Quarter 1 2019
Pump industry insight from
FOCUS ON: Hygiene Understanding NPSH to reduce cavitation
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Pump Industry News
Innovations
Applications
Expert Opinion
CONTENTS 3 Editor Chris Callander chris@flowmag.co.uk 01732 671123 Contributing Editor Suzanne Gill suzanne@flowmag.co.uk Publisher Andrew Castle andrew@flowmag.co.uk 07785 290034 Accounts Touchwave Media Ltd accounts@flowmag.co.uk Production G and C Media Ltd production@flowmag.co.uk
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’m delighted to welcome you to the first issue of flow, a new publication from the BPMA designed to provide insight and inspiration to users, installers, maintainers and manufacturers, of pumps and pumping systems. Alongside news from the BPMA, flow will provide industry news, new product information and system developments, expert opinion and analysis, plus in-depth features exploring a wide range of topics which will share valuable insights across the sector. In this issue we have a focus on hygienic pump applications where we explore the importance of selecting the right components in these applications. Elsewhere in this issue we look at the potential offered by the digitalisation of pumprelated systems, and the role collaboration is already playing in realising the benefits. The value in collaboration also features in an interview with Professor George Aggidis from Lancaster University, explaining the need for more joint working agreements between industry and academia to help tackle the current skills shortage and drive growth in manufacturing as a whole. Of course, we have created flow for you, and we’d be grateful if you would share your feedback or ideas for future issues with the magazine’s editor, Chris, at chris@flowmag.co.uk. Meanwhile I hope you enjoy the magazine! Richard Harden, President, BPMA
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.
PUMP INDUSTRY NEWS 4 Generation-Z shuns manufacturing 5 Pump Industry Awards finalists announced
BPMA National Metalforming Centre 47 Birmingham Road West Bromwich B70 6PY www.bpma.org.uk
Twitter @bpmapumps flow is a controlled circulation journal
16 Make NPSH add up and minimise cavitation
BPMA NEWS 6
The Association at work
7
Support for job seekers
FEATURE 18 Unlocking the potential in smart-pump technology
PRODUCTS
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.
8 New products for the pump industry
© BPMA. All rights reserved.
14 GDP growth forecast lowered
www.bpma.org.uk
Q&A
Focus on Hygiene 22 Choose wisely for hygienic applications 26 Gentle product handling
SKILLS
28 Hygienic product update
12 Tackling the skills challenge with collaboration 13 Act fast or lose Apprenticeship Levy contributions
MArket Trends
22
OPINION 30 Are set builders missing the mark? Quarter 1 2019
4 INDUSTRY NEWS
CHEMICAL INDUSTRY OFFERS AN OPPORTUNITY FOR INNOVATIVE PUMP MANUFACTURERS
GENERATION Z SHUNS MANUFACTURING
Chemical manufacturers need to focus on redefining their maintenance strategies for IIoT-enabled pumps, says Frost & Sullivan.
RESEARCH FROM BARCLAYS Corporate Banking shows that only 6% of Generation Z (16-23 year-olds) are considering a career in manufacturing. Almost half say this is because the career path does not appeal to them, while over one-third do not believe they have the skills required for the role. One reason why young people are reluctant to take up a career in manufacturing is due to misconceptions around the skills that they could develop: only one-third of young people believe a career in manufacturing will provide them with advanced technology skills. This is despite the fact that advanced technology is a key driver of growth for UK manufacturing companies. Furthermore, when asked about what
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he chemical industry in Europe is in the midst of a huge transformation with manufacturers looking to redefine their value proposition and explore new business models. Encouraged by the gradual recovery of oil prices, chemical manufacturers are increasing their demand for centrifugal and positive displacement (PD) pumps. Plus, the European Commission’s directive to industries to reduce energy consumption is creating a fertile market for smart, intuitive, Industrial Internet of Things (IIoT)-enabled pumps with asset monitoring features. The total pumps market in Europe generated an estimated revenue of $1,334.7 million from the chemical industry in 2018. Centrifugal pumps used in chemical processing plants represented 75.6% of the total pump market, and the remaining 24.4% of the market was held by positive displacement (PD) pumps in 2018. The compound annual growth rate for the total market is an expected 2% through 2025. “Pump manufacturers who are offering value-added services, such as end-to-end monitoring of pump performance throughout their lifecycle to increase energy efficiencies, will remain competitive,” says Kiravani Emani, Industry Analyst, at Frost & Sullivan. “Furthermore, the shift towards digital chemical plants will create opportunities for pumps embedded with connectivity and intelligence capabilities, as they can aid predictive maintenance, reduce asset
failure and, consequently, prevent the shutdown of plants. “As chemical manufacturers experiment with flexible and modular factories to efficiently manage various product lines, custom-made pumps that are robust and adaptable to mobile production lines will enjoy greater uptake,” noted Kiravani. According to Frost & Sullivan, pump manufacturers could widen their footprint and increase revenue share by tapping into several growth opportunities. These include differentiating through product performance and reliability rather than just price and product range; the provision of remote and condition monitoring services that help predict failures and reduce maintenance costs; mergers and acquisitions with automation and IoT vendors; the establishment of strong distribution networks to ensure timely delivery of services; and the provision of valueadded services that include remote monitoring of pump performance, proactively replacing and servicing the equipment before it fails.
COLLABORATION SUPPORTS PUMP INDUSTRY TRAINING
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eaders in the pump industry are collaborating to provide essential resources and equipment for NETA Training Group, one of the North East’s leading technical training providers. Pump manufacturer and distributor, Tomlinson Hall, has joined forces with Crane ChemPharma & Energy, ITT Goulds Pumps and Grundfos to provide equipment which aims to give students the opportunity to gain first-hand experience of how up-to datepump technologies work. Speaking about the initiative, David Thompson, Strategic Business Development Coordinator at NETA said: “With thousands of different pumps on the market it is essential that our students have a solid understanding of what various pumps are made from, why that material has been chosen and the different fluids that they can handle. “Through having experience with handling some of the best pumps on the market – all designed to serve different purposes – our students will benefit from the first-hand experience ultimately increasing their knowledge”.
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they want from their future career, 40% of young people say that the opportunity to constantly build their skills is one of their top priorities. This shows that, although a career in manufacturing could fulfil their future job aspirations, young people are unaware of the opportunities that the sector provides. The potential benefits of overcoming this situation were shown in economic modelling also undertaken by Barclays, which concluded that by 2023 manufacturers could add an extra £6.1bn to the UK economy each year if they invest more in recruitment drives such as apprenticeship programmes, graduate recruitment strategies and collaborations with Universities or other institutions. However, rather worryingly only 11% of firms surveyed have plans to promote the benefits of a career in manufacturing over the next five years. www.bpma.org.uk
INDUSTRY NEWS 5
PUMP INDUSTRY TO RECOGNISE ITS BEST AND BRIGHTEST From the entries and nominations received, the Pump Industry Awards judges shortlisted 37 finalists across seven categories at a judging session held in January.
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hose fortunate enough to make it through to the public vote were:
Technical Innovation of the Year – Products Sponsored by Process Engineering • •
• • • • • • • •
ABB: Ability Smart Sensor for Pumps Baker Hughes, a GE Company: Ring Sectional Diffuser Multistage Pump for Powergen Applications EMIR Software: EMIR Smart Site Siemens: Drive Train Analytics with SiDrive IQ Siemens: High Power High Availability Variable Speed Pump Drive System Siemens: HVC New High Voltage Motor Design Concept Sona Pumps: SPRC Hybrid Submersible Motor Home Pump Stuart Turner: Stuart Digital Pressurisation Unit Range Wilo UK: The K Series K10 Borehole Pump Xylem Water Solutions: Flygt Concertor XPC
Technical Innovation of the Year – Projects Sponsored by Wilo • •
• • • •
ABB, EDC and Scottish Water: Scottish Water Leakage Reduction Programme Baker Hughes, a GE Company: Escondida Water Supply Expansion Project - Desalinated Water High Pressure Pipeline Pumps Campion Pumps and Irish Water: Inniscarra Dam Project Peter Brett Associates, Stantec: Bells and Mocketts Pumping Station Siemens: Pump Blockage Protection for Anglian Water Siemens: MindSphere Installation for Anglian Water
Environmental Contribution of the Year Sponsored by SPP Pumps • • • • • •
Armstrong Fluid Technology: Armstrong Tango Parallel Pumping Solution Peter Brett Associates, Stantec: Bells and Mocketts Pumping Station Ru Well Systems: Scientific-Innovаtion Company Siemens: Pump Blockage Protection for Anglian Water Wilo UK: The K Series Borehole Pump Xylem Water Solutions: HydroInfinity
Distributor of the Year Sponsored by WEG UK • • • •
Campion Pumps Seal and Pump Engineering UK Tomlinson Hall Triark Pumps
Manufacturer of the Year Sponsored by Siemens • • • • •
Full details of the finalists are available on the awards’ website. The winners will be announced on March 21st at a gala awards ceremony taking place at the Heythrop Park Resort in Oxfordshire. The ceremony will be hosted by broadcaster, television and radio presenter Penny Smith who will be followed to the stage by one of the most original and exciting swing acts in the country, the Swinging Little Big Band. With a career spanning more than a decade, the band will be performing their unique blend of vintage Rat Pack classics alongside swing/jazz versions of a selection of contemporary songs. Limited places are still available for what promises to be a wonderful evening of great food, fantastic entertainment, networking and dancing until the early hours. For details, go to: www.pumpindustryawards.com
BJM Pumps SPP Pumps Tapflo Pumps UK Tomlinson Hall Wilo UK
Supplier of the Year Sponsored by Xylem Water Solutions • • •
ABB John Crane UK Siemens
Engineer of the Year Sponsored by World Pumps • • •
Ru Well Systems: Vyacheslav Fisenko SPP Pumps: Reuben d’Orton-Gibson Wilo UK: Cameron Gaunt
WE DON’T JUST SELL PUMPS, WE ENGINEER SOLUTIONS.
