SPRING EDITION 2018
BPMA CONTINUES LOOKING FORWARD WITH A NEW PRESIDENT Mr. Duncan Lewis, Managing Director of Xylem Water Solutions UK Ltd has been announced as the new President of the British Pump Manufacturers Association Limited (BPMA). The role was officially passed on at the recent BPMA Annual General Meeting, where Mr Peter Reynolds, Managing Director of Grundfos Pumps Ltd, completed his two-year tenure as President and graciously handed the baton onto his worthy successor. Steve Schofield, Director and Chief Executive of the BPMA commented, “This is a great accolade and one that reflects the continuing efforts that Duncan makes to raise the profile of the industry in general and
to tackle the tough issues that it faces today. The BPMA has enjoyed the support and engagement of some very talented people at its helm over the years, including of course Peter Reynolds, and we are delighted to have Duncan join that impressive line-up. I look forward to working with him as we continue to drive the association forward”. Duncan’s presidency coincides with the uncertainty that BREXIT is currently bringing to industry and when asked to comment, Duncan said, “Being elected as President of the BPMA is a great honour and to take on the role in these somewhat trying times will no doubt be challenging. Brexit is clearly a very important subject with potential opportunities and threats for our industry, but I am sure with the help and support of BPMA staff, its Board and its Council we will meet this challenge”
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red concern The new Radio Equipment Directive – it could have far reaching implications! In this article, Steve Schofield, Director and CEO, British Pump Manufacturers Association (BPMA) offers a quick overview of this contentious legislation. The Radio Equipment Directive supersedes the former R&TTE (Radio & Telecommunications Terminal Equipment) Directive and determines that all and any products that are equipped or combined with a device for transmitting or receiving signals via ‘radio waves’ is in scope of the Directive and so can, and will, be regarded as a RED product. Some would argue that this is an unsatisfactory situation, with most companies taking a pragmatic view and continuing to follow the well-known and fully established procedure in accordance with the R&TTE Directive – the predecessor of RED. In this historical approach, all the equipment that combines to make the machine (and which is now subject to the Radio Equipment Directive) is shipped accordance with the Machinery Directive. Clearly, the introduction of RED will create another layer of documentation and conformity requirement that will have far reaching implications for many equipment manufacturers, as they strive to effectively service the needs of the ‘connected environment’ and the ‘smart factory’. The European Commission has now published the updated list of harmonised standards in the framework of the implementation of the Radio Equipment Directive (RED), which came into effect on 14 July 2017 (C 229/24). Additionally, the Frequently Asked Questions (FAQ) document on RED has been recently updated. It covers key clarifications on the scope and application of RED, as well as the status of publication of harmonised standards, and how manufacturers can ensure compliance with the Directive in the absence of standards. An informal meeting on the Radio Equipment Directive was organised and hosted by the Commission on 3rd October. This meeting focused on the harmonised standards prepared for Articles 3(2) and 3(3) which prescribe the essential requirements of the Directive. More details on RED can be found in the Orgalime Guidance Document which is available from the BPMA, along with the list of FAQ’s. Please contact Steve Schofield at the BPMA s.schofield@bpma.org.uk - to request your copies.
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old or new Let BPMA help with your pump selection Old pumps not only consume too much energy, they are also prone to failure which can adversely affect your maintenance budget and in turn your business. By replacing them with new, correctly sized, energy-efficient pumps, you will enjoy reliable, low-cost pump operation. As a way of helping pump users to undertake that all-important pump selection, the British Pump Manufacturers Association (BPMA) developed a comprehensive online Pump Selection Search Facility, which is available for anyone to use. This easy to use online search facility can be readily accessed via the existing BPMA website www.bpma.org.uk/pump-search/1/ Pumps and is completely free of charge. How to use The Pump Search There are two ways to search for your perfect pump and its supplier: Search One: You know the type of pump you need If you know the type of pump you are looking for, you just need to click on the Pump Type drop-down menu, select your Pump Type then click Show Results. This will offer you a list of BPMA members who will be able to supply this type of pump. Search Two: You know the application, but not the pump type If you are not sure of your Pump Type, but know what it will be used for, simply click on the Pump Application drop-down menu, select your application and then click Show Results. This will offer you a list of BPMA members who can supply pumps suitable for that particular application. If your initial search delivers a large number of potential suppliers, it can be further refined by selecting extra parameters from the options available in the left hand column, which include Head, Flow, Drive Type, Material etc. Only BPMA members are displayed on this search engine and all BPMA members have agreed to adhere to the BPMA Code of Conduct, so you are assured of high quality, fully compliant, energy efficient pumps on every selection. You can now use the Pump Search to easily find the correct pump for your requirements and then manufacturers and suppliers of liquid pumps and other pump related equipment. Reader Enquiries to: Steve Smith, Administrator, British Pump Manufacturers Association Ltd. National Metalforming Centre, 47 Birmingham Road, West Bromwich, West Midlands B70 6PY Tel : +44 (0)121 601 6691 | Email : s.smith@bpma.org.uk | Web; www.bpma.org.uk
training young engineers Time to acknowledge and celebrate our engineers The prestigious Pump Industry Awards Dinner, which is produced annually by Touchwave Media on behalf of the BPMA, is the ideal opportunity to recognise the exceptional engineering talent that our industry currently enjoys. The skill, innovation, and dogged determination shown by this sector’s engineering staff ensure the delivery of effective and efficient pumping systems, time and again. From pump manufacturers and distributors, through to sector specific end users and system integrators, the depth of technical knowledge and application know- how is really first class. But this high level of engineering excellence doesn’t just happen of course! It takes a great deal of support and encouragement by the employers, and of course hard work, dedication and ongoing training by the individuals themselves. The BPMA is extremely proud of the training programmes that it has been able to offer the pump sector over the years, and remains committed to the ongoing progression of all those opting for an engineering career within the pump sector. This commitment to providing high calibre training modules (all of which are now CPD accredited), along with the constant drive to help pump companies and their engineers to improve their technical and operational knowledge of pump systems, also supports and underpins a healthy and robust industry. Additionally, it helps to encourage new engineers into the sector, by demonstrating the opportunity for personal ongoing development and career progression – something which is key to any industry, in helping address whatever skills gap might exist! However, this individual commitment to engineering excellence often goes unnoticed outside of the specific projects or companies with which these individuals are engaged. That is why the ‘Engineer of the Year’ category within the annual Pump Industry Awards programme is crucial to this endeavour. It provides the ideal platform through which to honour their achievements. Alan Burrows, Editor, World Pumps, commented, “Bringing new talent into the pump industry and keeping our young engineers motivated to stay there is a major challenge for all manufacturers. Without the support and incentive to grow, there will be no technical innovations within either product development or the all-important project and applications arena. Today’s young engineers will be at the heart of environmental contributions of the future and form the core talent of the top pump manufacturers of tomorrow; reason enough therefore to acknowledge and reward their efforts through this awards programme.” The 2018 Pump Industry Awards Ceremony will take place on 22nd March at the Heythrop Park Hotel in Oxfordshire.
