Efficiency Point). Unless there are exceptional circumstances, a pump should be selected that will operate at a point between 70% and 120% of its BEP. 4. NPSHr (NET POSITIVE SUCTION HEAD REQUIRED) Shown on the right-hand side of our example, reading down the vertical line, we can see that the pump at the duty point requires an NPSH of 3m. Generally speaking, NPSHr curves do not vary much between impeller trims which is why we see only one NPSHr curve, although three sizes of impellers are indicated on the curve.

5. POWER REQUIRED Reading further down the left-hand vertical axis, we can read the pump requires a power of 37.5kW at the duty point (for a 210mm impeller). However, the motor selected to drive the pump should take into account potential variations in the duty point, so it is common practice to choose the motor power for end-of-curve conditions.

6. SHUT OFF HEAD The performance curve will also show the maximum Quarter 2 2021

4

5 figure 1

head the pump can achieve at closed valve conditions.

In this example, we can read that the shut off head for a 210mm impeller is 55m.

When looking at pump curves, you may also come across tombstone or composite curves (figure 2). These are produced as a figure 2 guide to see the performance of a complete range of pumps. They are similar in their format and used to see which particular pump will suit the duty required, with specific details found on the individual pump performance curve. chevron-circle-right www.crestpumps.co.uk www.bpma.org.uk

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22 Projects

Thermal cycle testing of wound stator coils Rapid temperature changes within motor windings can stress insulation and, in time, lead to dangerous conditions or system breakdowns. Hayward Tyler explains how thermal cycle testing can be used to simulate operating environments and test the bonding between the copper widings and their insulation.

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arge rotating machines are subjected to rapid transitions from low power to full power and vice versa. For example, hydrogenerators (peaking duty and pumped storage), synchronous condensers, and gas turbine generators are often raised from idle to full power in a matter of minutes, are then operated at full power for hours, and then rapidly reduced to zero output. This load cycling leads to rapid temperature changes within the stator winding. As a result, an alternating shear stress develops within the ground insulation system (IEEE 1310).

If the bond between the copper and the insulation is not adequate, the copper may separate from the insulation. This results in the formation of voids between the insulation and the copper that may permit relative movement of the copper strands/turns, leading to abrasion of the insulation. Also, voids can develop between the layers of the groundwall insulation as a result of delamination. In high-voltage coils, these voids can lead to partial discharges and, under certain circumstances, to a puncture of the insulation (IEEE 1310).

Hence, a thermal cycling test under a controlled condition can simulate the effect of the above to verify the quality of the bonding between the copper and the insulations. This practice can be accelerated by repeatedly heating and cooling the power cables without any hold time at the maximum or minimum temperatures. Verification tests such as Megger, PI and PD can then be carried out at intervals to assess the dielectric condition of the power cables.

Hayward Tyler has a pressure & temperature test rig capable of conducting temperature cycling tests and thermal ageing tests. For temperature cycling, the test chamber can house up to six 2m cable and penetrator samples to test at operational temperatures ranging from ambient to 80°C. For thermal ageing tests, the chamber can be used for durations of up to six months and at temperatures up to 120°C thanks to pressure capabilities that stop the fluid from boiling. While in both test examples, Glythermin can be tested based on Polypropylene glycol (PPG).

PARTIAL DISCHARGE MEASUREMENT OF INSULATIONS Partial discharge (PD) is a localised electrical discharge that only partially bridges the insulation between conductors and which can or cannot occur adjacent

Quarter 2 2021

to a conductor. Partial discharges are, in general, a consequence of local electrical stress concentrations in the insulation or on the surface of the insulation.

Generally, such discharges appear as pulses having a duration of much less than 1sec (IEC 60270). Partial discharge measurements are a means to identify these potential insulation failures, which can result in an electrical breakdown and can endanger operators.

PD activity may occur in insulating materials for many reasons. In solid insulations, a defect in the manufacturing process could lead to a gas-filled void.

