BPMA News May 2016

NEWS

MAY 2016

ON WARDS & UPWARDS… We are delighted to say that recently we have added three new members to the fold. Namely March May, based in St Neot’s where from they have been manufacturing & distributing high performance magnetic drive seal-less pumps for 40 years.

Established in Bishop’s Stortford, DAB Pumps are recognised in the motor-driven water pump industry in which they have been operating in for 37 years. Our third new member is NOV, who, over a hundred years have been manufacturing pumping and mixing equipment & systems and can be found in Manchester.

2016 PUMP AWARDS… This year’s event was the 10th, held at The Heythrop Park Resort Hotel on the edge of the Cotswolds and was widely considered to be one of the best.

As usual it was ‘staged managed’

by Touchwave Media who as usual did so as ‘smooth as silk’. Results can be seen inside…

BPMA NEWS… I’ve forgotten the number of year’s that I have been editing ‘the News’, but it must be at least 12-14 and I’m delighted to say that recently there has been an increase in the number of members participating and bringing their information to you, complimenting the BPMA’s press activity.

We are always looking for ways to develop the BMPA News further and would welcome any feedback & suggestions – please email peterullmann@piimag.com

Installed Base - Everything from a single source We provide comprehensive customer care from a single source – and we can deliver this over the entire product life cycle. We offer an extensive range of pumps and valves for virtually every application, unique engineering expertise to fulfil every specific customer request, and tailored service and spare parts solutions. In other words, technology that makes its mark.

• KSB Limited • 2 Cotton Way • Loughborough • Leicestershire • LE11 5TF • 01509 231872 • www.ksb.co.uk

Our technology. Your success.

Pumps Valves Service •

•

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BPMA 75TH TH ANNIVERSARY DINNER The Heythrop Park Resort Hotel Celebrating The Past, While Embracing The Future

This year the BPMA achieves an impressive milestone – three quarters of a century serving the British pump industry. From its humble beginnings back in 1941, whilst the UK toiled with the inherent difficulties of the second Word War, through the numerous economic peaks and troughs that have inevitably followed, and against an ever changing legislative landscape, the BPMA has been a constant source of support, guidance and information.

To celebrate 75 years of unbroken service to both its members and the wider pump industry, the BPMA will be staging a special 75th Anniversary Gala Dinner. Held at the impressive Heythrop Park Resort hotel in Oxfordshire, on Thursday 6th October, the event promises to be the highlight of its year-long celebratory activities.

Heythrop Park boasts a unique and luxurious venue set in 440 acres of stunning Oxfordshire Countryside. Dating back to 1710 this quintessential English country estate seamlessly combines elegance with style. Located on the edge of the Cotswolds, with Oxford on the doorstep, it is also close to Blenheim Palace and the picturesque Cotswold villages of Burford & Chipping Norton.

The Resort also offers a championship 18-hole golf course, superb health club facilities, and exceptional dining.

A glittering champagne reception, held in the main hall and accompanied by live music, will be followed by a stunning 4-course dinner with fine wine, and further musical entertainment direct from London’s West End. More music and dancing courtesy of the Swinging Little Big Band, will ensure a great time is had by all.

Event Timings • 1.00pm - 5.00pm Arrival, Check-In and Leisure Time • 7.00pm - 7.45pm Drinks Reception in the Great Hall • 7.45pm - 8.00pm Move through to Dinner in the Enstone Suite • 8.00pm - 9.45pm - Anniversary Dinner • 9.45pm - 10.30pm - West End Musical Showcase • 10.30pm - Late - Dancing to the Swinging Little Big Band Prices Tables of Ten can be secured at £1000.00 + Vat (£200.00) = £1200.00 Individual Places can be secured at £120.00 + Vat (£24.00) = £144.00

Event Kindly Sponsored By

ATEX: EC GUIDANCE ON THE TRANSITION FROM ATEX DIRECTIVE 94/9/EC TO DIRECTIVE 2014/34/EU An EC Guidance document on the transition from the ATEX Directive 94/9/EC to Directive 2014/34/EU is now availablefrom BPMA. The new Directive does not bring about any changes as regards the scope, essential health and safety requirements and conformity assessment procedures. This document consists of a detailed FAQ section covering both horizontal questions (in line with the latest Blue Guide text) and sectorial ones (applicable to ATEX only) The key changes reflect the alignment with the New Legislative Framework (NFL) and mainly concern: · definitions (horizontal additions from the NLF) · more detailed information about the obligations of economic operators · more detailed requirements for notified bodies · updated references (presumption of conformity, CE marking) · simplified procedures for market surveillance · taking the contents and model of Declaration of Conformity (DoC) from the NLF · taking validity conditions for EU type-examination certificate from the NLF · practical transitional arrangements given for the DoC and the Directive numbering that needs to be stated (in accordance with the Blue Guide interpretation) To ensure that the transition to the new Directive is not too abrupt, the manufacturers are given the flexibility to indicate already today the following statement, as long as their product declares conformity with the Directive in force. This transitional arrangement can be applied to other NLF-Directives only too: “The object of the declaration described above is in conformity with the relevant Union harmonization legislation: Directive 94/9/ EC (until April 19th, 2016) and Directive 2014/34/EU (from April 20th, 2016)” Please note that this version of the Guidance is preliminary, due the ongoing drafting of the ATEX Guidelines and the pending publication of the Blue Guide.

BPMA GOLF DAY 2017 The 2017 BPMA Golf Day will be held at the

Heythrop Park Resort Oxfordshire

on

Thursday 25th May 2017

Tea, Coffee & Bacon Rolls at Registration 18 Hole Texas Scramble Team Competition with Buggies Individual Prizes Prize Giving Dinner Overnight Accommodation Breakfast on Departure

Only £199 + VAT Per Player

I/We would like to reserve Places at the 2017 event Contact Extra accommodation on the 24th

Company Email Rooms Invoicing January 2017

Fax Back: 0121 601 6387 Email: s.smith@bpma.org.uk Contact: Steve Smith 0121 601 6350

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DELEGATE NAME

CITY & GUILDS BPMA COMPETENCY ELECTRICAL COURSE (3 DAY)

CITY & GUILDS BPMA COMPETENCY ELECTRICAL TRAINING COURSE (3 Day)

City & Guilds BPMA Competency Electrical Course BOOKING FORM NEXT DATE: June 21 - 23 - 2016 It is usual in many industries to find that companies have radically streamlined their maintenance and technical workforce departments. This puts pressure on company managers to use non-electrical personnel for routine electrical duties. This three day course is specifically designed to assist non-electrical employees to prepare themselves for cross trade working, and to help companies comply with the requirements of current legislation regarding the use of such people for minor electrical tasks.

