Flow Magazine: Quarter 2, 2023 - Focus on Building Services

Page 1

SECTOR FOCUS: Building Services

Identifying poor assets and inefficient pumps

Quarter 2 2023 Innovations Pump Industry News Applications Expert Opinion A fire extinguishing system with maximum flexibility Pump industry insight from

Why choose Caprari

• M&E INSTALLATION AND CONTRACTING • PUMP REPAIRS, SERVICE, AND MAINTENANCE • PUMPS INSTALLATION AND MAINTENANCE • WATER / WASTEWATER TREATMENT INSTALLATION • PACKAGED PUMPING STATIONS* • SEWERS FOR ADOPTION PUMPING STATIONS* • WATER TRANSFER AND BOOSTING* • CLEAN WATER BOOSTER SETS* • PUMP STATION MONITORING AND CONTROL • PUMP STATION DESIGN • PUMP SALES AND SPARES • OEM - CAPRARI PUMPS • PREVENTATIVE SERVICE MAINTENANCE CONTRACTS * SUPPLY, INSTALLATION, COMMISSION & SERVICE CAPRARI PUMPS (UK) Ltd. Caprari House, Bakewell Rd, Peterborough, PE2 6XU - Tel +44 1733 371605 www.caprari.co.uk
24 HOUR Emergency call-out and break-down assistance 07980 425866 Just for you Caprari Site Services offers an extensive scope of clean water and wastewater services to a wide range of clients from domestic homeowners, through facilities and property managers, retailers, developers, and commercial organisations, to water authorities. QUALITY & CERTIFICATIONS ISO 9001 ISO 14001 ISO 45001 BUREAU VERITAS Certification

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.

Condition monitoring features heavily in this issue of flow. It plays a crucial role in maximising uptime, minimising costs, ensuring safety, and optimising performance in a wide range of industrial and commercial applications.

By monitoring the condition of pumps, potential issues or failures can be detected early on. This helps avoid costly unplanned downtime and reduces the risk of catastrophic failures that could lead to equipment damage or safety hazards.

Regular condition monitoring can identify inefficient operation, wear and tear, or minor issues affecting a pump’s performance. Addressing these problems early can optimise pump efficiency, reduce energy consumption, and prolong equipment’s lifespan, leading to significant cost savings over time.

In many applications, pump failures can lead to hazardous situations, such as leaks, spills, or equipment malfunctions, that may pose safety risks to personnel or the environment. By monitoring the condition of pumps, potential issues can be identified early, reducing the likelihood of accidents and ensuring a safe working environment.

Condition monitoring also helps to optimise pump performance and efficiency, ensuring that resources such as energy, water, or chemicals, are utilised effectively. By identifying abnormalities or inefficiencies, adjustments can be made to reduce waste and improve overall process efficiency – which is vital in the global push to reduce carbon emissions.

The capabilities of condition monitoring solutions are constantly advancing, and if you are not using them in some form yet, I would urge you to investigate the topic.

Of course an excellent place to start would be the following pages. I hope you enjoy this issue.

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.

Quarter 2 2023 www.bpma.org.uk CONTENTS 3
BPMA. All rights reserved.
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BPMA National Metalforming Centre 47 Birmingham Road West Bromwich B70 6PY www.bpma.org.uk BPMA Update PUMP INDUSTRY NEWS Features Building Services OPINION Product News 38 Restricting PFAS: It’s not as simple as it sounds 8 Compact booster set packs a punch 9 Massive expansion of chemical pump series 6 New Director and CEO for BPMA 4 Xylem completes acquisition of Evoqua 5 Award win for ABB 16 Open up predictive maintenance 18 Condition monitoring solution detects rotational direction 20 Putting the engineering into reverse engineering 26 How does MEI affect me 28 Vibration modelling eliminates pumping station’s critical resonance frequencies 30 A fire extinguishing system with maximum flexibility 34 Drainage solutions make complex projects a reality 36 Control noise in booster pump systems Twitter @bpmapumps Project Updates 12 Testing programme supports net zero commitment 14 Retrofit at Ardleigh Treatment Works Awards update 10 Pump Industry Awards nominations open PEFC/16-33-254 PEFC Certified This product is from sustainably managed forests and controlled sources www.pefc.org

Sulzer and Siemens announce digital collaboration

SULZER AND SIEMENS LARGE DRIVES

Applications (LDA) are using their collective expertise to provide operators of large centrifugal pumps with an enhanced digital value proposition. Bringing together their respective IoT platforms and services, BLUE BOX and SIDRIVE IQ, the two companies are collaborating to deliver an integrated solution that improves equipment reliability and cuts operational costs. The agreement has recently been made official with the signing of a letter of intent (LOI).

Sulzer and Siemens LDA are taking the first steps on a journey that is expected to deliver significant savings for operators of large centrifugal pumps. To offer a more holistic value-add that addresses the wider drivetrain, Sulzer’s pump-specific, AI-based analytics platform, BLUE BOX, will now be complemented by predictive maintenance data from Siemens LDAs’ SIDRIVE IQ, an IoT platform for smart fleet management of

drive systems & solutions.

Initially, with this move, operators will have access to more relevant information in one place, will be able to make better decisions based on the health and operations data of their entire pump drivetrains and will benefit from more effective service support in case of incidents. Furthermore, operators will be able to plan maintenance events more accurately and determine the health of the pump drive system on demand.

Sulzer and Siemens LDA have been working together to integrate and exchange data between their IoT platforms, enabling large pump operators to ensure their equipment is operating at

peak performance. Both the combined data from both BLUE BOX and SIDRIVE IQ, as well as the expert support, will allow the operators to identify actions that control lifecycle costs and reduce carbon footprints – objectives on the business agenda of every company’s environmental, social and governance (ESG) charter today.

THE EVENT FOR HEAT, WATER, AIR AND ENERGY PROFESSIONALS IS BACK

InstallerSHOW, billed as the UK’s number one destination for installers and specifiers of heat, water, air and energy technology, returns to the NEC on June 27-29 this year.

According to the event’s organisers, it is the place for installers and specifiers to see and try new product innovations, meet with their peers, connect with manufacturers and gain industry insights to keep their business ahead of the curve.

This year’s event is on track to be bigger and better than ever – with 450+ exhibitors set to welcome 15,000 industry professionals. Building on the success of its Birmingham debut last year, the 2023 show will feature an expanded offering for visitors to reflect the growing momentum towards net zero solutions.

Show features will include the Installer Plaza, sponsored once again by Glow-worm, which will host debates, interviews, live podcast recordings, celebrity appearances and more.

A stellar line-up of speakers, including ex-footballer Gary

Neville and former housing minister Esther McVey, will take part in debates and discussions in the two elemental content areas – the Housing Hub and the Decarbonising Buildings Theatre. BEAMA, the UK trade association for manufacturers and providers of energy infrastructure technologies and systems, will be hosting the Net Zero by Design feature theatre, with a packed timetable of live events.

Installing the Future. NOW! is a ‘working’ showcase demonstrating the installation and operation of renewable and energy efficiency products in both retrofit and new build settings.

And back for 2023, InstallerINVENT offers visitors the opportunity to see first-hand new products being brought to market.

Parking (in designated car parks) and entry to InstallerSHOW are completely free and visitors can register for a pass at https://installer-2023-visitor.reg.buzz/bpma-flow

XYLEM COMPLETES ACQUISITION OF EVOQUA

GLOBAL WATER TECHNOLOGY

company Xylem has acquired Evoqua Water Technologies Corp., a leader in mission-critical water treatment solutions and services, in an all-stock transaction valued at approximately $7.5 billion. The combination creates the world’s most advanced platform of capabilities to address customers’ and communities’

critical water challenges.

Headquartered in Washington, D.C., the combined company becomes the world’s largest pure-play water technology company, with $7.3 billion in pro forma revenue and more than 22,000 employees. Xylem’s portfolio of solutions across the water cycle, including advanced technologies, integrated services and deep application expertise will

help customers in utilities, industrial and commercial end markets address their most pressing water needs.

The combined company’s executive leadership team will be led by Patrick Decker and include senior leaders from both Xylem and Evoqua. Xylem has also appointed Lisa Glatch and Lynn C. Swann, former Evoqua directors, to serve as members of its Board.

INDUSTRY NEWS 4 Quarter 2 2023 www.bpma.org.uk

CHEMUK RECORDS A 41% INCREASE IN VISITORS

CHEMUK 2023 OPENED ITS DOORS on May 10 and 11 at the NEC in Birmingham to a record attendance of 3956 visitors (excluding exhibitor staff) over the two days, representing an increase of 41% from the 2022 edition. The total two-day attendance (visitors plus exhibitors) was 5559.

CHEMUK show founder, Ian Stone, summed up this year’s event: “The industry is now responding to the single destination experience of CHEMUK which provides deliberately segmented zones of specialist industry capability and solutions, supported with unmissable intelligence, whilst at the same time uniting the entire UK chemical industry’s value chain under one roof annually.”

A dedicated video address from the Minister of State at the Department for Science, Innovation and Technology, George Freeman, underpinned a comprehensive UK Government presence and input across the two days, with show floor presence and vital conference input from the Department for Business and Trade, the Department for

Environment, Food and Rural Affairs, and Health and Safety Executive.

Sustainability was the common thread across the event this year, with progressive energy and emissions reduction solutions, process optimisation and greater operational efficiency of petrochemical-based plants, through to a wealth of coverage on developing ‘green chemistry’ innovation, supporting the transition towards bio-based chemicals and downstream products. Industrial biotechnology and bio-process innovations were reflected across all three zones and through the conference programmes.

ABB and Wellington Water win Global Water Award

ABB HAS WON A

2023 Global Water Award in the category ‘Smart Water Project of the Year’ for its collaboration with Wellington Water, the water services provider for the Wellington region of New Zealand.

Wellington Water manages the water infrastructure for six New Zealand councils. This infrastructure includes 105 water pump stations, 248 wastewater pump stations, 148 reservoirs and 27 storm water pump stations at various sites.

The utility worked closely with ABB to take the resiliency of its drinking water infrastructure to the next level, implementing smart flow meters that track water flow in real time, and variable frequency drives to deliver crucial efficiency gains.

Built-in verification tools and anomaly detection capabilities enable operators to secure the longevity of devices. Recorded data is easily exported for further analysis and evaluation so that critical factors can be identified earlier, and corrective actions are taken more quickly.

CHEMUK has become the destination in the UK where all the key bodies, major companies, and industry stakeholder groups embracing organic and inorganic synthetics, formulation chemistry, analytical and materials chemistry, industrial biotechnology, and chemical and process engineering are predictably in the same time and space, under one giant roof, alongside a wealth of downstream chemical-dependent industries.