bpma & brexit BPMA Delivers Brexit Position Statement On March 29th 2019 the UK will leave the European Union, it is clear from daily news that this is possibly one of the most complex scenarios a UK Government has ever had to deal with. This very important subject will offer potential opportunities and no doubt threats for the pump industry. To assist BPMA members in understanding Brexit, a group of BPMA Council members have held meetings to discuss the possible issues and opportunities and from this they have written a position paper. This has subsequently been approved by the full BPMA Council and then endorsed by members at the recent Annual General Meeting. Since then the position paper has been circulated to MP’s, civil servants and government departments dealing with Brexit and has received a positive response. The make-up of this position paper is detailed below: About the BPMA Established in 1941, and incorporated as a company limited by guarantee in 2009, the British Pump Manufacturers Association’ (BPMA) is a not-for-profit trade association representing the interests of UK and Irish manufacturers and suppliers of liquid pumps and other pump related equipment. BPMA members account for approximately 85% of the total UK production of pumps, of which half a billion pounds worth of pumps is exported to Europe and over one billion pounds worth of pumps is imported from Europe to the UK. It is estimated that the pump Leaving the European Union Leaving the European Union will affect all of us in the UK in some way. The BPMA have surveyed its members and the following issues are major areas of concern. The Single Market and Customs Union If Britain decides to leave the Single Market, there is no point in being part of the Customs Union; leaving would allow the British Government to subsequently agree its own trade deals. International trade deals however are known to take many years to agree and it will require a lengthy transition period to avoid major issues within the pump sector. The best option from an economic perspective is for Britain stay in the single market or the customs union and to continue with “Free Trade” in both directions with unrestricted movement of capital within a company across Europe. The British Government may give a new name to a new agreement with the European Union; however it is imperative that there are no barriers to trade in either direction. EU Nationals and possible Skills crisis Almost 80% of our industry employs EU Nationals and they wish to continue to do so. We believe that a controlled movement of people with a certain level of skills will continue to be a benefit to our sector and the UK in general. As a manufacturing sector our industry uses staff within a shop floor environment to a board room, from technical design office to on site commissioning and we currently have EU nationals in many of these positions. Universities should be able to continue to offer placements for overseas students from within and outside of the EU. They should be given a privileged status to remain in the UK 2 years after their tertiary education before applying for permanent residency. We request that any future agreements regarding EU Nationals working in the UK does not create a skills shortage in our sector. CE Marking and the Declaration of Conformity of Products Pumps placed on the market within the EU are currently required to meet certain safety, environment and energy related Directives and regulations. The CE mark along with the declaration of conformity gives customers the satisfaction that pump products meet these strict requirements. After Brexit pumps sold into the EU will still require a CE mark and to meet all of the Directives and regulations. Our sector requests that the CE mark remains without change along with retaining the Technical File in the UK if needed and using UK Notified Bodies. For further information on the BPMA’s Brexit Position Paper, please contact BPMA Directorand CEO, Mr Steve Schofield - s.schofield@bpma.org.uk
welcoming members
bpma joins euris
BPMA Membership Continues to Grow
BPMA Follows-up its Brexit Position Statement with Membership of EURIS
The British Pump Manufacturers Association (BPMA) which represents the business interests of UK and Irish suppliers of liquid pumps and related pumping equipment on both the domestic and international stage, reports continued growth in its membership numbers, with another three companies recently joining the organisation. One such company who will begin to enjoy the benefits of membership is Teesside based distributor, Tomlinson Hall & Co Ltd. Founded in 1919, Tomlinson Hall has gained considerable expertise in the pump industry, and has a proud history of innovation. As an approved global distributor for a wide range of leading pump brands, Thomlinson Hall works with high profile clients in both the UK and overseas markets, including Europe, the Middle East, North America, South America and Asia. From its headquarters in Billingham, North East England, the company works closely with end-users to find the right pump system solution for them; offering a total service to industry – including pump selection and supply, site visits, problem solving, servicing and repairs. Speaking of the decision to join the BPMA, Managing Director, Tony Keville, said, “We’ve considered becoming members of the BPMA for a good number of years, but now seems to be the right time for Tomlinson Hall to join its peers. We are primarily known in the Industry as Pump Distributors however we are also a Pump Manufacturer in our own right; producing “Liquivac”, a range of Liquid Ring Vacuum Pumps. I feel sure our engagement will help in our continued efforts to deliver the best possible service to both our existing clients and of course to our expanding list of new customers across the domestic and global market place. Another company to realise the benefits of BPMA membership is Derby based Exalto Bearings UK Ltd, which manufactures bespoke and standard sized rubber- lined and composite cutlass bearings for the pump and marine industries. All its bearings are produced in-house and the company specialises in the manufacture For the Pump industry, Exalto Bearings works with some of the biggest pump manufacturers and pump repair companies in the world – creating custom-made pump bearings to suit any application. Its innovative modular production tooling system means non-standard items can be produced with little or no additional tooling costs. Dennis Rawle, Managing Director, commented, “We’re delighted to be joining the BPMA, which will no doubt provide an opportunity for both our businesses, Exaltoand Graphalloy® (each part of the Graphite Metallizing Group), to work more closely with pump industry professionals in showcasing our range of bearings. Membership will enable us to improve our networking opportunities, in what is a key industry sector for us, and in turn support the continued growth of both our companies.” Blackwood Engineering, a global supplier of castings and counterweights, has also made the move into BPMA membership. Founded in 1946 as a general foundry, the company has diversified and expanded its product offering to include ductile iron and steel as well as more complex engineered castings. Commenting on the recent additions to the BPMA membership, Steve Schofield, Director and Chief Executive of the BPMA said, “We are delighted to welcome these companies into the BPMA, and afford them all of the support services at our disposal. Their varied product and service offerings dovetail nicely with that of other members, and we look forward to developing strong and mutually rewarding relationships with each of them.”