Course Objectives: After completing the course, students should be able to: • Recognise safe working practices (related to electricity in the workplace) • Work within the requirements of current electrical legislation (relating to topics covered) • Understand the fundamental principles of electrical energy • Perform routine electrical tasks at a basic level • Perform safe isolation of electrical circuits • Enhance their workplace skills • Relate to electrical circuit diagrams Who should attend: The course is primarily aimed at mechanical or un-skilled tradespersons that are preparing themselves for work upon electrical systems. The course may be of great benefit to companies that intend to employ non-electrical personnel to perform routine electrical duties, such as, lamp replacement or portable appliance testing etc.

Prerequisites: Basic numerical and literacy skills are required.

Topics Covered: • Health and Safety legislation (related to electricity in the workplace) • Basic electrical principles • Electrical power and units of measurement • Safe isolation of electrical circuits • Safe working practices • Electrical test instrumentation • Conventional circuit layout • Basic first aid (related to electrical hazards) • Electrical diagrams • Cable and wiring system

Next Course Date: 21 - 23 JUNE 2016

BOOKING FORM Delegate Cost : £450.00 + Vat Please complete all sections where applicable and then click the "submit" button at the bottom of the page Company Name: Address Your Name: Main Contact Email: Purchase Order No:

Authorised by:

21 - 23 June 2016

No. of Delegates

DELEGATE NAME

Course venue: British Pump Manufacturers Association Ltd, National Metalforming Centre 47 Birmingham Road, West Bromwich, B70 6PY

Amount

(J1, M5) (SatNav B70 6QE) Each day will consist of: A morning session from 0.900 - 12.30 pm (10.15 am start on the first morning) followed by lunch and :

Sub-total

An afternoon session from 1.30 - 5.00pm.

VAT @ 20% TOTAL:

There will also be refreshment breaks

PAYMENT OPTIONS IMPORTANT - PAYMENT MUST BE RECEIVED NO LATER THAN 7 DAYS PRIOR TO COURSE DATE CARD (MASTERCARD/VISA ONLY

INVOICE

CHEQUE Please make cheque payable to: "British Pump Manufacturers' Association and post with a copy of this form to BPMA, National Metalforming Centre, 47 Birmingham Road, West Bromwich, B70 6PY

Card No: Cardholder: Address:

Expiry:

Cancellations: Cancellation should be in writing Charges are as follows 0-7 days 100%, 7-14 days 75%, 14-21 days 50%. 21 days and above 0%

Security No;

Further details will follow once all registrations are received

Postcode:

Submit If you encounter a problem in submitting this form please email s.smith@bpma.org.uk

WASTE ELECTRICAL & ELECTRONIC EQUIPMENT DIRECTIVE DEVELOPMENTS In August 2018 the WEEE2 Directive will enter into force in the UK . Under the existing WEEE Directive in the UK it has been fortunate that other than Garden Pumps no other pumps have been included in scope. This first revision of the Directive has now brought in many products that were previously out of scope.

To try and clarify if pumps will be in scope of WEEE2 the BPMA met with the UK government, BIS ( Business Innovation & Skills) who unfortunately advised the BPMA that they are overwhelmed with the amount of items that require clarification. To assist in making a decision in the UK for the Pump Industry they have now requested that the BPMA write its own position paper after assessing all the Commission Guidance documents for both domestic and non-domestic pumps. If BIS agree with the BPMA document then that will position for pumps in the UK .

This gives the BPMA and its members an opportunity to control the situation on WEEE2 Even if the UK population agree to leave the European Union on the 23rd June 2016 it will be many years before the existing European laws are repealed , on this basis it has been decided to form a new BPMA working group to write the WEEE2 position paper for the pump industry.

The first meeting of this working group will take place in July.

For further information relating to the BPMA please contact British Pump Manufacturers Association, National Metalforming Centre, 47 Birmingham Road, West Bromwich B70 6PY, UK Tel: 0121 601 6350 Fax: 0121 601 6373 E-mail: enquiry@bpma.org.uk or visit our website: www.bpma.org.uk The BPMA takes no responsability for the statements, claims or opinions expressed in this Newsletter 3

Launched 16 years ago, the Pump Industry Awards are now widely regarded as the industry event. Whether it’s recognising companies and individuals who go the extra mile or acting as a motivator to encourage more companies to fulfil their potential, the core values of the awards have not changed over the years.

This year’s Pump Industry Awards Gala Dinner was held at the Crowne Plaza Hotel, Heythrop Park on the fringe of the Cotswolds on Thursday 10th March. The awards ceremony was the highlight of the evening, hosted by the enchanting BBC News Presenter Mary Rhodes and held in association with the BPMA and sponsored by Process Industry Informer, KSB, SPP Pumps, AESSEAL, WEG, Tomlinson Hall & Co and World Pumps.

The 2016 finalists were awarded certificates on stage and the eight worthy winners announced and presented with certificates & trophies to the usual ‘unruly’ celebrations. After dinner entertainment followed with the hilarious Dominic Holland whose performance was greatly received by the guests.Finally and to round off the evening we held a charity raffle to raise money for WaterAid, we managed to raise a staggering £1800.00!

For further information about the Pump Industry Awards & view the photo gallery of this year’s event please visit www.pumpindustryawards.com. If you are interested in sponsoring, nominating and/or attending the 2016 event please contact Andrew Castle at Andrew@touchwavemedia.co.uk

MEET THE WINNERS

The awards focus on key areas of manufacture and supply, including innovation and achievement, energy saving, engineering excellence, customer care and employee motivation. On the night, six companies and two individuals were awarded, and a fantastic night was had by all!

TECHNICAL INNOVATION – PRODUCTS SPONSORED BY: PROCESS INDUSTRY INFORMER WINNER: FLOWSERVE SIHI : THE SIHIBOOST

Dramatically faster evacuation down to deep vacuum levels with less power, smaller footprint, quieter, safer, and cleaner by harvesting the Kinetic Energy of heavier rotors which run five-times faster than usual machines. Mass inertia is stored during idle periods and released immediately on demand. Game-changing hydraulic optimisation allows pump pressure gradients of one-million-to-one while in the rough pressure area. This is unique and would normally need a high number of pressure stages. Mechatronically synchronised, contact-free, moving parts removes the need for oil-centric lubrication.

TECHNICAL INNOVATION – PROJECTS SPONSORED BY: KSB WINNER: NEPTUNO PUMPS : ENERGY EFFICIENT PUMPS HELP FIGHT CLIMATE CHANGE

Los Pelambres Mining Co., located at 3600 m.a.s.l. in Chile, wanted to increase its pumping capacity, improve its energy efficiency and reuse components from its old equipment. Neptuno Pumps designed and manufactured new pumps under a circular economy approach with recycled materials and 30% less components, which increased the pumping capacity by 5%, using 33% less pumps, while improving energy efficiency by 15.4%, saving US$ 579,033 and reducing 3798 tons of CO2 emissions annually.