CHEMUK 2024 is scheduled to run on May 15 and 16, 2024, at the NEC, Birmingham.

2 WEEKS

Quarter 2 2023 INDUSTRY NEWS 5

BPMA WELCOMES ITS NEW DIRECTOR AND CEO

WAYNE ROSE HAS OFFICIALLY become the new Director and CEO of the British Pump Manufacturers Association (BPMA) following the retirement of his longstanding predecessor, Steve Schofield.

Wayne joined the BPMA in January and spent the following three months shadowing Steve during an essential handover period. The CEO role for a multifaceted trade organisation like the BPMA is complex, especially as the UK transitions away from the European Union and the established product compliance and legislative landscape.

Having previously spent 24 years in various management roles at Manchesterbased Armstrong Fluid Technology, Wayne brings a wealth of pump industry experience. With over 1200 employees worldwide and operating eight manufacturing facilities on four continents, Armstrong is known globally as a leader and innovator in the design, engineering, and manufacture of intelligent fluid-flow equipment. That depth of knowledge will undoubtedly serve him well, as he helps to guide the BPMA through its next chapter, and ensure the Association continues to serve the interests and needs of its members.

Reporting to the Board and assisted by Gary Wild as Technical Officer and Steve Smith as Associate Director, Wayne will assume commercial responsibility for the day-to-day running of the organisation, whilst also engaging with the elected members of the BPMA Council.

Commenting on Wayne’s appointment,

current BPMA President, and Managing Director at KSB, Dale Croker, said: “The BPMA Board and Council are delighted to have secured the engagement of Wayne as a successor to Steve, who had been with the BPMA for a good many years. Indeed, he has left some big shoes to fill, but we know Wayne will bring his vast experience to bear and play a key role in the future development of the Association and the important service delivery it offers to members.”

Dale continued: “We are enormously grateful to Steve Schofield for all he achieved on our behalf, and we wish him a long and happy retirement. But we are equally happy to have Wayne on board, and we wish him every success as he helps to guide the BPMA through its next phase of development.”

On taking up his new role, Wayne Rose said: “Assuming the post of CEO of the BPMA is a real privilege, as I am fully aware of the important position the Association holds within the pump sector and the value placed on it by its members. My entire career has been spent working with pumps or their related systems, and throughout, I have engaged heavily with the Association. I have seen first-hand what influence it has across the international arena and how that influence has served the commercial interests of its members, whatever their specific pump type or related discipline. As such, I look forward to building on the great work carried out by my predecessor and to further developing the support structure it provides to this most important of industry sectors.”

UPCOMING TRAINING FROM THE BPMA

FEATURE 6 www.bpma.org.uk Quarter 2 2023 BPMA Update 6
Date Course title Duration Location 10 July 2023 Pumping Fundamentals 1 day Online 11 July 2023 Pump Selection 1 day Online 12 July 2023 Pump Testing 1 day Online 19 September 2023 VSD’s an Introduction - NEW Course 1 day West Bromwich 20-21 September 2023 BPMA Pump Repair & Maintenance 2 days West Bromwich 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.
BPMA President, Dale Croker (left) welcomed Wayne Rose to his new role as BPMA CEO.

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CONDITION MONITORING SOFTWARE WITH BUILT-IN ANALYTICS.

USING ARTIFICIAL INTELLIGENCE,

the new Alfa Laval Analytics for online condition monitoring helps hygienic industries prevent unplanned downtime, extend the lifetime of valuable assets and reach sustainability targets.

“This is a big step for the hygienic industries. Our new Alfa Laval Analytics solution detects potential machine faults before they occur and helps diagnose the root cause. In close dialogue with our customers, we have developed an easyto-use and reliable solution that brings peace of mind and keeps equipment at peak performance at all times,” said Torsten Pedersen, Head of Connectivity and Monitoring at Alfa Laval Fluid Handling.

Alfa Laval Analytics is a value-adding feature that can be added to all new and existing pump installations from the company. The solution includes a one-year subscription, including online installation, training in using the dashboard and ongoing support.

Alfa Laval Analytics collects and analyzes pump vibration data around the clock. The philosophy behind the development of the AI-based solution has been to create peace of mind for plant operators and management. Analytics provides a clear and intuitive overview of the health condition of the equipment through a simple dashboard. Green for ok, yellow for pay attention, orange for warning and red for immediate action.

“No matter where they are and regardless of time, operators and plant managers can check plant status in their pocket. All it takes is a glance on the app dashboard to check the health status of the pumps and take action if needed to prevent costly downtime”, added Torsten.

He explained that Analytics not only detects faults but also pinpoints the likely causes of the problem, which can, for instance, be related to misalignment of the pump installation, potential process improvements or mechanical faults.

“The diagnostics capabilities of the Analytics tool make it much easier for operators and technicians to locate the problem fast and fix it before any damage is done. When running Analytics, we can even

extend the warranty on equipment if the pumps are monitored continuously and if inspection and repair recommendations are followed”, concluded Torsten.

With its ability to predict failure and identify parts that need repair or replacement, Analytics paves the way for implementing predictive maintenance strategies that eliminate extra costs and prevent unplanned downtime.

At the same time, Analytics supports the sustainability agenda by allowing plants to do more with less. By keeping assets running flawlessly at all times, Analytics enhances energy efficiency and helps reduce carbon emissions.

www.alfalaval.com/analytics

COMPACT BOOSTER SET PACKS A PUNCH

THE NEW META SMALL SELF-PRIMING booster set from Calpeda offers reduced energy consumption, low noise, improved recycling potential, and plug-and-play functionality in a compact package.

Available in single- and two-pump sets, the Meta Small features near-silent operation thanks to an innovative fanless design employing an asynchronous motor.

The pump is equipped with an integrated pressure transducer, and check valve and a built-in pressure vessel and has been designed for light industrial, commercial and domestic water boosting applications. Thanks to its versatility and robust design, the Meta Small is also suitable for a wide range of applications such as irrigation.

The Meta Small is controlled by an integrated variable frequency drive (VFD) which minimises energy usage, an environmental benefit which is also an advantage in the current cost of living crisis. Running for five hours per day over ten years, the Meta Small will use around 9,100kWh less energy than an alternative booster

set not using a VFD. This equates to a saving of 8,200kg of CO2. The use of 304 stainless steel in its construction further demonstrates the booster set’s sustainability credentials, making it easier to recycle the set compared to plastic-based alternatives. While the use of stainless steel has also ensured the device is fully Regulation 4 compliant and KIWA approved for potable water

Commenting on the launch of the Metta Small, Ryan Hall, Sales Director at Calpeda UK, said: “Despite being one of the most compact booster sets on the market, the Meta Small packs a real punch and offers a wide range of benefits. Installers will appreciate the plug-and-play functionality, which means that parameters can be set up quickly and easily. End-users will benefit from the near-silent operation and, of course, the low running costs. And companies supplying the set can keep their inventory holding down thanks to the wide duty range the Meta Small can cover.”

www.calpeda.com

Quarter 2 2023 www.bpma.org.uk Product News 8

MASSIVE EXPANSION OF CHEMICAL PUMP SERIES

KSB SE & CO. KGAA HAS ADDED 19 sizes to its MegaCPK type series. Users can now choose from 55 sizes with more than 78 hydraulic systems for these standardised chemical pumps. The available materials of grey cast iron, nodular cast iron and cast steel, stainless steel, as well as duplex and special alloys such as titanium and Hastelloy, result in an extensive range of applications. Fluids that require heating or cooling can also be handled.

The pumps are characterised primarily by their high output per size and their low energy consumption. Not only does this save on electricity consumption, but it also reduces the user’s initial investment. KSB’s developers have placed particular emphasis on good suction behaviour, with a low NPSH value to minimise the risk of cavitation. This enables smooth and stable pump operation even under difficult operating conditions. It also ensures a high degree of reliability and improves the availability of an entire system.

By using the finite element method (FEM), a calculation method for the simulation of solids, the developers were able to achieve a high degree of strength and rigidity of the installed components while at the same time optimising the use of materials. After optimising all hydraulic contours using computational fluid dynamics (CFD) the improvements were verified in test set ups.

The new seal chamber design allows the installation of gland packings, all common mechanical seals compliant with EN 12756, and many cartridge-type mechanical seals. Fully confined casing gaskets and minimised axial thrust ensure long service life. To control and monitor operation, the pumps can be equipped with speed control, vibration and bearing temperature measurement

PUMP MOTOR FOR THERMAL POWER STATION

MENZEL ELEKTROMOTOREN HAS MANUFACTURED a motor with a special flange for a condensate extraction pump in a combined heat and power plant. The original motor, which was over 30 years old, had to be matched precisely in all mechanical and electrical interfaces.

Works included the manufacture of a flange with special dimensions for vertical installation and repositioning of the main terminal box. The energy supply company, already a customer of Menzel Italy, awarded the order because Menzel could fully confirm all technical requirements. Menzel’s MEBKGR series comprises high-voltage squirrel cage motors with a good price-performance ratio. For the current application, the manufacturer designed a 4-pole motor with size 500, 6000V nominal voltage, 1100kW nominal output, protection class IP55 and cooling type IC 411 (fin cooling with external fan).

Menzel took the motor all the way through to commissioning, which was carried out to the customer’s satisfaction.

www.menzel-motors.com/pump-drive

and operating point monitoring.

In line with KSB’s common practice for industrial pumps, every pump is supplied to the customer with the impeller diameter trimmed exactly to the duty point. Impeller trimming, combined with the large range of pump sizes, helps ensure that the pump’s energy consumption is kept to the minimum necessary, even when run at a fixed speed.

www.ksb.com

£100k ($130,000)

Product News 9 Quarter 2 2023

NOMINATIONS SOUGHT FOR INDUSTRY-WIDE RECOGNITION

It’s that time of year again when the Pump Industry Awards are calling for your nominations.

The BPMA’s annual awards programme has recognised and rewarded the achievements of pump businesses, large and small, for over two decades. Over that time, it has become one of the leading events to serve the industrial and commercial arena.

If you or your company has a pump-related success to shout about, then this awards programme provides the perfect platform. The closing date for all entries is Friday, January 5, 2024, giving plenty of time to consider, prepare and submit entries. Entering is simple, and putting forward a nomination demonstrates confidence in the quality of an organisation’s work, people, products, and projects.

Maintaining the early Spring timeline and following the success of the 2023 event, the next Gala Dinner and Presentation Ceremony will take place on Thursday, March 14, 2024, at our fantastic new venue – the Hilton at St George’s Park in Burton on Trent.