Gas bubbles in liquid insulations also could be a reason for PD. ‘Corona’ is another form of partial discharge that occurs in gaseous media around conductors which are remote from solid or liquid insulation. Partial discharges are often accompanied by the emission of sound, light, heat, and chemical reactions.

Hayward Tyler has test capabilities to carry out partial discharge measurements on a wide range of new or in-service electrical products up to 50 kV. A fully shielded enclosure and a PD free high-voltage transformer are used to conduct the measurements, which can guarantee minimum impact from external sources of PDs. chevron-circle-right

If the bond between the copper and the insulation is not adequate, the copper may separate from the insulation.

www.haywardtyler.com www.bpma.org.uk

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24 Mining, Quarrying & Construction

Selecting the right dewatering pump Suzanne Gill finds out what needs to be considered to help identify the right dewatering pump for an application.

A

t some point in their operational lives, mines and quarries will certainly need a dewatering pump. With construction managers and engineers increasingly coming under pressure to improve efficiencies across their sites, the correct choice of dewatering pump can contribute by offering both cost and efficiency benefits.

Hrishikesh Kulkarni, Product Marketing Manager, Pumps, at Atlas Copco Power and Flow, says that the first consideration should be the nature of the liquid being pumped as this will have a significant impact on the type of pump needed. “Important factors to consider include general composition, the concentration and size of suspended particles, as well as the liquid’s pH level, temperature, and chemical content,” he said.

“Consider, for example, whether the water will contain fine particles or a much thicker fluid, and how aggressive the media might be.”

Where high concentrations of solids are present, Hrishikesh advises using slurry pumps, as they are designed to handle corrosive and abrasive media. “If the liquid is particularly aggressive, ensure the pump is robust and designed with protection features such as hardened, clog-free impellers, and wearresistance,” he said.

According to Hrishikesh, one of the most critical performance considerations relating to a dewatering pump will be the flow requirement – how much liquid needs to be moved and how quickly? For example, a pump with a maximum flow rate of 138m3/hr might remove water from a pool that is 36m3 in 15 minutes, while a pump with a flow rate of 350m3/hr would empty the pool in just six minutes.

For the best value and efficiencies, the pump selected should handle the flow requirements with enough capacity to cope with fluctuations in water level. A pump that is over-specified and can handle a much higher flow capacity will be more costly and will not provide the most cost-effective solution. On the other hand, a pump that has been under-specified will struggle to transport the media and is likely to wear

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out more quickly, resulting in a shorter life span.

The height to which the fluid needs to be pumped and how far it needs to travel are other considerations that will impact the pressure that the pump needs to deliver to ensure it can pump efficiently and reliably.

The greater the distance the water needs to be pumped, the more friction is created, which results in pressure loss from the pump.

Pumps need to overcome gravity resistance as well as friction losses.

Hrishikesh advises that if the suction lift required for dewatering with a surface pump is more than around 7m, a submersible pump should be considered. “These units are designed to be totally submerged, using the proximity and pressure of the surrounding water to aid fluid movement through the hose, which means that less energy is needed to move the water,” he said.

“If the liquid is particularly aggressive, ensure the pump is robust and designed with protection features.”

UNDERSTANDING NPSH Weir Minerals has highlighted the importance of understanding net positive suction head (NPSH).

The available NPSH (NPSHa) is the static pressure www.bpma.org.uk

Mining, Quarrying & Construction 25 available in a system to force the water into the pump. This, says the company, will largely determine which model within a style of pump is suitable for an application.

NPSH can be affected by several variables, including the static differentiation between a pump’s suction and the water level, the length of the suction pipeline and the pump’s elevation above sea level. Other factors, including temperature and specific gravity, play a role.

Every pump will have a minimum NPSH requirement to ensure continuous flow, which depends on its operating duty point. So the net positive suction head available (NPSHa) needs to be compared to the net positive suction head required (NPSHr) to select a dewatering pump.