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6 BPMA News
BREXIT, PRESIDENTS, GOLF AND GROWTH The BPMA has been active on many fronts, to ensure it continues to represent the interests of its members – suppliers of liquid pumps and pumping equipment.
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s part of its role as one of the 13 members of the EURIS taskforce, the BPMA has been working hard to ensure the UK Government is very clear about the negative implications the association believes the pump sector will face in the event of a no-deal Brexit. In addition to its support of a EURISled call for an extension to Article 50, the BPMA has shared emerging information relating to changes to CE Marking which will take effect either immediately, in the event of a no-deal exit, or following a transition period in the event of an orderly exit. This support for its members has been backed up by further advice from the BPMA around key actions which should be taken to prepare for the possibility of a disorderly exit from the union. A new president of the BPMA was announced following the association’s AGM in late 2018 – Richard Harden,
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Managing Director of Wilo UK. Commenting on the appointment, Steve Schofield, Director and Chief Executive of the BPMA said, “The BPMA has enjoyed the support and engagement of some very talented people at its helm over the years, and we are delighted to now have Richard join that impressive line-up”. The BPMA has also recently shared details of a Mutual Co-operation Agreement with Lancaster University. This agreement covers a range of collaborative ideas and opportunities, primarily geared around the development of improved skills and enhanced technology understanding across the sector. The bedrock of the arrangement will be exploring additional content to strengthen the BPMA’s existing range of training courses and evaluating the scope for funded collaboration across a range of technologies pertinent to pump systems engineering.
Details of the Association’s annual golf day have been announced, with the event set to take place on May 16th at Oulton Park Hotel & Golf in Leeds. This event is always popular and promises to offer those that take part an excellent opportunity to network with peers, to reward staff or treat customers to an event they will remember. The Association continues to grow and has recently welcomed three new companies as members. Sealing solutions provider O Rings Ltd, pump repair and servicing specialist Houghton International and heating, cooling and plant engineering technology company Reflex Winkelmann have all recognised the benefits of BPMA membership to their organisations. Finally, BPMA members continue to gain recognition for the work they do. Pump distributor and manufacturer, Tomlinson Hall, was crowned SME Business of the Year at this year’s North East Automotive Alliance Awards, while AESSEAL, a mechanical seals and support systems designer and manufacturer, won the Developing Future Talent award at the prestigious EEF Future Manufacturing Awards.
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BPMA NEWS 7
SUPPORT FOR JOB SEEKERS The British Pump Manufacturers Association (BPMA) has launched a free service designed to help individuals who are unemployed or facing redundancy, and who have a relevant engineering background, to find work within the pump sector or its associated trades.
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hrough this online service, the BPMA will help match job seekers to those companies with vacancies specific to the pumps and pump systems related industry. Many BPMA members have highlighted the difficulties they face in finding, recruiting and nurturing new talent. The launch of the Pipeline Vacancy Board, where the Association’s members are encouraged to display any vacancies they have, responds to this challenge. The BPMA is also keen to work with UK-based universities which have engineering faculties to help place suitable students within UK pump companies. Pump-related companies with an appropriate engineering vacancy, or indeed any candidates interested in promoting themselves via this service, are encouraged to contact Steve Smith at
the BPMA by email on s.smith@bpma.org.uk. No individual name or company will be identified on the website, as vacancies will have a unique reference number which must be quoted on any application or CV request. The BPMA will contact the relevant parties for further information as requested, and it is expected that by subscribing to this service all parties will have read and be bound by the BPMA Privacy Statement.
BPMA TRAINING NOW OFFERS CPD ACCREDITATION
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s part of its ongoing commitment to the development and delivery of high-quality industry-specific training for both its members and the wider pump using sector, the BPMA has secured Continuing Professional Development (CPD) accreditation across its full training programme. The organisation’s suite of lecturebased courses – which includes pumping fundamentals, pump selection, pump testing, pump systems and the hydraulic design of centrifugal pumps – and two e-learning courses covering an introduction to pumping technology and the essentials of pumping technology, have all reached the required CPD standards and benchmarks which offers those engaging in the training an assurance of the integrity and quality of the course. In addition, both e-learning courses are independently accredited by the National Open College Network (NOCN), which brings further credibility and value to the courses and the resulting qualifications.
Recipe for a perfect system: One part efficiency. One part quality. All parts KSB.
It’s all in the mix – even in Life Science Applications. KSB’s extensive range of Vita products with CIP/SIP capabilities can be implemented in your primary and secondary processes. www.ksb.co.uk - 01509 231872
8 PRODUCT NEWS DOMESTIC PUMPS OFFER REDUCED ENERGY CONSUMPTION SOLAR POWERED PUMP THE FIRST PRODUCTS RELEASED by Calpeda under the company’s e-idos brand are now making their way onto the market. The stainless-steel domestic pumps have been re-engineered to work with a new motor technology, coupled with an onboard pressure control and monitoring system. This new range includes the Calpeda self-priming pumps, NGX Eco and MXA, along with the MXP series of multi-stage centrifugal pumps. There are 12 models in all, capable of flows up to 100 ltr/min and heads up to 50m. The new fully programmable plugand-play system introduces many features, including a high efficiency asynchronous single-phase motor, a capacitor not stressed in voltage, uniform and lower motor operating temperatures and motor power control. Programmable re-start pressure is also offered along with no hydraulic losses from the sensing devices, voltage and current control, monitoring of the maximum starting current, the elimination of water hammer and a reduced need for an expansion tank.
MOTOR CONTROL
The technology also offers built-in dry-run protection, air detection in the pump and during the filling cycle, overload control and motor overheating motor protection, pump jamming protection, overcurrent protection, power supply control, system leakage control and high flow-rate pipe failure detection. The units incorporate an easy to use interface with an LCD screen to facilitate programming and operational monitoring. Tests have confirmed a reduction in energy consumption of up to 24% when compared to some other pumps. www.calpeda.co.uk
CHEMICAL PUMPS PROMISE LESS DOWNTIME CHEMICAL PUMP MANUFACTURER, Crest, has introduced the AME range of heavy-duty magnetic drive process pumps. Constructed using a high purity PFA lining the pumps are suitable for use in corrosive of applications even up to temperatures of 150°C. Traditionally, the biggest concern with seal-less pumps made from engineering plastic has been the shaft support system which must be strong enough to withstand the radial forces during operation. Under high temperatures and pressures the shaft support can weaken, resulting in vibration and wear which can significantly reduce the pump’s life. According to Crest, the AME’s doubleended shaft support is stronger than any other with an integral ‘V’ shape front support which is part of the metal casing armour that has been PFA lined. This
Quarter 1 2019
approach improves the liquid flow to the impeller, increasing operational efficiency and reducing net positive suction head (NPSHr). The rear of the shaft is then supported in the PFA lined containment shell and reinforced by a metal support ring and carbon fibre cover. The second key factor to consider if a seal-less plastic pump is genuinely to be heavy-duty is whether the impeller is built to last. Traditionally, an ETFE or PFA mag drive pump will be fitted with a separate impeller and inner magnet. But in applications of high pressure or temperature, the impeller can deform, resulting in damage and reduced performance. The AME pump is also constructed in such a way that the impeller and magnet capsule is formed as one piece which eliminates the possibility of the impeller loosening. For further operational stability and rigidity, a metallic structure is embedded from the magnet capsule to the impeller blade. Together, these two approaches to the AME pumps’ design ensure they are truly heavy-duty, meaning a longer life resulting in less downtime and increased productivity.