ENVIRONMENTAL CONTRIBUTION OF THE YEAR SPONSORED BY: SPP PUMPS WINNER: BEDFORD PUMPS SAVE STAKEHOLDERS £3M ON FISH FRIENDLY SCHEME

Bedford Pumps’ Fish Friendly pumps successfully pass eels and fish in compliance with the EU Eel Regulations. They worked with Peter Brett Associates to evolve the civil engineering and pipeline design at Webb’s Hole Pumping Station to mitigate damage to eels and fish whilst also delivering stakeholders £3M in capital savings against their national framework estimate. It is the first of its kind to fully embrace the regulations from concept to commissioning.

MANUFACTURER OF THE YEAR SPONSORED BY: AESSEAL WINNER: KSB

KSB is one of the largest manufacturers of pumps, valves and automation products in the world.

Founded in Germany in 1871, and now with 16,000 employees, KSB is truly a global company. Present in the UK since 1896, KSB is able to offer customers a large variety of products and services. Investing in people, manufacturing and innovation has helped maintain KSB’s place as a market leader in the supply of pumps to many industries.

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DISTRIBUTOR OF THE YEAR SPONSORED BY: WEG WINNER: TOMLINSON HALL & CO. Tomlinson Hall’s engineering heritage – built up over 97 years and reinforced by our team’s technical expertise – enables us to create bespoke solutions for customers. We ensure clients can meet the challenges they face, whatever the scenario. As both a pump manufacturer and a pump distributor, we understand industrial challenges from multiple perspectives. Remaining committed to service excellence, in 2015 we significantly enhanced our customer service provision and also invested heavily in training.

SUPPLIER OF THE YEAR SPONSORED BY: TOMLINSON HALL & CO WINNER: JOHN CRANE John Crane is a global leader in engineered technology, supplying engineered products and services to energy services customers and other major process industries. The company designs and manufactures a variety of products including mechanical seals, couplings, bearings, filtration systems and artificial lift equipment. John Crane employs about 6,900 people and has more than 230 sales and service facilities in 50 countries.

ENGINEER OF THE YEAR SPONSORED BY: WORLD PUMPS WINNER: RYAN PEARSON, GRUNDFOS PUMPS Ryan has worked in the water industry for 12 years and is passionate about what he does. He has a helpful ‘can do’ attitude, which he combines with practical ‘hands on’ knowledge and excellent communication skills, making him a highly thought of, well-respected member of the Grundfos team. Ryan understands the importance of sharing knowledge, he always goes the extra mile.

LIFETIME ACHIEVEMENT AWARD SPONSORED BY: BPMA WINNER: KEN HALL, MANAGING DIRECTOR OF CALPEDA PUMPS Ken joined with Calpeda Pumps in 1986 and in 1995 became MD. He has been a member of the BPMA council for over 20 years, and been BPMA President on two occasions. Still a Director of the BPMA, and BPMA representative on the council of the European Pump Manufacturers Federation (Europump) Ken has been their President in 2007 and 2008. The architect and driving force behind Europump`s acclaimed energy policy ECOPUMP, he has promoted the pump industry European and UK energy policy across the world and continues to serve on the Europump council.

WEG PRESENTS NEW FLEXIBLE & EFFICIENT GEARED MOTORS

BREWERY LAPS UP ENERGY SAVINGS

WEG, a leading global manufacturer of motor and drive technology, is launching the WG20, a new range of highly versatile modular geared motors that offer worldwide interchangeability and up to 96% energy efficiency across a wide range of industrial applications requiring precise and reliable power transmission. The new geared motor will enable users to increase the energy efficiency of systems in their plants significantly, reducing associated energy costs.

Developed in cooperation with the company’s subsidiary – gear technology specialist Watt Drive - the WG20 comes in standardised mounting dimensions to suit both new and existing drive systems, ensuring ease-of-installation and flexibility when retrofitting. It is designed to cover virtually all international supply voltages thanks to internal voltage switching, which makes it easily interchangeable.

Available in energy efficiency classes IE2 and IE3, the motors feature an advanced design, with the pinion directly mounted on to the motor shaft resulting in a two-stage gear unit (in place of the commonly used three-stage unit). Fewer stages means reduced friction, which translates into lower power and heat dissipation and thus more efficiency. Additionally, the improved gear geometry featuring optimised gear teeth and high quality ground gear parts ensure low-loss power transfer and low noise levels, along with reliable performance and extended service life.

The compact gear unit design also has a positive impact on the required lubricant volume. The gear arrangement and the advanced housing interior allow the gear units to operate with a low oil level. The optimised oil fill level and low friction losses in turn prolong the life of the seals and extend the oil change intervals, therefore minimising time and costs associated with maintenance.

The WG20 is built with helical, parallel-shaft and helical bevel gear units with rugged pressurecast aluminium housings and is suitable for most industrial applications requiring torque ratings between 50 and 600 Nm. International certifications further enhance the geared motor unit’s versatility, enabling users to operate it at 100 or 120 Hz with variable speed drives.

For more information on WEG visit www.weg.net/uk.

When a well-known name in the brewery industry in the UK approached Grundfos Pumps to undertake an Energy Check on a part of their operation, they were sure they could help to deliver real savings. This is because Grundfos have been at the forefront of energy optimised pump development for years and take real pride in their achievements and their approach to sustainability.

Finding out what energy savings could be achieved is straightforward as Grundfos provide a range of diagnostic tools such as an Energy Check and Pump Audit that will establish the current pump system performance. Not only that, but these tools also provide various post-analysis reports that include details regarding the potential savings and payback periods as well as the various pump options you could opt for.

This is what happened in this particular case, when an energy check was undertaken which showed a potential energy saving of 148,645 kWh could be achieved by changing just 2 pumps. Better still, the payback period was just 6 months. The pumps were duly replaced with 2 x Grundfos NB 65-200 these reliable single-stage, standard bloc pumps.

With their enviable reputation the Grundfos NB(E), are manufactured at ISO 9001 certified facilities, and today the range comprises of a complete series of close-coupled (NB family) and long-coupled (NK family) pumps that are compliant with DIN EN733 or ISO2858. All are nonself-priming single stage, centrifugal pumps with axial suction port, radial discharge port and horizontal shaft. The pumps have now been installed for some time and are delivering not only in terms of the promised energy efficiency, but also are proving to be very reliable as they continue to deliver optimised pumping operation. A particular key customer benefit in this instance is that the pumps can be automatically slowed down at weekends when production is not as high. This is a great way of saving additional energy and means these pumps are contributing towards their global energy reduction targets. All in all are supplying many good reasons for saying cheers.

For more information or Literature request contact Grundfos Pumps Ltd, Leighton Buzzard, Bedfordshire. Tel: 01525 850000, E-mail: grundfosuk.com Web; www.grundfosuk.co.uk

The path to a greener future...