Situated on the edge of the National Forest, this impressive hotel is part of St. George’s Park – the training ground for all 28 English national football teams – and is recognised the World over as the Home of English Football. Sporting excellence is synonymous with this venue, and early next year, it will once again become the location for heralding engineering excellence across the pump sector.

The online entry forms, which seek submissions for activities and achievements that took place in the 18 months up to December 2023, will remain on the dedicated awards website – www. pumpindustryawards.com – until the entry deadline of 5.00pm on Friday, January 5, 2024.

The pump sector continues to play a crucial role in ensuring our food production, utilities, manufacturing processes, transportation and other essential services are maintained, and the 2024 awards programme will again give special recognition to those companies and individuals who have gone that extra mile to meet, and more often exceed, the demands and challenges presented by the sectors served. This recognition and acknowledgement will be represented by eight award categories that collectively honour the full breadth of product and service delivery by the pump industry:

• 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 YearSponsored by WEG UK

• Distributor of the Year –Sponsorship Available

• Supplier of the Year - Sponsored by Wilo

• Contribution to Skills & Training –Sponsored by Crest Pumps

• Rising Star Award - Sponsored by World Pumps

Once again, the event has secured the support and backing of a host of leading brands, all of whom recognise the value and importance of promoting excellence across the sector. In addition to the main category sponsors highlighted above, other sponsorship options also help support specific elements of the 2024 presentation evening. Several opportunities still exist, so please get in touch if you would like your brand aligned to outstanding engineering achievement.

Wayne Rose, Director and CEO at the British Pump Manufacturers Association, commented: “This year’s awards ceremony – the 22nd such event - was as good as any I can remember. The atmosphere was fantastic, and the competition was intense. Business and professional excellence deserve to be acknowledged and celebrated, and these awards do just that for this most important of sectors. I would therefore encourage all those involved in the pump industry to prepare and submit their entries for the 2024 awards programme.”

www.pumpindustryawards.com

www.bpma.org.uk Quarter 2 2023 Awards Update 10
0

THE START OF A NEW ERA.

www.tomlinson-hall.co.uk WELCOME TO THE TH FAMILY > SteriTecTM For more information call 01642 379500 for the future thanks to optimised planning certainty and maximum sustainability. Find out more at www.ksb.co.uk - 01509 231872 - sales@ksb.com
Flow; 210x145; June 2023.indd 1 16/05/2023 10:54:49

AUTOMATIC SUMP PUMPS FOR CROCODILE ENCLOSURE

THANKS TO THE SUCCESS OF THE last two wildlife-friendly pumps installed by T-T Pumps, The Tropical Butterfly House in Sheffield returned to select and install pumps in their crocodile enclosure, including two new waterfalls.

Any pumps installed in an enclosure must be animal safe and able to handle debris from the wildlife themselves. A pump unsuited to the application will likely become blocked and break down.

A third pump was needed as a replacement in the swamp area, where the previously installed pump was experiencing constant failures. The T-T team selected three Goliath 150 Automatic Sump Pumps for the job.

These pumps were specially selected for their robust construction due to the submersible environment of the application. The automatic sump pumps comprise a stainless-steel outer casing, reinforced plastic construction and a cast iron impeller for maximum durability, increasing the longevity of the equipment as it can withstand up to 10m submersion pressure and erosion from water flow over time.

The pump’s heavy-duty impeller also means that the Goliath can handle solid

matter with a diameter of up to 35mm, including natural debris such as plant matter or sediment, feeding debris or crocodile waste. By replacing the swamp’s existing pump with a Goliath Automatic Sump Pump, the water will be circulated much more reliably, reducing the risk of stagnant water harm.

Double mechanical seals are used in the pump’s construction to prevent fluid from leaking from the shaft. This could cause

TESTING PROGRAMME SUPPORTS WELSH WATER’S NET ZERO COMMITMENT

AS PART OF ITS COMMITMENT TO ACHIEVING NET zero greenhouse gas emissions by 2040, Dŵr Cym-ru Welsh Water is collaborating with Riventa to test the efficiency of 424 wastewater pumps at 132 treatment works.

Riventa’s expertise in next-generation pump system optimisation will support Welsh Water in evaluating asset performance and reducing energy consumption, resulting in significant savings.

Over the next two years, Riventa will gather accurate and high-quality data to determine the health and efficiency of all 424 pumps. This data will identify inefficiencies and enable Welsh Water to address poor assets, driving investment and refurbishments to improve performance.

Andrew Heygate-Browne, Energy Projects Analyst at Welsh Water, said: “As one of the largest energy users in Wales, with a gross energy bill of £77 million in 2021/22, we recognise the need to reduce our energy consumption and play a significant role in Welsh Government’s de-carbonisation targets for

a loss of pressure and result in low flow, stopping the water from being pumped through the waterfalls at the desired rate. Lastly, bespoke strainer baskets were fabricated in-house at T-T to further protect the pumps from any large debris that could cause a pump failure – due to the wild nature of the application, T-T needed to be able to guarantee an effective solution.

www.ttpumps.com

Wales. Working with Riventa to ensure our pumps operate as efficiently as possible is one of several critical steps we are taking towards Dŵr Cymru Welsh Water achieving net zero greenhouse gas emissions by 2040.”

www.riventa.com

www.bpma.org.uk Quarter 2 2023
Project Updates 12

Solutions for INDUSTRY

MOTION FLEET MANAGEMENT

Online monitoring and intelligent management of the equipment and assset fleet.

The ideal solution for monitoring and increasing the availability of your fleet equipment and assets. Based on cloud computing technology, motors, drives, gearboxes, pumps and compressors can be tracked and monitored at any time and from anywhere in the world. This allows planned and predictive maintenance avoiding costly downtime and ensuring the efficiency and performance of equipment.

MFM X2000 WEGscan App X1000
www.weg.net

RETROFIT AT ARDLEIGH TREATMENT WORKS

ANGLIAN WATER IS THE LARGEST water and wastewater recycling company in England and Wales by area, providing drinking water to more than 4.2 million households in the east of England. However, it’s not just clean drinking water that Anglian Water provides, with just over 5.5 million people also benefitting from wastewater services. The region covered by Anglian Water is approximately 27,500km². That’s around a fifth of the area of England and Wales.

When Anglian Water wanted to upgrade an old SAMI GS inverter serving a pump at its Ardleigh water treatment works, ABB Authorised Value Provider, Gibbons Engineering Group was approached to deliver the project. With a team of electricians and a vast knowledge base,

Gibbons was in a position to respond quickly to minimise any downtime caused by an outdated drive.

After removing the old inverter, a new 110kW ACQ580 variable-speed drive –specifically designed for water industry applications – was fitted, along with a new contactor, isolator handle, relays, potentiometer, and timer. Gibbons’ retrofit service included panel modifications to accommodate the new drive, along with fitting an emergency stop and reset on the panel door.

Once setup and commissioning had been carried out, the pump was put back into operation, with disruption to Anglian Water’s customers minimised.

As well as increasing the energy efficiency of the process, the new ABB ACQ580 drive

SELF-PRIMING MAG-DRIVE PUMP FOR LABORATORY APPLICATION

MICHAEL SMITH ENGINEERS provides a lot of pumps for laboratory applications. These pumps tend to be quite small and precise and are used in applications where the flow rate is relatively low. However, that is not always the case, and sometimes a customer has a laboratory application that calls for something a bit more substantial. One such customer was DQD Engineering, a company committed to designing and manufacturing accurate and high-quality process systems and pumping stations. They were asked to assist a client in the pharmaceutical industry, involved in the laboratory research of medical solutions against allergies and corona viruses. The project involved transporting base saline solution between laboratories via sterile, hygienic Flexsafe collapsible bags with a capacity from 50 to 1000l. For this application, they required a pump with particular attributes, and they came to Michael

has improved reliability, ensuring the site can provide uninterrupted service for residents and businesses.

www.gibbonsgroup.co.uk

Smith Engineers Ltd for a solution. The solution chosen by Roberto Mori, one of Michael Smith’s sales engineers, was a Finish Thompson SP series magnetically driven self-priming centrifugal pump directly coupled to a 2900 rpm single phase fixed speed motor. This pump was selected as it is self-priming, can run dry at the start/end of each operation and is resistant to the high temperature caustic soda cleaning solutions used for the sanitation of the units.

Gary Barker, Project Manager at DQD Engineering, said: “We approached Michael Smith Engineers with a requirement for 20+ pumps for emptying waste totes at a vaccine manufacturing unit in the UK; their engineer Roberto Mori worked with us from the design stage to ensure we had pumps suitable for the task.”

www.michael-smith-engineers.co.uk/

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

Project Updates 14

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Open up predictive maintenance with a reliability partner

Akshat Sharma, Global Monitoring & Controls Manager at ITT, looks at the benefits of taking a predictive approach to plant maintenance with condition monitoring, and explains how working with a reliability partner can overcome some of the barriers to its adoption.

We live in a world full of machines. From cell phones and cars to the pumps we manufacture and the industrial plants where they operate, we’re living in an age of technology never seen before.

Unfortunately, we also live in an age where machine unpredictability is a constant challenge. And while installing updates on our cell phones or getting routine maintenance on our cars is part of life, machine downtime in an industrial facility leads to lost time, money, and resources. Fortunately, the same advancements in technology that have brought about these new machines have also revolutionised how we monitor and maintain equipment.

REACTIVE VS PREVENTATIVE VS PREDICTIVE

The challenge many facility managers face is that most of their maintenance falls into one of two buckets: reactive or preventative. Reactive maintenance is simply corrective actions that happen after a breakdown. Extending the car analogy above, this would be taking your car to the shop after you get a flat tire. In other words, you have a problem, so you get it fixed. That’s great if you’re near a tyre shop, but if you’re out on the road, you’re looking at significant costs and lost time, in addition to a potentially dangerous situation.

It’s also easy to see how this applies to the industrial world. If a machine breaks, the repair process can be tedious, often needing a multistep diagnostic process since machine issues aren’t as easy to diagnose as a flat tyre. And if you don’t have the right technology or service in place, it could drain resources by requiring multiple different

employees to collect and analyse data before determining a solution. And every minute the machine is down, that could be hundreds or thousands of dollars in lost revenue.

To avoid these critical issues, many facility managers turn to preventative maintenance plans instead. Once again, using the car analogy, this would be the equivalent of rotating your tires every three to six months and checking the tire pressure routinely when you stop to fill up your tank. This is certainly better than simply relying on reactive maintenance, but once again, you’re incurring costs to take the car (or machine in industrial settings) out of commission to check for problems that may or may not exist. And there’s still no guarantee that a problem won’t arise between these check-in points and cause a significant headache.