The British Pump Manufacturers Association (BPMA) which represents the business interests of UK and Irish suppliers of liquid pumps and pumping equipment throughout both the domestic and international arena has joined with other leading trade associations in its membership of EURIS. The European Union Relationship and Industrial Strategy is an advisory body for the potential impacts of the changing relationship between the UK and EU for the UK Government, manufacturers and media. EURIS members include such notable bodies as BEAMA, GAMBICA, EAMA, REA, CESA, FETA, MTA, BFPA and TechWorks, which between them represent over 4000 companies across electro- technical, electronics, renewables and mechanical engineering products. It has a focus on product manufacturers covered by the Single Market and the supporting regulations and standards. The member associations have extensive relationships with equivalent European trade bodies, and parts of the European Commission. The EURIS Taskforce produces Position Papers and Reports relating to the Brexit process relevant to the manufacturing sector. It also issues a weekly economic report to its members based on a tracked set of macro market indicators ranging from international trade and the general economy through to productivity costs and price indices. Steve Schofield, Director and CEO of BPMA commented, “Following hard on the heels of our own Brexit Position Paper, which we issued to Government at the end of last year, I am delighted that the BPMA Council has decided to join EURIS.” He continued, “Through our membership of this advisory body, we can ensure that our Members are kept abreast of all developments relating to Brexit and its likely impact on the UK’s engineering sector.” Steve Brambley, CEO of GAMBICA and Vice Chair of EURIS, added, “We are delighted to welcome BPMA into membership, and to enhance the strong and co- operative working relations that already exist between our various organisations through the auspices of EURIS.” Further information on EURIS can be found via www.euristaskforce.org.
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
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members Double awards delight for Manufacturer of the Year Weir Minerals Europe Weir Minerals Europe has been named Manufacturer of the Year by the EFF (formerly Engineering Employers’ Federation) at the annual national award ceremony. The Todmorden-based company competed against other leading manufacturers such as Jaguar Land Rover, Airbus and BAE Systems to claim the title at the EEF Future Manufacturing Awards in London. It also triumphed in the Health and Safety award. The panel of judges, made up of business leaders, industry experts and academics, was impressed with Weir Minerals’ continued commitment to investing in technology and efficiency, in addition to its ‘zero harm’ workplace policy. While the company has a strong focus on health and safety, it has invested specifically in addressing ergonomic and musculoskeletal risks, driving home the message across every service centre and office in its region which covers Europe, North Africa, Turkey and Central Asia. Jan Peter van Leeuwen, Weir Minerals Europe’s Managing Director, said the award highlighted both his team’s dedication to health and safety excellence, and the company’s culture of innovation. “This is an incredible team effort,” he said. “We are proud to have secured this ahead of so many leading companies and it is an acknowledgement of our exceptional people, who make these milestones possible. We must continue to work closely together to deliver outstanding solutions for our customers.” Weir Minerals was named as the regional winner for the north east, Yorkshire and the Humber in the Health and Safety category in November last year. Representatives travelled to London for the national ceremony, on January 25, where the company was named Healthand Safety winner before being awarded the overall title of Manufacturer of the Year. The company manufactures wearresistant, highly engineered processing equipment sold to’ a diverse range of sectors including mining and minerals processing, aggregates, water and industry in general. Pictured: Dan Carr and Chris Wadsworth from Weir Minerals accept the Manufacturer of the Year and Health and Safety Awards at the EEF Future Manufacturing Awards ceremony.
