Flow Magazine - Quarter 4, 2020: Food & Beverage Focus by GC Touchwave

Quarter 4 2020

Pump industry insight from

FOCUS ON: Food & beverage

Maintenance solutions drive huge savings

The pump industry's drive for energy efficiency 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 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.

elcome to our last issue in 2020. As I write, despite being in lockdown and a new series of tiers suggesting there are still tough times ahead, there is light on the horizon. With vaccine news emerging daily, we have to believe that things will slowly improve as we move into 2021. And to that end, we are bringing you another issue packed with insight and information designed to help improve your business. In the food and beverage focus section, we look at a variety of considerations needed when specifying pump systems for applications in this sector, where the wrong decisions can have a significant impact. The feature discusses control solutions, drive mechanisms and material choices, all of which can affect a pump systems suitability for its task. Elsewhere in this issue, we explore the role pumps play in tackling environmental challenges such as the effects of erosion. We report on a project aiming to clean up parts of Canada’s Lake Ontario which required 12 pumps collectively capable of pumping 23,600 l/sec, with a solids content of up to 190mm. A little closer to home, we find out how a new water supply system at a care facility solved a quality issue which saw the site failing statutory quality tests. We also have tips on using variable speed drives with submersible pump systems. On top of all this, we have our usual round-up of product and industry news. Plus, we share news from the BPMA, which reached a milestone in November by signing up its 100th member. So as the BPMA ends the year on a positive note, I’d like to wish you all a more prosperous 2021! Richard Harden, President, BPMA

PUMP INDUSTRY NEWS 4

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

Partnership expands training offer 6 Engineering company invests in future growth

Twitter @bpmapumps

BPMA NEWS

flow is a controlled circulation journal published quarterly on behalf of the BPMA by Touchwave Media Ltd and G and C Media Ltd. For a copy of the magazine’s terms of control and to request a copy please email circulation@flowmag.co.uk The content of flow magazine does not necessarily reflect the views of the editor, publishers or the BPMA. The publishers accept no legal responsibility for loss arising from information in this publication and do not endorse any products or processes mentioned within it. No part of this publication may be reproduced or stored in a retrieval system without the publisher’s written consent. © BPMA. All rights reserved.

Bringing the industry together physically and virtually

BPMA signs its 100th member

PRODUCT NEWS 10 New grinder can process thicker sludge 11

Boosting pharma and biotech process efficiency

12 Wireless condition monitoring suite gains automated machine health diagnostics

www.bpma.org.uk

Key appointments at Sundyne

Radar transmitter controllers enhance pump operations

Compliance 14 The pump industry’s drive for energy efficiency

features 18 Cleaning up the shoreline 20 Safe water supply ensured at care facility 22 Controlling and monitoring pumping systems

Focus on food & beverage 24 Specifying pump systems for food and beverage applications 26 Maintenance solutions drive huge savings 28 Food & beverage sector news and updates

OPINION 30 Consider a submersible pump’s VSD carefully Quarter 4 2020

4 INDUSTRY NEWS

KEY APPOINTMENTS AT SUNDYNE THE GLOBAL PUMP AND COMPRESSOR manufacturer, Sundyne, has announced three new senior appointments in support of its strategic growth plans and focus on first-class customer service. Colin Guppy takes up the role of Chief Commercial Officer. In this newly created role, Colin will lead the original equipment and aftermarket strategies for Sundyne’s vertical markets in the Americas, Europe, the Middle East, Africa and India. Neil Langdown has been promoted to a new strategic role as Commercial Excellence Leader. Neil will also continue to serve Sundyne customers in his current role as Vice President for Asia.

In his newly appointed role, Neil will focus on creating value by leveraging IOT condition-based monitoring to develop new business models and service offerings. He will also work to improve efficiency and profitability by digitising business processes and enhancing the customer experience through seamless platform integration. In the third appointment, Andrew Matsuyama has been appointed Chief Financial Officer. Andrew brings with him extensive experience as a financial leader and a proven track record in driving through strategic initiatives on a global scale.

BENCHTOP PUMPS CHOSEN BY JAPANESE BIOTECH

PARTNERSHIP EXPANDS TRAINING OFFER PLANT RELIABILITY AND ASSET management specialist, AVT Reliability, has expanded its training offering in a new partnership with international skills provider Mobius Institute. The partnership will enable the AVT Reliability group of companies to deliver on-site, accredited courses in Europe, United States of America and Canada, as well as remote learning courses

across the globe, in addition to its longestablished UK and Ireland offering. In conjunction with Mobius, AVT Reliability will offer Category I to III Vibration Analysis, Certified Level I and II Ultrasound, as well as Asset Reliability Practitioner (ARP) training, with certification through public, on-site and online courses, as well as iLearn self-study programmes.

SYSTEMS INTEGRATOR JOINS WEG DISTRIBUTION NETWORK MOTOR, DRIVE AND GEARBOX manufacturer WEG, has welcomed Quantum Controls to its distribution network. Quantum Controls will now supply WEG’s products to its customer base throughout the UK. The Northumberland-based business is not just a distributor of motors and drives, but also a systems integrator offering 24-7 service. This offering adds a wealth of experience, knowledge and expertise to WEG’s distribution network. With 20 years of supplying motors and drives from a range of manufacturers, Quantum Control’s move to the WEG distribution network is a carefully considered business decision. It coincides with Quantum Control’s plans to open new distribution centres in Scotland and the South of England, as it expands its customer base. “This new alliance extends far Quarter 4 2020

beyond offering WEG motors and drives,” explained Kevin Brown, Director of Quantum Controls. “As systems integrators for any production line that requires motion, we help our clients reduce downtime and be as energyefficient as possible. This closely aligns with WEG’s ethos, which played a big part in our decision to move forward with WEG.

A LEADING JAPANESE manufacturer of fermentation and bioreactor systems, Able Biott, has chosen 120 benchtop pumps from Watson-Marlow Fluid Technology Group (WMFTG) for use in biopharmaceutical processing equipment, including a range of multi-purpose bioreactors. The pumps were selected for their compact size and ease of installation, overcoming issues with tube loading in previous pumps. Able Biott chose the 120U/DV benchtop pump for its superior control. It comprises a 114DV flip-top pumphead powered by a drive which offers both manual remote control and automatic control options. This combination makes the pumps easy to use whilst offering excellent flow rate accuracy. The choice of pumps allows ease of incorporation into Able’s bioreactors as they are ultra-compact and stackable offering multiple feeds such as pH control, antifoam, nutrient and buffer addition to maximise yield in fermentation and cell culture applications. The compact size of the pump saves valuable space in cleanroom, LAF and biosafety cabinet environments whilst maintaining important functionality. Multiple flow rates and superior speed control produce consistent and repeatable flow. www.bpma.org.uk

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6 INDUSTRY NEWS

AESSEAL ACHIEVES NET ZERO UK CO2 EMISSIONS AESSEAL PLC HAS REACHED A significant environmental milestone by achieving net zero carbon emissions in its UK operations. This achievement covers all scope 1 (direct emissions from owned or controlled sources) and 2 (indirect emissions from the generation of purchased electricity, steam, heating and cooling) greenhouse gas (GHG) emissions plus those associated with business flights. The Rotherham-based company, which designs and manufactures mechanical seals and support systems, is now on target to achieve global net zero GHG emissions across all its locations worldwide by 2029. In light of its accomplishment AESSEAL has launched a global

campaign – Betterworld – to drive collective action to mitigate climate change across all industries. Through the Betterworld. solutions web site, the company aims to demonstrate how sustainable policies and practices can lead to net zero carbon emissions without negatively impacting on productivity or profit. Chris Rea, Managing Director of AESSEAL, said: “I believe the move towards net zero is not a matter of choice for industry – it is an urgent imperative.

“We have shown that it is possible to make a valid contribution to the UN target to reduce global warming but we cannot do this alone. Betterworld. solutions is our first step in supporting other industry executives who wish to join us to secure a more sustainable future for the planet.”