Therefore, what we’ve seen in recent years is the advancement in technology that leads us to the future of maintenance, which is called predictive maintenance. In the car example, this would be the dashboard function that constantly measures your tire pressure, alerting you as it starts to drop and letting you know which tire may have a small leak.

In the industrial world, it’s the use of smart sensors that work by monitoring and logging different parameters such as vibration, speed, pressure and temperature, thereby capturing transient events and malfunctions in real time. This data can be quickly processed to identify developing issues and establish potential solutions. However, this takes knowledge and experience that industrial businesses don’t necessarily have in house. But this doesn’t have to create a barrier. By working with a reliability partner with

knowledge and experience, predictive maintenance, enabled by real-time condition monitoring, can offer substantial benefits.

FLEXIBILITY OF SERVICES

Companies can choose to be hands on with their analysis of this data or work with a monitoring partner who will ensure that problems with machines are quickly identified, evaluated, and resolved. Since many facilities may already have a process to maintain their machines, this solution allows for the program and resources to be optimised for faster and better results.

INCREASED PRODUCTIVITY

As we’ve established above, when something goes wrong, it wastes time, money, and resources. There could even be injuries or property and environmental damage that hurts the business. But staff training on using a condition monitoring system for enacting predictive maintenance can lead to a healthy and efficient facility. Educating operators about monitoring techniques and how to flag data indicative of a machine failure could resolve an issue before it causes a major shutdown.

STABLE, EXPERIENCED SUPPORT STAFF

Finding top talent in today’s environment is also a major hurdle for many

FEATURE 16 www.bpma.org.uk Quarter 2 2023 Condition Monitoring 16
“With advancements in technology, it’s clear that predictive maintenance will save facilities time, money and resources.”

manufacturers. Companies that do not have condition monitoring solutions tend to be very reactive, spending more money than necessary on diagnostics and solutions while incurring high costs of unplanned downtime. Working with sensors and a reliability partner can ensure uninterrupted support.

24/7 RISK MITIGATION

In today’s demanding manufacturing environments, technicians often wear multiple hats and can’t focus their undivided attention on monitoring equipment. For critical equipment and processes, having installed sensors for condition monitoring and a reliability partner at the ready ensures that unplanned events are not the norm. All the data is transferred in real time, where experts review it. In fact, most companies will find that the lead time for response will be reduced by approximately 50%.

There is no one right way to maintain your equipment, but with advancements in technology, it’s clear that predictive maintenance can save time, money and resources. Don’t get stuck waiting for a machine to break. Take control and have a pulse on your machines’ health with condition monitoring through sensors and a reliability partner. chevron-circle-right

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Condition Monitoring Quarter 2 2023
FIRE PUMP HORIZONTAL SPLIT CASE
FIRE PUMP END-SUCTION FIRE PUMP VERTICAL IN-LINE FIRE PUMP VERTICAL TURBINE
(HSC)
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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condition monitoring solution detects rotational direction

Flemming Munk, Chief Engineer, Condition Monitoring at Grundfos Water Utility, provides insight into what he believes is an exciting new condition monitoring solution developed by Danish start-up, EWA sensors.

As a pump manufacturing company, Grundfos is approached by companies offering condition monitoring solutions for our pump systems on a weekly basis. The business potential of condition monitoring and customer service agreements are huge, and this has triggered an explosion in the number of companies offering Condition Monitoring Solutions (CMS) that can detect every possible machine fault in rotating machinery. As a customer, it can be difficult to navigate between all the CMS offerings, but a simple and fundamental question is: “Can your system detect the rotational direction of my machine?”.

For a rotating machine, the RPM and direction of rotation are fundamental parameters, and if the CMS system is not able to measure these two parameters, the foundation for further detection of imbalance, bearing failures, gear issues etc., becomes a little frivolous. It is a good measure of the insight and understanding of rotational machinery that the CMS provides, and will flag, a ‘wannabe’ CMS system. A good CMS takes many years to build and demands deep technical knowledge about applications, signal analysis and sensor design. In this regard another interesting measure is the ISO 18436 certification level of developers. No certification is for me a clear flag, that they are in it for the quick win – I would never consider adopting such a system.

However, one system has recently caught my attention – the solution from EWA Sensors. EWA stands for Early Warning Analytics and it is a small start-up company from Denmark. The system measures a range of parameters including RPM, rotational direction, imbalance, cavitation and gear issues, and the founder is ISO 18436 Cat-IV certified from both Möbius Institute and Technical Associated from Charlotte PO - so the company passed the acceptance test .

THE EWA PLATFORM

The founder of EWA sensor has chosen to follow a different approach to what we normally see in this age of IoT devices. The sensor is a pure edge device with no cloud support and no human-in-the loop. All analytics are performed by the sensor, using a built-in Cortex-M7 microcontroller. It is a wired sensor for Modbus communication and with 24VDC power. All parameters are accessible to the customer through Modbus/SCADA. The sensor measures vibration, magnetic field and temperature and applies a combination of vibration signature analysis and motor current signature analysis, which make the parameter set very robust. It is a true plug-andplay platform with no pre-configuration of parameters, like motor pole pairs – the sensor will find the number by analysis. The sensor is designed as a pressure capsule and can be used in both dry installed and submerged (10m) applications. For water utility applications, there is generally no benefit in using wireless IoT – if we are going to use 50m of cable to the gateway, it is not a problem to use an additional 4m to the sensor. The sensor is equipped with four LEDs – for power, direction of rotation, Modbus communication and alarm/ machine health.

The sensor calculates a large number of condition monitoring parameters, but I want to focus on two that are new to the market.

ROTATIONAL DIRECTION

Many CMS seek to provide very high-level conclusions in relation to alignment, cavitation, bearing condition etc., but miss fundamental low-level operational parameters. When we are talking about condition monitoring for rotating machinery, it is important to know ‘is my machine rotating or is it standing still’ and if it is rotating ‘what is the rotation direction’ – counter

clockwise (CCW – negative RPM) or clockwise (CW – positive RPM). Many CMS cannot tell if a machine really is rotating as vibration on the line frequency is not a clear sign of an operating machine, it could be the adjacent machine. The EWA sensor measures the rotational direction of the motor every second and provides this information both through an LED on the sensor with CW (green), CCW (red) and no rotation (no light) and outputs it as a Modbus parameter. It sounds very simple, but I don’t see this feature very often. It is an important parameter, as rotational direction can be shifted after a service, if the power cables are incorrectly reconnected by mistake. Numerous real-life cases exist with sewage pumps that have been operating for years in the wrong direction, without anybody noticing anything other than lower performance. If a CMS is not able to measure rotational direction, it is not a condition monitoring system for rotating machinery, but a condition monitoring system for vibrating machinery.

As a side-effect of measuring the direction of rotation, the EWA sensor also detects whether the installation is a horizontal or vertical machine.

Quarter 2 2023 www.bpma.org.uk Condition Monitoring 18

HIGH RESOLUTION RPM

The rotation speed of the pump impeller is often regarded as a fixed number, but nothing could be more misleading. RPM is a time function, and the RPM fluctuation of a pump impeller contains a lot of information about the pump loading and the liquid homogeneity – this will be evidenced when the RPM is estimated with high time resolution, like every second.

The EWA sensor estimates both the RPM of the rotor rotation and the magnetic field rotations, and also the number motor pole pairs. RPM estimation from a pure vibration spectrum can be very difficult in environments with simultaneously operating machines (like a booster station), but this combination of vibrations signature analysis and motor current signature analysis makes the RPM estimation very robust. Figure 1 shows the magnetic (blue) and vibration (orange) RPM measurements from a sewage pump performing deragging to reduce clogging.

It is clear that the deragging is successful, as the fluctuation of the impeller RPM is reduced (the orange curve) after deragging.

As the sensor also measures the pump’s direction of rotation, the RPM is a signed variable. This is illustrated in Figure 2.

From the RPM measurement it is also

clear that every operation cycle is ended by a short reverse rotation – following the pump manufacturer’s requirements.

Another interesting feature of the EWA sensor, that I have not seen from other CMS providers, is its submerged robustness. The sensor has been pressure tested to 30m and approved to 10m. We are currently testing this with our mixer program, and the results look very promising.

The sensor provides us with a depth of insight into an application that is normally not accessible. Information about slip, RPM, 3D RMS, gear mesh frequency, etc. and corresponding baselines are now calculated with one second intervals, providing us with insights that we did not have before. This is valuable for both the pump manufacturer (in terms of pump performance and design considerations) and for the customer (to indicate machine

health and process performance).

CONCLUSION

The EWA Sensor is offered as a onetime purchase with no subscription fee, which makes the economic part simple. It is targeting customers with their own SCADA or cloud system for the display of parameters, baseline data and alarm handling. The sensor is glued onto the outside of the pump unit, or could be built into the pump, perhaps in the terminal box. The approach is generic and will work on machines with an electric motor with no specific brand required.

All in all, it is an innovative condition monitoring solution that is different from what is currently being offered by the CMS market. chevron-circle-right

www.grundfos.com ewasensors.com

www.bpma.org.uk Quarter 2 2023 Condition Monitoring 19
Figure 1. The magnetic (blue) and vibration (orange) RPM measurements from a sewage pump performing deragging to reduce clogging. Figure 2. As the sensor also measures the pump’s direction of rotation, the RPM is a signed variable.

Putting the engineering into reverse engineering

Huw Rodway, Global Re-Engineering Manager at Celeros Flow Technology, explains how taking reverse engineering a stage further and re-engineering parts when repairing pumps can offer a wide range of benefits.

Working with older flow control equipment can present challenges. For example, it can be difficult to source replacement parts for equipment that has existed for many years. Sometimes, the pump manufacturer is unknown, no longer in business or unwilling to support aged products.

Ensuring that spare parts are available for servicing equipment is key. However, how much time and effort is invested in locating spare parts? How frustrating is it to find pumps are obsolete? Would the traditional approach of replacing the worn parts with identical parts solve any issues or allow for any performance or reliability improvements to be implemented as part of the repair?

Likewise, new replacement pumps can be an expensive solution, especially since it is not only the cost of a pump that needs to be considered. A plant may have a complex layout, and replacing associated pipework may not be practical.

Throughout a pump’s life, there may have been alterations in operating conditions, duty or the medium being pumped now differing from the original design requirements. Operating equipment outside its design parameters will accelerate and exacerbate wear, corrosion, cavitation, and erosion, resulting in pumps no longer performing as required and, ultimately, premature failure.