BPMA Announces 2018 Pump Industry Awards Finalists Following another exhaustive Judging Panel session at the offices of the BPMA on 31st January, the 2018 Pump Industry Awards Finalists have been determined. From all the entries and nominations received, the Judges shortlisted 34 Finalists across the seven award categories to go through to the public vote. Those that were fortunate enough to be selected are as follows:-
Innovation Company - Xylem Water Solutions Foss Barrier Project
- Solutions in I.T. - Tapflo Pumps UK
Environmental Contribution of the Year Sponsored by SPP Pumps - Danfoss Drives for its contribution to Aarhus Water Project - Grundfos and Marriott Hotels improvements to their carbon footprint - HIGRA Brasil’s Cataguases/MG Project - Xylem Flygt 4320 Mixer
Engineer of the Year Sponsored by World Pumps - Prof. Dr. Emad Kamil Hussein, ATU - Luke Gardener, Grundfos Pumps - Greco Tusset de Moura, HIGRA Brasil
Distributor of the Year Sponsored by WEG UK Technical Innovation of the Year - Clyde Associated Engineers Product Sponsored by Process Industry - GM Treble Informer - The Pump Company - Aspen Pumps Max Hi-Flow Tank Pump - Tomlinson Hall & Co - ETM Direct Drive Pump Motor - Triark Pumps - Flowserve IPS Node - T-T Pumps - Grundfos SCALA2 - Siemens IQ Motors Manufacturer of the Year - The Tapflo UK LEAP – Low Energy Air Pump Sponsored by Siemens - Wilo UK Ceram-Teflon Coatings - Aspen Pumps Technical Innovation of the Year – Projects Sponsored by Wilo - Danfoss Drives for its work on the Aarhus Water Project - Amphibious Pump Model Installed in Maringá /PR Brazil at SANEPAR,HIGRA Brasil - Indicators of high energy efficiency of centrifugal pumps operating with avariable load profile, Ru Well Systems Private Research
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- Grundfos Pumps - KSB - SPP Pumps - Wilo UK - Xylem Water Solutions UK
Supplier of the Year Sponsored by Tomlinson Hall & Co - ABB - Danfoss
Details of all of these Finalists awards are now available to view on the dedicated website: www.pumpindustryawards.com/finalists. An online voting form will be operational from 22ndFebruary -2nd March 2017 allowing readers to vote for who they think should be the outright winner in each category. So if you would like to have your say in which Finalists receive the Winners Trophies at the Gala Awards Dinner & Presentation on 22nd March at the Crowne Plaza, Heythrop Park, be sure to place your vote. Places are still available at this ‘not to be missed event’ so whether it’s taking a table to host customers or booking a few seats for you, your team & partners, don’t miss this fantastic opportunity to enjoy a wonderful evening of great food, fantastic musical entertainment, networking & dancing until the early hours. Places can be booked either online at www.pumpindustryawards.com/buy-tickets or via the downloadable booking form.
Have you got the energy to make savings? Saving energy as well as CO 2 have become increasingly important targets for many companies. It will come as a pleasant surprise to realise that there are occasions when it is possible to achieve these ambitions and pumps are often a major contributor, as they provide the potential to deliver major
savings on both fronts. So how can you achieve this? Well at Grundfos Pumps, we offer a range of diagnostic tools including an Energy Check that will help to establish the current pump system performance. This is exactly what we found out when we recently worked with a range of clients to see how we could help them. This included a brewery where we delivered an energy saving of 75% simply by identifying and changing key pumps; a chassis manufacturer that benefitted from a pump upgrade and saved 51%, while a power plant saw a saving of 50% from taking Grundfos’ advice. This means that regardless of if the priority is cost reduction, CO 2 savings, ROI, a water usage reduction or just simply to get advice on your current installations, Grundfos have the tools, expertise and integrity to help you to achieve your ambitions. To find out more visit www.grundfos.co.uk and see how you can put your energy to better use or for Literature Request Email: grundfos-uk@sales.grundfos.com or Tel: 01525 850000
Grundfos centers on customers
MAKING LOW FLOW MORE EFFICIENT
The Grundfos Product Center (GPC) is an online selection support hub that will give anyone who has a requirement to design or replace a pump or pump system, straightforward access to a wide range of information. By simply inputting basic head and flow parameters, the GPC will not only offer a choice of pump options, classed in various way, including by efficiency, but will give you access to a range of supplementary information. In addition, it provides you with a range of useful support tools such as a pipe friction loss calculator, NPSH calculator, cable calculator as well as a template for sizing a pumping station. Like all good systems the GPC is a work-in- progress that is under constant development so it continues to scope and monitor how people are using it, where they are visiting to work out what more they may require from it. With so much flexibility and a range of bespoke options that can help you to configure it to meet your own needs, the GPC is the place to head to, when you need more from your pumps and your pump supplier.
Combining the proven technologies of Sundyne Barske Wheel hydraulics with the HMD Kontro sealless magnetic drive, the GSPLF (LF for Low Flow) sealless pump has been developed to fill a gap in the market for a high-efficiency low flow magnetic drive centrifugal pump with a single stage high head capability. The GSPLF meets the requirements of API 685 and has full ATEX compliance, making it ideal for chemical and hydrocarbon processing applications. Sundyne has over 50 years of experience in offering Barske Wheel pumps, designed to provide efficiency in the low specific speed regime often referred to as low flow, high head applications. These pumps have an open impeller with straight blades and a tapered conical diffuser to produce the desired performance. Development and testing demonstrates that this combination produces a head factor (ratio of developed head to theoretical head) considerably higher than that of traditional back-swept Francis vane impellers. The combination of Sundyne Barske Wheel hydraulics with the HMD sealless magnetic drive, reliability, design flexibility, and efficiency is further optimised, ensuring trouble-free, safe and environmentally conscious plant operation. An additional advantage of the GSPLF is the flexibility inherent in the diffuser and impeller combination, which can easily be rerated should the duty point change without replacing the pressure casing. HMD Kontro has more than 25 years’ experience in API applications and a 70 year track record in magnetic drive technology, being the first company to develop a magnetic drive sealless pump. Further information visit www.sundyne.com/hmdkontro. Alternatively, please call Tel: +44 1323 452141 or email vince. lee@sundyne.com.