Engineering company invests in future growth ELECTROMECHANICAL engineering specialist, Houghton International, has agreed a deal with Siemens Energy which will see it take over the former blade manufacturing factory at the birthplace of the steam turbine, the CA Parsons Works in Heaton. The 120,000sqft of world-class engineering space will be used to consolidate five of the company’s operational sites alongside the existing pump repair facility currently housed on the site, also creating significant room for further growth. The move represents a significant milestone for the company, which has experienced rapid growth over the past five years and will create a best in class facility from which to service its growing domestic and international customer base. Positioning itself for future growth in emerging markets, the company also intends to retain its large machine

facility on Shields Road adjacent to a new workshop to service an increased demand for larger repairs from around the UK, providing a total combined footprint over 135,000sqft. The factory will be named The Ronnie Mitten Works after one of the company’s

founders, Ron Mitten, whose technical legacy still brings work into the business each day, well over a decade after his death. The move into the new site is intended to be completed by the end of 2020.

QUALITY MANAGEMENT CERTIFICATION GIVES CUSTOMER CONFIDENCE PMF CONSULTANTS, WHICH joined the BPMA in June 2020, has announced that its quality management system is now UKAS certified to BS EN ISO 9001:2015. This certification provides Quarter 4 2020

reassurance to clients that failure analysis at PMFC is performed using controlled and consistent processes with a focus on customer satisfaction and continual improvement. www.bpma.org.uk

Your Asset Care Partners Working with us to ensure the care of your assets means having an experienced team on hand to help you meet your manufacturing targets cost-effectively. Our Ou team will help keep your assets safe and achieving their full potential through reliability-centric care and can help deliver fast-track improvement of o your entire plant maintenance regime, reduced costs and increased productivity.

Plant Maintenance Reliability Improvement Condition Monitoring Engineering Compliance For further information and case studies visit www.ejmusk.co.uk

8 BPMA News

BRINGING THE INDUSTRY TOGETHER – BOTH VIRTUALLY AND PHYSICALLY IN WHAT WAS A RARE OPPORTUNITY FOR THE BPMA’S members to get together this year the association’s annual golf day went ahead on September 12th, observing social distancing requirements. This year’s event was held at Belton Woods in Grantham and commenting on the event, BPMA CEO, Steve Schofield, said: “It was pleasing to see that even in a pandemic our members were still keen to support this event, fielding 47 players across 12 teams.” Representatives from the industry also came together before the second national lockdown to attend the first Certified Pump System Auditor (CPSA) Training Course since 2019. Following months of uncertainty due to the ongoing COVID-19 restrictions, the BPMA finally ran its latest course to a small but knowledgeable group of delegates, which included Shane Bates of KSB, who gained his place by being the first person to score a perfect 100% on the BPMA’s Essentials E-Learning Course. Recognising the need for social distancing, the association’s annual AGM was held virtually this November. As well as looking at the past 12 months activities and how BPMA has responded to the challenges faced by everyone, Terry Boniface, Assistant Director – Electronics and Machinery from UK Government Department for

Business, Energy & Industrial Strategy (BEIS), joined the meeting to give a Brexit update. Also organised as a virtual meeting, the BPMA brought together representatives from the industry to hear from certification, inspection, testing and training specialist, Kiwa Watertec, about its Regulation 4 product approval scheme for manufacturers and distributors of sanitary and plumbing products and components intended for installation in the UK. This alternative approval method will be covered in more depth in a future issue of flow.

BPMA WELCOMES ITS 100TH MEMBER THE BRITISH PUMP MANUFACTURERS ASSOCIATION (BPMA) has reached the milestone of 100 member companies. The most recent company to recognise the benefits of membership and achieve the accolade of being the BPMA’s 100th member is Surrey-based repair, service and supply specialist, PumpServ. Formerly known as London Pumps the business is now part of the Keltic Engineering Group. Currently, the group employs over 75 people and has nationwide coverage with warehouse and offices in Surrey and Hampshire, and regionally based engineers operating throughout the UK. PumpServ is one of the top three distributors in the UK, supplying major brands such as Armstrong, Dab, Ebara, Grundfos, KSB, Sulzer, Wilo, and Xylem. Its services range from commercial heating pumps and chilled water pressurisation units through to wastewater and drainage pumping stations. Commenting on its membership of the BPMA, Matt Magee, CEO of PumpServ, said: “Like the 99 members that preceded us, PumpServ have recognised the value offered by BPMA membership. We are excited to capitalise on the first-class

training, excellent networking opportunities and improved access to technical standards.” Another company to appreciate the commercial opportunities afforded by membership is Polypump Ltd. Based in Wallingford, Oxfordshire, the company represents leading professional rotating equipment manufacturers with a bias towards centrifugal and positive displacement pump systems, mixers, chemical dosing systems, larger gear drive systems and speciality motors. Rapid Solutions (International) Ltd has also signed up to be a full member of the BPMA. Founded in 1996, it provides repair, overhaul, upgrade, installation, and commissioning services for virtually all types and brands of pumps, compressors, heat exchangers, valves, and other rotating equipment. Commenting on this latest milestone achievement, Steve Schofield, Director and Chief Executive of the BPMA, said: “I am thrilled to welcome these three businesses into our association and provide them with all the support services at our disposal. “This would have been a significant achievement in any year, but to have secured our 100th member during the challenging times we have all been experiencing throughout 2020 is really quite remarkable.”

For details of the full range of training available from the BPMA download the FREE training guide at:

bit.ly/BPMAtraining BPMA TR AINING

DELIVERIN

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E-LEARNING

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CE THROUGH

BASED

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GUIDE INDEPEND

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ADDITIONAL

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10 product news

NEW GRINDER CAN PROCESS THICKER SLUDGE SULZER HAS EXTENDED ITS 10K MUFFIN MONSTER series of grinders with the approved use of a 4kW motor. The motor allows the 10K Muffin Monster to process thicker sludges and heavier solids in lower flow environments without damage to the integrity of the grinder, protecting pumps and other critical equipment from costly clogs and damage. The compact 10K Muffin Monster can reduce the size of potentially damaging solids to downstream equipment. Its dual-shafted grinder uses low speed and high torque to shred a wide range of difficult sewage debris. Its inline pipe configuration is available with 100mm and 150mm pipe flange diameters with flow rates up to 125m3/hr. The open channel configuration of the system has a cutter opening height of 185mm with a flow rate of up to 41.4m3/hr. Sulzer believes it can offer a complete solution for handling the challenge of the increased volume of tough solids in wastewater with the Muffin Monster grinder and its pump technology. The combination is said to ensure troublefree operation of pump stations and other critical operations. www.sulzer.com

PREDICTIVE MAINTENANCE SYSTEM OFFERS 24/7 EXPERT SUPPORT HAYLEY 247’S INNOVATIVE CONDITION MONITORING software platform – Asset Minder – monitors data from a variety of wireless sensors strategically attached to critical assets, each one measuring issues such as vibration, temperature, pressure, flow and thermography. Customers adopting Asset Minder receive 24/7 support on alerts detected by the sensors and have subsequent access to the comapny’s knowledge base and expertise. Equipment is much less likely to fail if corrective action can be proactively administered in a planned and timely manner. Mark Brady, Hayley 247’s Managing Director, believes a significant aspect of the solution’s value comes from having experienced engineers analysing the data: “Our engineers understand the equipment. There is nothing more powerful than having the best understanding of the equipment and the data at the same time. This, in turn, benefits our customers as it ensures that their site engineers can have meaningful conversations with our

team. We can also help our customers make the right decisions by discussing issues and determining effective and long-lasting solutions.” www.hayley-group.co.uk

WE DON’T JUST SELL PUMPS, WE ENGINEER SOLUTIONS.