Going beyond simply replicating a part, a solution to addressing these challenges is ‘re-engineering’, but what exactly is involved?

Part replication and reverse engineering generate like-for-like parts, potentially without any engineering assessment. Whilst this may deliver a spare part, it does nothing to address the root cause of any failure or poor performance experienced and could replicate the exact failure mechanisms.

By contrast, re-engineering takes a holistic pump repair and maintenance approach. By using an existing part only as a template and incorporating engineering

input, mating part analysis, component design optimisation, modern materials and manufacturing techniques, the enhanced solution can have an extended service life and lower total cost of ownership.

Re-engineered components are offered on multiple levels, with several benefits:

• Engineered replacement parts are a secure source of parts, particularly for obsolete items.

• Upgraded enhanced parts can be designed to last longer and solve recurring issues.

• Re-rated parts with altered hydraulic performance can realign a pump’s performance to current or future system requirements, extending its life.

• Upgraded and re-rated parts offer maximum life, performance, and benefit.

Therefore, whenever pumps require spare parts or repair, there is an opportunity to make changes, incorporating these additional benefits.

ENGINEERED REPLACEMENT PARTS

Perhaps the most apparent application of re-engineering is in being able to supply spare parts – particularly those that are no longer available or supported.

Re-engineering ensures a secure supply route for all future spares, giving long-term assurance.

If a pump is deemed obsolete, it is likely that a replacement pump would have a different footprint, making installing a new pump with different dimensions problematic. Re-engineering an obsolete pump’s internal components and casing allows these parts to be supplied as and when required. This mitigates the requirement to purchase a complete replacement pump, and allows the retention of the existing base plate, footprint and auxiliary equipment, thus saving significant expense and possible infrastructure changes. This is likely the fastest and most cost-effective solution.

The re-engineered parts can be designed to ensure replacement parts or sub-assemblies fit precisely with existing components. They can even be made compatible with a fleet of pumps, standardising parts to reduce inventory.

UPGRADED AND ENHANCED PARTS

What if the life of the components that require replacing could be increased? By reviewing the system and pump operations, carrying out route cause analysis of

www.bpma.org.uk Quarter 2 2023 FEATURE 20
Pump Repairs 20

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Pump Repairs

failures, and assessing current and future requirements and worn components, companies like Celeros FT that re-engineer parts can provide recommendations for mechanical and material improvements.

For example, rotor dynamics can be optimised to increase asset reliability. This could include improvements to shaft stiffness and wear ring geometry and the addition of swirl brakes.

The materials used for re-engineered parts can include increased corrosion and erosion resistance, which can extend service life and mean time between failure. Or hardened running surfaces can reduce wear and maintain efficiencies for longer, while modern composite materials can mitigate failures.

Bearing life can be extended with an engineering review of current bearing arrangements, appropriate guarding on housings, water in oil monitoring, and using composite materials for line shaft bearings.

Emission leakage can also be improved with upgrades from gland packing to mechanical seals and from component to cartridge seal assemblies.

RE-RATED PARTS

What if changes to operational performance are desired but have not yet been implemented due to concerns regarding feasibility and any impact on a pump’s health and performance?

Equipment efficiency can be improved to reduce running costs. Material enhancements, particularly of wear parts, can allow tighter running clearances, reducing recirculation losses while hydraulic surfaces can have efficiency coatings applied, reducing friction losses.

A pump’s performance can be aligned to system characteristics to establish the best efficiency point and optimise the reliability curve.

Output can be reduced to suit system or process changes. This may require the rotor to be de-staged or the impeller diameter reduced, or it could also include implementing a variable frequency drive. Similarly, the output can be increased. In either case, a detailed analysis of the impact on the motor and other drive train equipment would be undertaken.

A RAPID AND ROBUST PROCESS

For Celeros FT, the re-engineering process begins with a customer consultation to review the equipment details, operational issues, and performance to determine potential solutions.

Next, laser scanning is used to obtain data on the existing components – not just the parts intended to be replaced, but also mating parts.

Component materials are then analysed to assess potential upgrades and ensure the compatibility of existing and replacement parts.

The data captured at this stage is stored for future reference when there is a demand to supply a part. This methodology facilitates scanning parts when they are available for future requirements.

Based on analysis of all the available data, new components are designed, material grades specified, and manufacturing quality plans are generated. 3D models are created to facilitate CADCAM and additive manufacturing for casting purposes. Computational fluid dynamics and finite element analysis benchmark and validate designs.

Finally, parts are manufactured to stringent quality requirements, rotating components are balanced to applicable grades, pressure-containing parts are hydrotested, and parts are QA/ QC approved before being shipped or incorporated into an overhaul at a Celeros FT Service Centre.

ADDING VALUE

One example where re-engineering added value to a customer of Celeros TF was a UK Oil & Gas operator that required a solution when its (2.5 MW) 12-stage BB3 sea water injection pump failed in service.

The customer consultation defined that the pump, providing seawater injection duty to support field production, required a solution which increased the mean time between failure and optimised its performance.

Celeros FT worked with the customer to improve critical features within the pump, including upgrading the mechanical seals and modifying the existing bearing housings to allow for the provision of bearing isolators.

During a strip inspection, several impellers were shown to be damaged beyond repair. Even with the extensive damage, Celeros FT could re-engineer the hydraulic components appropriately.

Damage to the rotating assembly had resulted in areas within the stationary components that needed repair. The large and heavy top and bottom half pump casings were repaired and machined back to the design intent, re-inspected

and hydrotested to the project duty requirements.

3D models of the pump casings were then used as the basis for the mechanical layout. Given the large number of stages, a thorough assessment needed to be completed to ensure full mechanical integration between the mating components, especially when both existing and re-engineered parts were being used.

The shaft was re-engineered and upgraded, and a full rotor dynamic assessment of the pump unit, including a lateral critical speed analysis in accordance with API 610 Latest Edition, was completed.

This assessment, coupled with an in-house performance test at full speed (4000rpm), pressure (>2000m head) and power, gave the customer confidence that the re-engineered and upgraded pump would perform as required.

CONCLUSION

To ensure critical flow equipment is working to its best, operators need to consistently evaluate equipment behaviour and act quickly to rectify any problems. Reengineering can provide the appropriate engineered solution to overhaul, upgrade, renew or replace older legacy equipment, optimise operation, and simplify spare parts management – irrespective of pump brand – to minimise downtime, reduce total cost of ownership and save the expense and disruption of having to install new systems throughout a plant. chevron-circle-right

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FEATURE 22 www.bpma.org.uk Quarter 2 2023
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Identifying poor assets and inefficient pumps

Despite soaring prices brought on by an energy crisis that shows no signs of diminishing, ask pump and blower operators about the efficiency of their equipment, and the truth is that most don’t know – according to the monitoring technology provider, Riventa.

Pumps might often be described as ‘working fine’ and ‘doing their job’, but is that, now more than ever, a strategy? How about saving money now and in the future?

“The opportunity to truly maintain, protect and optimise assets is here and now, with a Return on Investment (ROI) that is shorter than ever”, said Julian Lowe from Riventa. “The cost of solving asset management challenges is on a much smaller scale than most companies imagine”.

So, how can you make hidden costs more visible?

At a minimum, put some testing in place. By obtaining accurate, quality data, this first proactive step will give you a snapshot of performance, health, and efficiency. Even this entrylevel testing will help identify poor assets and inefficient pumps.

Julian added: “All we hear about at the moment, understandably, is the massive hike in energy prices, so best test your pumps (and blowers and turbines) to reduce energy consumption and maximise savings. This will almost immediately help identify actions to improve performance. In addition to pump efficiency, measuring key parameters such as flow rate, head and electrical power, current pump performance characteristics can be compared to ‘as new’ and ‘post-refurbishment’ conditions. This provides the same accuracy as a pump manufacturer’s test facility – but with the distinct advantage of real operating conditions”.

Across numerous industries, where for some, running pumps until destruction is the modus operandi, Julian has a point. He claims that the ROI can be as little as 18 months for

larger pumps, blowers and turbines.

OPTIMISATION

A level up from pump testing is to look at an Optimisation Service, utilising secure on-site pump monitoring equipment to provide real-time data. This enables users to start seeing what’s happening across a system by capturing data over 14 days or longer. This doesn’t have to involve tons of ‘spaghetti’; systems can now be cable-free and up and running in around one hour per pump – at low risk and with minimal disruption to existing operations.

Dr Tom Clifford from Riventa explained: “Once in place, realtime data for each asset can be evaluated, with information-driven insights highlighting performance issues and supporting decisions. This can establish best practice recommendations, realistic payback calculations and a business case for moving forward – all backed by precision measurement and innovative analytics”.

Riventa has recently worked with a food manufacturer in testing the company’s cooling system, which is

split into two pumping sub-systems. Five factory pumps send chilled water from heat exchangers to the factory, and evaporator pumps send chilled water from the factory to refrigeration heat exchangers.

“To test the pumps, we used the thermodynamic measurement technique (with our specialist software) to measure suction and discharge pressures on either side of the pump, differential temperature, and motor input power,” explained Tom. “These measurements enabled us to calculate differential head across the pump, hydraulic efficiency and volumetric flow. The pumps were altered gradually. After each change, a test point was taken while allowing enough time to obtain the best statistical average. Tests also involved a routine of testing performance at an incumbent set point, followed by throttling the pump to reduce its flow rate. The latter action allowed other pumps running in parallel to increase in speed to compensate, with a final test point taken at that moment.”

Tom continued: “Throttling meant we could observe the maximum

www.bpma.org.uk Quarter 2 2023 FEATURE 24
Pump Efficiency

possible flow through each pump under test without altering the overall flow to the plant. At times this was challenging because conditions downstream in production would change, altering the cooling load and, in turn, the flow set point. Nevertheless, good quality performance information was obtained.

“We found that all pumps were showing signs of wear. Moreover, manufacturer performance levels were not being achieved. None of the pumps we tested reached the manufacturer’s best efficiency point (BEP) (81%). In fact, the maximum pump efficiency possible was found to be 75% (achieved by pumps one and two only). Our findings enabled us to put pumps into a descending order of repair: one to five. While pumps one to three achieved a good relationship between power and flow, pumps four and five did not perform at lower flows. This indicated a high likelihood of internal recirculation – from high to low pressure parts of the impeller –

being caused by high wear. We built a strong case for robust savings through the pump refurbishment. Broadly, two options were made available. The first was a basic refurbishment which involved applying an internal coating and replacing wear rings, bearings and seals. The second, more comprehensive refurbishment included the elements in the basic refurbishment, plus a new tailored impeller.