NPSHa must always be more than NPSHr – typically with a 1-1.5m safety margin to prevent suction cavitation, advises Weir Minerals.

POWERING YOUR PUMP If mains electricity is available, electric pumps are considered to offer the best and most efficient choice. Electric submersible pumps are considered by many to be the simplest, most energy-efficient and economical approach.

If the site is remote and prone to a fluctuating mains supply, consider a pump whose motor and

starter are equipped with inbuilt electrical protection against varying voltage, phase failure and human error.

Diesel is used mainly in mobile dewatering pumps, such as those operating at the bottom of a mine pit, which require frequent relocation alongside the mine’s sumps as the mine develops.

In such applications, a manually primed centrifugal pump would result in a timeconsuming exercise each time it was moved – the advice here would be to look closely at the benefits that self-priming pumps can offer.

Do give careful consideration to the liquid being pumped, together with the physical demands of the application.

CONCLUSION When specifying dewatering pumps, do give careful consideration to the liquid being pumped, together with the physical demands of the application – such as flow, elevation and distance the fluid travels. Selecting the most appropriate pump for the task will go a long way towards helping engineers meet the efficiency and productivity demands that are increasingly being placed on them. chevron-circle-right

NEWS Quarrying & Construction 26 Mining,

Pump solutions for mining, quarrying and construction Harvinder Bhabra, Head of Business Segment – Fertilizers, Mining, Metals and CPI at Sulzer Pumps, discusses how the variation in process fluid types can determine the pump and materials designs in the challenging mining, quarrying and construction sectors.

S

ome of the most challenging applications encountered by centrifugal pumps are in the mining, quarrying and construction industries. The range of liquids handled varies significantly across these processes – from clear water to heavy slurries and pH neutral to highly corrosive fluids. The processes must also deal with the difficulties posed by the fluids handled, which is why product designs must cater for environmental and legislative constraints at the same time.

WATER, CHEMICALS AND SLURRY Whilst the mining, quarrying and construction industries may seem quite far removed from each other, there are several similarities in the process fluids handled across all three industries. All incorporate an element of fluid removal as part of ground excavation, followed by transfer to various parts of processes as well as the disposal and treatment of waste. One way to distinguish between the various pump designs utilised is to segregate the fluids into process ‘streams’. In simplified terms, these are: • Slurry – fluids (typically water) carrying medium to large solids.

When the carrier fluid has corrosive properties, the criteria for materials selection changes significantly • Dirty water removal (dewatering) – fluids carrying small amounts of fine solids • Process water – clear fluid • Other process fluids – often with various degrees of corrosive properties The pump types for each of these streams may vary by hydraulic design or materials of construction.

MINING AND METALS PROCESSING Mining and metals processes carry fluids through several stages. Whilst there are

Quarter 2 2021

some variations in this, depending on the final product, the most common sequence involves ore extraction, comminution, separation and thickening followed by the transport of the desired product to the refining and finishing process, whilst the waste has to be safely disposed of.

Extraction: To ensure safe mining, residual or incoming groundwater has to be removed continuously. Water seepage may come from a high water table as well as from rainfall, localised flooding or snowmelt. Deeper mines may also be affected by subterranean waterways or pockets of water in the ore body. Dewatering fluids are defined as being contaminated with < 50g/l of fine solid particulates, which may be abrasive, and the carrier fluid may also have some corrosive properties. Fluids with a solids content above this are classified as slurry.

Comminution: The mined ore starts as large rocks and undergoes a series of steps to reduce its size to separate the desired metal from the rock. The initial crushing and screening are dry processes, and water is not added into the process until the ore gets to the grinding mills. Here

the particle size becomes small enough to liberate the commodity from the rock through a separation process before it is finally thickened for the refining and finishing process. The waste part of the processed ore forms the largest volume, and this then has to be disposed of safely.

Slurry and auxiliary water pumps of various designs are used throughout this process.

The metal refining and finishing processes utilise transfer pumps another dimension to the pump design requirements. Erosion wear becomes significant, and corrosion becomes the bigger challenge.