Efficiency l Strength l Reliability Since January 2015, EU MEPS have stipulated that any new motors on the market ranging from 7.5 kW to 375 kW power output have to meet the IE3 efficiency standard or IE2 efficiency standard if used with an inverter drive. From January 2017 this will be extended to motors from 0.75 kW to 375 kW. Our inverter drives will work with new and existing motors to help you reduce energy consumption and meet legislation when used with an IE2 motor.

For a greener future www.weg.net

WEG also offer a complete range of IE3 and IE4 energy efficient motors both for safe area and hazardous area applications to WIMES. Watt Drive high performance gearboxes are built to withstand the toughest industrial applications meeting the demands for operation across different industries.

LV

Individually, our gearboxes, drives and motors are amongst the most energy efficient available. Together they give you unbeatable levels of reliability and performance.

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THE PUMP INDUSTRY – PAST, PRESENT AND FUTURE

The definition of a pump is a device which uses suction or pressure to raise or move liquids. Back in Egyptian times, 2000 BC, this meant a long suspended rod with a bucket at one end and a weight at the other. 1800 years later, in arguably the greatest invention of all time, Archimedes devised a mechanical method of lifting low lying water for irrigation and land drainage purposes known as the Archimedian Screw Pump. This method is still very much in use today.

Mechanical pumps require power in order to operate, in 200 BC this source of power was the human hand. Animal, wind and water turbine power sources followed, thanks to the development of mechanical power transmission linkages.

Steam engines became the main power source at the end of the 18th century, whilst gas and early oil dominated the 19th century.

In 1790 Thomas Simpson coupled a reciprocating pump to James Watts rotary motion steam engine, to drive municipal water works pumps on the River Thames. This ultimately led to the formation of Worthington Simpson in 1917, which is now a part of Flowserve.

In 1851 John Gwynne filed his first centrifugal pump patent.

His early pumps were again steam engine driven but used primarily for land drainage. Allen Gwynne Pumps closed their manufacturing plant within the town of Bedford in 1987, which led to the formation of Bedford Pumps by former members of the pump department at W H Allen.

The first electric motor driven pumps finally emerged in the early 1900’s. Whilst electric motors now dominate the pump industry, electricity cannot reach all locations and the diesel engine driven pump, with its high torque engine, still plays a significant role in today’s mobile pumping market.

VARYING PUMP OUTPUT AND PERFORMANCE Since Archimedes time there has been a desire to vary the output and performance of a pump. This was originally achieved by changing the rotational speed of the screw or by varying the depth of water over the intake of the screw. Both concepts still hold true today. In 1972 the Swiss engineer, Martin Stähle, invented the “Prerostal” system that much like the Archimedes Screw, varies the output of a Hidrostal screw centrifugal pump without changing its speed!

20” Environment Agency Hidrostal mobile pump driven by JCB Diesel Engine Archimedes and the modern equivalent Prerostal system Prerostal uses gravity to drive the pump inlet head, but with the addition of controlled pre-swirl through a specially designed pump basin. This system holds all the non-clog benefits of the Archimedes Screw but with the added advantages of a smaller footprint and lower power consumption and is a great example of how the pump industry tends to enhance and build upon successful designs and experience that have gone before.

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All engine driven pumps can adjust performance by changing the shaft speed and or gear ratios on the drive train to the pump. With the fixed speed electric motor driven pump, adjustment to performance was initially possible through belt and pulley drives between pump and motor. This was not really improved upon until dual speed motors became commercially available from the late 1950’s on.

It was not until the late 1980’s that the possibility to infinitely vary the speed and performance of an electric motor driven pump became commercially available to the wider market. This took the form of the variable speed drive or frequency converter.

DEVELOPMENTS IN PUMP TECHNOLOGY It could be argued that the main developments in pump technology have been driven by an end users application requirement (eg. to be able to vary a pumps output) since Archimedes time. This need was progressively met through the many changes to pump power/drive source as new technology became available and was adopted into the pump arena. The alternative to speed control was to throttle a valve or close a sluice gate. This however wastes energy across the restriction barrier to flow.

The need to vary pump performance within an installation experiencing changing system characteristic’s, is not that new, the possibility to achieve this comprehensively however, is.

Today improved motor and variable speed drive technology provide the solutions to varying load or demand patterns on pumping systems.

Whilst this has opened up new opportunities it has also brought new challenges. The main one ensuring that the latest technology is applied appropriately, therefore delivering the best results that add value to a system, i.e. Whole Life Cost or Totex.

A variable speed drive alone does not always guarantee optimal results in terms of efficiency, reliability or reactive maintenance.

This can be apparent on some wastewater applications and systems with a high static head component to a duty point.

Here a technology such as a Prerostal (perhaps with dual speed motors) will often deliver a better Whole Life Cost outcome.

The trend to better match pump performance to system requirements looks set to continue and probably intensify, particularly as we run out of options to improve product efficiency and look into the system to obtain further savings.

Having said that we must not lose sight of the fact that not all systems require infinite variability in pump performance and sometimes a belt drive, dual speed motor, fixed speed motor or even the halfway house of a Prerostal system may be the most appropriate Totex solution where fewer set-points of performance are required.

WHAT’S THE FUTURE? We are all aware there is a limit to product efficiency. As we get closer to that limit, the magnitude of savings which pumps, motors and variable speed drives alone can realise, is decreasing.

Perhaps the next generation of significant savings for pump users belongs to a wider pumping system optimisation approach? This would no doubt require a middle way, taking the right mix of the most appropriate technology combinations for given applications.

By not just looking at the pumps in isolation, but aligning controls and monitoring to adapt and match performance to the more dynamic systems, a lower energy outcome should be possible with improved reliability from planned maintenance driven by monitoring equipment.

The BPMA has offered members valuable guidance on many aspects of evolving pump efficiency, standards and testing for some considerable time, helping us all separate fact from fiction.

BPMA is also currently actively involved in the developing scene of an “Extended Product Approach” which Europump are currently proposing.

Beyond this we are then into the huge diversity and knowledge challenge of “System Optimisation”. Could the future of the BPMA lie more in the realms of optimum system integration for pumps as opposed to the ‘pump itself?

Whatever the challenge may look like we can be assured the BPMA will continue listening to the members, balancing the arguments and representing the British Pump market needs successfully for many years to come.

For further information please contact Andy Wilson, Business Development Manager for Hidrostal Ltd.

HIGH EFFICIENCY API 685 PUMP WITH INTERNAL VAPOUR MONITORING SOLVES HYDROCARBON APPLICATION CHALLENGES Sundyne HMD Kontro Supplies ZeroLoss™ and VapourView™ technologies to US Customer on light hydrocarbon application Experiencing operational and fugitive emissions issues with an existing mechanically sealed API pump application in Washington, USA, a pump user reviewed whether the application of a magnetic drive sealless pump solution would improve the situation.