Find yours at tri-ark.com Quarter 4 2020

01621 781144 www.bpma.org.uk

Product news 11

BOOSTING PHARMA AND BIOTECH PROCESS EFFICIENCY, PRODUCTIVITY AND PRODUCT QUALITY AS WELL AS IMPROVING EFFICIENCY, PRODUCTIVITY and product quality, Alfa Laval’s new LKH Prime 10 UltraPure self-priming pump and upgraded LeviMag UltraPure magnetic mixers are also said to reduce total cost of ownership while ensuring more responsible use of resources for sterile processing applications. Both product ranges are backed by the Alfa Laval Q-doc documentation package for full supply chain transparency. “To improve manufacturers’ ability to compete, the UltraPure portfolio optimises pharma and biotech processes, pushing the boundaries of sterile production,” said Per-Åke Olsson, Industry Owner, Biotech & Pharmaceutical, at Alfa Laval. The LKH Prime 10 UltraPure is the most compact ever in the LKH self-priming pump range. It is well suited to duties up to 35 m3/h and is primarily engineered for cleaning-in-place (CIP) return, but also transfers product in sterile processes. This is said to deliver savings of up to 50% in capital expenditures and installation, and 30% in annual operating expenses. Other advantages are said to include up to 60% more energy savings than liquid ring pumps and up to 25% more than other airscrew pumps, a fully CIPable, EHEDG-certified hygienic design,

80% lower noise levels for a better working environment and easy maintenance with a streamlined spare parts inventory due to the common LKH platform. bit.ly/ALBiotech

THREE-DAY DELIVERY NOW AVAILABLE ON SELECTED ARMSTRONG PUMPS

POLYMERIC MATERIAL FAILURE CONSULTANTS

RESOLVE FLUID LEAKAGE CAUSED BY SEAL FAILURE SPECIALIST INVESTIGATORS OF POLYMERIC AND ELASTOMERIC COMPONENT FAILURE IN FLUID CONTAINING HARDWARE ARMSTRONG FLUID TECHNOLOGY HAS ANNOUNCED that several of its Design Envelope pumps are now available with a three-day quick-ship delivery time. Encompassing the most widely-used Armstrong pumps for commercial-scale applications, the three-day delivery includes key Vertical In-Line, End Suction, and award-winning Tango models. Kevin Goodison, Wholesale Distribution Sales Manager for Armstrong Fluid Technology, commented: “Our three-day delivery time will help customers by shortening project schedules and reducing downtime, especially in breakdown situations. We’re delighted to be the first in our sector to offer quick-ship delivery times on these larger, commercial scale pumps’. www.armstrongfluidtechnology.com www.bpma.org.uk

ISO 9001

O-RINGS GASKETS SEALS HOSES

Material identification and condition assessment Damage documentation and characterisation Forensic information gathering Evidence based root cause analysis

Tablet-alt

07851 086922 01992 509470

PHONE � philip.clarke@pmfconsultants.com desktop www.pmfconsultants.com

Product news 12 FEATURE 12

WIRELESS CONDITION MONITORING SUITE GAINS AUTOMATED MACHINE HEALTH DIAGNOSTICS ITT INC’S I-ALERT BRAND IS ADDING a new best-in-class automated machine health diagnostics offering to its portfolio, as an expansion to its wireless condition monitoring capabilities which are widely used by oil & gas, chemical, power, and general industries. Further elevating i-ALERT’s customer support with immediate notification in the event of machine faults, the new offering includes information about the severity of the fault and recommendations to resolve it with the accuracy of a skilled analyst. Thanks to the addition, customers can securely and instantly understand machine condition and see

recommended actions from anywhere in the world on their mobile device or computer, ultimately reducing the

downtime and extending the life of their machines. “As the adoption of wireless condition monitoring grows, our customers need to be able to process vast amounts of data, quickly and efficiently,” said Dan Kernan, Global Product Director, Aftermarket Solutions, at ITT. “Our new automated diagnostic software helps customers to easily upgrade their i-ALERT sensors to provide key insights into their machine’s health. Customers can have peace of mind about the condition of their machines and can protect them no matter where they are.” www.i-ALERT.com

RADAR TRANSMITTER CONTROLLERS ENHANCE PUMP OPERATIONS, LEVEL AND FLOW MEASUREMENT SIEMENS HAS LAUNCHED A NEW series of Sitrans LT500 level, flow, and pump controllers for radar and ultrasonic transmitters or any other two-wire 4-20 mA devices. From basic level control to complex pumping routines, these instruments deliver the accuracy and reliability demanded by a variety of applications. Complete with up to two measuring points, six control or alarm relays, two discrete inputs, three analogue outputs, and communications options, Sitrans LT500 is an attractive option for controller applications. Ensuring environmental compliance, the controllers keep operations in

line with local legislation, helping companies protect the environment while also keeping accurate records of their process. High-precision flow measurements meet ISO standards, and onboard data logging makes sure data backup is reliable for regulatory compliance. Users can retrofit older equipment with Sitrans LT500, as improved system control delivers savings directly to a company’s bottom line. By scheduling pumps before highdemand periods begin, users can avoid peak energy hours and the increased

prices that accompany them. Other programmable features help to reduce costly maintenance, including grease ring reduction, pump runtime and alternating pumps. www.siemens.com/sitransLT500

PUK VARI COM is now WRAS approved PUMPS UK HAS RECEIVED WRAS approval on its PUK VARI BOOST commercial water booster pump. The company took the extra step to assure its customers that its pumps are built to the highest standards. The PUK VARI COM is built in the company’s Rochester workshop with each order tailored (port location and flow direction) to its intended application. This approach can reduce pipework requirements and offer better planning and quicker installations. The booster pump’s Slow Fill program

Quarter 4 2020

has been designed to reduce the risk of water shock damage to pipework during system start-up after power cuts. As standard, the booster pump is supplied with BMS controls and a minimum threshold cutout if the water supply is lost. Full technical details for the range are available on the company’s website along with a new detailed booster pump selection brochure. www.pumpsukltd.com/pukvaricom

www.bpma.org.uk

ABB Ability™ Smart Sensor for low voltage motors Up to

Up to

less unplanned downtime

extended motor lifetime

reduction in operating costs

higher system efficiency

70% 30% 30% 10% — Your motors are talking to you Are you listening?

http://bit.ly/ABBSmartSensor

SPECIALTY OF THE HOUSE: EVERYTHING YOUR SYSTEM REQUIRES. With Vita pumps, we can cater to every one of your needs. KSB’s extensive range of Vita products with CIP/SIP capabilities can be implemented to cover all LSA processes – primary and secondary. Find out more. www.ksb.co.uk - 01509 231872

Pumps Valves Service

FEATURE 14 Compliance

The pump industry’s drive for energy efficiency Last year, the European Commission (EC) announced its commitment to delivering on its energy efficiency and carbon reduction objectives through its new Green Deal proposition. With pumping systems consuming up to 15% of all energy in Europe, Europump, of which BPMA is a member, looks at the significant contribution the sector has already made to energy savings.

cross Europe water pumps have the potential to save 50TWh of electricity every year. This is equivalent to the output of five large coal-fired power plants. Even though the pump industry’s contribution to gross domestic product is smaller than other sectors, by comparison, the energy consumption of pumping systems is much higher. It ranges from 10-15% of the overall annual electricity production throughout Europe and that is why the energy-saving potential of pumping systems is extremely high and why pump manufacturers place a great deal of importance upon it. Energy efficiency is, and always has been, a major part of the business model adopted by pump manufacturers. So, it is no wonder that the EU Commission, in its efforts to reduce energy consumption, considered regulating pumps at an early stage in the process. However, to help avoid any misunderstanding around how these reductions can be achieved, the

following should be noted: it is not the pump itself which uses the high levels of energy, it is the system in which the pump is operating. Without the right match of pump operation to a system’s overall requirements (or duty), even single component efficiency gains can result in increased losses across a system. A pump with a high stated efficiency, but which is too large for the system (a common occurrence across industry), consumes far more energy than the peak efficiency levels promise. At the opposite end of the spectrum, if an existing fixed-speed motor which drives a pump is replaced by a motor with higher efficiency (but without adding a speed control), it results in higher energy consumption, because the pump’s output into the system is higher than the system’s demand. ACTIVITY TO DATE Let us look at the activity timeline of the European pump industry in relation to improved energy efficiency in pumping systems (Figure 1). The Pump Industry: Start EN 16297 (circulators)

VDMA: Pump User Forum 2000: Main topic: life cycle costs

HI / EUROPUMP: LCC-Guide HI/EUROPUMP: Variable Speed Pumping

VDMA: Start LCC-Project

EUROPUMP: Circulator Self Committment EUROPUMP and Europ. Comm.: Guide to Pump Efficiency

EUROPUMP: Attainable Efficiency of Volute Casing Pumps

1994

1996

European Commission: IPPC Directive (product focus)

1998

dena / VDMA: Campaign Energieeffiziente Systeme in Industrie und Gewerbe

2000

2002

European Commission: Draft Directive on Eco Design of End Use Equipment (EUE)