Sulzer HPH mine dewatering pump.

Image © Sulzer

www.bpma.org.uk

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28 Mining, Quarrying & Construction

Sulzer EMW heavy duty slurry pump. Image © Sulzer

QUARRYING Quarry pits are essentially smaller open cast mines, and the need for dewatering the working areas are very similar to those of mining. The product being extracted may be inert, e.g., sand, rock or gravel, or may contain minerals such as kaolin. With mineral quarrying, the key difference from mining is that the product is often slurrified in situ and pumped out of the pit for further processing. One of the consequences of this is that stones and rocks can also find their way into pumping equipment, and the hydraulic and material design has to cater for this. Gravel pumps are also often mounted inside the quarry pit and can be operating on a suction lift, and deeper quarries require correctly configured booster pumps. Quarries may also be hydro mined, requiring high-pressure water pumps feeding the monitors.

This subsequent processing of the product is often done locally close to the quarry pit, and a range of slurry and water handling pumps will be utilised within the plant.

TUNNELLING Major tunnelling projects involve the movement of large volumes of rock and soil as well as water. The selection, operation and maintenance of pumps and related equipment can therefore have a significant impact on costs and schedule compliance. Once again, water management involves the removal of, as well as the addition of, water.

Initially, the construction site may need to be stabilised to prevent flooding Quarter 2 2021

of the work area, involving proactive and reactive dewatering. The amount of water that needs handling can vary significantly depending on the site location, and seasonal conditions can also result in a need to increase or decrease dewatering. Tunnel boring machines and drilling equipment require a reliable supply of cooling water, which, once utilised, must be recovered, extracted and treated.

Cuttings are also slurrified for removal, and this may require pumps designed for high wear and with large solids handling capability.

There are a number of factors affecting design and material selection for pumps in mining, quarrying and tunnelling.

Slurry pumps: The majority of slurry pumps are centrifugal end suction or vertical shaft pumps. Key features are abrasion resistance through suitable materials, large clearances, largediameter impellers for low operating speed to reduce wear, high hydraulic efficiency, and ease of maintenance.

In long-distance pumping applications, high-pressure pumps are required to allow staged pumping.

Froth pumps: These can be horizontal slurry pumps as above, adapted to handle an excessive slurry volume due to the presence of froth. Other designs include vertical shaft pumps with integral tanks designed to allow froth venting.

Gravel pumps: Gravel and dredge pumps are also slurry pumps and have much larger gaps between the impeller shrouds for solids handling and have

low NPSH characteristics as they often operate under suction lift conditions.

Process water pumps: Standard ISO/DIN/ANSI end-suction pumps designed for high hydraulic efficiency.

Chemical process pumps: Standard ISO/DIN/ANSI end-suction pumps designed for high hydraulic efficiency with a variety of material options to handle various chemicals within the process.

Dewatering: Several technologies may be used in dewatering applications, and the pumps can be fixed or mobile installations. Mobile installations typically use submersible or self-prime skid-mounted pumps, whereas fixed installations can have horizontal end suction, multi-stage or vertical shaft centrifugal or turbine pumps.

MATERIALS TECHNOLOGY For abrasive slurry applications, white iron alloys and elastomeric materials are used. Where the carrier or process fluid in a slurry application is corrosive, a fine balance between erosive and corrosive wear is sought to find the optimal performance.

The majority of chemical process pumps are metallic designs in various stainless steels, duplex or super duplex alloys to suit the application. In some instances, non-metallic pumps may also be used where a metallic construction does not provide the required performance.

Water pumps tend to be more straightforward, with cast iron or stainless-steel alloys most commonly used. chevron-circle-right www.sulzer.com

Sulzer Ahlstar pump. Image © Sulzer

www.bpma.org.uk

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FEATURE 30 Opinion

ten point plan for a green industrial revolution misses the potential in pumps Pumps are inextricably linked with energy use. However, Steve Schofield, Director & CEO at the British Pump Manufacturers’ Association, believes the Government’s Ten Point Plan for a Green Industrial Revolution misses a significant opportunity to reduce emissions by failing to focus on the energy efficiency of our pumps and pumping systems.