The application liquid, a highly volatile hydrocarbon, presented several sealing and operational challenges that would be overcome by the elimination of the mechanical seal. The proposed solution was a magnetic drive pump complying with the API 685 standard fitted with an engineered composite containment shell and internal flow regime monitoring.

The engineered composite containment shell (ZeroLoss™) eliminates induction losses normally associated with metallic containment shells and provides much improved handling of volatile and heat sensitive liquids. It also provides a more robust solution for magnetic drive installations that might experience marginal system conditions. The containment shells are produced to comply with the 40 bar (580 psi) API 685 design pressure requirements and feature highly chemical resistant composite material that is tough, durable and robust.

Non-invasive internal flow monitoring (VapourView™) was proposed to provide constant monitoring of the hydrocarbon inside the pump. Early detection of the presence of gas in the internal cooling and lubrication system is given, providing an early warning of adverse conditions that might impact the safe and reliable operation of the pump. One of the key features of the system is that it measures the primary cause of a potential problem (presence of vapour), and not a secondary condition such as change in power or temperature. Further, the system ensures correct priming and venting of pump is performed during start-up, a desirable feature, particularly on hydrocarbon applications.

After consideration the user chose to implement the proposed magnetic drive pump solution. During the commissioning phase of the installation, the internal flow monitoring device detected a number of priming and venting issues that enabled the user to revisit their start-up procedures, ensuring these issues were overcome. After start-up the presence of gas was also detected inside the pump, which originated from the presence of vapour in the pumps suction pipeline, this condition was also corrected.

By reviewing and applying the latest magnetic drive pump technologies, the user is now enjoying improved reliability and reduced fugitive emissions in this hydrocarbon pump installation.

Full details of the GSP pump range and VapourView™ and ZeroLoss™ technologies can be found at www.sundyne.com/hmdkontro.

For further information and literature, please telephone +44 1323 45200 or email vince.lee@sundyne.com.

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BRDO & NMRO COMBINE TO SIMPLIFY REGULATION FOR BRITISH BUSINESS

SPP MAKES FURTHER INVESTMENT INTO DEWATERING BUSINESS

BRDO and NMRO brought together into a single BIS directorate from 1 April 2016.

The Better Regulation Delivery Office (BRDO) and National Measurement and Regulation Office (NMRO) were brought together into a single BIS directorate from 1 April 2016 to focus on regulation and enforcement.

BRDO were previously responsible for improving the way in which local and national regulators enforce regulations, saving money for business and taxpayers. NMRO operated as an Executive Agency within BIS, sponsored by BRDO, aiming to simplify technical regulation for the benefit of UK businesses.

The new Regulatory Delivery directorate is led by BRDO Director, Graham Russell and reports to Small Business, Industry and Enterprise Minister, Anna Soubry. The directorate will work to ensure that the way regulation is enforced is proportionate and risk based. It will deliver existing functions such as Primary Authority, legal metrology and hallmarking policy, technical regulation and enforcement work.

BIS Permanent Secretary, Martin Donnelly, said:

“Combining NMRO and BRDO will bring together policy expertise and practical experience. This will ensure that government policy is effectively delivered in ways that reduce burdens on business, save public money and properly protect people and communities.”

The director of the new Regulatory Delivery directorate, Graham Russell, said:

“This is an exciting opportunity to raise standards of protection for vulnerable people and encourage businesses to grow, by improving the way we regulate in the UK. Combining two organisations is challenging but I know that we are committed to working well together, using fewer resources for better outcomes.”

Martin Donnelly has written to all BRDO and NMRO staff about the decision to combine the two offices into one Regulatory Delivery directorate. Staff will continue to be supported by senior leaders and line managers during the transition.

AESSEAL® IS PLEASED TO ANNOUNCE THE LAUNCH OF THE SHORT CANISTER MIXER SEAL (SCMSTM) The seal has been designed to meet the modern day mixing requirements of faster more efficient mixing from smaller vessels and is suitable for side entry (flooded) or top entry (running in vapour) mounting.

The SCMSTM is designed specifically for Mixer, Agitator and Reactor applications and is available in sizes ranging from 30mm to 125mm (1.250” to 5.000”). The dual seal is ideal for both mature and modern mixer designs with its reduced height for applications where space is limited and is available for ATEX applications.

The range is dual balanced ensuring that the seal can maintain containment through a range of process fluctuations. The range also incorporates fail safe protection through independent seal face loading using a unique common multi-spring design ensuring production safety.

The SCMSTM can accommodate up to 3.5mm of radial T.I.R movement on larger sizes and also has self-adjusting axial movement compensation. Engineered solutions are available for difficult or non-standard applications.

For more information contact Aesseal Plc, Rotherham, South Yorkshire. Tel: 01709 369 966 E-mail: marketing@aesseal.com Web: www.aesseal.com

GRUNDFOS MD GETS THE ROYAL SEAL OF APPROVAL At a special ceremony the Queen of Denmark, Margrethe II, presented Peter Reynolds, Managing Director of Grundfos Pumps with an important award in recognition of his achievements.Peter’s 25 years of hard work were acknowledged when he recently was the recipient of two awards - The Diploma of the Danish Export Association and HRH Prince Henrik’s Medal of Honour – which were presented to him at the Danish Embassy in London at a special ceremony. The event was hosted by the Danish ambassador to the UK, Claus Grube and the Danish Queen Margrethe II, presented Peter with his awards.

Behind this recognition lies Peter’s long and impressive career with Grundfos that has culminated in his leadership role as Managing Director in the UK, a position that he has now held for ten years.

After receiving the awards, Peter said “I feel very proud to receive such an important recognition,” while Group Executive Vice President Poul Due Jensen added his words to underline Peter Reynolds’ importance in shaping Grundfos’ success “in his 25 years, Peter has managed to forge deep and lasting relationships with all customers and partners in our value chain. This has helped consolidate Grundfos’ leading position in the UK market,” he said.

The Diploma and Medal are awarded in recognition of an outstanding effort in promoting and marketing Danish products and services abroad.

For more information or literature request contact Grundfos Pumps Ltd, Leighton Buzzard, Bedfordshire.

Tel: 01525 85000 E-mail: grundfosuk@grundfos.co.uk

8

SPP Pumps has announced investment into its dewatering division, with the appointment of a new sales manager and a partnership with a new Australian distributor.

Colin Baker has been appointed UK and Ireland Sales Manager, and will hold responsibility for maximising opportunities in the market, growing existing relationships and expanding the company’s customer base in the dewatering sector.

With nearly 20 years in the pump industry, Colin is excited about the challenges that lie ahead: “When I first met with SPP I was impressed with the scale and set-up of the company - the scope of opportunity is immense and I feel really positive about the future of the dewatering sector.”