MOTOR AND DRIVE TECHNOLOGY manufacturer, WEG, has unveiled a new optional kit for its CFW500 series of variable speed drives (VSDs) that facilitates pump motor control through photovoltaic (PV) solar cells. The compact, energy saving CFW500 Solar Drive comprises a plug-in module to simplify set up and installation. It is said to be suited to the control of centrifugal and submersible motor pumps installed in places where the power grid is unavailable or unreliable. The CFW500 Solar Drive works by converting the DC feed from PV panels into AC that can serve and control the motor pump. Importantly, the new kit has a function which provides automatic start/stop according to the available solar energy. Principal features of the CFW500 Solar Drive include continuous maximum power point tracking (MPPT), double PID for simultaneously controlling both DC voltage and pipeline pressure, and up to four distinct speed and pressure setpoints.
www.crestpumps.co.uk
www.weg.net www.bpma.org.uk
Motors | Automation | Energy | Transmission & Distribution | Coatings
WEG MOTOR SCAN CONDITION MONITORING FOR INDUSTRY Connectivity for performance control WEG Motor Scan is a monitoring solution for electric motors, helping to predict problems before they happen. The data is extracted and sent to the cloud allowing preventative actions and avoiding risks of unplanned downtimes.
Transforming energy into solutions.
www.weg.net
10 PRODUCT NEWS
KEEPING THE CHOCOLATE FLOWING THE LATEST ADDITION TO THE Viking CHC range of internal gear pumps, available in the UK through Michael Smith Engineers, features a seal modification which has been specifically developed for pumps used on chocolate processing and other similar applications. The seal modification features an O-ring Seal Bushing (OSB), which is effectively a combined bracket bushing and seal gland, with double O-ring seals, housed in a cast-iron cylinder and with back pullout accessibility. The OSB ring seal has been designed to fit all the pumps in Viking’s Universal Seal Series with the specific aim of keeping chocolate (and other similar foods) from leaking out along the pump shaft. The static O-ring seals between
the OSB and the bracket prevent leakage outside of the OSB, while the area between each set of inner and outer rings is filled with food-grade grease to provide lubrication and to act as a double seal barrier to prevent leakage. To ensure optimum reliability, Viking focused on three areas where chocolate solids can build-up and seize a pump – the bracket, the area behind the pump rotor and the idler bushing. The OSB keeps chocolate out of the bracket and so eliminates a key area of chocolate entrapment. The pump casing features flush and suck back grooves which create flow behind the pump rotor, helping prevent solid product build-up
and reducing thrust on the bearings. Finally, the pump incorporates a drilled idler gear with hard cast iron bushing and special internal clearances to prevent chocolate caking and build-up as well as reducing burning and binding. www.michael-smith-engineers.co.uk
FIELDBUS COMPATIBLE PRESSURE BOOSTER SYSTEMS FREQUENCY CONVERTER KSB GROUP’S NEW DELTA PRIMO speed control in the VP and SVP FOR INFRASTRUCTURE pressure booster systems, available in variants. With its fieldbus interface, K, VP and SVP variants, offer a range of the system can also be operated from APPLICATIONS features. The fully automatic systems an external PC. On the control cabinet are supplied ready-to-connect, equipped with either two or three Movitec highefficiency centrifugal pumps and they provide a maximum flow rate per system of 67.5 m3/hr, and a maximum head of 134 metres. The Booster Control Advanced microprocessor control unit starts and stops the pumps using cascade control in the K variant or a frequency inverter for
display, LEDs in easy-to-read traffic light colours indicate the operating status of the system. Should a duty pump fail, the control unit will immediately start up the next pump. For transmitting warnings or alerts to a higher-level control station, two additional volt-free contacts on terminals are provided. The SVP variant is fitted with a highefficiency IE5 synchronous reluctance motor while the more economical K and VP variants come with IE3 motors. All three options require a mains frequency of 50 Hz. The pump is started up by a pressure drop in the piping when a consumer installation is opened. When the pressure in the membrane-type accumulator rises, KSB Delta Primo stops. Should a lack of water occur in the inlet, the microprocessor control unit will automatically stop the system to prevent any damage caused by dry running. The systems are approved for drinking water to the French ACS and British WRAS regulations, which are among the strictest in Europe. All installed valves are also approved under the German DVGW drinking water regulation. www.ksb.com
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SIEMENS NEW SINAMICS G120X frequency converter series has been optimised for infrastructure and industrial water/wastewater applications as well as pumps and fans in building automation. With a power range of 0.75 to 630 kW, Sinamics G120X converters can be operated with any motor. The converters are said to be at their most effective when running with synchronous reluctance motors from Siemens. The Sinamics G120X are configured for cost-optimised and resource-saving operation across all voltages and supply networks, and their characteristic compact design saves space in the control cabinet. Jason Peel, Head of Motion Control, Siemens UK, said: “In an increasingly competitive and pressurised environment, introducing digitalisation to boost productivity can seem like a challenge. That’s why we have developed solutions such as Sinamics G120X, which are designed to help users reach new levels of simplicity, energy efficiency and durability across their sites.” A high C2 (optionally C1) EMC category and a protection rating of IP20 (optionally IP21 in UL open type) ensures the converters can be used in any industrial environment. Sinamics G120X converters comply with all relevant EU energysaving standards and offer an operating efficiency level of more than 98%. www.sie.ag/2TmRpuV www.bpma.org.uk
DO YOU MAKE, SELL, INSTALL, REPAIR OR ASSEMBLE PUMPS AND SYSTEMS? BPMA membership offers a wealth of information, advice and opportunities designed to help your business thrive. • • • • • • • • • •
Tender alerts Free commercial, health & Safety and legal advice Free and discounted technical and market insight guides Expert advice on standards, legislation and technical issues Discounted training Energy auditing Discounted insurance UK and EU representation at political and executive levels Exclusive promotional opportunities Valuable networking opportunities
Visit the BPMA website, call or email for more details
www.bpma.org.uk • +44(0)121 601 6692 • g.wilde@bpma.org.uk
NEWS 12 SKILLS
Tackling the skills challenge The British Pump Manufacturers Association (BPMA) recently signed a collaborative agreement with Lancaster University. To better understand the importance of this type of collaboration between industry and academia, flow spoke to the agreement’s co-signatory, Professor George Aggidis from the university. flow: What is the scale of the skills challenge facing the engineering sector? Professor Aggidis: Engineering faces some key challenges in skills development that will have long-term implications for productivity within the UK manufacturing industry. Also, the demand for higher level skills is increasing and matching relevant supply to this demand is crucial. By 2022, two million more jobs will require higher level skills. More than one-infive of all vacancies are ‘skills shortage’ vacancies, where employers cannot find people with the skills and qualifications required. This means a greater focus is needed to ensure that we develop the higher-level skills required in the labour market to secure future economic stability and prosperity. f: What role does collaboration, such as the recent agreement between your university and the BPMA, have to play in addressing the skills challenge? PA: Collaboration between industry and academia has a significant role to play in supplying highly skilled people to meet demand from businesses both now and in the future. The UK has a strong track record of higher skills development, but we need to do more. Employers are acutely aware of the skills their businesses need for future growth so it is employer needs that must drive skills development. The best outcomes are produced where employers are actively involved in the design and delivery of programmes. Both universities and employers need to be innovative and engaged in promoting different and non-traditional routes into higher skill roles. We need more well-articulated, vocational and technical pathways for both young people and experienced engineers. These pathways will then open routes to higher-paid careers for a broader group of talented people. f: There is an investment required from all parties – financial, time and other resources – what returns can be expected from that investment? PA: Both industry and academia stand to benefit from longterm cooperation. Companies will gain greater access to cutting-edge research and scientific talent at a time when corporate R&D budgets are increasingly under pressure. Universities will gain access to financial support and partners in research at a time when Government funding is shrinking. Most importantly, society will benefit from a stream of previously unimaginable advances that will vastly improve everyone’s life.