For Literature request email: grundfos-uk@sales.grundfos. com or Tel: 01525 850000
Motors | Automation | Energy | Transmission & Distribution | Coatings
WEG Variable Speed Drives CONTROLLED PERFORMANCE WEG Variable Speed Drives are the easy answer for greater energy efficiency, control and versatility for all pump applications. For machinery, pumping systems, HVAC-R or general purpose, WEG have a range of variable speed drives that are suitable for all purposes which are easy to set up and flexible to use. From 0.18 to 630 kW our drives are the easiest way to improve the energy efficiency and prolong the lifespan of your electric motor. For more information visit www.weg.net Visit us on Stand D710
Turning energy into solutions.
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Technology Focus:
Waste management With access to a reliable water supply predicted to fall short of demand by at least 40% by 2030 the need for a strong focus on sustainable water management has never been greater. Tom Grove, CEO of AESSEAL Inc, explains the water management systems which can massively reduce unnecessary usage and waste, whilst also improving plant reliability and achieving long term operational savings. Water - one of our most valued resources but also one that is often written off as a simple by-product of industrial processes. Wastage is particularly acute in industries such as pulp and paper, where up to six litres of water a minute can be injected into pumps and systems to flush and cool them before being treated and discarded at the end of the cycle. But all companies using these systems can take simple steps to limit, and in some cases completely prevent, the wastage resulting from injected seal water – whilst at the same time improving reliability and reducing operational costs. A highly cost-effective solution is upgrading the seal support systems on industrial pumps. Mechanical seals perform a simple but vital role - to prevent fluid leaking from the shaft region of process pumps and other rotating equipment. They are a key component of machinery across a wide range of industries. To function correctly it’s important the mechanical seal faces are kept cool and clean. This is often achieved by flushing a cool, clean liquid such as water, often provided from a separate system. A properly configured seal support system provides lubrication, prevents overheating (caused by dry running) and maximises reliability. There are many ways of configuring a seal support system, documented by the American Petroleum Industry (API), and standard configurations are defined by detailed ‘piping plans’. The way a seal support system is configured heavily influences the amount of cooling liquid used and energy consumed. The configuration can have a serious impact on the reliability of equipment, with cost implications in terms of downtime and repairs as well as wastage, so making sure they function to optimum capacity is essential for any company with a keen focus on sustainability and financial efficiency. When water is injected into processes and subsequently needs to be evaporated off, wastage is inevitable. Likewise, once through
‘quench to drain’ configurations require a constant flow of clean water to be effective. Simply reducing the amount of liquid being injected into a system to conserve water is not a long term or cost-effective solution. Lower fluid levels compromise the reliability of seals, increasing the risk of leakages and subsequent costly downtime and process outages. Innovative developments in mechanical seal support systems mean leakages, wastage and excessive energy consumption do not have to be an accepted part of industrial life. Companies can replace once-through quench to drain with continuous loop water management systems which use recycled water as a cost-effective and environmentally sustainable alternative to the wasteful once-through piping plans. These systems use an integral vessel to store flush water for continuous recycling. The barrier fluid is circulated to and from the mechanical seal by thermosiphon, a method of passive heat exchange which circulates the fluid, minimising water wastage and providing more efficient cooling. These systems come with the added benefit of improving pump reliability. Because the system is connected directly to the plant water line, which becomes the system’s fluid and pressure source, the seals can be protected from harmful products, making the pump more reliable. The costs of installing continuous loop water management systems may be higher than those for simpler flush configurations, but they reap considerable rewards in terms of long term operational cost savings, as well as delivering improved plant reliability and making a powerful contribution to environmental sustainability, as evidenced by Netherlands based sugar producer Suiker Unie.
Reducing energy usage & improving reliability For Suiker Unie saving energy is a key element of its sustainability programme. It aims to cut energy consumption by 50% by 2030. It was using packing to seal juice circulation pumps at its Dinteloord sugar refinery. Typically after three 120-day campaigns the packing needed replacing, and wear caused by the packing meant the shaft sleeves also required replacement. Water used to maximise the life of the packing leaked into the product and needed to be removed by evaporation. To address the leakage and shaft wear issues AESSEAL ® recommended replacing the packing with a CDSA dual seal along with a SW2 seal support system on
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twelve pumps coupled with a single FDU installation. Changing from packing to a dual mechanical seal eliminated shaft wear and after six years of operation (approximately seven campaigns) the system is operating without failure. Changing to dual seals with support systems has resulted in no significant leakage of water and therefore saved energy as there is now no need to evaporate off seal water. With packing, water usage was measured to be 48 litres per hour, per pump, giving water usage per campaign to be 1,658m³ or 1,658 tonne return flow. To evaporate 1 tonne of water requires approximately 100m³ of gas. Total gas usage to evaporate the injected seal water is therefore 165,888m³. As a result of the excellent performance the plant subsequently installed additional seals and support systems on 43 pumps, saving more than 5,944m 3 per year of water and reducing gas usage by 594,432m 3 per year. This is equivalent to approximately £181,000 per year saving. Ab Barendregt, of Suiker Unie Dinteloord said: “For Suiker Unie, saving energy is one of our highest priorities, both during cultivation and in the production process. “Energy savings in production: Suiker Unie’s energy saving target was to cut energy consumption throughout the supply chain by 4% by 2014 relative to 2005, the year in which the Multiyear Energy Efficiency Agreement was signed for businesses participating in the EU emissions trading system. Energy consumption was reduced further in 2011. Suiker Unie has invested in a compressor park in Dinteloord. All compressors are now air-cooled instead of water-cooled. This has produced an energy saving of 304,000 kWh. “The sugar factories at Dinteloord and Vierverlaten operate cogeneration plants to produce steam and electricity they use in the production process during the campaign. Suiker Unie produces more electricity than it actually needs. Suiker Unie is also working with the Brabant Environmental Federation to reduce its CO 2 emissions. “Concerning seals: The biggest cost reduction was based on the flush water what went into the process. This water needed to be evaporated. Now Suiker Unie have almost no water entering the process due to the support systems. A smaller cost reduction is based on the energy for the motors. They needed a lot of energy because of the breaking or chucking impact of the packing on to the shaft. A seal hasn’t got any friction.” Continuous loop water management systems have a proven record of achieving significant gains in water conservation, operational reliability and cost efficiency across many industries. But one of the incalculable benefits is the huge boost to a company’s reputation as sustainability leaders.