Colin will be working across the entire dewatering portfolio, promoting SPP’s range of Autoprime pumps … vacuum assisted, self-priming pumps that have become the benchmark for reliable, durable and compliant dewatering applications such as flood protection, ground water control, sewage management and well point dewatering.

In addition to the new appointment, SPP Pumps is teaming up with Australian distributor FITT Resources. The partnership will seeSPP’s dewatering range of pumps sold throughout Australia and New Zealand, and an order has already been placed for nearly £200k worth of SPP’s Q Series pumps.

FITT Resources specialises in the supply of premium mechanical engineering products, parts and servicing, offering premium pumps across a wide range of industry sectors, including flood protection and water management.

Gregg Fowler, Director at FITT Resources, said: “We’re delighted to be working with SPP. Both our companies operate on the same ethos of putting the customer at the heart of everything we do. We respond to customer needs and provide the best solutions.”

Duncan Jackson, Business Unit Manager for dewatering at SPP, concludes: “SPP has a versatile range of pumps and box canopies that can provide our customers with the pump solutions they need, when and where it really matters. We have the ability to be versatile and responsive, and that is what enables us to be successful. With Colin Baker on board and FITT Resources already working to sell throughout Australia, I’m feeling confident 2016 will be a great year.”

For more information contact SPP Pumps, Reading, Berkshire.

Tel: 0118 932 3123 E-mail: enquiries@spppumps.com Web: www.spppumps.com

KSB SUPPLY PUMPS TO THE RENFREW FLOOD PREVENTION SCHEME ON THE RIVER CLYDE

i-ALERT2 EQUIPMENT HEALTH MONITOR “NOW AVAILABLE FOR ANDROID”

KSB and Ferrier Pumps Ltd recently continued their long standing partnership working on a flood prevention scheme for Renfrewshire Council. This involved planning and collaboration on the front end design, pump testing, supply, installation and commissioning of all the pumps and ancillary equipment. The project involved KSB supplying four variable speed submersible pumps from their axial flow Amacan pump range and one variable speed sump pump of type Amarex KRT, to the North Renfrew Flood Prevention Scheme near Glasgow. KSB also supplied the 800mm diameter pump discharge canisters which are currently installed in the Storm Pumping Station situated on the south bank of the River Clyde.

The flood prevention scheme will protect more than 300 homes and businesses in North Renfrew and comprises a 3m high embankment and a new underground pumping station at the Mill Burn at Fingal Road. The embankment, which runs westward for 1km from Ferry Road, provides a barrier against direct flooding from the Clyde. The pumping station containing KSB pumps will ensure that tidal surges on the Clyde do not cause the Mill Burn to overflow and flood local properties.

The pumping station provides a capacity of 5.5m3/s to provide standard protection against tidal flooding from the River Clyde and fluvial flooding from Mill Burn. The pumping station’s maximum flow rate has been specified to cover a 1 in 200 year flood event. KSB Amacan pumps were chosen for this station as their characteristics ideally suit the transfer of very high flows of water at low heads. KSB’s technically advanced pumping equipment is well-suited for flood control and the Amacan pumps ensure flood-prone areas are reliably drained.

KSB Amacan submersible pumps are typically used in land drainage applications and have a compact and slim design, but are extremely powerful. The Amacan’s slim design makes the submersible pump ideal for installation into narrow discharge canisters. Ferrier Pumps Ltd carried out the mechanical installation at the Renfrew project site and found the pumps were easy to install as the Amacan pump’s own weight ensures self-centering seating of the O-ring seals in the discharge canisters, a simple but effective design feature. The Amacan pumps come with bearing temperature monitoring, thermal motor protection and leakage sensor in the motor. They also have a low-vibration hydraulic system and a bellmouth optimised for vortex-free inflow making them an excellent choice for the Renfrew project.

Ferrier Pumps also installed in the main sump chamber a KSB Amarex KRT submersible solids-handling centrifugal pump, specifically manufactured in abrasion resistant materials to remove storm water as well as handling a relatively high concentration of solids in the pump station.

This variable speed pump is used for sump drain down following cessation of a storm event.

KSB have also supplied the pump discharge canisters, which were designed by KSB at their UK Head Office in Leicestershire, and were digitally prototyped and tested using the latest 3D design software. The canisters were manufactured by Powerrun Project Management Ltd of Keighley and each 800mm diameter canister was supplied to site in 3 off individual double flanged sections with a combined weight in excess of 3000 Kgs and an overall assembled length of nearly 10 metres.

Before any manufacturing of products or site work began, a report covering the testing and development work was undertaken on a physical hydraulic model of the proposed North Renfrew Ferrier Pumps Ltd, a KSB distributor in Scotland, carried out the mechanical and electrical installation for George Leslie Ltd who was the main contractor for the £3.6m project. The work was commissioned by Renfrewshire Council as part of the overall £10m flood prevention scheme for the town.

For more information contact KSB Ltd, Loughborough, Leicestershire.

Tel: 01509 231872 | E-mail: sales@ksb.com | Web: www.ksb.com

The i- ALERT2 Equipment Health Monitor is a Bluetooth Smartenabled machine health monitor that allows customers to identify potential equipment problems before they become costly failures.

ITT’s i-ALERT2 Equipment Health Monitor is an inexpensive Bluetooth Smart-enabled equipment health monitor that allows customers to identify potential problems before the machines become costly failures. It tracks vibration, temperature and run-time hours and wirelessly syncs the data with a smartphone or tablet through the i-ALERT2 mobile app.

The i-ALERT2 condition monitor combines the latest in Bluetooth low-energy and sensor technologies commonly used in the newest consumer health and fitness trackers and smart watches.

The i-ALERT2 device is the first condition monitor to successfully integrate these technologies into an industrial package in a small footprint [2.24 in. (L) by 1.54 in. (W) by 1.04 in. (H)] which is half the size of a credit card. It is engineered and rated for use in a wide range of industrial environments. It is chemical resistant, rated for extreme temperatures (-40 to 183 F) and is rated to operate in environments with explosive gases, dust and fibers.

With 24/7 monitoring, a wireless range of up to 100 ft and the ability to scan multiple i-ALERT2 devices at once with a mobile device, customers will be able to quickly and safely inspect multiple pieces of equipment and be alerted of potential problems before they become critical failures. Through the i-ALERT2 mobile app, customers can now view real-time and historical data, diagnostic information and machine records. This provides them with the data necessary to make informed decisions. Customers can now spend less time collecting data and more time solving problems. Buy a Goulds ANSI and ISO process pump and these are supplied with i-Alert fitted as standard and a 5 year warranty - you’d have to ask yourself, why not?

For more information contact ITT Goulds Pumps, Axminster, Devon. Tel: 01297 630473 Email: www.gouldspumps.com/Contact-Us Web: www.gouldspumps.com or Web: www.ittproservices.com

9

WILO

- TAKING PUMPING TO A HIGHER LEVEL… Wilo and the BPMA share longevity. In congratulating the BPMA on its 75th anniversary this year, this highlights the fact that the BPMA is a comparative youngster as Wilo will celebrate its 144th anniversary this year – heading for its 150th in six years time!