“We calculated that pump refurbishment would bring potential savings of £19,200 per year, with possibilities to refurbish two, three or five pumps”.

This is just one example of what Riventa says it is helping companies achieve across a range of industries that include water, power, mining and petrochemical.

Advanced pump monitoring

and optimisation are available too, continuously focusing efforts by evaluating and understanding performance gains across priority pumps and sites. And for some organisations, full optimisation of networks is available.

CHANGING MINDSETS

“Nobody wanted an energy crisis,” concluded Tom, “but as prices soar, we are beginning to see a change in mindset about just how important it is to know how your assets, such as pumps, blowers and turbines, are really performing. Initially, some basic testing might reveal some not altogether pleasing facts, but you can soon put yourself on a positive course to make some excellent, ongoing savings”. chevron-circle-right

www.riventa.com

FEATURE 25
“We calculated that pump refurbishment would bring potential savings of £19,200 per year.”
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How does MEI affect me

When pumps account for half of a typical industrial plant’s running costs and studies show the vast majority are running inefficiently, there are opportunities to reduce running costs and carbon footprint whilst maximising uptime and profitability.

James Dashwood, Managing Director at Crest Pumps, explains how focusing on the minimum efficiency index of pumps and their wider systems can help.

Because of the significant potential for energy savings in pumping systems, EU Regulation

EU 547/2012 sets out minimum efficiency requirements for water pumps, expressed by the Minimum Efficiency Index (MEI), a ratio of the actual efficiency of a pump to the best efficiency point (BEP) for that pump type. The MEI rating considers the hydraulic efficiency of the pump, the motor efficiency, and the power factor of the motor. An MEI of 1.0 indicates that the pump is operating at its highest possible efficiency, so the higher the MEI rating, the more efficient it is.

In 2009, an EU commission mapped out all the pumps available on the market and measured their efficiency. Based on this, they decided that the least efficient 10% of pumps would be removed, meaning pumps with an MEI of 0.1 or less. Since January 1, 2015, all pumps must operate with an MEI rating of more than or equal to 0.4. Any pump with an MEI ≥0.7 exceeds the highest efficiency standard set.

What are the benefits of a pump with an MEI greater than 0.7? The first benefit is lower operating costs. A pump with a higher MEI will consume less power, which translates into lower operating costs resulting in significant cost savings over the pump’s lifetime. A further benefit is a reduced carbon footprint. An energy-efficient pump will also have a lower carbon footprint, helping users achieve their corporate sustainability goals. A pump with a higher MEI will also have improved reliability, resulting in less downtime and reduced maintenance costs.

This Regulation only applies to rotodynamic water pumps for pumping clean water and includes end suction and vertical and horizontal multistage pumps. Even though MEI doesn’t currently include chemical-resistant pumps, the Crest Assoma AVF-X range has been developed to be one of the first magnetic drive thermoplastic pumps to exceed the highest standard set above 0.7. Choosing any pump that exceeds this standard means you can rest assured knowing you are using one of the most energy-efficient pumps available and benefiting from exceptional energy savings in your production processes whilst reducing your overall carbon footprint.

THE BIGGER PICTURE

The pump, however, is just one element of a pumping system. The Extended Product Approach (EPA), developed by Europump and supported by the British Pump Manufacturers’ Association, calculates the Energy Efficiency Index (EEI) of an Extended Product (EP) – which covers the pump, its drive motor and a variable speed drive if used – and incorporates load profiles and the control method. The EEI is derived from the total efficiency of the pump unit at different loads. This system approach focuses on optimising the energy consumption of the pump unit in the actual flow system it is intended to operate and to ensure that only the electrical energy necessary to achieve the required performance is used.

When looking solely at the pump, an MEI rating of 0.4 can save 5TWh a year in the EU,

but with the extended product approach, there is the potential to save 59TWh annually. So, taking a wider perspective can create much more significant energy savings and all of these worldwide savings start with the pumps in your factory.

Today, an ideal pump set up will consist of a pump with an MEI greater than 0.7, an IE4 (or even IE5) motor, plus an inverter. But with a higher initial cost outlay, you want to ensure you get an adequate return on investment. For peace of mind, investigate the entire Life Cycle Cost (a helpful comparison tool can be found at bit.ly/CrestLCC), which considers every area of cost when it comes to the operation of a pump over its estimated life. You can then compare the two and find out how long the payback will be for the higher efficiency option compared to the higher running costs of the cheaper pump. chevron-circle-right

www.crestpumps.co.uk

www.bpma.org.uk Quarter 2 2023 FEATURE 26 Pump Efficiency 26
Although MEI regulations don’t currently cover chemical-resistant pumps, the Crest Assoma AVF-X range has been developed to be one of the first magnetic drive thermoplastic pumps to exceed the requirements.

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Vibration modelling eliminates Pumping Station’s Critical Resonance Frequencies

Asset reliability specialist Van Geffen Reliability, which is part of the AES Reliability Group, explains how it used Finite Element Analysis to predict the vibration behaviour of a large sewage pumping station, using the results to optimise the design to reduce the potential for damage to the system once in operation.

Finite Element Analysis (FEA) uses mathematical models to understand and quantify the effects of real-world conditions on an asset.

FEA can be used to model a modification to an existing asset or for a newly developed asset design and is an essential tool when design functionality is absolutely critical.

The analysis carried out on a pumping station design included a numerical modal analysis and harmonic response simulations to predict the vibration behaviour of the pumping station.

A numerical modal analysis is a technique used to determine the mode shapes (vibration patterns) and resonance frequencies of structures and systems. This is done through FEA calculations to simulate and analyse the dynamic behaviour of structures. In numerical modal analysis, the ‘free vibration mode’ is calculated, meaning no external forces are applied to the system.

When carrying out an analysis of the sewage pumping station, in the operating range of the pumps (1x speed range of 5001000 rpm) two critical resonance frequencies were calculated, which will be excited by the first order vibrations of the pumps. These are shown as the two black dots in Figure 1.

A harmonic response simulation is an analysis of the response of a system or structure to an excitation force with a constant frequency. This simulation is used to determine the vibration amplitude and sensitivity to different resonance frequencies, providing insight into preventing harmful vibrations and improving the overall design. A model of this can be seen in Figure 2.

In the operating range of the pumps (1x speed range of 500-1000 rpm) the following load cases were calculated:

• Imbalance force on all five pumps: equivalent to balance grade 6.3.

• Pressure pulsation on the piping: 1% to 5% of operating point 4 (24.5 mwk = 0.245 MPa Long-Arrow-Alt-Right 0.003 and 0.015 MPa).

A response of 17.8 mm/sec RMS is calculated, which implies a pipework vibration concern factor of 3.0.

THE SOLUTION

To prevent high vibrations, the starting point is to have no resonance frequencies of the main piping system in the operating range of the pumps (1x rpm). The resonance frequencies that have been calculated can be shifted by adjusting the support stiffness. Reducing stiffness will lower the resonance frequencies but risks lowering

the current resonance frequencies below the operating range and into the operating range of the pumps. Increasing stiffness will raise the resonance frequencies, with the goal of placing all (main) resonance frequencies of the installation above the operating range of the pumps. chevron-circle-right vgreliability.com

FEATURE 28 www.bpma.org.uk Quarter 2 2023
Figure 1. Figure 2.
Reliability 28
Increasing support stiffness moves the main resonance frequencies above the pump’s operating ranges.

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A fire extinguishing system with maximum flexibility

Power management specialist, Eaton, explains how Alfred Schneider GmbH, a leading manufacturer of protective cabinets for fire extinguishers and water-based fire extinguishing products, has used its DG1 variable frequency drive to develop a highly flexible variable-speed booster pump system that can be adapted to a wide range of requirements, for example buildings with multiple pressure zones.

The booster pumps in fire extinguishing systems ensure enough water is available at the hose connection points or fire hose reels installed inside a building. The system uses a pump to increase the water pressure in the pipes to the required level. But, despite all the recent developments in drive technology, pumps are still often switched using contactors. “This particular industry is very conservative when it comes to new technologies,” said Lars Biskupek, Head of Fire Protection at Alfred Schneider GmbH. “In general, people are sceptical of electronic systems because it is often believed that they offer limited reliability in an emergency.”

THE DISADVANTAGES OF CONTACTORS

The traditional design of contactor systems comes with certain disadvantages: On the one hand, waterbased fire extinguishing systems that are switched using contactors can only run at a specific speed, so the pump power and water pressure cannot be adjusted. This is sufficient for ‘simple’ fire extinguishing systems. This type of contactor-based set-up gets more complicated; however, if different extinguishing devices need to be connected to the same water pipe, each of which requires a different level of pressure. On the other hand, starting the pumps this way also generates a high starting current. This places a high load on the grid and the entire electrotechnical equipment. During operation, i.e. when pumping large amounts of water for fire extinguishing purposes, overcurrents can also occur, as Lars explained: “The pumps have been designed with a specific capacity in mind. If this capacity is exceeded – for example, because water is taken from too many fire hose reels at the same time – the system will operate outside its intended characteristic curve,

which will result in an overcurrent. As the applicable standard prohibits the use of motor-protection devices to prevent the motor from shutting down, there is a risk that the emergency generator will fail as a result.” For Alfred Schneider, this was the decisive factor in the decision to redesign the drive technology of its booster pump system so that it could be safely powered by emergency generators.

THE PERFECT SOLUTION

The company decided to use variable frequency drives to develop a fire extinguishing system with a variablespeed booster pump. The contactor was thus replaced with an Eaton PowerXL DG1 variable frequency drive. “The DG1 comes with an integrated fire mode as standard,” which according to Lars, was one of the reasons the company chose this particular product. This fire mode –which is also offered by Eaton’s compact DC1 drive for less complex applications – deactivates the internal protection functions. When this mode is activated,

the motor-protection devices in the pump circuit will only be used to signal a fault but not to shut down the pump. As such, the drive also meets the requirements of DIN 14462 and the VdS guidelines. If the booster pump system itself is exposed to fire, smoke or high temperatures, it will continue to operate even if the thresholds or response values are exceeded, reliably supplying the fire hose reels or sprinklers with water for as long as possible. The fire mode can be configured using a range of options, including fixed setpoints, switchable setpoint inputs and fail-safe activation. The DG 1 is also robust and heat-resistant. Alfred Schneider uses an IP54 variant that can be installed outside the control panel and therefore requires no ventilation or cooling.