Pump Industry et.al.: Start EN 17038 – parts 1-4 (EEI methodology, single stage pumps, booster sets, submersible pumps)

EUROPUMP: Assessing the energy efficiency of pumps and pump units

Pump Industry et.al.: Positive vote on EN 17038 – parts 1+2 (industry and EC consultants)

EUROPUMP: System Efficiency Guide

EUROPUMP: Start EuP Joint Working Group

2004

Pump Industry: Start EN 16480 (MEI water pumps)

VDMA: Einheitsblatt 24262 – „Effiziente Pumpensysteme“

EUROPUMP: Start Ecopump Initiative

Pump Industry ISO 14414 Pump system energy assessment

2006

VDMA: Extended Product Approach –> Meeting DG Enterprise

2008

European Commission: Ecodesign Directive Electric Motors

2010

EUROPUMP: Extended Product Approach presented at EEMODS, Alexandria, US

2012

2014

European Commission: Mandate M/498 for EN standards on water pumps (MEI+EEI)

2016

System approach Extended product Approach EPA

European Commission Joint Research Center: Motor Challenge Programme

C D

European Commission: Ecodesign Directive 641/2009 Circulators

2020

European Commission: Mandatory Energy audits

High saving potential

2018

European Commission: Ecodesign Directive 547/2012 Water Pumps (Outlook: Extended Product Approach)

European Commission: Consultation Forum: Revision 641/2009 and 547/2012 EPA accepted

Product approach

Low saving potential

Source: Sönke Brodersen, KSB SE & Co. KGaA 2020

Figure 1: The pump industry energy efficiency timeline.

Quarter 4 2020

www.bpma.org.uk

compliance 15 main activities of the sector are dominated by the approaches marked in green, which offer potentially high levels of saving. But why is that? Well, since pump manufacturers deliver their products into a wide variety of applications, such as general manufacturing, water/wastewater, food & beverage production, energy generation, building services, mining, and so on, they know very well how their pumps are installed, operated and serviced. They therefore know where the big savings can be found and perhaps more importantly, achieved. In simple terms, if a pump’s operation continuously and accurately matches the requirements of its overall system, and all purchase, installation and operational costs are considered (the life cycle costs), the highest savings will be achieved, and this is regarded as the system approach. By contrast, if the efficiency of just the pump is being considered, which is known as the product approach, the pump would no doubt save energy if continuously operated at its best efficiency point. However, this is rarely the case, either because the pump is oversized or because the demand typically changes during its operation. As a minimum requirement, it should be possible to adjust the speed of a pump according to the flow rate changes in a variable flow application or to match the duty point in a constant flow scenario. This can be achieved by defining a new product category which is called the Extended Product. This new classification describes a ‘pumping’ product as consisting of a pump + motor + drive, together with a harmonised load profile for the special product application. Because this knowledge inherently exists amongst pump manufacturers, our industry has been pushing the ‘system approach’ for the best part of 25 years. Indeed, the Extended Product Approach (EPA) was introduced by the pump industry when the EC was struggling with some of the definitions being used in its Eco-Design Directive. The Directive referenced pumps as stand-alone products, much the same as light bulbs and other domestic appliances, which of course they never are. As we have demonstrated, pumps are always embedded into systems, with their overall energy efficiency being subject to the operational parameters of that system. So, to overcome this problem, Europump developed the EPA. This important initiative was undertaken in close and fruitful cooperation with the European motor and drive industry and supported by leading universities. Since before the turn of the century the pump industry has pushed for energy-saving measures with distinct initiatives, campaigns, conferences, guidelines, and publications (especially on life cycle costing, system efficiency and variable speed pumping). In 2005, all these activities were brought together in Europump’s Ecopump Initiative and the associated Europump Joint Working Group on energy-using equipment. Since 2006 this working group has supported the EC and has undertaken a great deal of standards-based work to help push energy savings in pumping systems. www.bpma.org.uk

The work that has gone into the creation of the Ecopump Initiative, designed to push both the ‘system approach’ and the ‘extended product approach’, has collectively cost Europump members over €4 million. And this is on top of all the additional work necessary for manufacturers to fulfil their obligations under many other laws and regulations, such as Machinery Directive, ATEX, REACH, RoHS etc. The pump industry is highly regulated, due to its product delivery into such a wide variety of applications and in all regions of the world, which of course carry their own specific regulations. For a small sector of industry this is a huge burden, and so it deserves to harvest the fruits of its labour on the EPA in the short-term. As such, the revised Eco-Design Directive for Water Pumps must be introduced as soon as possible. With a look into the digital future, the pump industry again proves to be a pioneer. For the past two years a group within VDMA, the European network of mechanical engineering businesses, has been working hard on an OPC UA companion specification for use in the industrial internet. It sets a standard which allows pumps to be plugged into systems like a mouse into a computer, ready to play an integral role in an industrial system. One basis for digitalisation in our sector is again the EPA, i.e. pumps equipped with variable speed drives, which allow the adjustment of pumps to the system needs. Based on pump manufacturers knowledge of the correct matching of pumps to duty, the manufacturers have already developed algorithms and cloud-based digital solutions, which allow energyefficient matching of pumps to various systems, and this approach can deliver maximum energy savings.

“For more than 25 years, the European pump industry has been pushing energyefficient solutions.”

SUMMARY For more than 25 years, the European pump industry (through its representative body, Europump) has been pushing energy-efficient solutions and energy savings in fluid movement. During this time, it has always pioneered technical solutions, supported the EC, and developed appropriate Standards. Unfortunately, it seems that the pump industry has for some time been ahead of the game in its energy-saving recommendations, but it is hoped that the high saving potential of its various initiatives, do not suffer further delays. It is now quite clear that pumps with variable or adjustable speed drives can play a significant role in reducing energy usage going forward. Specifically, we should urgently act upon the proven energysaving potential of pump sets in water applications, and in doing so, remove five large coal-fired power plants from our annual power generation output. chevron-circle-right www.europump.net Quarter 4 2020

16 COMPLIANCE CALENDAR

ur compliance calendar outlines developing legislation that manufacturers and end users of pumps and pumping systems need to be aware of. At the time of publication this information is correct. However, ongoing Brexit negotiations mean any of the details below could change at any time, particularly on January 1st 2021. If you would like further guidance or the latest available information, contact the author at s.schofield@bpma.org.uk.

August 2018

31 October 2019

1 July 2019

1 July 2021

By 2023

WEEE 2012/19/EU In the UK, since August 2018, pumps have been included in the scope of the WEEE regulations and companies that produce and sell pumps need to be registered with the Environment Agency and with a recognised collection scheme.

ATEX (EXPLOSIVE ATMOSPHERES) 2014/34/EU IEC standards 80079-36 & 37 were published in 2016 and include major changes to the marking and documentation of non-electrical goods such as pumps. Pump manufacturers should all be working to these two new standards which became a legal requirement on 31 October 2019.

ECO Design requirements for electric motors – repealing of Commission Regulation (EC) No 640/2009 (EU) 2019/1781 Motors • IE2 level applies to three-phase induction motors rated at 0.12kW to 0.75kW with 2, 4, 6 or 8 poles (Exception Ex eb). • IE 3 level applies to three-phase induction motors rated at 0.75kW to 1,000kW with 2, 4, 6 or 8 poles, TEAO motors new in scope, (exception Ex eb and mining motors).

ECO Design requirements for electric motors – repealing of Commission Regulation (EC) No 640/2009 (EU) 2019/1781

Motors • IE 2 level applies to the following products: • Three-phase induction motors rated at 0.12kW to 0.75kW 2, 4, 6 & 8 poles • IE 3 level applies to the following products: • Three-phase induction motors rated at 375kW to 1,000kW with 2, 4, 6 & 8 poles • ATEX (excl. Ex eb)/non-integrated brake motors rated at 0.75kW to 1,000kW • Variable speed drives (VSDs) • IE 2 level applies to variable speed drives rated for operating with motors with a rated output at or between 0.75kW to 1,000kW. • The following drive technologies are excluded: • Regenerative drives (AFE, active front end). • Drives with sinusoidal input current (THD <10%).