f: Finally, aside from a desire to tackle the skills challenge, what is fuelling an increased willingness for this type of collaborative working? PA: In the last decade there has been an explosion in the number of research deals between companies and universities. Companies, which have been reducing their spending on early-stage research for three decades, have been increasingly turning to universities to perform that role, seeking access to the best scientific and engineering minds in specific domains. And faced with reducing Government support of academic research and calls for them to contribute more to their local economies, universities have been more receptive. Instead of one-off projects, both sides have become much more interested in forging long-term, collaborative relationships like the one between BPMA and Lancaster University. chevron-circle-right
For details of the full range of training available from the BPMA download the FREE training guide at:
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BPMA TR AINING
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www.bpma.org.uk
SKILLS 13 LEARN HOW VARIABLE SPEED DRIVES CAN REDUCE LEAKAGE ABB HAS LAUNCHED A LUNCH ‘N’ LEARN TRAINING session that shows how water companies can use variable speed drives to make dramatic improvements in leakage rates. Industry statistics from the UK’s Consumer Council for Water state that a staggering 3.1 megalitres of water is lost every day through leakage in England and Wales. That is an enormous amount of water which the UK water sector regulator, Ofwat, has recognised by setting targets to reduce water leakage by at least 15% over five years in its 2019 price review. Variable speed drives (VSDs) can reduce leakage by controlling water pressure and preventing the rapid pressure transients that occur when pumps are switched on and off. These transients can cause damaging water hammer – a common cause of burst pipework. “Our training session is a convenient way to ensure that those responsible for specifying, operating or maintaining pumps learn how they can use VSDs to reduce the waste caused by leakage,” says Dan Banks, ABB drives water framework manager. Topics covered include how VSDs tackle common causes of leakage, the role of inbuilt VSD smart functions and the increasing use of cloud-based monitoring techniques. Attendees will also hear how one ABB customer is set to save £4.5 million on repairs and energy costs by 2021 by using VSDs to maintain correct water pressure. The 45-minute session is free to attend and can be delivered to individuals or groups at customer premises or an ABB facility. www.bit.ly/2UaE3iM
COMPANIES NEED TO ACT FAST TO AVOID LOSING APPRENTICESHIP LEVY CONTRIBUTIONS LARGE COMPANIES WILL begin to lose their unused Apprenticeship Levy payments from April this year. Companies with payrolls over £3 million per annum have been contributing to the Apprenticeship Levy since it launched in April 2017. If they invest these contributions in apprenticeship programmes for staff, as long as they work with approved training providers, they can reclaim contributions. However, under the scheme’s rules, after two years, unclaimed contributions are returned to the Treasury. This means that this coming April, unused contributions will effectively begin being wiped out, and they will continue to do so on an ongoing basis. A combination of confusion surrounding the way the scheme works, along with concerns that a limit of £15,000 per student is ruling out a large number of highly technical apprenticeships, have contributed to a decline in the take-up of apprenticeships since the launch of the levy. As a result, there are some £3bn in unclaimed contributions, with around £168m expected to be passed to the Treasury in May alone. Of over 50,000 business who meet the contribution threshold and contribute 0.5% of their annual wage bill, it is estimated that around 80% have yet to make use of their contributions.
14 MARKET UPDATE
UK GDP growth forecast lowered Oxford Economics, global forecasting and quantitative analysis specialist, and producer of the annual Global Pump Report, shares its outlook for the UK economy.
Diary MARCH 20-21 21 26-27 28
Scotland Build Expo
SEC, Glasgow www.scotlandbuildexpo.com
Pump Industry Awards
Heythrop Park Resort, Oxfordshire www.pumpindustryawards.com
Future of Utilities Summit 2019 London www.bit.ly/FoESumm
British Water BIM Conference Cannon St, Birmingham www.bit.ly/BWBIM
April MAy
O
xford Economics has lowered its forecast for UK GDP growth in 2019 to 1.4%, reflecting a run of weak data around the turn of the year and the impact of the slowdown in world trade. But, provided that Brexit is orderly, the organisation expects a modest acceleration in GDP growth through 2019. The company believes that one of the key drivers for this acceleration is a recovery in household spending – the recent plunge in the oil price and an expectation that sterling will strengthen, once the Brexit deal has been approved, is likely to dampen inflationary pressures. The organisation also expects firmer wage growth to support household spending power. With a very low savings ratio, households became more wary about borrowing last year, and Oxford Economics expects consumers to retain a relatively cautious attitude in the future, with spending growth moving in line with real incomes. Looser fiscal policy should also offer modest support to GDP growth this year, although the Office of Budget Responsibility forecasts imply that it will revert to dragging on growth in subsequent years. On the downside, the boost to export growth in 2017, due to stronger global growth and a weak pound, is expected to fade this year. Looking ahead, Oxford Economics’ forecast suggests world growth will cool as the impact of more protectionist trade policy is seen, with growth in world trade (weighted by UK export shares) slowing in 2019. Oxford Economics’ modelling suggests that the pound is heavily undervalued so, assuming that Brexit proceeds in an orderly fashion, the pound should recover strongly. The forecast goes on to suggest that investment is expected to remain a drag on growth this year. Although firms are in solid financial shape, they have been reluctant to spend. Uncertainty around Brexit has been a critical factor, and this is likely to persist until the UK’s future trading relationship with the EU becomes clearer. After falling by 0.9% last year, Oxford Economics expects business investment to decline by a further 1.5% in 2019 before recovering and growing in 2020. Overall it expects investment to be firmer, growing by 0.2% this year and 2.9% in 2020. chevron-circle-right
Quarter 1 2019
1
National Construction Expo Arena MK, Milton Keynes
www.nationalconstructionexpo.co.uk
1-2 7-10 16 21-22 23-25 JUNE
ChemUK 2019
Yorkshire Event Ctr, Harrogate www.chemicalukexpo.com
Certified Pump System Auditor training The Park Inn, West Bromwich www.bpma-cpsa.co.uk
BPMA Golf Day
Oulton Park Hotel & Golf, Leeds www.bit.ly/BPMAGolf
Utility Week LIVE
NEC, Birmingham www.utilityweeklive.co.uk
Europump Annual Meeting
Naples, Italy www.europump2019.com
2019 BPMA Pump Buyers Guide & Directory publishED
www.bpma.org.uk/publications
5-6 20 26
BlueTech Forum 2019
Kew Gardens, London www.bluetechforum.com
BPMA Technical Committee Meeting London www.bit.ly/BPMATech
Future of Utilities: Innovation in Networks Raddison Blu, London www.bit.ly/FoEInnov
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16 Q&A
make NPSH add up to reduce cavitation
To help readers understand what NPSH is and how to calculate it, flow spoke to Shaun Hampson, Managing Director, Flowserve’s Manchester Quick Response Centre.