SAFE CURRENT LIMITING

“Most importantly, however, the drive also comes with a current limiting function,” added Lars. On the one hand, the drive can be configured in such a way that the starting current does not exceed the rated > 32

FEATURE 30 www.bpma.org.uk Quarter 2 2023
Operating the DG1 drive is easy, thanks to the user-friendly display directly on the device. To prevent tampering, the entire display can also simply be removed after a maintenance intervention.
Building Services Focus 30
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current of the emergency generator. As a result, the generator can be configured based solely on the requirements of the other building services – the high starting currents that were caused by the contactor-based system in the event of an emergency (or during tests) no longer need to be taken into account. For operating the equipment under emergency conditions, Alfred Schneider’s experts have also programmed the DG1 to reduce the speed in the event of excessive current consumption. Although this reduces the water pressure at the outlets, the current will be back to normal – thereby protecting the emergency generator against damage or even failure. This considerably increases the operational reliability of the entire system.

UP TO FOUR PRESSURE ZONES

Controlling the booster pump system by means of a variable frequency drive also offers additional advantages: “We can achieve a very high level of flexibility in terms of adapting the system to local conditions,” continued Lars. “For example, the DG1 makes it possible to configure up to four different pressure zones. This means, for instance, that the speed can be controlled in such a way that each outlet is supplied with the appropriate level of pressure for that particular type of outlet. We implemented this in the fire extinguishing system of an industrial facility, where the same system is used to supply water at 1.5 bar to fire hydrants and at 4 bar to fire hose reels”. The outlets are equipped with contacts, thanks to which the drive ‘knows’ which outlet has just been opened, and will then ensure the necessary level of pressure by adjusting the pump speed. “Depending on which extinguishing device is used, we can optimally adjust the pressure in the pipe via the variable-speed booster pump system,” noted Lars.

In another application, Alfred Schneider installed a variable-speed booster pump system to compensate for a leaky underground water pipe and to ensure sufficient levels of pressure. As soon as the pressure in the pipe drops below 0.5 bar on account of the leakage, the drive will start up the pump and bring the pressure level. And in the event of a fire, the pressure level will be raised to 6 bar while the water is being drawn. In addition, the pressure can also be readjusted via the variable frequency drive: If a hydrant is opened, for example,

the pressure in the pipe will drop. With variable speed control, the pump output can be gradually increased until the desired or required level of pressure has been restored. The level of pressure is monitored by means of a pressure sensor inside the water pipe.

DIFFERENT PRESSURE ZONES

In high-rise buildings, the Eaton DG1 can also be used to configure up to four separate pressure zones. If a fire hose is opened on a particular floor, the drive will raise the pump output only to the level that is actually required to ensure the right amount of pressure. For this purpose, a limit switch is installed at each outlet – i.e. at the fire hose valve –that will indicate if it has been opened. Via fireproof cables (which are also monitored for open/short circuits), the switches are individually routed to the control system, which will then communicate the required pressure level to the drive, depending on which valve is actually open. As such, the control system receives reliable information about the exact floor and pressure zone where the fire is being fought. However, this is a custom solution that may only be implemented with a special permit from the responsible fire protection authority in Germany. Multiple pressure zones are only mandatory for buildings higher than 35m. So far, one pressure zone was sufficient for most of the systems that Alfred Schneider has implemented because the height of the buildings (including numerous apartment buildings in Hamburg) did not exceed 30m. While the system relies on conventional wiring, Eaton’s DG1 also offers communication interfaces for various bus systems, including Ethernet and BACnet, which

are widely used in building services engineering.

Thanks to the DG1 drive from Eaton, Alfred Schneider was able to develop a variable-speed booster pump system that can be adapted to various building types and requirements. By reducing the load, the drive’s integrated current limiting function also enables the use of smaller emergency generators – but more importantly, the drive protects the generator against overcurrents. All in all, this reduces the power consumption of the entire system, which also lowers the capital costs. By using contacts or pressure sensors to control the system, different levels of pressure for different outlets can easily be implemented. In addition, the ‘soft’ starting of the pump protects the entire system and subjects it to significantly less mechanical stress compared to switching via contactors. chevron-circle-right

FEATURE 32 www.bpma.org.uk Quarter 2 2023
www.eaton.com Building Services Focus 32
For fire hose reels, the water pressure needs to be between 4.5 bar and 8.0 bar. Consequently, pressure zones are normally only mandatory for buildings whose height exceeds 35m pump speed.
Engineered Design Multistage Pumps Vertical Configuration HS RANGE HP RANGE ISF RANGE API RANGE ISO 5199 Pumps in Custom Alloys Coatings API 610 12th Edition Custom Pump Arrangements Kiwa UK Regulation 4 (KUKreg4) The Kiwa UK Regulation 4 Product Approval Scheme (KUKreg4)a robust method for demonstrating compliance with the Water Supply (Water Fittings) Regulations 1999. E: jonathan.price@kiwa.com W: www.kiwa.co.uk/water T: +44(0)1495 308185

Drainage solutions Make complex projects a reality

Drawing on real-life examples, Saniflo looks at of how macerators and pumps are used to overcome severe drainage challenges.

For the past 60 years, Saniflo macerators and pumps have been used behind the scenes to solve complex drainage issues in domestic and commercial projects, and in many cases, you’d never know it. Many buildings rely on macerators and pumps for the smooth functioning of bathrooms, kitchens, laundry rooms and extensions, and in commercial projects, macerators and pumps can guarantee business continuity. Sometimes these rooms are in the most unlikely of places, such as a shed at the bottom of a garden that’s become an artist’s studio, a garage-turned master bedroom with luxury en-suite, a basement converted into an apartment, a glamping site, an ancient historic building converted into a hotel, and much more.

Macerators and pumps are the perfect choices for a bathroom, en-suite, cloakroom, utility room, laundry room, kitchen or any other type of ‘wet area’ where mains drainage is a problem. As long as a water supply can reach the area, you can create any wet area you like with macerators and pumps. They work by taking wastewater – and macerating the contents where necessary – and pumping it away from the area to the site of the mains drainage, wherever that may be. This means you don’t have to worry about digging the ground to create main drainage facilities. This can save time, money, mess and hassle.

The SFA UK (Saniflo) range of Sanifos 1600/2100/3100

underground lifting stations can be tailor-made to any project requirements. With over 90 configurations possible, there

is an option to efficiently discharge black and grey water waste from any domestic or commercial application, whether one large public building or several smaller buildings. Three differing tank sizes hold 1,300, 1,600 or 3,100 litres, respectively and can be specified with either one or two cast iron Sanipump displacement pumps in singlephase or threephase and in five power options. When twin pumps are chosen, these operate alternately to ensure continuity of service. In the unlikely event that one fails, the other will take over its operation. Installed below ground near the building they service, these Sanifos pumps lift wastewater to sewage level. Three covers are available: Class A, B and D. The latter makes the lifting station suitable for installation within a road as the cover can withstand 40 tons.

WHEN GRAVITY DOESN’T WORK

SFA Ireland helped a modern new property come to life by providing a solution to take the waste from

the whole building. The house is situated on a hillside in a residential street in County Tipperary, Ireland, but its position is lower than the main sewer, rendering gravity drainage impossible. Working within guidance and recommendations from Irish Water, an engineer proposed a Sanifos 2100 with a ZFS twin pump installed, and it has been fully operational for over 12 months. With an impressive 1370-litre tank to guarantee plenty of capacity, the Sanifos 2100 pumps waste from two bathrooms and a range of kitchen appliances. With multiple connection points on the unit, all waste is channelled by gravity through standard sewer pipework to the Sanifos, which is activated automatically and discharges the waste through DN50 pressure pipework to the sewer on the main road which is some 60m away horizontally, but also 10m above the location of the property.

Robin Jackman of SFA Ireland oversaw the project and proposed the Sanifos solution: “The beauty of this pumped solution was the huge savings made over the civil work that would have been required to install gravity drainage. The builder would have had to raise the house, drive

www.bpma.org.uk Quarter 2 2023 FEATURE 34 Building Services Focus 34
The Sanifos 2100 lifting station can be tailor made to a project’s requirements

and garden to get sufficient falls to the drainage. This would have also added a lot of cost and time to the project, whereas the Sanifos was cost-effective and quick to install by comparison.”

SFA UK has successfully completed a wide range of quirky projects that rely on macerators and pumps, including a new build that was featured on the TV programme Grand Designs when a young London couple turned a tiny 38m² house into a two-bedroomed, two-bathroom property: a fantastic feat of design for such a small house. The quirky home features a basement and six half floors. One bathroom sits half a floor down from street level and uses a pump to take the waste to the discharge point. The industrial-design wet room features a shower, basin and WC, each feeding into a macerating pump directly beneath the wall-hung WC in the basement. The pump also takes waste from a washing machine in the basement and has additional outlets to connect future appliances. It is quite an achievement, and by having a second bathroom, the couple can add significant value to their property.

Macerators and pumps also come in handy in old buildings. Built in 1813, The Old Watermill in Durham was originally a flour mill, with a house which was added 50 years later. Before the conversion, the mill stood derelict for 60 years, and the house was empty for 15 years. Today, this stunning building houses two two-storey luxury apartments. The bathrooms of one of the apartments are below ground level. Here, a pumping station takes the waste from the basins, WCs and showers to the ground-level main drainage. In the other apartment, two units provide drainage for two en-suites, and a macerator pump enables the smooth functioning of a cloakroom off the kitchen diner.

SUPPORTING A LIFE AFLOAT

Not all homes in the UK are bricks and mortar. A World War I ammunition carrier converted into a houseboat at Kew Bridge on the River Thames, relies on a

combination of macerators and pumps for all its drainage needs. Amazingly, this property has four double bedrooms – one of which features an en-suite complete with bath, shower, basin and WC – a kitchen, a cloakroom, a main bathroom, a lounge with dining area and even a utility room. No job is too complex when using the right combination of macerators and pumps.