Revisions To Water Pumps regulation 547/2012 The following thresholds still require ratification and an impact assessment. This regulation is expected to be in force by 2023. • EEIv (variable) for single stage pumps up to 45kW pump input power and booster sets up to 150kW pump input power. • EEIv threshold value of EEIv <0.62 for single stage pumps. • EEIv threshold value of EEIv <0.50 for booster sets. • Two tier approach: 1st product information, 2nd threshold. • EEIc (constant) or MEI for all other pumps in scope. • EEIc threshold value EEIc <1.00. • MEI threshold value MEI <0.40.

ECO Design requirements for electric motors – repealing of Commission Regulation (EC) No 640/2009 (EU) 2019/1781 1 July 2023

Quarter 4 2020

Motors • IE 2 level applies to the following products: • Single-phase induction motors rated at above 0.12kW • Increased safety motors (Ex-eb) rated at 0.12kW to 1,000kW with 2, 4, 6 & 8 poles • IE 4 level applies to the following • Three phase motors from 75 kW to 200 kW with 2, 4 & 6 poles

www.bpma.org.uk

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24/11/2020 15:26:03

Is Your Business Thriving

Post-Lockdown? Take a look at this guide designed to help electro-mechanical businesses conquer new challenges

18 wastewater

cleaning up the shoreline KSB explains how its Sewatec pumps are contributing to the clean up of Canada’s Lake Ontario, as part of a project to tackle years of environmental degredation along the shoreline of Hamilton Harbour.

he 45-kilometre long shoreline of Hamilton Harbour on Canada’s Lake Ontario has been at the heart of surrounding communities for many centuries. Once a pristine source of fresh fish and a place of leisure for the local population, industrialisation and the growth of the City of Hamilton has had a detrimental effect on the life of the harbour. By the middle of the twentieth century, decades of toxic sediment, storm water runoff, habitat loss, water quality deterioration and other factors had caused severe damage to the Hamilton Harbour ecosystem. In 1987, the International Joint Commission (IJC) – the organisation overseeing the Canada-United States Great Lakes Water Quality Agreement – identified the 500km2 Hamilton Harbour as one of 43 areas of concern (AOC). Being on a list of locations where environmental degradation seriously impaired the use and environmental health of the Great Lakes was a wake-up call for the city. Over the past few years significant environmental engineering programmes have been implemented – the largest of which being the multiphase Clean Harbour programme.

has a direct and powerful impact on the harbour’s water quality and environmental health. Costing $340 million, the upgrades include elevating the plant’s final treatment process from the secondary level to the tertiary (third) level. This increases the processing of the plant’s treated wastewater and will allow the plant to reach strict discharge limits described by the Hamilton Harbour Remedial Action Plan for phosphorus, ammonia and suspended solids. A significant sub-project is the construction of a new raw sewage pumping station and collection system control to support wet weather and flooding control initiatives. Having an effective pumping station capable of handling current and projected flows is essential to the functioning of the wastewater treatment and the prevention of overflows in the harbour. Construction on the upgrade began in May 2017 and is projected to be complete in July 2021. THE PUMPING STATION Now approaching 60 years of age, the existing wastewater treatment plant has a rated average capacity of 409 million litres per day (MLD) and peak rated capacity of 614 MLD. If this is exceeded the excess water, being a mix of industrial and domestic waste and run-off from the land, is discharged into the harbour. To comply with the long-term projected processing requirements, the upgraded plant will have a maximum receiving capacity of 1,700 MLD.

WASTEWATER TREATMENT PROJECT In 2008, the City completed the Woodward Avenue Wastewater Treatment Plant (WWTP) Service Area Environmental Study Report to determine a plan for upgrades to the plant. This recommended investment to manage wet weather flows, provide treatment capacity, and meet treatment objectives defined by the Hamilton Harbour Remedial Action Plan. Located near the southeast corner of the harbour, it is the largest wastewater treatment plant in the Hamilton Harbour watershed and is amongst the largest in Ontario. The Harbour also contains one of the largest toxic sediment sites on the Canadian side of the Great Lakes. Because the plant is the largest single source of water flowing into Hamilton Harbour, the The first of the pumps being installed and anchored to their mountings. (Image courtesy of KSB Canada). quality of that effluent Quarter 4 2020

www.bpma.org.uk

wastewater 19 To meet this requirement, considerable effort had to be put into designing a highly efficient pumping station containing pumps with a proven track record in handling high volumes of untreated wastewater. After due consideration of the various pump options available, Maple Reinders, contractors for the pump station, together with the City of Hamilton, selected KSB Pumps Inc., Canada. The design of the existing pump house at Woodward Avenue is rather unusual in that it is a circular construction. Clearly, this has proved to have its advantages and benefits, as the new pump house now under construction is also circular, containing a circular split wet well located inside a circular dry well where 12 KSB Sewatec K700-950 G1 VGW vertical dry pit solid handling pump sets are installed. The pump house has a total elevation of 81m above sea level, and at almost 30m the subterranean wet well is much deeper than its predecessor. This larger and deeper wet well prevents system flooding and provides increased system storage. There are several benefits of the wet well inside the dry well configuration. Firstly, dry well pumps, as opposed to wet well pumps, enable easy access to all pump parts for in-situ maintenance and repair. When components need to be removed from the dry well, they can be easily craned to the surface. The split wet well design, with six pumps allocated to either side, allows one side to be taken off-stream for cleaning without there being any adverse impact on the efficiency of the pump house. THE CHALLENGE With the pump house being of a rather unconventional design, KSB had to address several design challenges imposed on the configuration of the pump mountings. Formulating a layout for the pumps around the exterior of the wet well was the first issue to contend with. The solution was differing installation angles of pressure for the connection piece/inlet pipe. This, in turn, meant coming up with mountings peculiar to the configuration. For this KSB provided a tailor-made volute casing for each pump with an integrated mounting flange foot, which allows the pumps to be anchored directly to the castin-place foundation blocks. To handle the optimum flow of wastewater through the plant, ten pumps would be required for full-time availability, and a further two for standby demands. In addition, collectively the pumps had to be capable of handling up to 23,600l/sec and a potential solids content size of 190mm. The third significant issue to address was varying flows. At times when the effluent level is low, cavitation has to be avoided and when storm conditions arise, high flows have to be accommodated. By installing four variable frequency drives (VFDs) all the pumps automatically respond to the incoming flow. Finally, the pumps had to deliver high levels of efficiency. Being able to handle large solids and control flow velocity allows the treatment plant to drain the www.bpma.org.uk

interceptors for cleaning through the manipulation and control of the interceptor. On the existing plant, it is not possible to lower the level in the wet well to control the velocity in the interceptors. Thus, when storms occur, extra inflow and increased velocity result in the interceptors losing the ability to contain accumulated sediment, and this passes directly to the head works, creating an overload condition. With the new pump house design, it will be possible to drain the interceptors as necessary and remove the extra grit load to the plant. THE PUMPS All the vertically mounted Sewatec pumps are supplied with a 15m long carbon fibre driveshaft, 700hp motor, split mechanical seal, long 1050 x 750mm radius suction elbow and vibration monitoring system. The smooth finish reducing suction elbows contain a 200mm clean out port. The motors are at an elevated level in the dry well, so cannot be affected by the possibility of flooding from the wet well. Whilst the pump is designed to operate in a dry environment, there is an external clean water flushing line for the mechanical seal. The provision of redundant seal technology adds an extra layer of protection that prevents wastewater from getting out of the pump. With a variety of impeller options and mounting methods, the pump provides the perfect answer for transporting raw wastewater as well as thicker mediums such as bio-solids/sludge. “This contract required a combination of high pumping efficiency, good NPSH performance and the ability to deal with solid materials in the un-screened wastewater and storm run-off”, commented Marcus Henderson, KSB Pumps Canada Regional Sales Manager. “Each of the pumps contains an 898mm non-clog multi-vane radial flow K design impeller giving a free passage of 190mm, and has the capacity to pump 1968l/ sec at 21m.w.c. TDH. The upper end of the normal operating range is 26.25m.w.c. TDH and the lower end is 16m.w.c. TDH.” By spring of 2020, construction of the dry and wet wells, including the cast-in-place foundation blocks for the pumps, had been completed and work on the service areas at and above ground level were underway. The first of the pumps had been craned into position and anchored to the mountings. Complete installation of the pumps, drives and shafts is expected in early 2021 chevron-circle-right