ITT unveils i-ALERT® Ai Platform
The simple online asset intelligence (Ai) platform is the latest service to be introduced since the i-ALERT2 Bluetooth Smart-enabled machine health monitor was launched in May 2015. The breakthrough innovation and the various features added over the past two years enable customers to spend less time collecting data from their rotating equipment and more time solving problems. i-ALERT Ai Online Platform With the i-ALERT Ai platform, customers can monitor and manage all their i-ALERT enabled machines and sensors in a simple web interface. This subscription service requires no software to download or dedicated hardware to run. It allows customers to view trend data, machine notes, technical data and vibration spectrum data collected via the i-ALERT2 application (app), all visualized in a simple timeline. Data Collection Time Reduced by 50 Percent This online web interface complements the route customization feature introduced in
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2016, which cuts collection of machine performance data by as much as 50 percent. Customers can manage the data collection via the i-ALERT mobile app by setting up designated routes and the app will automatically guide a user to which assets and what type of date to collect on the route. Once a route is completed, the app will automatically generate a report and email it to the customer. Features & Benefits With the i-ALERT2 sensor, the mobile app and the Ai platform, customers can have a seamless monitoring solution that will enable them to safely inspect multiple pieces of equipment and be alerted of potential problems before they become critical failures. Broadly, some of the features and benefits are: - Asset Intelligence: Monitor the equipment health of any rotating machine such as pumps, motors, fans, mixers, gear boxes and more. It tracks 3-axis vibration, temperature, kurtosis and machine run-time. It logs data at every hour or on an alarm event. · Easy to Use: With the free mobile app and simple interface, it puts machine monitoring in the hands of the everyday user. · Save Time: The app will quickly scan multiple machines at once and cover more equipment with fewer resources, freeing time for analysis and troubleshooting. · Stay Safe: A Bluetooth® Smart wireless connection allows monitoring from a safe distance. · Early Detection: Unplanned machine failures can be avoided with the early detection feature of the i-ALERT monitoring solution. 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. · Solve Problems: Advanced vibration diagnostic tools are available to anyone who can use a smartphone or tablet. With the Ai platform, customers will be able to monitor i-ALERT2 enabled machines anywhere they have an internet connection. With the i-ALERT Ai platform, customers have access to a seamless monitoring solution that is easy to use and access. The i-ALERT2 monitor is certified in 78 countries and the mobile app is available on iOS and Android platforms. Request a copy of the iAlert Application guide from – gouldssalesuk@itt.com or telephone 01256 311904
Bredel pumps deliver 25% improvement to process uptime & contribute to reduced CO2 emissions at Italian organic waste recycling plant A total of seven Bredel 80 hose pumps from Watson-Marlow Fluid Technology Group (WMFTG) have replaced competitor models on buffer tanks feeding the digester at a major Italian recycling plant. The previous pumps were undersized when running at high speeds and subsequently demonstrated gearbox wear and hose life issues. However, these problems have been completely eliminated with the introduction of Bredel pumps. In fact, such has been their success that Bredel 65 pumps are now being
considered for a further application. Montello SpA is a market leader in sorting, recovery and recycling of post-consumer plastic packaging, as well as treatment, recovery and recycling of organic waste. At the company’s 350,000m2 plant near Bergamo, waste is used to produce biogas from an anaerobic digestion process that in turn generates electric and thermal energy, as well as high quality organic fertiliser. Heavy-duty application The company uses pumps to feed the digester from buffer tanks. This is a high temperature and high flow (21m3/hr), 24/7 application. The sludge is viscous with high dry solids content (up to 60-70%), which can include sand – a highly abrasive constituent. Pressure is a further issue: for safety reasons involving the production of gas, the digesters are located far from the plant, so the discharges are up to 100 metres distant. As a result of these challenges, Montello’s existing pumps and hoses were falling short of expectations in terms of process uptime and operational costs, particularly when running at elevated speeds. In search of a solution, the company turned to WMFTG, requesting a trial of two Bredel 80 pumps. The closed loop, speed controlled pump, running against a discharge pressure of 5.5 bar delivered an impressive process uptime by 25% using an NR (natural rubber) hoses. With the new pumps and hoses in place, the customer now achieves a reliable process that offers predictable gas generatio and known maintenance costs. Today, seven Bredel 80 hose pumps are installed. “This is a perfect example of the growing demand for pumps in waste recycling applications,” says Pietro Spagnolo, Sales Engineer at WMFTG. “Fermenting biowaste is the current focus of many recycling companies and energy producers in Europe, as the process provides significant reductions in CO2 emissions. The Montello plant alone achieves annual CO2 savings of around 90,000 tonnes. This is why the installed capacities in biogas plants fermenting municipal and industrial bio-waste will increase from 900 MW in 2014, to around 1,750 MW in 2023. We expect the number of plants in Europe to grow from 800 to over 1,450 in this time, representing significant opportunities for Bredel hose pump technology.” More potential Montello is already looking at Bredel 65 pumps for further applications, this time on the pretreatment prior to the buffer tanks. Here, flow is 10m3/hr, and once again abrasion is proving a concern. The customer has spoken with experts at WMFTG, discussing the principal technology differences of Bredel pumps, namely the use of direct-coupled technology versus the close-coupled technology of the encumbant pumps. The next stage will be the acquisition of a single Bredel 65 pump for use in a long term trial against existing pumps. For more information contact Watson-Marlow Fluid Technology Group, Falmouth, Cornwall. Tel: 01326 370370 E-mail: info@wmftg.com Web: www.wmftg.com