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avitation can cause significant damage to centrifugal pumps and their components, resulting in costly repairs and unplanned downtime. However, understanding NPSH and using its calculation as part of the pump specification process can significantly reduce the effects of cavitation. flow: What is the meaning of NPSH and how important is it to a centrifugal pump application? Shaun Hampson: A commonly used acronym within the pump industry, NPSH stands for Net Positive Suction Head. It is a consideration in centrifugal pump selection because it represents the adequacy of liquid feed relative to the need of a pump. Starving the suction of a pump with poorly available NPSH can rapidly cause cavitation damage. NPSH is relatively simple to calculate, but some factors, such as where liquids approach their boiling point (vapour pressure), or applications where there are long torturous suction pipe-lines, can make it more challenging to accurately assess. There are several areas which need to be considered when calculating NPSH. The first is cavitation, a very aggressive form of damage. The second is pressure head which is measured in metres, as opposed to conventional pressure measurements in bar, psi, Pascals, etc. The properties of the liquid being pumped also affect the NPSH calculation – where a special focus is needed when pumping LPG and liquids near to their boiling point, for example. CAVITATION In broad terms, cavitation starts with the partial evaporation of the liquid because it is being sucked hard, in a non-linear, and turbulent environment. As its vapour pressure is compromised, it starts to evaporate into entrained pockets of vapour. These tiny pockets of vapour enter the pump impeller in their thousands, but are condensed as the surrounding fluid is internally pressurised toward the discharge. Bubbles collapsing in the vicinity of the impeller ignite damage, as surrounding liquid rapidly fills each of these little voids. The impeller material acts as the backstop to liquid entering these cavities at supersonic speeds and the result is impact erosion known as cavitation damage, which can quickly destroy even hard material pumps. Consequently, it is vital to protect against cavitation by ensuring that
Quarter 1 2019
there is adequate NPSH available from within the pumping system. A specifier needs to distinguish between the NPSH required for the pump and the NPSH available from the application. NPSH required by the pump is commonly known as NPSH(r) and this information is provided by the pump manufacturer. NPSH available is termed NPSH(a) and needs to be calculated from the system Cavitation in action characteristics. To minimise cavitation there should be more NPSH(a) than NPSH(r) plus a reasonable safety margin in which to account for entrained liquid impurities which may distort its vapour pressure. PRESSURE HEAD Pressure head is used in the calculation of NPSH because conventional pressure is influenced by liquid density. As centrifugal pumps handle liquids of all types and with varying densities traditionally measured pressures vary. So, rather than a manufacturer creating thousands of pump selection curves for an infinite variety of density options, it is standard practise to employ ‘head’, a column of liquid expressed in metres and which doesn’t change. Head is the height of liquid which will be generated above the pump centre when an impeller of a given diameter is spinning at a given speed. While this remains constant, a conventional pressure measurement taken at the pump discharge will vary with different liquid densities. f: How is NPSH calculated in a typical application? SH: The key to understanding NPSH lies in the first term, ‘Net’. This represents the total positive suction head once all plusses and minuses have been netted off. There are four suction pressure variables needed www.bpma.org.uk
Q&A 17 to calculate NPSH(a). Two are always negative, they simply need to be added together and are easy to remember: 1. Static height of liquid. This is either above or below the pump (with suction lift pumps for example) and can be either a positive or negative figure. 2. Vapour pressure of the liquid. This must be removed and is therefore always negative. 3. Pipework and valve losses. This is measured upstream of the pump, back to the liquid source, and is always negative. 4. Atmospheric pressure head. This is the pressure acting on the liquid surface. While this pressure is in its absolute form, it is always positive, regardless of any possible suction vessel vacuum applications. When calculating NPSH all units need to be consistent. This means converting the atmospheric pressure head (p) and vapour pressure (Vp) from millibars to metres. This is done using the following formula:
It would be good practice to allow a safety margin and 0.5m would suit such an application. So, we are now looking for a pump with NPSH(r) of less than 13.19m at the duty point on the pump curve. Most conventional end-suction liquid centrifugal pumps are in the region of 1 to 5m and would be suitable for this application. f: How do liquids close to their boiling point, or those under pressure such as LPG, affect the calculation? SH: Pumping LPG follows the same characteristics as any liquid being transferred at its own boiling point. Like boiling water at 100°C, its vapour pressure will equal the surrounding pressure and these two components ultimately cancel each other out. This leaves a calculation for NPSH with only two components, (a) static height, and (c) pipework losses.
p=ρgh or h=p/ρg Where: p= pressure (pa) ρ= density (kg/m3) g= gravity (9.81m/s²) h= liquid column height above its dadtum (m) NPSH CALCULATION In an example where the system is pumping water at 50oC with flooded suction and a positive height of 5m, the calculation is as follows: a. Static height: This is 5m b. Vapour pressure (Vp): At 500C, the vapour pressure of water is 0.12335 bar. This converts to 1.27m using the above formula. c. Pipework losses: This is an involved topic in itself, but for this example 0.5m is assumed. d. Surrounding pressure (p): In an open vessel this would be atmospheric pressure, but it could be much lower, especially in chemical applications, while a vessel is under vacuum. Assuming 1.014 bar, read from a barometer, the converted figure is 10.46m. Using these values, NPSH(a) = a-b-c+d = 5m –1.27m – 0.5m + 10.46m = 13.69m.
LPG or any liquid at its boiling point In an example with a minimum static height of 1.5m and pipework losses of 0.5m, NPSH(a) calculates as 1.0m If a safety margin of 0.5m is also applied in this example, a pump with an extremely low level of 0.5m NPSH(r) at the duty point is required. Alternatively, by excavating the pump or raising the vessel, the static height can be adjusted to change the NPSH value. Or indeed the users can accept the results of the cavitation and the additional maintenance it will require. However, these alternatives are often expensive and impractical and low NPSH pumps do exist. Low NPSH pumps are, arguably, better when constructed in a horizontal configuration. Unlike vertical pumps, any internal or entrained vaporisation can flow upwards naturally and escape through the discharge of a horizontal machine. Because the mechanical seal sits in the uppermost cavity of a conventional vertical pump it can become surrounded by vapour and its life can be compromised through insufficient lubrication. It is also worth mentioning that the NPSH required for a conventional centrifugal pump can also be reduced by adding an inducer to the impeller. This volumetric feed screw type device induces flow into the eye of the impeller. Arguably, inducers are designed to operate in a very precise duty (flow vs differential head) envelope and become unstable when the user varies the process due to temperature, demand, speed, or simple valve opening and closing. chevron-circle-right www.flowserve.com
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Quarter 1 2019
18 SMART PUMP SYSTEMS
Time to GET SMART Several reports have highlighted a growing trend for ‘smart’ pump systems. flow finds out what this could mean for both pump manufacturers and operators.
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he findings of a recent Frost & Sullivan report identified an increasing demand from pump system operators to derive the maximum output from their legacy equipment, and this is said to be driving pump manufacturers to integrate enhanced technological features into existing pumps. This trend started with the integration of variable speed drives (VSDs) and controllers into the pump systems with the aim of helping to conserve energy, monitor performance, control speed and measure a few vital parameters. However, according to the report, end-users are now calling for more, and the increased adoption of Industrial Internet of Things (IIoT) technologies has intensified the need to add more smart capabilities. “With IIoT comes a growing demand for more sophisticated techniques such as predictive maintenance, remote monitoring, digital twin technology, Artificial Intelligence (AI), and virtual reality/augmented reality (VR/AR),” said Srividhya Murali, Senior Research Analyst, industrial team at Frost & Sullivan. A 2018 IHS Markit report also focused on the increasing trend towards the addition of IIoT technologies to pump systems, which it says is providing an opportunity for pump manufacturers to innovate and deliver full pump solutions, as opposed to merely adding a component to their overall equipment portfolios. IHS Markit found that pump companies – including KSB, Sulzer and WILO – have developed connected machines to enable real-time monitoring on the production line to improve productivity and reduce downtime. Intelligence is also being increasingly embedded into devices, supporting decentralised analytics, and even performing some decision making. WILO, for example, has implemented augmented reality technology onto its manufacturing line, using glasses that act as training devices in place of paper manuals. The glasses replace paper instructions by providing virtual work instructions that also display complex work steps. According to IHS Markit, the numbers of connected nodes in pump (centrifugal pumps and positive displacement pumps) and compressor applications is set to grow substantially with a compound annual growth rate (CAGR) of 46.5% from 2016 to 2021. Centrifugal pumps have more variable flow applications than positive displacement pumps, so it is expected that they will utilise more connectivity for live monitoring purposes. Additionally, European motor and pump efficiency regulations require full awareness by the suppliers regarding overall system efficiency; therefore, the use of smart and connected Quarter 1 2019
technology is expected to increase rapidly going forward. Connected pumps enable predictive maintenance, giving the ability to monitor and regulate pump efficiency and thereby improve both uptime and energy efficiency. In high-risk, high-cost, and errorprone industries, the use of connected pumps allows the transmission of important data enabling a range of IIoT applications. For example, pump sensors could capture key parameters of a pump such as pressure, temperature, and liquid level to measure hardware performance and predict downtime and failure through an analytical model. The oil and gas, water and wastewater, and commercial building sectors are currently the biggest adopters of these technologies as they operate in already competitive and price-sensitive markets, and it is here that the most ingenuity is expected to be sparked in the near future.
“Fixing a problem before it happens is the most cost-effective form of maintenance.”
COLLABORATION IS KEY Steve Hughes, Digital Lead, robotics and motion division at ABB UK told flow that ABB is seeing a growing interest towards the addition of smart sensors and intelligent functions within, or surrounding, OEM packages. He said: “Digitalisation of VSDs and motors will directly and positively impact on the resilience of pump systems.” ABB believes that collaboration is key to success to help unlock the potential offered by the digitalisation of pump-related technology, as well as the increasing provision of cloud-based technology and services. “For example, by working with suppliers, utility providers are finding that it is possible to improve system resilience by utilising functions built into existing assets, such as digital VSDs, low-voltage motors and pumps,” said Steve. ABB has recently partnered with Swiss pump manufacturer, Emile Egger, to adapt its smart sensor (initially designed for motor use) to monitor pump operation remotely. “We believe that collaborative relationships like this are the way forward. The aim of this collaboration was complete transparency to improve operational safety for the pump and motor. Continuous monitoring of the operating state of the pump unit increases the availability of the entire wastewater system,” said Steve. “The smart sensors deployed monitor pump speed, overall vibrations, imbalance, cavitation and early detection of pump failures.”