“To handle the optimum flow of wastewater through the plant, ten pumps would be required for full-time availability.”

www.ksb.com Quarter 4 2020

20 Water conditioning

Safe water supply ensured at care facility When it became clear that the water supply at a specialist residential care facility was failing statutory quality tests, a new solution was needed. The answer came in the form of a pressurised and conditioned system from Stuart Turner, as flow found out.

ibury Hall is a charity that offers supported living within a residential care setting for adults who, due to mental health issues, need practical, emotional or social support. All the residential accommodation offers a unique pathway of recovery for 39 men and women aged 40 and over. It is a comfortable and friendly home surrounded by some of the most beautiful farmland in Hertfordshire. It provides four high-quality cottages in half an acre of landscaped grounds, four individual apartments within an Italian style courtyard, a twobedroom high needs bungalow offering one-to-one specialist care, whilst the main house consists of 17 state of the art residential rooms. In addition, Libury Hall offers a Day Centre where residents can socialise, participate in activities and gain life skills. So, when it became apparent that the water supply from the borehole to the main home was failing its statutory tests, quick and expert support was needed to ensure the home could remain open. The existing water supply system came from the local borehole and saw 6,000 litres of water from the borehole stored in tanks in the roof of the building and all the outlets across the site were gravity fed. The reality was that the facility didn’t need 6,000 litres of stored water – it wasn’t using enough to keep the water flowing, and the quality of the stored water was falling below the quality required by statute. The local Environment Department said the water was not at a quality to satisfy the regulations – posing a huge problem for the facility. Michael Harvey from Harvey’s Heating in Hunsdon was called in to suggest a solution. There was a mains supply to the facility available as a backup – should the stored water supply not be adequate – so there was an option that would not involve major issues in getting a new supply to the buildings. Michael discussed the options with Darren Cooper of Stuart Turner Pumps, and together they decided the most efficient and cost-effective solution was to provide a pressurised drinking water supply from the existing mains connection. The home had regular water tank cleaning and maintenance services, but it wasn’t enough to keep the water quality at the required level. Michael ordered the Stuart Turner equipment – 8 x 450l composite tanks and a Stuart Turner water conditioner system. Together the equipment would ensure fresh, clean constantly Quarter 4 2020

available water with far less maintenance than the old system required, and the ability to ensure that the water was in prime condition for the residents at all times. The new system is providing quality water between 3 and 4 bar, depending on usage through the shared main – a huge improvement over the old gravity-fed system. The water conditioner effectively polishes the water, ensuring it is always of the highest standard. Commenting on the new water system, Angela Smith, the director of Libury Hall, said: “When we realised that there was a problem with the water our hearts sank. We have been so grateful to Michael and his team, along with Stuart Turner, for providing the expertise to solve what for us was a very complex issue. We now have excellent quality water coupled with high pressure which has made a huge difference for all the residents. We feel we have invested in the home for the future. A cost-effective solution was vital for the charity. The trustees who are responsible for the facility are delighted with the reduced costs associated with the maintenance and with the speed and efficiency of the works that were undertaken.” chevron-circle-right www.stuart-turner.co.uk www.bpma.org.uk

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customers up to date with the latest technology in pumps. We specialise in the supply, manufacture, installation, repair and maintenance of booster sets, pressurisation units, HVAC and commercial pumps and all associated equipment. A specialist Waste Water Division, operating from our depot in Hampshire, deals with sewage and waste water pumps, pumping stations, macerators, grease traps, stormwater attenuation and rainwater harvesting applications. For further information please contact our ofﬁces 020 8337 7249 or enquiries@pumpserv.co.uk.

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22 Pump Control

Controlling and monitoring pumping systems for best performance Good pump selection is based on achieving the Best Efficiency Point (BEP); however, to truly get the best from a pumping system, it needs to be continually monitored and controlled effectively. T-T Controls, a division of T-T Pumps, outlines the benefits of this approach.

he days of just having an isolator on the wall, with a pump operating flat out when there is little or no demand, are gone, as energy is too valuable a commodity to waste. Operational performance, therefore, needs to be both monitored and controlled effectively to meet the needs of the system or process whilst giving maximum efficiency at all times. Even the most basic of motor starters today will offer some form of pump protection from short circuit via fuses or MCBâ&#x20AC;&#x2122;s, or overload protection either by a thermal relay or thermistor device. However, these offer very little indication of the demands of the system, and at best would only offer system monitoring in the form of simplistic volt free contacts for use with building management systems (BMS). With the various solutions available today for collecting, storing and transmitting data, what is required for truly efficient control is a technically advanced intelligent remote monitored control system, overseeing several elements seamlessly in real-time. Variables such as pressure, flow rate, rate of change in level and the current consumption a motor, can all be logged to get a full understanding of both instantaneous demand and to build up a database of historical information. Instantaneous data, for example pressure drop, can be evaluated and processed via the use of a PID (proportional integral derivative) control loop. This approach looks at congruent variables and determines the rate of change in these values to regulate and fine-tune operational control. An example of this would be evaluating pressure drop in a system to establish whether a pump needs to operate fully using maximum energy, or whether it can use less energy by operating at a lower frequency with the use of a Variable Speed Drive. The same PID control philosophy could also be applied to temperature variations on closed-loop heating systems, or heat recovery applications, or inversely, chilling and temperature reduction systems and other systems where continuous modulating control is required. Stored historical data monitoring enables comparisons to be made on specific maintenance indicators, such as bearing temperature or vibration

Quarter 4 2020

monitoring which can prevent costly breakdowns. Additionally, real-time analysis of multiple factors such as wet well level, motor current consumption, power supply, and voltages can all indicate if a pump motor is running beyond its Best Efficiency Point. The use of remotely monitored data collected on a day-by-day, hour-byhour, minute-by-minute basis, gives a true indication of how a pump is used, and in the case of a pumping station shows how the wet well system is used 365 days per year by residents on a housing development. This valuable insight can be used to schedule service visits and assess the urgency required to attend breakdown visits, with data used to determine any underlying issue in the system. In the ever-changing world where access restrictions and physical site visits are becoming more problematic, the reliance on, and need for, remote monitoring and intelligent control is more prevalent than ever. The starter on the wall will eventually become a thing of the past. chevron-circle-right

â&#x20AC;&#x153;The reliance on and need for remote monitoring and intelligent control is more prevalent than ever.â&#x20AC;?

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24 food & Beverage

specifying pump systems for food and beverage applications flow spoke to a cross-section of BPMA member companies to identify some of the challenges facing the food and beverage production industry, and to gather some advice on pump system specification for this sector.

t goes without saying that hygiene is a paramount consideration when specifying any systems for food and beverage production, but it would appear that a need for reliability comes a very close second – stoppages on food production lines can result not just in lost productivity, it can also lead to costly product losses. Picking up on the issue of reliability, Stuart Foster, Sales Manager for ABB’s UK drives, points out that a pump system will only ever be as reliable as the motor that drives it. He advocates the use of variable speed drives (VSDs) as a solution to provide efficient control of the motor to ensure optimum pump system operation. The use of VSDs and motors can offer energy savings and reduce production downtimes. “A VSD can help save energy because it allows for pump speed adjustment to match flow to the needs of the process. If your pump uses throttling to control flow rates, you will save energy by upgrading to VSDs,” said Stuart. “The software functionality of today’s VSDs also makes them ‘pump and pipe friendly’. They can help combat cavitation to extend pump lifetimes and help avoid pressure peaks in pipes by building up the flow in a controlled way. Stuart advises that, when specifying a VSD for use in food and beverage pumps systems, users should consider the availability of the following: • Safe torque off (STO) function to maximise the safety of personnel, production process and equipment. • Compact size for easy installation, commissioning, and maintenance. • Fieldbus adapters to ensure connectivity with all major automation networks. • Remote monitoring service for drives (and motors) to help reduce unplanned downtime. Stuart goes on to point out that digital technologies hold the key to minimising downtimes and maximising productivity in food production. He said: “Smart sensor technology, for example, can offer an affordable way to convert traditional pumps into smart, wirelessly connected devices.” Smart sensors can measure vibration and temperature from the surface of the pump, and this data can be used to gain meaningful information relating to the condition and performance of the pump. Smart sensors can also use measurements to calculate health indicators for detecting common problems in pumps, such as cavitation, bearing failure, blade problems, looseness, unbalance and overheating. Bob Nash, Managing Director at T-T Pumps, also highlights reliability as being a critical requirement when