Sometimes even ‘normal’ houses require macerators and pumps. One example is a three-bedroom 1930s terrace in Ruislip built with no soil or vent pipes at the back or front of the house, only a rainwater gully. One upstairs bedroom had a shower in the corner but wasn’t a complete en-suite. To complete the en-suite, the owners wanted to fit a WC and a basin, but there was no mains drainage, and the space in the corner of the bedroom beside the shower was tiny. Using macerators and pumps, it was possible to pump the waste vertically into the roof void above and horizontally across the loft to drop down to the ground floor, entering the ‘S’ trap discharge spigot at the back of the existing WC. By providing this tiny additional en-suite area, the owners were able to make

their lives more comfortable and add value to an old property. Here you have a series of apparently unsurmountable drainage challenges; in each case, macerators and pumps provide a good solution. Next time you face a challenging drainage scenario, consider using macerators and pumps before saying the job’s impossible or going ahead with excavation works. Be sure to consult SFA UK’s portfolio of products and obtain expert advice from approved engineers, plus quality products backed by a guarantee and aftercare should you need it chevron-circle-right www.saniflo.co.uk

Quarter 2 2023 www.bpma.org.uk
A combination of macerators and pumps support this Thames-based house boat’s drainage needs
Building Services Focus
The lifting station is suitable for installation within a road as the cover can withstand 40 tons.
Building Services Focus 35
Being lower than the main sewer was not an issue at this Tipperary house thanks to a Sanifos 2100 with a ZFS twin pump installed

Control noise in booster pump systems

Mawdsleys Pump Services looks at reasons why booster pumps make noise, how you can control it and essential regular maintenance checks you can carry out to ensure pumping systems run efficiently without generating excessive noise.

The key reasons booster pumps make noise are higher water demand than the pump can facilitate, an incorrectly positioned pump, worn components such as bearings, old or unmaintained pumps, and excessive vibration from the pump pipework within the building.

Thankfully, with a few controls and proper maintenance, noise from booster pumps can be adequately controlled without impacting the performance of the system

USE THE RIGHT PUMP FOR THE JOB

Using the right tool for the job is key to achieving any task, and it’s the same with your pumping system. In older buildings, older and inefficient systems are often used to boost water pressure.

Not only does this mean lower efficiency and higher bills, but when everyone in the facility uses water, such as the morning shower, all pumps in the booster set are needed to provide adequate water, creating excessive noise.

In an efficient system tailored to building requirements, the whole bank of boosters would never need to run simultaneously to supply the required water.

POSITION THE PUMP CORRECTLY

Following the selection of the most suitable pump for the job, the location of the pump is essential for achieving zero sound disruption. In most cases, it is recommended that the pump is installed in an enclosed space, such as a soundproofed control room.

If your pump is already set in place and relocation would be impractical and expensive, erecting a control room or sound barrier around the pump is still possible to reduce noise.

USE VIBRATION ISOLATORS

One of the most common causes of noise from booster pumps is vibration. Vibration generally comes from the pipes or the pumping system itself vibrating against the structure of the building.

Using vibration isolators is a cost-

effective way of reducing noise from a pump – the most effective method will depend on the level of vibration a system is producing:

Low vibration level – If a pumping system produces a low noise and vibration level, a vibration mat is a simple and cost-effective control method. This is essentially a thick mat or pad on which the pump is placed to prevent vibrations from being carried up the building.

Mid-level vibration – If a pumping system produces a medium level of noise and vibration, vibration springs or mounts can be fitted, which absorb the vibrations from the pump.

High vibration – If a pump produces a high level of vibrations, an inertia base can be constructed. This is a robust measure that will absorb the maximum amount of vibration.

Vibrations from pipework – If the vibrations come from the pipes instead of the pump, fitting vibration isolators such as springs to pipework will prevent them from vibrating against the building.

Of course, if a pump is vibrating excessively or the vibrations are getting worse over time, it could be that vital components within the pump have become damaged, and a specialist inspection would be required.

noise and further damage to the system, it is essential that these components are regularly inspected and replaced as required.

Putting a proper pump maintenance plan in place is the most effective and cost-efficient way of controlling noise and preventing failure within a system. A weekly visual inspection should ensure problems are spotted before they evolve. The inspection should include checking all valves for free travel, checking water and air pressure gauges, testing alarms and inspecting and lubricating bearings as required. It is also important to regularly check for any damage to the pump or any of its main components, taking note of any unusual noises or ‘struggling’ from the system during start-up. A note of any excessive vibration or unusual noise from the pump should also be taken, as should the temperature within the room.

Mawdsleys has created a free inspection checklist for use by responsible persons, which can be downloaded from its website. chevron-circle-right

www.bpma.org.uk Quarter 2 2023
Building Services Focus 36
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Restricting PFAS: It’s not as simple as it sounds

Wayne Rose, Secretary of the Europump Marketing Commission and newly appointed CEO of the BPMA, explains the pump sector’s position in relation to the restrictions of using Per- and polyfluoroalkyl substances.

For many years, Europump, the Association of European Pump Manufacturers, has been at the forefront of the health & safety, environmental and sustainability agenda, advising and lobbying Governments as they look to update and improve the legislative landscape for industry.

It is commonly recognised that pumps and their related equipment are essential for many applications affecting daily life. From central heating and water supply in our homes, sewage and wastewater treatment in our cities, through to the extraction and processing of raw materials to manufacture finished products, pumps and pumping systems play a fundamental role. Industrial applications can range from water treatment, food processing, chemicals, oil & gas, mining, paper mills, firefighting, dredging, waste removal and many more. Future applications linked to the allimportant green transition would include the transportation and storage of hydrogen, geothermal, and other green gases.

Due to their unmatched thermal and chemical resistance, unique tribological properties, and any combination of these characteristics, Per- and polyfluoroalkyl substances (PFAS) containing materials are used in virtually all of the applications outlined above, as sealings, bearings, cable sheaths, coatings, pump inserts and membranes. However, given that PFAS materials, are up to 100 times

more expensive than any of the natural or synthetic elastomers, they are only used in those cases where absolutely no alternative is available, and currently no alternative material can guarantee the same levels of performance, safety, and lifetime.

Therefore, any substitution with other, less suitable, materials would lead to rapid failures and leakages, which could result in the release of aggressive media, harmful gases or steam, which could, in turn, cause serious injury to both humans and the environment.

Furthermore, the challenge faced by the lack of PFAS-free alternatives for essential use is not limited to pump applications. It applies equally to other key pieces of equipment, such as valves and compressors in downstream industries like pharma, chemicals, petrochemicals, and aerospace. Additionally, some electronic components which are critical for the safe and efficient operation of these applications also require the use of PFAS.

So, although Europump fully supports any regulations aimed at preventing PFAS substances from entering the environment, it must be stated that in certain pump (and other related product) applications, the use of PFAS remains essential due to safety, efficiency and

functionality concerns. And given that no suitable substitutes for these specific applications are currently available, the use of PFAS materials should remain possible so that the pollution of the environment by other acutely hazardous substances can be prevented, and any harm to humans is avoided.

Europump’s full position statement on the restriction of PFAS materials can be downloaded from the Europump website at bit.ly/EuropumpPFAS, or you can request a copy by contacting s.smith@bpma.org.uk

www.bpma.org.uk Quarter 2 2023 FEATURE 38 Opinion 38
“In certain pump applications, the use of PFAS remains essential due to safety, efficiency, and functionality concerns.”

Here’s your chance to shine!

The BPMA’s annual Pump Industry Awards programme has been recognising and rewarding the achievements of pump businesses, large and small for over two decades. Throughout that time it has become one of the leading events to serve the industrial and commercial arena. So, if you or your company have a pump related success to shout about, these awards provide the perfect platform.

The gala presentation dinner caps off the awards programme in style, providing excellent networking opportunities, great food and superb entertainment. It’s your chance to celebrate with colleagues, interact with peers, entertain customers and be part of the pump industry’s biggest and best celebration. Manufacturing and distribution prowess, product development and application, environmental consideration, skills development and customer support will all be acknowledged through this wide reaching awards programme. So why not consider which of your engineering successes are deserving of industry wide recognition, and be sure to join us at our wonderful venue - the home of English football - on Thursday 14th March 2024.

Event Calendar

Nominations Open : 1 st August 2023

Nominations Close : 5 th January 2024

Judging Session : Mid-January 2024

Voting : 12 th -16 th February 2024

Winners Announced : 14 th March 2024

Award Programme Partners

Venue: Hilton at St George’s Park, Burton upon Trent

Date: Thursday 14th March 2024

The 2024 entry forms open on the 1st August, so be sure to visit the Pump Industry Awards website to review the award categories and decide which ones you will be entering!

Dale

be a hotbed

competitiveness,

the constant search for greater operational performance and improved efficiencies amongst its broad customer base, demands all those operating within this important sector to be at the top of their game. This BPMA backed awards programme allows the pump industry to come together in celebration of that drive for engineering excellence.”

www.pumpindustryawards.com

Organised by on behalf of
opeNomiNatioNs N1staugust
PUMP INDUSTRY AWARDS 2024 Croker, BPMA President, says of the Pump Industry Awards, “The pump industry continues to of where

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Articles inside

Here’s your chance to shine!

1min
page 39

Restricting PFAS: It’s not as simple as it sounds

2min
page 38

Control noise in booster pump systems

3min
pages 36-37

Drainage solutions Make complex projects a reality

5min
pages 34-35

A fire extinguishing system with maximum flexibility

6min
pages 30-33

Vibration modelling eliminates Pumping Station’s Critical Resonance Frequencies

2min
pages 28-29

SUPERIOR BALANCING MACHINES FOR PUMP MANUFACTURERS

1min
page 27

How does MEI affect me

2min
page 26

Identifying poor assets and inefficient pumps

4min
pages 24-25

Pump Repairs

3min
pages 22-23

Putting the engineering into reverse engineering

2min
page 20

condition monitoring solution detects rotational direction

5min
pages 18-19

Open up predictive maintenance with a reliability partner

4min
pages 16-17

SELF-PRIMING MAG-DRIVE PUMP FOR LABORATORY APPLICATION

1min
page 14

RETROFIT AT ARDLEIGH TREATMENT WORKS

1min
page 14

TESTING PROGRAMME SUPPORTS WELSH WATER’S NET ZERO COMMITMENT

1min
page 12

AUTOMATIC SUMP PUMPS FOR CROCODILE ENCLOSURE

1min
page 12

NOMINATIONS SOUGHT FOR INDUSTRY-WIDE RECOGNITION

2min
page 10

PUMP MOTOR FOR THERMAL POWER STATION

1min
page 9

MASSIVE EXPANSION OF CHEMICAL PUMP SERIES

1min
page 9

COMPACT BOOSTER SET PACKS A PUNCH

1min
page 8

CONDITION MONITORING SOFTWARE WITH BUILT-IN ANALYTICS.

1min
page 8

BPMA WELCOMES ITS NEW DIRECTOR AND CEO

2min
page 6

ABB and Wellington Water win Global Water Award

1min
page 5

CHEMUK RECORDS A 41% INCREASE IN VISITORS

1min
page 5

XYLEM COMPLETES ACQUISITION OF EVOQUA

1min
page 4

THE EVENT FOR HEAT, WATER, AIR AND ENERGY PROFESSIONALS IS BACK

1min
page 4

Sulzer and Siemens announce digital collaboration

1min
page 4
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