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WILO BRINGS THE FUTURE. Discover the future of pump technology:www.wilo.co.uk/future
*We understand a smart-pump as a new category of pumps, which goes far beyond our high-efficiency pumps or pumps with pump intelligence. Only the combination of the latest sensor technology and innovative control functions (e.g. Dynamic Adapt plus and Multi-Flow Adaptation), bidirectional connectivity (e.g. Bluetooth, integrated analogue inputs, binary inputs and outputs, Wilo Net interface), software updates and excellent usability (e.g. thanks to the Setup Guide, the preview principle for predictive navigation and the tried and tested Green Button Technology) make this pump a smart-pump.
20 SMART PUMP SYSTEMS According to Steve, the benefits to pump operators of adopting IIoT technologies include increased process uptime and output, with less risk. This, he says, is because the use of smart sensors, coupled with data analysis, will enable the system to be monitored to ensure that it is always working at optimum efficiency. A recent addition to the ABB Ability range of digitally enabled industry solutions focuses on this. The Ability Digital Powertrain integrates sensor and drive data with cloud-based analytics along a whole chain of industrial equipment used in factory environments. An essential element of the solution is that each powertrain element – including drives, motors, bearings and pumps – sends measurement data to the cloud, which is then visible to the operator via a simple dashboard which visually highlights whether the assets are functioning correctly. MAXIMISING MOTOR UPTIME WEG recently launched Motor Scan, a remote performance monitoring solution for its motors, to help maximise uptime and enable predictive maintenance. “Fixing a problem before it happens is the most cost-effective form of maintenance,” said Andrew Glover, European Low Voltage Motors Product Manager at WEG. The WEG Motor Scan leverages IIoT and analytics to connect sensors and other devices to collect and analyse real-time data.
Technologies such as the new breed of smart sensors and performance monitoring solutions provide the actionable information that can help maintenance teams make betterinformed decisions about the health of installed motors. Such solutions can help take the guesswork out of preventative maintenance tasks and eliminate the Collaboration will help unlock the potential offered by the digitalisation of need for reactive pump-related technology maintenance following a component failure. So, while pumps have not traditionally been considered to be the smartest of devices, there is now a growing opportunity for both pump system manufacturers and operators to benefit from the increased capabilities offered by smart, connected systems. chevron-circle-right www.abb.com www.weg.net
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22 FOCUS ON HYGIENE
Choose wisely for your hygienic applications Suzanne Gill looks at pump system requirements for use in hygienic applications and finds out why it is so important to specify the right equipment and materials.
P
ut simply, in addition to helping ensure consumer safety, correctly specifying a pump system for use in a hygienic application will help prevent bacterial growth, batch contamination and ultimately will reduce product waste. To achieve this, hygienic equipment needs to be carefully designed to ensure it is able to resist the build-up of process soils, and it must be easy to clean between uses. There are also regulatory requirements to be considered when it comes to hygienic equipment. The Machinery Directive EC 2006/42, for example, requires that machinery intended for use with foodstuffs is designed and constructed in such a way as to avoid any risk of infection, sickness or contagion. This means that all surfaces in contact with foodstuffs must be smooth and have neither ridges nor crevices which could harbour organic materials. And they must be easy to clean and disinfect where necessary after the removal of any easily-dismantled parts. Expert advice relating to the design features of hygienic equipment is available from the European Hygienic Engineering and Design Group (EHEDG), a global consortium of over 400 food processing equipment manufacturers whose aim is to ensure the hygienic design of process equipment. It publishes guideline documents and sets best practice, as well as certifying that equipment meets the highest standards of food hygiene, providing a globally recognised test method for establishing the cleanability of hygienic equipment, using a specified cleaning and testing regime. The latest version of the EHEDG Guidelines was published in March 2018 and this document can be freely downloaded from www.ehedg.org. Equipment certified by EHEDG offers the user a guarantee that the product meets strict engineering principles, stringent design guidelines and test procedures. EHEDG was started by Unilever in 1989 following a series of food contamination issues. Despite its best efforts to clean the plant between production runs, the company found that contamination and spoilage organisms were still being carried from one batch of food to the next. Unilever realised that the problem must, therefore, lie with the design of equipment. With a number of its competitors suffering from the same issues, EHEDG was born. OPERATOR BENEFITS It is important to bear in mind that hygienic design is not just about ensuring product safety. It can also offer operator benefits in terms of reductions in cleaning times as well as providing substantial savings in the
Quarter 1 2019
amount of water and chemicals needed for cleaning. For this reason the ease of cleaning and maintenance of pump systems should form part of the total cost of ownership (TCO) equation. Capital outlay forms just a fraction of the total operating expense. Watson Marlow Fluid Technology Group (WMFTG) warns against falling into the ‘cheapest is best’ trap. This, says the company, is short sighted for hygienic applications and it is important to look at overall product performance, reliability and suitability of equipment for an application. There is little point in buying a cheap product if it ultimately costs more in terms of maintenance, installation or integration into a machine or system. The MasoSine pump range, for example, has full steam-in-place and clean-in-place compliance and offers the reassurance that it has been designed and tested to meet the requirements of EHEDG Type EL Aseptic Class I. BEYOND THE PUMP Paul Green, UK sales manager for AESSEAL, moves the discussion on. He explained that ensuring you have a suitable pump system requires more than just specifying a hygienic pump. He said: “Mechanical seals are crucial to the reliable function of processing equipment. Despite this AESSEAL has identified a serious knowledge gap around key pieces of regulation relating to them. As a result, mechanical seals manufactured from unsafe materials are routinely specified in pump design and ongoing maintenance, creating a hygiene risk at several points along a production line.” Food Contact Materials regulation EC 1935/2004 states that any mechanical seal on a food and drink production line must be 100% traceable and a statement of compliance must be clearly marked on the packaging it comes in.
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Pump services - more than a standard overhaul as standard With more than 30 years’ multi-industry experience in electro mechanical engineering, in house pump repair and servicing expertise, we offer: • Specialist repair, maintenance and life extension • Upgrade and refurbishment • Improved efficiency and reliability • Reverse engineering and design capabilities • Fault finding, diagnosis and root cause analysis • Dynamic load testing and diagnostics • Supply of new pumps and spares • Condition monitoring and preventative maintenance • Laser alignment • 24 hour/365 onsite support and condition monitoring • All brands – independent of OEM Combined with our other electro mechanical engineering services, which include motor repair and maintenance, we offer a full multi discipline service covering the whole pump and motor set. Houghton International Riverside Court, Fisher Street Newcastle upon Tyne NE6 4LT United Kingdom
T: +44 (0)191 234 3000 E: info@houghton-international.com W: www.houghton-international.com
At AESSEAL® we pride ourselves on exceeding customer expectations for over 40 years.
AESSEAL® develops, manufactures, and sells mechanical sealing and reliability focused engineering solutions, to major blue chip customers around the world. Since establishing in 1979, UK based AESSEAL® has quickly grown to be the fourth largest mechanical seal manufacturer in the world, employing over 1,800 employees, with operations in more than 100 countries.
www.aesseal.com
24 FOCUS ON HYGIENE
“The complexity of source materials and supply chains means that traceability can very easily get lost along the way,” continues Paul. “Those who work with an external supplier to maintain their equipment also assume – sometimes incorrectly – that the supplier has properly interpreted and implemented safety legislation. “Our advice to companies seeking to guarantee compliance is simple. Look at the label and if the seal comes in packaging which does not clearly state its source, do not use it. This is the easiest solution to a potentially serious problem within hygienic applications.” MATERIAL CHOICES Eric Partington, chairman regional section of the European Hygienic Engineering and Design Group (EHEDG), also commented on issues relating to the selection of materials when putting together a pump system for hygienic applications. He said: “Article 3 of EC 1935/2004 demands that materials shall not transfer their constituents into food at levels harmful to human health. “The end user must be able to correctly describe the conditions, in detailed technical terms, to the supplier so that they can react appropriately and select the correct materials for a particular application. Simply telling a supplier that a pump will be for food use is not good enough! It is the responsibility of the operator to determine the operating conditions under which the equipment will be expected to perform. It is important that the supplier knows the chemistry of the products being pumped, the temperature of the pumped product and for how long the product will be in contact with the material. Similar information is also required for any necessary cleaning procedures,” continued Eric. For metal, alloy and glass demonstrating compliance with EU legislation can be covered by proving ‘significant and relevant past experience’. Stainless steel, for example, has been proven over many years in food production plants, as has nitrile rubbers and PTFE. However, where there is no such significant and relevant past experience of a material Quarter 1 2019
then it is necessary for the material to be tested in order to demonstrate that any constituents that may be released into a processed product are below the levels stipulated by the World Health Organisation. Eric continues: “It is a common misunderstanding that the way around food contact materials legislation is for the buyer simply to stipulate that all food contact materials must be FDA approved. This is not the case,” warned Eric. “It is a meaningless claim and is insufficient to meet the obligations laid down in the UK. It is compliance with EC 1935/2004 that must be demonstrated.” So, while the primary responsibility for meeting EC 1935/2004 lies with the equipment supplier, the end user does have a secondary responsibility to provide its supplier with sufficient technical data for them to be able to ensure compliance. According to Eric, the buck actually stops with the person who puts the materials and equipment in contact with the product.