Flowserve Offers Seal Failure Analysis APP
Providing a solution to the challenges associated with mechanical seal failures, Flowserve now offer a very simple tool to help diagnose the root-cause of seal failure. According to its own analysis, some 98% of mechanical seals prematurely fail long before they have reached their optimum design life-time expectancy. The Flowserve Seal Failure Analysis app’ is a web-based tool that has been specifically designed to visually identify and prevent future mechanical seal failures. Accessible via desktop, tablet and mobile devices, this easy-to-use reference tool is an invaluable resource for Reliability Engineers and Maintenance staff, tasked with troubleshooting and preventative maintenance. While Mechanical seal failures are the number one cause of Pump and Mixer down-time, this area represents a great opportunity to reduce whole life costs on site across all pump systems. Shaun Hampson, General Manager of the Manchester (UK) facility said, “This new way of supporting our customers, on a 24/7/365 basis, provides engineers with more than 100 years of acquired knowledge at their finger-tips. When a seal fails, it is often a critical breakdown situation and companies don’t have the time to wait for an engineering expert to visit the site in order to provide a diagnosis. The App is incredibly easy to use and can lead to extended mechanical seal life. Our own members of staff use this tool!” For more information on Flowserve mechanical seals, pumping equipment, upgrading, repairs, or other flow-control equipment please contact customer support team via email at ProcessUK@Flowserve.com.
AxFlow strengthens service operations with German acquisition AxFlow Germany is strengthening its service offering with the acquisition of Pumpen Karrer, a family-owned company specialised in industrial equipment repair and maintenance, especially pumps. Pumpen Karrer’s major business segments are chemicals, food & beverage, and building & construction. The acquired operations will become a regional base for AxFlow Germany service in the Allgau region west of Munich. Pumpen Karrer has been a KSB Pump service partner for 46 years, and AxFlow will take over the service agreement with KSB as part of the transaction. The benefits of the transaction flow in both directions, with cross-selling opportunities for both Pumpen Karrer and AxFlow. “Pumpen Karrer’s service business complements our pump business without overlapping,” says Georg Niebch, Managing Director, AxFlow Germany. “Their workshop will be used to reinforce AxFlow’s existing pump repair and maintenance business. Meanwhile, their service business can benefit from increased visibility through AxFlow’s market presence and field sales network.” Founded in 1966, Pumpen Karrer is now owned by the founder’s son and daughter, who will continue to be involved in operations. “The company matches AxFlow’s values very well,” Niebch adds. “It is a good, independent service company with a long history, great team and excellent reputation. We are looking forward to building the business together.” Pumpen Karrer CEO Roland Karrer also sees big benefits in working together. “We are very much looking forward to our future as part of AxFlow Germany, and we are sure that we can add an important part to the further development of this company,” he says. AxFlow Germany is part of the AxFlow Group, the Fluid Handling Solutions business group within Axel Johnson International. The AxFlow Group serves customers in the ceramics, chemical & petrochemical, food, pharmaceutical, pulp & paper, and water & waste water industries with equipment from world-leading manufacturers. For more information, please contact: Georg Niebch, Managing Director, AxFlow GmbH, Tel: +49 211 23806-0, georg.niebch@axflow.de Lars Carlson, CFO, AxFlow, Tel: +46 (0)8 545 476 71, lars.carlson@axflow.com
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Examining the benefits of Screw Centrifugal pumps by Malcolm Walker - Product Manager Centrifugal Pumps, AxFlow
In any pumping application, it is always necessary to match the pump type to the application in order to achieve the desired result. One aspect of this selection process is matching the impeller type to the nature of the fluid being pumped. Where liquids with a large solid content of a delicate nature are concerned then free passage through the pump housing and a gentle pumping action are essential. One particular centrifugal pump fits this particular bill perfectly and does so across a wide spectrum of applications in food processing and beverage production; and that is the screw centrifugal pump.
The Technology Although centrifugal screw pumps work on the same principle as any other centrifugal pump, the impeller’s relative length, which results in a more gradual increase in the impeller’s diameter along with the design of the inlet blade profile, means that media entering the pump undertakes a long slow turn around the long radius, low angled vane. The hydraulic gradient within the pump generates a gradual pressure and slow change from axial to radial flow in a smooth process with little shear. As a result the screw centrifugal pump offers several important benefits to the food production engineer. The low shear pumping action enables them to handle delicate products; the wide fluid channel within the impeller allows the free passage of solids up to 120 mm in diameter while the gradual pressure increase results in a very low Net Positive Suction Head requirement (NSPHr).
The impellers come in different profiles each designed for the nature of the fluid being pumped. Open impellers are most typically employed for handling abrasives, coarse suspended solids, fibrous materials and viscous fluids, whereas closed impellers are associated with highly abrasive media or the gentle movement of sensitive media(Fig.2).
Applications
Fig. 1 Hidrostal Blue End suction pump Furthermore, the internal components experience less wear than many alternative pump types contributing to lower maintenance costs and a longer working life. The efficiency of the screw impeller pump (Fig.1) is significantly higher than other types of pumps used for similar applications. The pump head curves are continuous and steep, making it costefficient to adjust the pump operation to the specific pumping requirement and in particular speed- controlled operation.