Wilo was formed in 1872, as Kupfer-und-Messingwarenfabrik Louis Oplander, originally a copper and brassware manufacturer, and has had an impressive track record since those very early days. Today Wilo – based in Dortmund in Germany - is one of the world’s leading manufacturers of pumps and pump systems for heating, cooling and air-conditioning technology as well as water supply and sewage disposal. The company had a turnover of 1,234.7 billion euros in 2014.

With an eye to the future, the company is heavily involved in research and development and is increasingly transitioning from a component to a system supplier. Behind the name are more than 7000 employees in over 60 subsidiaries around the world. Together they turn visionary ideas into intelligent solutions that regularly set new standards in the industry developing innovative, high-quality products that make life easier and more efficient.

As well as providing a huge range of products and helping to provide system solutions for customers, Wilo offers leading edge training facilities, accredited CPD information and a first class servicing operation.

In the UK, Wilo is based in Burton-on-Trent, with a

10

team of around 100 in impressive offices that serve as the head office, provide an assembly facility, a sizeable warehouse and an impressive training centre. Wilo UK operates across a number of sectors as pumps are components of so many different business areas.

Wilo has been a member of the BPMA since the early eighties and sees its membership as an essential business partnership.

The pump market is changing and has changed radically in recent years, in many ways and not just in the achievement of higher levels of efficiency. Perhaps the most important change that has been seen, is the move away from being just a pump manufacturer, simply supplying pumps that consultants and contractors are ordering for a project. The move has been towards the adoption of a proactive approach to supplying total solutions, offering a total response to the need to reduce energy usage, lower energy bills and reduce emissions, whilst seeking innovative new ways of responding to the challenges of modern day building provision and renovation.

Every major building relies heavily on pumps of various designs, shapes and sizes to run the heating, air conditioning, chilled water, potable water supply, to distribute harvested rainwater and to remove the sewage and greywater from

the building. Their roles are many and various, but all are vital. Modern pump technology allows these tasks to be undertaken far less expensively in upgrade and renovation projects, simply by replacing elderly existing pumps with modern high efficiency pumps, designed to do their jobs better, quicker, less expensively, in a more environmentally friendly way and more reliably. In new buildings, where you can start from a blank sheet of paper, modern pump technology allows specifiers and consultants to seek the optimum solution for that building without any restrictions on infrastructure, incorporating system solutions that include the latest pump technology from top to bottom, along with the necessary building management system to take advantage of all that new technology offers, within the budgetary restrictions they will inevitably have to work with.

The key words when looking at system-based solutions are ‘lifecycle costs’. Modern pumps carry a more expensive capital cost than their elderly relatives. The new technology in the modern pumps comes with a price. But the payback from modern pumps is usually extremely fast in relation to the capital cost, because the energy required to run these new pumps is far less. Over say, a fifteen year lifecycle, huge savings in terms of energy cost can be made, large emission reductions can be shown and with far less energy use, come far lower energy bills and maintenance costs for the building.

Find out more at www.wilo.co.uk.

ATLAS COPCO EXTENDS ITS REVOLUTIONARY RANGE OF GHS VSD+ VACUUM PUMPS TO 1900 M³/H Atlas Copco has extended its portfolio of GHS VSD+ vacuum pumps with the launch of a new model offering power of up to 1900 m3/h while retaining the revolutionary level of energy efficiency that has been a hallmark of the range. The new GHS 1300-1900 VSD+ is built upon the success of the GHS 350-900 VSD+, which set a new benchmark for vacuum pumps when it was unveiled in 2015.

Incorporating variable speed drive (VSD) technology to keep power closely aligned with fluctuating production demand, the GHS VSD+ range delivers energy savings of up to 50% compared with conventional fixed-speed vacuum pumps. In addition it offers plug-and-play simplicity, advanced control features and lower-than-average noise levels.

The GHS 1300–1900 VSD+ is an oil-sealed rotary screw vacuum pump with a range of 1300 to 1900 m3/h and an ultimate pressure of 0.35 mbar(a). However, its footprint is less than 2.3 m3, enabling easy installation without taking up valuable floor space at a production facility.

Alongside a clear and detailed front-panel display, SmartLink connectivity is available as an additional option, which provide users with greater insight and control into the machine’s operational performance and thereby maximise uptime. The vacuum pump also boasts Atlas Copco’s Elektronikon for state-of-the-art monitoring, enabling full control to enhance energy savings.

Optional water cooled versions are available, with an integrated energy recovery system that could recover up to 100% of the used energy as hot water (90°C), which can be used for process requirements to save on excess fuel usage.

The vacuum pump’s market-leading oil retention means that the quality of the exhausted air is optimal, which contributes to employee wellbeing and eradicates oil spills for a cleaner working environment.

The GHS 1300–1900 VSD+ is suitable for centralised vacuum systems, glass bottle manufacture and canning, as well as many other applications. The new vacuum pump is also available as a turbo version if fast evacuation times are needed. It enables faster cycle times for higher production and is ideal for meat, cheese and chicken packaging, as well as cooling.

For wet applications such as plastics, clay moulding and drying of pipelines, customers can choose the GHS VSD+ as a humid version. You can learn more about the GHS VSD+ oil-sealed rotary screw vacuum pump range by visiting: www.atlascopco. com/vacuum

Magnetic Drive

AXFLOW LAUNCHES RANGE OF ELASTOMER COATED ROTARY LOBE PUMPS AxFlow has extended its range of positive displacement pumps with the introduction of the Boyser LB suite of elastomer coated rotary lobe pumps for flows of between 5m³/hr and 130m³/hr.

The LB pump has been designed from the ground up following an assessment of products currently on the market with a view to producing an economical process quality pump with the best combination of design features.

The LB range offers a combination of innovative features.

Ergonomic rotors designed in conjunction with Universitat Autonoma in Barcelona, maximise the sealing face while allowing the passage of particles up to 50mm in size. The rotors can be coated in NBR (FDA), EPDM and Viton or supplied in AISI-410 and 316 stainless steel.

Also to be noted is the unique intermediate chamber that isolates the pump head from the gear box, therefore avoiding any kind of cross contamination. The pumps utilise robust, high precision gears with self-aligned roller bearings that ensure that the rotary lobes deliver exceptionally high levels of accuracy and efficiency and use a range of process quality mechanical seals.

Lastly, stainless steel axial liners incorporated in the pump chamber protect the pump casing, help to maintain the pump’s performance and are easy to replace, thereby significantly increasing pump life.

AxFlow believes that the LB benefits from having the optimum design features that make it suitable for all but the most demanding process duties.

For more information contact AxFlow Ltd, Ealing, London.