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he crucial issue of securing maximum operational efficiency from our pumps and pumping systems – to help Government’s across the World reduce their energy consumption and meet the designated carbon reduction targets – must remain a key objective for all those involved in the supply, installation and operation of pumps, whatever the application.

Advancements in pump technology will, of course, continue to play a role, as determined by the Eco-design Energy Related Product (ErP) Directive. But far greater savings will come through the adoption of the Extended Product Approach, whereby the energy use of the entire system – pump, motor and control – is fully assessed, rather than just the pump itself. The BPMA, along with counterparts across Europe, has been pushing this approach for many years, including the development of the international standard ISO 14414 – Pump System Energy Assessment.

However, for these huge energy savings to be identified, and more importantly, realised, there needs to be a far stronger emphasis on the ‘systems approach’ and a commitment to make this happen from both the pump industry and the final end-users – those who will ultimately benefit from lower energy bills, and in the case of businesses, improved profits.

Quarter 2 2021

There is a raft of laudable energy use improvement programs being developed around the world, with the Energy Efficiency Directive and Drinking Water Directive key amongst them within Europe.

However, following the UK’s exit from the European Union, we seem to have a ‘watching brief’ in terms of how closely our Government will follow the EU’s legislative regime in relation to environmental issues. Some argue for a strong alignment, whilst others predict a degree of divergence, particularly in relation to water pumps. Either way, the BPMA will continue to play a significant role in lobbying all parties for the best possible outcomes for both its pump manufacturer members and their broad and multi-faceted customer base.

Indeed, the BPMA has recently endorsed the Betterworld Solutions initiative, which calls into question the UK Government’s 10-Point Plan for a Green Industrial Revolution.

Detailing clean energy, transport, nature, and innovative ‘new horizon’ technologies, the blueprint is intended to allow the UK to achieve its climate

change obligations. However, the contribution of pumps to global warming is not being addressed in this ambitious plan. This is a serious oversight, given the high energy use of pumps and their critical role in maintaining our infrastructure, industrial productivity, and living standards.

We therefore believe the improved energy efficiency of our pumps and pumping systems should become the 11th point in the Government’s plan and receive the same levels of attention, support and surveillance chevron-circle-right

The contribution of pumps to global warming is not being addressed in this ambitious plan.

www.bpma.org.uk

PUMP INDUSTRY AWARDS 2020/21

th 0 2 Anniversa r y Eve nt

Join us at the pump industry’s biggest and best celebration!

It’s your chance to network and party with the industry’s best & brightest at this special 20th anniversary event.

The PI Awards Gala Dinner is the highlight of the pump industry’s social calendar, celebrating the achievements of both companies and individuals, as finalists and winners are awarded in the charged atmosphere of the presentation ceremony.

This event heralds the 20th anniversary and two decades of recognising and rewarding excellence throughout the pump sector.

Whether it’s taking a table to host customers or booking a few seats for you, your team and partners, don’t miss this fantastic opportunity to enjoy a wonderful evening of great food, fantastic entertainment and networking until the early hours.

Just visit the website www.pumpindustryawards.com and complete the simple online booking form to secure your places at this must-attend event, taking place on Thursday 23rd September at the Chesford Grange Hotel, Warwickshire.

DATE & VENUE Thursday 23rd September 2021 Chesford Grange Hotel, Kenilworth

THE TIMINGS 7.00pm - Drinks Reception

7.45pm - Pump Industry Awards Banquet

9.30pm - Pump Industry Awards Ceremony 10.15pm - Entertainment and Charity Raffle held on behalf of Wateraid 11.00pm - Fun Money Casino and Networking 12.30am - The Survivor’s Breakfast

2020/21 Award Programme Partners

www.pumpindustryawards.com

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