Quarter 4 2020

it comes to equipment specification for food processing applications. He said: “We deal with some big food processing organisations and for all of them equipment reliability is paramount because downtime is so costly in a manufacturing sector that is generally producing highquantity, low-cost items.” Pump control solutions can help ensure reliable pump system operation, highlighting any potential problems in a timely way. “We are seeing a growing interest in automated condition monitoring solutions – due, in part to the often low-skills levels of operators on food production lines,” continued Bob. T-T Service provides 24/7, 365 days a year monitoring of pump systems, utilising the Seer monitoring system which employs cloud-based technology to allow continual monitoring of pump system reliability – including flow monitoring, flow rates, heads etc. It can offer many channels of information relating to pump system reliability, and this data can be translated into actionable information which can be displayed on a dashboard and viewed from the control room or remotely. “It offers an important tool in the food processors armoury to help minimise unnecessary production line downtimes. Because it is a cloud-based system, it can help reduce maintenance costs as unnecessary site visits are eliminated. It is also possible to undertake data analysis and performance trending to allow for early intervention to prevent system failure,” said Bob. MATERIAL CHOICES Turning to the choice of materials for a food pump system, Paul Green, UK Sales Manager at AESSEAL, points out the importance of ensuring that all materials www.bpma.org.uk

food & Beverage 25 used in construction comply with EU regulations. These include Regulation EC1935/2004 on materials and articles intended to come into contact with food (FCM Regulation) and Regulation EC2023/2006 on good manufacturing practices (GMP) for materials and articles intended to come into contact with food. “Adherence to these regulations should extend to every component – including the mechanical seals,” said Paul. “Seals which do not come with proven traceability could contain inappropriate carbons and carry a significant risk of contamination. Mechanical seals which comply with industry standards will come with certified material traceability clearly evidenced on the packaging.” Paul goes on to highlight several specification considerations which can maximise pump reliability and minimise the risk of unscheduled downtimes. “I strongly advise the specification of advanced non-contacting bearing isolators in place of traditional lip seals – as these are a common cause of bearings failure.” Explaining further, he said: “Lip seals have surface contact with the rotating shaft, which means they start to deteriorate almost immediately after installation, allowing particle and fluid ingress into the bearings chamber, contaminating the lubrication oil and causing corrosion. Bearings failure leads to unscheduled downtime and added maintenance and repair costs. The use of bearing isolators can eliminate external contamination ingress and lubrication egress, which accounts for 52% of bearing failures. They are noncontacting so, unlike traditional lip seals, they do not contribute to shaft wear, while their non-contact design reduces friction, which can result in energy savings. “Non-contacting bearing isolators can better protect bearings from water, process or particle ingress, extending the bearings’ lifespan, improving pump reliability and reducing the risk of contamination,” continued Paul. When it comes to food industry applications, we see the word ‘reliability’ being used again and again. Choosing the right sealing solution provides yet another tool to help food processors achieve the reliability they need. Paul said: “A number of sealing solutions can be specified which will achieve long-term gains including improved pump reliability, reduced downtime and quantifiable savings in terms of energy use and water management and treatment costs. They also support adherence to extremely high standards of hygiene.” The choice of seals can affect the other critical food processing challenge – the need for hygienic solutions. Paul points out that the use of standard sealed vessels limits access to the interior of the vessel, which makes the clean-in-place (CIP) process challenging. The risk of bacteria growth leading to product contamination is high. AESSEAL’s EasyClean water vessel is designed to meet stringent hygiene standards and alleviate this risk. A selffilling unit, it incorporates internal filler welds to eliminate bug traps and has a detachable lower section with a quick-release clamp. Easy visibility into the interior means residue can be captured before it can become a breeding ground for bacteria, and cleaning is both more efficient and more effective. www.bpma.org.uk

SELF-LUBRICATING COMPONENTS Morgan Advanced Materials provides a range of self-lubricating bearing and seal components for use in pump systems, using a variety of carbon/graphite, silicon carbide, alumina and zirconia materials to engineer lightweight, low-friction bearings and seals. Valentina Anzoletti, Product Manager at Morgan Advanced Materials, explained that the company is able to combine critical materials in powder form that can then be compacted and furnaced in order to create customer-specific components. In the food and beverage industry, these components could be used to create the vanes, bearings and internal chambers of a rotary vane pump. “We collaborate closely with our pump manufacturer customers to help them find solutions to improve their pump system performance, reduce wear rates and improve pump efficiency. This ensures a reliable and efficient pump solution for the end-user of the pump. For applications in food production, we can also ensure that only food-safe materials are used.” The materials can help overcome a variety of challenging pump system applications, such as handing abrasive products or aggressive cleaning chemicals which are often required in food industry applications. Essentially, carbon graphite does not require the use of external lubricants and can be submerged in the medium so it can be used in direct contact with food products. “We call it a solid lubricant material,” continued Valentina. “The need for lubricant is eliminated as the material is lubricated by the fluid in the system. Our carbon graphite materials also have NSF, WRAS and FDA approvals, for direct contact use with food. The materials are approved for USP Class VI chapter 87 & Chapter 88 applications – while hygiene specification requirements will usually come from the pump manufacturer, we can help them to ensure that the finished product will meet requirements, for example those set out by the European Hygienic Engineering and Design Group (EHEDG).”

“The need for lubricant is eliminated as the material is lubricated by the fluid in the system.”

CONCLUSION There are many elements to consider when specifying pump systems – the pumps themselves, the drive mechanism, the control solution and the materials of choice for the components. All of these elements can affect the suitability of the pump system for its task. In the food industry, in particular, it is vital to do your research and make the right choices. chevron-circle-right new.abb.com www.aesseal.com www.morganadvancedmaterials.com www.ttpumps.com Quarter 4 2020

26 Food & Beverage

maintenance solutions drive huge savings flow found out how a focus on pump reliability and non-intrusive pump maintenance has enabled asset care engineering services provider, Musk Process Services, to save its clients hundreds of thousands of pounds a year.

usk Process Services maintains and upgrades a wide range of manufacturing equipment for its industry clients, but the company has recently found that improvements to pumps and their maintenance plans are providing especially large savings for its customers, both in time and money. “Pumps are a key element in most manufacturing environments and are often put under a lot of strain which can lead to accelerated degradation and premature failures,” said Stef Smith, Head of Asset Care at Musk. “Because of the huge production impact that taking pumps offline can have – whether because they have broken down or have been disconnected for maintenance and repair – it is paramount to not only minimise the frequency of pump breakdowns, but also to ensure that any maintenance work can be carried out with minimal disruption to production.” One of the ways Musk has been able to minimise pump downtime and increase reliability is by using condition based monitoring techniques in place of intrusive maintenance. A recent example of this was the implementation of a new maintenance strategy for liquid-sugar recirculation pumps at a large food manufacturing plant. The reactive maintenance strategy was resulting in poor reliability for an asset that required 24/7 functionality, as well as an excessive spend on spare parts for repairs. After conducting a reliability centred maintenance and root cause analysis study on the progressive cavity pumps, a new programme of monthly vibration analysis was implemented. The non-intrusive vibration analysis is carried out whilst the pump is running, and allows Musk to capture potential failures in the early stages of defect. This means individual components can be replaced instead of a full pump change which was previously necessary, when component failures would cause collateral damage to other pump components. The results of this new predictive maintenance strategy include both a significantly improved mean time between failure and a saving in the region of £30,000 per annum for the client in component spend on one pump alone. In addition to condition monitoring, Musk has also found that more unusual upgrades to pumps can produce large savings. At a paint manufacturing client, following a computerised maintenance management system review, the Musk engineering team noted that a set of pumps the client had previously installed were overengineered for their application. The pumped fluid’s high solids content