Tel: 020 8579 2111 | E-mail: info@axflow.co.uk | Web: www. axflow.co.uk

Safe, Seal-less, Reliable!

As a UK based manufacturer with over 40 years experience, we are at the forefront of magnetic drive technology.

Today we have the largest range of mag drive pumps in the world, covering all industries and applications.

We offer products with unparalleled quality, quick lead times and competitive pricing.

WWW.MARCHMAY.CO.UK 11

POWERFUL PERFORMERS Thames water pump application As the BPMA celebrates its 75th anniversary, we take a look at the development of the electric motor, one of the key underpinning technologies of the pump manufacturing industry.

Electricity is the driving force of modern life. It powers our factories and illuminates our homes. It fires up our laptops and charges our phones. Without it, our day-to-day existence would be totally unrecognizable.

Perhaps surprisingly, it is the humble electric motor that is the biggest single consumer of electricity – with electric motor-driven systems (EMDS) using around 45% of total global consumption1.

That statistic reveals a truth: electric motors are the workhorses of the modern industrial world, converting electrical energy into mechanical energy for a wide range of applications including fans, blowers and pumps, machine tools, household appliances and power tools. As such a major consumer of electricity, it is vital that electric motors are as energy efficient as they can possibly be.

To fully understand the role that electric motors perform in modern society, it’s useful to trace their development. It’s quite some backstory. As long ago as the 1820s, scientists and inventors were intrigued by the practical applications of the newly discovered phenomena of electricity, magnetism and electromagnetism, and set about developing the first wave of electric machines. The bases of these inventions were the creation of the battery in 1800 by Alessandro Volta, the discovery Werner von Siemens of magnetic field generation by electric currents in 1820 by Hans Christian Oersted and the invention of the electromagnet in 1825 by William Sturgeon. The first device powered by electromagnetic force was created by Peter Barlow in 1822 and, twelve years later, Moritz Herrmann von Jacobi created the first actual rotary electric motor.

But despite advances, these machines did not meet the requirements for large-scale production as they lacked operating ease and efficiency. Those limitations began to disappear when, in 1866, the German engineer Werner von Siemens created the first economically viable electric machine: a DC generator. The difference from earlier machines was that the voltage required for magnetism could be obtained from the rotor winding itself, meaning that the machine was self-excitable. In an instant, Siemens created the possibility of supplying electric motors with

Old Motor 12

low-cost energy.

After Siemens’s invention, various DC motors began to be manufactured for industry and transport. Nonetheless, they still had problems: they were large, noisy and generated sparks every time the commutator shorted to reverse the direction of the electric current.

The search for a cheaper, more efficient and safer motor encouraged research and inventions in the late nineteenth century.

That is how AC motors were improved. In 1885, electrical engineer Galileo Ferraris built a biphasic AC motor. The invention’s low yield prevented its commercial production. The same happened with a biphasic motor with a rotor in short circuit, created in 1887 by inventor Nikola Tesla.

It was in 1889, that the electrical engineer Michael von DolivoDobrowolsky patented an efficient AC motor. It had three phases and a rotor cage. With 80 watts and an energy return on energy invested of 80%, it was simpler, safer and quieter, and had fewer maintenance problems. From this notable advance, the era of the more efficient electric motor was finally underway.

During the early twentieth century, with many manufacturers active in the market, there was no standardisation of motors.

This created difficulties when replacing one machine for another, requiring constant adjustments. After several attempts, in 1950, the International Electrotechnical Commission initiated the work of creating separate standards for weight and power, the application of which is linked to the technical requirements of each country’s standards.

With effective standards in place, the second half of the twentieth century witnessed an evolution of electric machines. In 1961, WEG Industries was formed in Brazil and achieved notable advances in the design and production of electric motors. WEG’s engineers were at the forefront of weight reduction, experimenting with new materials like plastic, aluminum and new insulators to create different possibilities for the application of these machines. The main revolution, at WEG and other manufacturers, was the use of electronics, both in composition and in manufacture of electric motors.

Today, it is possible to construct highly accurate and efficient motors to perform various tasks, especially repetitive or highly complex ones. It is also possible to build large electrical machines for special uses in industries, power plants and agribusiness. The flexibility of the electric motor isn’t in doubt – the challenge lies around improving their efficiency, and reducing their burden on electricity supplies.

Take the standard induction motor – it alone uses about 30% of all the electricity generated in the world. Armed with that statistic, it is not hard to realise why better efficiency is crucial for the leading electric motor manufacturers makers in the world.

At the heart of these efforts is regulation. In the EU, the Ecodesign directive has been in force since 2011.

The 640/2009 regulations mandated that, from June 2011, motors within its scope had to meet at least IE2 efficiency rating, and a more efficient IE3 rating in 2015, unless controlled by a variable speed drive (VSD). With further studies being conducted as part of the revision of the regulations, the requirement for motors to meet IE4 rating is also set to come into force in the foreseeable WEG’s first motor future.

The key to designing a more efficient motor is to understand where the losses occur. When compared to IE3 motors, IE4 designs will need to reduce their losses by between 10 to 24%. At WEG, engineers have investigated numerous techniques to achieve this target – such as reducing the resistance of stator windings, redesigning the shape of rotor bars and short-circuit rings, and using new materials creating motors that already meet anticipated IE4 rating. Development of permanent magnet motor drive systems are now able to offer even further efficiencies.

Motors play a key role in improving energy efficiency in fluid / air-flow applications, including pumps, compressors and blowers.

Significant advances in the power electronics and control techniques have led to an increasing use of VSDs as a way of increasing energy efficiencies in fluid-flow applications. Permanent magnet and synchronous reluctance motors can deliver IE5 or even higher efficiency levels, with IE6 already being discussed at the moment.

WEG’s IE5 WMagnet Drive System

Ultimately, engineers will ensure that the design of the electric motor will continue to evolve to meet the changing requirements of the world that we live. The electric motor has taken 200-years to reach this stage, and there’s no sign of that journey coming to an end.

The electric motor is based on the interaction between electric and magnetic phenomena. In a simplified representation, the motor is composed of coils (the rotor) arranged on top of fixed magnets (the stator).

A magnetic field is generated around the coils when electric current flows through it, which interacts with the field of the magnets causing the coils to turn. The coils will not stop turning when a current reversal is applied at a determined frequency. When a shaft is coupled to these coils movement is transferred to the outside of the structure.

Several researchers have contributed to the technological advancement of these machines. In addition to Werner Siemens and his DC motor and Nikola Tesla, who invented the two-phase induction motor, two other researchers stand out: Galileo Ferraris, one of the pioneers of AC power systems and the inventor of the induction motor, and Mikhail Dobrovolsky, who developed the three-phase electrical generator and a three-phase electrical motor.

1.http://www.iea.org/publications/freepublications/publication/ee_for_ electricsystems.pdf