“If the seal comes in packaging which does not clearly state its source, do not use it.”
CONCLUSION In conclusion, when hygiene is an issue it is important to choose wisely. Buying decisions for products used in hygienic applications should never be made solely on price and it is important to have good technical dialogue between the equipment manufacturer and the user. As stated in the EHEDG Guidelines documents it is more effective to incorporate hygienic requirements into the initial design because upgrading an existing design can be prohibitively expensive and may fail. Benefits are not only product safety but also the potential of increasing the life expectancy of equipment, reducing maintenance requirements, enhancing sustainability and lowering operating costs. chevron-circle-right www.ehedg.org www.watson-marlow.com www.aesseal.co.uk www.bpma.org.uk
As one of the UK’s leading pump distributors and pump manufacturers we are proud to be celebrating 100 years in business. To mark this anniversary we have launched our ‘100 for 100’ campaign. We have nominated 12 good causes, including local community projects and charities, as well as national charities and each month we will donate 100 sought-after items to one of them.
100 for 100
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26 FOCUS ON HYGIENE
Gently does it
When it comes to the dairy industry, in addition to specifying pump systems that meet scrupulous hygiene standards, it is also vital to find a solution that can offer gentle product handling.
W
hen a UK-based manufacturer of dairy-based ingredients identified a possible contamination issue related to its existing positive displacement (PD) pump, it quickly set out to find a solution. Eddy Smeaton, a food sector specialist at WatsonMarlow Fluid Technology Group (WMFTG), takes up the story: “Our customer had a number of PD pumps on site, and although they performed well and were food-grade rated, there was always the worry of potential contamination from the wear parts of the pump. As a result, the company started looking for a pump that could do the same job, but which could take away the risk.” By chance WMFTG was already talking to the company about a separate dosing pump application, so it was already aware of the features of the MasoSine Certa pump. It ticks all the boxes when it comes to suitability for use in hygienic applications, meeting the requirements of 3-A design, EHEDG Type EL – Class I and even EHEDG Type EL – Class I Aseptic. The aseptic certification confirms the bacteria-tight design when using a double mechanical seal. In addition, it proves that the pump can be steam sterilised. WMFTG provided the company with a trial pump so that it could assess its suitability for transferring soft cultured products. Further, unlike traditional pumps, with rotors that cut through the fluid, the sinusoidal rotor of the MasoSine Certa gently carries product through the pump to reduce shear – an important factor when handling dairy-based products. Further advantages delivered by sinusoidal technology include energy efficiency. It can cut power consumption by up to 50% when used with high-viscosity fluids. Importantly for this application, separation between the wet end and dry end ensures that there is no potential for contamination. The customer has since expanded one of its facilities with the introduction of a new filling machine, for which another Certa pump has been specified, bringing the total number of units in the facility to 10. Each is used for transferring different soft cultured products such as yoghurt, butter, cream and soft cheese. It moves them either from intermediate bulk containers (IBCs) to plant or from tanks to plant, or pushes them through pasteurisers. The pumps are also used for blending ingredients in various viscosities. In terms of transfer distance, the farthest is 20 metres with a four metre head. Flow rate tends to be dictated by other parts of the process. CREAM CHEESE A German dairy, Goldsteig Käsereien Bayerwald, also put its trust into the MasoSine Certa Sine pump Quarter 1 2019
for the production of cream cheese because gentle handling was a key requirement for transferring the cream used by the dairy to produce mascarpone and whey for ricotta. “Pumping is an important stage of production, where due care and gentle handling matter most,” said Günter Schlattl, operations manager at Goldsteig. “If the shearing forces are too high, then the binding – and thus the structure of the mixture – can be damaged. Ultimately, the final quality of the cream cheese will suffer, and for ricotta and mascarpone, the texture of the end product is essential.” Another critical consideration when choosing a pump for this application related to the need for regular clean-inplace (CIP) operations. “The appropriate certification was crucial for the application as we perform a daily CIP clean with caustic,” said Günter. “After one of our first CIP operations following installation, we opened the pump to check the results and found that it was totally clean.”
“Using a centrifugal pump would churn the cream into something like butter.”
www.bpma.org.uk
FOCUS ON HYGIENE 27 CLOTTED CREAM Another advocate of Certa pumps in the dairy sector is A E Rodda & Son which has been producing Cornish clotted cream since 1890. In 2012, the company installed a MasoSine SPS 200 sine pump as part of a new clotted cream line, and its performance impressed the maintenance team. “We were in the process of investing in a new depositing machine, which essentially deposits cream into a pot and seals it with a lid, so we needed to look for a suitable hygienically-designed pump to transfer the product from mobile storage tanks,” explains Paul Johnson, maintenance supervisor at Rodda’s “Over six years of hard work we had virtually no maintenance issues with an existing MasoSine SPS 200 which has looked after itself. Importantly, the pump does not damage or compromise product integrity, which is crucial to our production process.” The same approach was needed for the company’s new pouring cream production facility – low shear, low pulsation and gentle handling. “Using a centrifugal
pump, for example, would effectively churn the cream into something like butter,” said Paul. “A sine pump was the way forward and we were keen on the new Certa from WMFTG, especially because of its energy-efficiency attributes.” WMFTG’s technical team advised A E Rodda & Son that the smallest pump in the Certa range, the Certa 100, would meet the application requirement as it was able to deliver the required flow rate of up to 4,200 l/hr. In terms of the process, a mobile storage tank is wheeled up to the new depositing machine, and the pump transfers cream from one to the other. The pump is mounted low, facilitating a two meter head into the machine’s hopper. No priming is required. “We have had the MasoSine Certa 100 for around 12 months now and there have been no issues whatsoever,” concluded Paul. “From experience we have now also learned that it is three times more expensive to run a pneumatic pump than an electric pump.” chevron-circle-right www.watson-marlow.com
Solutions for systems of all types and sizes
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28 Hygienic Product NEWS
OPTIMAL PRODUCTIVITY AND CLEANLINESS NATIONAL OILWELL VARCO (NOV) has made its new Hygienic Range pump commercially available in the UK. NOV developed the new pump to meet the food and beverage industry’s need for a cost-effective, reliable and hygienic solution that ensures optimal production levels while adhering to the highest standards of cleanliness. The pump adheres to the design standards of the 3A and EHEDG certification bodies to ensure that it is one of the most hygienic on the market. The gentle pumping action of the progressive cavity pump handles applications such as food processing, dairy, pharmaceutical, cosmetics and chemicals production. According to NOV, the Hygienic Range pump is cleaner and more cost-efficient than pin-joint pumps and other flexible joints consisting of one solid piece. Titanium Flexishaft technology allows pump users to remove retention areas that can harbour and promote bacterial growth, improving hygiene and complying with food standards. The pump is tie-bar free to reduce the
number of components and aid strip and inspection, while hygienic foot mounting holds the stator in place. In addition to easier maintenance and fewer expensive parts, the titanium Flexishaft is shorter in length than comparable steel pumps, increasing flexibility and allowing for its use in space constrained applications. With no wearing parts, the Flexishaft offers lifetime cost savings over conventional drive train designs and extends intervals between routine maintenance. NOV designed the Hygienic Range pump to suit varying conditions and to overcome challenges, giving users installation flexibility for clean-in-place and clean-out-of-place situations. The Hygienic Range pump transfers solids up to 25mm in diameter and incurs minimal product degradation in shear-sensitive applications. It also efficiently moves viscous slurries and can handle thin liquids and corrosive applications. www.nov.com
SEALS DELIVER BOTTOM-LINE SAVINGS THE DUPONT KALREZ LS390 SERIES of perfluoroelastomer sanitary seals, available in the UK from Dichtomatik, have been designed specifically for use in sectors such as life science, food and beverage, and pharmaceutical. Several problems can be experienced in sanitary seal applications, many of which are related to thermal and chemical resistance challenges, compression set (permanent deformation), and high static friction (stiction). These issues can lead to intrusion in the production line or dead space, which in turn elevates the risk of contamination or leakage. The Kalrez LS390 series has been