Quarter 4 2020

and quick drying properties were causing accelerated wear to the pumps, creating inflated running costs from excessive breakdowns and the need to engage specialist labour from abroad to maintain the pumps. After interrogating the process conditions and chemicals involved, Musk was able to propose a downgrade to the pumps’ seals to a standard over-the-counter gland packing seal which was more suitable for the process conditions. Whilst a downgrade may be an unusual solution, it is a profitable one for the manufacturer. For a total of seven pumps, this has reduced the annual maintenance costs from £25,000 to £205 for a £10k initial investment. The solution is currently being rolled out across a further 25 assets at the client plant, each of which will achieve similar savings. However, these savings are a drop in the ocean compared to another upgrade made at the same client plant. A non-foolproof computerised operating system that controlled the paint wash pumps, valves and pipework was costing the manufacturer 175 hours and over half a million pounds in loss of paint volume per year. A project to diagnose the paint wash faults culminated in a simple upgrade to the Computerised Maintenance Management System’s HMI screens – a solution which now allows the client engineers to find and diagnose pump and valve problems with a 70% reduction in faults. This has been recognised by the paint manufacturer as an expected £380,000 per annum saving across the six lines it has been installed on. “Pumps may not be the most glamorous of production assets, and they can be some of the most expensive to maintain,” said Musk Operations Director Darren Martin, “but that also means that they are where some of the most effective reliability improvements and considerable cost savings can be made.” chevron-circle-right

“ Individual components can be replaced instead of a full pump change.”

www.ejmusk.co.uk www.bpma.org.uk

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28 food & beverage

DETECTABLE VALVE SEATS ENHANCE FOOD SAFETY SPX FLOW HAS ANNOUNCED THE release of new metal and X-ray detectable seats for its Waukesha Cherry-Burrell (WCB) range of singleseat valves. When combined with metal or X-ray detectable O-rings, the new seats are designed to add further security to critical dairy, food and beverage, and personal care processes. Chris Sinutko, Global Portfolio Manager at SPX FLOW, said: “Contamination by foreign objects is a key concern for processors. The new Tef-Flow P-MD seats add an essential extra level of safeguarding that was not available before, giving processors added peace of mind for product safety.” As well as being metal and X-ray

detectable, the new valve seat can handle temperatures up to 137°C, is chemically inert, has a clean-in-place design, and complies with stringent FDA regulations. Furthermore, like metal parts, the seats are extremely durable, offering excellent longevity. The new seats are available as options across the WCB single seat valve range and also offered as full stem assemblies to easily upgrade existing installations. “SPX FLOW continues to work tirelessly to provide marketleading solutions for enhancing the safety of processing food and beverages. The detectable valve seat is an important step and sets a new

benchmark for valve safety in the industry,” concluded Chris. www.spxflow.com

FOOD SAFE MOTORS WITHSTAND OVER 1,100 WASHDOWN CYCLES RIGOROUS TESTING AT A STATE-OFthe-art hygiene laboratory has verified that ABB’s food-safe stainless-steel motors can withstand frequent sanitation. The motors emerged in full working order after being subjected to tests simulating years of operation in harsh washdown environments. Maintaining product safety in food and beverage plants requires strict hygiene standards. Frequent washdowns are required to avoid contamination. The challenge is that electric motors used in these facilities can be damaged by aggressive cleaning. Motors specifically designed for these applications can help ensure food safety, improve reliability and reduce the risk of unscheduled plant downtime. To address the washdown challenge ABB food safe motors feature a stainlesssteel housing to resist corrosion, and IP69 ingress protection to ensure that hightemperature, high-pressure spraying will not cause damage. They are also easy to clean, with a smooth, self-draining outer surface that has no angles where contaminants could gather. “Our Food Safe motors are already in use at several customer plants,” said Tero Helpio, Global Product Manager, IEC Food Safe Quarter 4 2020

motors, ABB Motion. “To prove their longterm performance under realistic washdown conditions, we worked with a state-of-the-art hygiene laboratory in Sweden to devise a set of tests replicating industrial-type sanitising procedures.” The test regime reproduced typical cleaning practices in the food and beverage industry with a seven-stage cycle representing a full week of daily washdown procedures. Detergent and sanitiser were applied during every stage, with acid applied once per cycle. This reflects the common industrial practice of washing down with acid once each week. Temperatures up to

55oC and pressures up to 25 bar were used. In all, a total of 158 cycles were performed, corresponding to 1,106 daily washdowns or 418 total hours of testing. Two IEC stainless steel Food Safe motors were subjected to the tests and were largely unaffected and still in full working order at the end of the test program. In particular, no water, condensation or indication of corrosion was found inside the motors. All the three main O-rings and drain plugs remained tight. new.abb.com www.bpma.org.uk

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FEATURE 30 Opinion

consider A submersible pump’s VSD carefully ABB’s Martin Richardson highlights some issues to consider when installing a submersible pump system with variable speed drives.

nlike conventional pump applications, the use of variable speed drives (VSDs) with submersible pumps requires some careful engineering considerations to achieve a long system life and high system reliability. Filters: Motors in borehole pumps can have a motor cable length anywhere between 100 and 300m. It is often necessary to fit output reactors or sine filters to reduce the rate of voltage change (du/dt) and the peak motor voltage, which helps to protect the motor from premature failure. Network distortion: If the VSD uses a simple diode bridge network, distortion can result. This can be avoided if ultra-low harmonic (ULH) drives are used. High rates of voltage change can lead to radio frequency interference unless special care is taken during the installation phase, as the cabling design and install is critical. Over-speed: During storms, VSDs can be used to increase speed if there is sufficient motor power available. However, it is necessary to check the operational limits of the pump and the motor. As the speed changes, there is a change in noise levels from the pump and motor – higher speed brings greater noise and the potential for vibration. With higher speed, it is necessary to ensure that the net positive suction head available at the pump is still sufficient to prevent cavitation. Reverse rotation: Without a non-return valve in the discharge, reverse rotation may occur on shutdown. Here the column of fluid can pass back through the pump hydraulics and turn the motor into a generator, causing the VSD to trip. A regenerative drive can feed the power back to the supply network. Quarter 4 2020

Alternatively, a non-return valve can be installed. Avoiding critical speeds: A VSD increases the risk of the pump or motor reaching a critical speed at which the mechanics vibrate or resonate. Programming the VSD to lock out certain speeds or speed ranges from the continuous operating speed range avoids this. Motor plate data: A VSD is a source of current and must always be selected based on the motor nameplate current. When using submersible pumps, ignore catalogue kW ratings as these are given for a conventional motor application. It is common for submersible pump motors to have lower power factor and lower efficiencies than standard motors purely because of their mechanical design. Motor insulation: Variable speed puts a higher voltage stress on a motor’s insulation system, so either a reinforced insulation system or a filter between the motor and the drive is recommended. EMC shield: Submersible motors ensure the lowest impedance path on the shield connection to ground as the water surrounding the housing provides a perfect electromagnetic compatibility (EMC) shield. All metal construction elements have equalised electric potential. A continuous cable connects the VSD to the motor, thereby completing a Faraday Cage. To reduce the cable length between the pump and VSD, the drive should be installed as close as feasible to the wellhead. Unscreened cables supplied with the pump package can be problematic for sensors. This issue can be reduced by using a filter, moving the sensor cable away

Martin Richardson, Water Framework Manager at ABB.

from the drop cable, enclosing cables in steel pilot tubes and using a good screen on the sensors. Remote monitoring: Submersible pumps often operate in remote locations. Fitting a sensor to the pump motor will enable remote conditioning monitoring to track parameters such as motor winding temperatures which can affect ageing and lifetime. Do seek advice on which sensor type is right for an application in terms of the screened cabling, monitoring relays and filters. Generator supply: Borehole pumps demand a reliable power supply so are fed by generators – either permanently or as a backup. The VSD manufacturer should specify the maximum allowable voltage dip at start and during running. Generators can be a source of, or susceptible to, harmonics and these must be considered when dimensioning feeder cables and the generator itself. As with diode rectifier VSDs, the generator may have to be at least twice as big as the VSD rating. chevron-circle-right

“Variable speed puts a higher voltage stress on a motor’s insulation system.”

www.bpma.org.uk

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Flow Magazine - Quarter 4, 2020: Food & Beverage Focus

Articles inside

Opinion

Food & Beverage Product News

Food & beverage

Food & Beverage

Pump Control

Water Conditioning

Wastewater

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Product News

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Industry News