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Originally designed for use in the water and waste water industry where they have proved excellent at handling various types of solid-ladened sewage and the safe transfer of fresh water containing fish, screw centrifugal pumps have found numerous applications within the food and beverage industry where delicate solids are an issue. Hidrostal’s F-Type pump is a good example of where the screw impeller pump is used extensively in the food industry. This version uses a shrouded single spiral vane impeller that is axially extended for smoother operation. Because of their ability to pump liquids with a high solid content delicately F- Type pumps can be found in brewing where they are commonly used in malt production for carrying grain in water without any damage to the germ, as well as for mashing, lautering, wort circulation and trubbing. The transfer of fresh produce such as fruit, vegetables and
Fig.2 Impeller principles chart
fish is another area where Hidrostal screw centrifugal pumps have proved very successful, particularly as they offer the versatility to operate within closed pipe transfer systems as opposed to being restricted to conveyors, elevators or containers. The enclosed pipework system has the benefit of being more hygienic and cleaner as it is protected from any potential harmful elements in the immediate environment. Operational costs are also reduced with enclosed pipeworks as maintenance is far easier than with conveyors and belts. There is also health and safety advantages as there are fewer exposed moving parts. Sensitive handling of raw ingredients is not all that the F-Type pump offers users. The pump is ideally suited to the energy efficient circulation and removal of wash water used in the cleaning of raw ingredients and applications where there is limited NPSH available.
Summary The screw centrifugal pump provides yet another example of a technology finding applications in sectors for which it wasn’t originally developed and one where the higher initial investment is more than offset by the economics of its longer term reliability and aptitude to a good job.
WEG introduces a powerful addition to the W60 motor series Drive specialist extends its W60 power range up to 16,000 kW and offers frame sizes up to IEC 1000 (NEMA 1600) WEG, has extended its W60 motor series, which now covers a power range of 50016,000 kW at frequencies of 50 or 60 Hz. The three-phase induction motors are designed for the 2,300-13,800 V voltage range and are available with frame sizes from IEC 450 to IEC 1000 (NEMA 7000 to 1600). Designed for industrial applications such as compressors, pumps and fans, the W60 line provides high performance and reliability even under the most difficult operating conditions. The W60 is used mainly in the oil and gas sector, in mining, for electrical generation in power plants, in cement production, as well as in water and wastewater applications. Robust, light, space-saving and efficient Due to its optimised design, the W60 series motors are not only more compact, but also lighter than their predecessors. The compact dimensions offer a significant advantage: the W60 motors take up to 50 % less installation space than comparable motors. This makes them one of the most compact modular motors of this type on the market. The rugged design with high-quality housing and end shield are made of grey cast iron up to the IEC 560 standard. Sizes above IEC 560 feature a steel housing. A specially designed motor shaft prevents critical flexural vibrations at rated speeds – as well as below the rated speed in the case of two-pole motors – and ensures particularly low vibration levels. As a result, the W60 motors are also suitable for applications with frequency converters or heavy vibration loads. Thanks to the high-quality rotor and stator lamination, low-loss fans and optimised heat exchangers, the W60 series motors achieve unusually high efficiency and power density (output power relative to the weight). As a result, standard W60 series industrial motors are among the most efficient of their type on the market. What’s more the W60 motors are engineered for continuous use, horizontal mounting configuration and are easy to install and commission. They are also ideal for use with medium-voltage frequency inverters as standard, with no speed restrictions due to critical vibration speeds. The three-phase induction motors are designed for protection classes IP24W to IP55 and are suitable for safe or hazardous areas (Safe or Hazardous: Ex-n, Ex-t, Class I Div. 2, Class II Div. 2). For more information contact WEG (UK) Ltd Tel: +44(0)1527 513800 | Email: wegsales@wegelectricmotors.co.uk | Web: www.weg.net/uk
Albany Pumps A N E M P LOY E E O W N E D CO M PA N Y
A fresh approach from Albany Pumps
Albany Pumps makes a wide range of reliable and robust standard, customised and specialised positive displacement pumps. If you require an external gear pump, a twin screw pump or an internal lobe pump, we think you’ve found the right place: • 100+ years of experience and British manufacture
TOMLINSON HALL CELEBRATES 99TH YEAR WITH INNOVATIVE SCRAPPAGE SCHEME
• Employee ownership with a Trust to guarantee longevity
Billingham, UK-based pump distributor and manufacturer Tomlinson Hall is celebrating its 99th year in business by launching a pump scrappage scheme which can help end users save money on the running of older, energy inefficient pumps, and support the Royal National Lifeboat Institution (RNLI) in the process. Under its ‘99 for 99’ initiative, the firm will give £99 to any company which replaces any old pump on their UK premises with a new DEPA® air operated double diaphragm (AODD) pump, which will be supplied by Tomlinson Hall. The firm will safely dispose of the old pump and the scrap value of each pump replaced will be donated to the Royal National Lifeboat Institution (RNLI). Pump users can either take their scrap pumps to Tomlinson Hall’s premises for disposal, or under the scheme, Tomlinson Hall’s engineering team will de-install the pumps on the customer’s site. The DEPA® AODD range of pumps are designed and manufactured by CRANE, for which Tomlinson Hall is the sole UK distributor. The range includes stainless steel pumps, cast metal pumps, non-metal pumps and powder pumps, and they are used across a wide range of applications. For more information, visit www.tomlinson-hall.co.uk
• Standards for every industry ATEX, CE, BSI, VdS and API
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