purpose-designed to overcome these common challenges by providing high hardness properties (Shore A3 88), low stiction, temperature resistance up to 220°C and outstanding chemical resistance to process chemicals, WFI (water for injection), and steam-inplace (SIP) and clean-in-place (CIP) processes. For users, these properties facilitate greater MTBR (mean time between repair), delivering bottom-line cost savings. www.dichtomatik-kalrez.co.uk
AVOIDING CONTAMINATION
FLOTRONIC’S E SERIES PUMPS HAVE been designed to enable ease of cleaning for all product contact and non-product contact parts. The 10-inch version, with 2-inch connections, offers a pump solution to customers with low to mid-range flow rate applications, while customers seeking flow rates as high as 500 ltr/min can use the 12-inch pump with ½-inch to 3-inch connections. The 10-inch E Series pump has a support stand allowing the pump to be rotated for easy and effective draining. Gravity separates the ball valves from their seats in this inverted position allowing cleaning fluids to drain away from the delivery nozzle quickly. The 12-inch E Series pump has check ball valve seats that are engineered to allow drainage without inversion. This avoids the need to rotate a relatively large machine. Reinforced diaphragms are standard on the E Series. Reinforcing plates ensure the pumps can withstand cleanin-place (CIP) and steam-in-place (SIP) pressures up to 6 bar in a production line. This means the pumps can be cleaned in place using fully automated CIP units incorporating external CIP pumps, without the need to bypass the pump. Tested to exacting performance standards by EHEDG (the European Hygienic Engineering & Design Group), the E Series is suited to use in any application where avoidance of product contamination is paramount. www.flotronicpumps.co.uk
Quarter 1 2019
www.bpma.org.uk
Established in 2006 TEC Electric motors is now considered to be the largest independent electric motor supplier within the UK & Ireland. From humble beginnings 12 years ago, TEC has consistently grown at a rate of £1.5 million pounds per annum. Sales of £20 million GBP are expected in 2019. TEC's policy of re-investment in the business has resulted in a move to a new modern 90,000 square foot facility on Europe's largest industrial estate. The stock holding of £12 million GBP and approximately 150,000 units is the largest in the UK. All Backed by 24/7 365 day call out; "Exceptional customer service" is at the core of company beliefs. Facilities to modify motors to customer requirements on short lead-times; in particular to"WIMES" specifications and non-standard paint finishes (ISO12944/C5M) makes TEC the preferred supplier of choice to many industries in particular the pump sector. TEC continues its pursuit of continuous improvement with a recently re designed website which allows customers to access electrical data sheets and drawings in 2D & 3D formats instantly. However TEC is not just a local supplier, forming part of a global organisation with TECHTOP's partners in America, Australia, France, Germany, Spain, Greece, Holland and Italy to name but a few. This allows access to an additional stock holding of over £50 million offering global support to your business. If you are looking for an electric motor supplier with a dedicated team, integrity and reliability, we are sure you will not be disappointed.
otal ngineering ommitment
.tecmotors.co.uk
Year formed: 2006 Number of staff: 47 HQ location: Worcestershire Turnover: £19 million Markets: HVAC, Conveyor, Pump, Hydraulic, Offshore, Distribution. Website: www.tecmotors.co.uk
• 0.09kW-8MW • 2/4/6/8/10/12 Pole • 56-630 frame • Multi mount 56-200 Aluminium • Multi mount 80-280 Cast Iron • Fixed feet 315-630 Cast Iron • High Voltage: 3.3, 6, 6.6, 10, 13.8kV • TEFC, CACA/CACW • IE1, IE2, IE3, IE4 Efficiency motors • IE3 motors ECA approved • Increased output IE1, IE2, IE3 • 1ph motors 56-112 frame 1ph motors 230v/110v • 60hz 1ph motors also available • ATEX Exde Zone 1 71-355 frame • ATEX Zone 2/22 56-355 frame • ATEX Zone 21 & ATEX 1ph • Brake motors, retro brake fitting • Special voltage, special shaft • Vector encoder motors • Forced ventilated motors • In-line gearboxes • Right angle worm boxes • • • • •
Mechanical speed variators TECDrive Inverters - IP66 and IP20 Double reduction units Helical in-lines Slipring Motors on request
FEATURE 30 Opinion
Are UK SET BUILDERS MISsING THE MARK? Gary Wilde, BPMA Technical Services Officer, believes that M&E consultants should be doing more for the safeguarding of the industry under CE, or the soon to be introduced UKCA, Marking requirements.
A
t the time of writing, it is unclear when the recently announced UKCA Marking, set to replace CE Marking for goods placed on the UK market, will come into effect. However, with the UK Government confirming that the rules for UKCA Marking will essentially mirror those for CE Marking, one requirement is unlikely to change – the need for any piece of machinery brought to market to carry the appropriate mark, even if all the component pieces of that machine have been assessed independently. This means that any mechanical and electrical (M&E) consultants or end users specifying pumping equipment such as water booster sets, pressurisation, rainwater harvesting, heating systems, sewage tanks or any other bespoke units, should ensure that the complete set is CE, or in time UKCA, marked. However, it seems that a significant number of UK set builders believe it is acceptable to bring together components from different suppliers and rely on the CE Marking placed on the individual items as compliance for their packaged set. My research has led me to believe that only a few set builders currently comply with the requirement to CE mark the packaged set. CE Marking of a packaged set is a legal requirement, and consultants who fail to comply are breaking the law, putting themselves at risk of prosecution, hefty fines and possibly even imprisonment. They are also putting the final user at risk of breaching health and safety rules. The British Pump Manufacturers Association (BPMA) is keen to ensure that all assembled equipment sets, especially those with pumps incorporated, are put into service correctly. Original pump manufacturers incur tremendous costs to correctly implement the required legislative programmes so that the products they bring to market meet all appropriate certifications. The BPMA and its members are therefore calling on all consultants, M&E contractors, design and build specialists, distributors and installers to work together to use and install only CE marked equipment. Many people are not aware that if assemblers, suppliers and installers market other manufacturers’ products under their brand names, Quarter 1 2019
they take over the original manufacturer’s responsibilities, and they will be assuming the legal responsibility and CE marking obligations of the products they build. A complete set needs to have its own identification label affixed with an appropriate CE mark and will need to comply with the legislation which applies to it. The label needs to carry a minimum amount of information along with contact details for the set builder and details of where the packaged set was manufactured. Each assembled set will need to be supplied with a full and comprehensive instruction manual. The set will also need to be supplied with a Declaration of Conformity (DoC) referencing the appropriate legislation and EN standards where applicable. Most importantly, the set assembler will need to prepare a technical file that will include risk evaluation, product data, product features, production methodology and health & safety considerations. So, what should you do if you come across a product in the supply chain that is not CE marked? You can ask your supplier at any time for full details of the CE Marking of their products. If they cannot give you these details, then you should contact Trading Standards. Packaged pump set builders must play their part when placing products onto the UK market to comply with the law. It, therefore, makes sense only to specify, purchase and install CE marked, or when relevant, UKCA marked equipment. chevron-circle-right
“The BPMA and its members are calling on all consultants, M&E contractors, design and build specialists, distributors and installers to work together to use and install only CE marked equipment.”
www.bpma.org.uk
PUMP INDUSTRY AWARDS 2019
Welcome to the pump industry’s biggest celebration! Your chance to network and party with the industry’s best & brightest. The PI Awards Gala Dinner is the highlight of the pump industry’s social calendar, celebrating the achievements of both companies and individuals, as finalists and winners are awarded in the charged atmosphere of the awards ceremony. Whether it’s taking a table to host customers or booking a few seats for you, your team and partners, don’t miss this fantastic opportunity to enjoy a wonderful evening of great food, fantastic entertainment, networking and dancing until the early hours.
EVENT CALENDAR ED FINALISTS NOW ANNOU N C VOTING OPENS
WINNERS ANNOUNCED
February
March
Just visit the website www.pumpindustryawards.com and complete the simple online booking form to secure your places at this must-attend event, being staged on the 21st March at Heythrop Park Resort.
Penny Smith is an English television presenter, newsreader and radio presenter. She has presented for Sky News, GMTV, Classic FM, BBC Radio London and is the current presenter of Weekend Breakfast on Talkradio.
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THE TIMINGS 19.00 - Drinks reception 19.45 - Dinner served 21.30 - The Pump Industry Awards Ceremony 22.15 - Charity raffle on behalf of Wateraid 22.30 - After party with entertainment, music and dancing 01.00 - The survivor’s breakfast
2019 PARTNERS
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www.pumpindustryawards.com
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environmental contribution of the year
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