Quarter 1 2021
Pump industry insight from
FOCUS ON: Water & Wastewater
Dealing with changing water demands
Post-Brexit pump conformity: What you need to know Pump Industry News
Innovations
Applications
Expert Opinion
CONTENTS 3 Editor Chris Callander chris@flowmag.co.uk 01732 671123 Contributing Editor Suzanne Gill suzanne@flowmag.co.uk Publisher Andrew Castle andrew@flowmag.co.uk 07785 290034 Accounts Touchwave Media Ltd accounts@flowmag.co.uk Production G and C Media Ltd production@flowmag.co.uk
For over three-quarters of a century the British Pump Manufacturers’ Association (BPMA) has been serving the interests of UK and Irish suppliers of liquid pumps and pumping equipment.
T
hanks to a tremendous effort by all those involved in the COVID vaccination programme, the prospects of a return to some normality in the coming months have now started to look much more likely. While the pandemic has seen some sectors almost grind to a halt, for some it has meant an increase or significant shift in activity. This is the case for some of the areas served by the pump industry. A good example is the water and wastewater sector, which has seen changes in demand as the population changed its habits overnight, and this is the theme for this issue of flow magazine. We look at how technology can help the sector handle unexpected surges or slumps in demand. We also cover how the efficiency of river abstraction can be improved with the use of variable speed drives. Compliance also features elsewhere in this issue as we outline how the BPMA is continuing to work with EU-based partners to drive revisions to the Eco-Design Directive. Plus we outline what manufacturers and users of pumps and pumping systems need to know about products standards and legislation following the UK’s exit from the EU. Finally, we have introduced a new section for 2021. On our technical solutions page, experts from the BPMA membership answer readers technical questions. In this issue, Tony Keville, Managing Director of Tomlinson Hall, covers topics including minimum pressures on boiler feed pumps and over pressure problems tripping a water system. This feature has been added to coincide with the introduction of the BPMA’s new online technical forum. If you have questions you would like an expert to answer, either email our editor, Chris Callander at chris@flowmag.co.uk or head to the forum at forum.bpma.org.uk where you can post your questions online. Richard Harden, President, BPMA
PUMP INDUSTRY NEWS BPMA National Metalforming Centre 47 Birmingham Road West Bromwich B70 6PY www.bpma.org.uk
4 6
Twitter @bpmapumps flow is a controlled circulation journal published quarterly on behalf of the BPMA by Touchwave Media Ltd and G and C Media Ltd. For a copy of the magazine’s terms of control and to request a copy please email circulation@flowmag.co.uk The content of flow magazine does not necessarily reflect the views of the editor, publishers or the BPMA. The publishers accept no legal responsibility for loss arising from information in this publication and do not endorse any products or processes mentioned within it. No part of this publication may be reproduced or stored in a retrieval system without the publisher’s written consent. © BPMA. All rights reserved.
www.bpma.org.uk
AESSEAL helps children access remote learning MBO for Apex Pumps Hayward Tyler reacts to UK SMR opportunity
BPMA NEWS
Compliance 14 Post-brexit Pump conformity – what you neeed to know
Q&A 16 Tomlinson Hall’s Tony Keville, answers readers’ questions
Features
7
Pump maintenance and repair course developed
18 Pumps: Missing in climate action?
Membership continues to grow
Focus on Water & Wastewater
PRODUCT NEWS 8
Aquaboost range expanded
Wireless condition monitor boosts process uptime
Skills 10 BPMA training calendar 12 Keep an open mind to develop the best engineering talent
22 Improving river abstraction efficiency 24 Dealing with changing water demands 28 Demonstrating compliance with the Water Supply Regulations
OPINION 30 We must continue to work with the EU on key standards Quarter 1 2021
4 INDUSTRY NEWS
AESSEAL HELPS CHILDREN ACCESS REMOTE LEARNING AESSEAL PLC HAS DONATED £400,000 to Laptops for Kids – enough funding to supply connectivity to every disadvantaged child in South Yorkshire. The charitable organisation will use £300,000 to supply refurbished laptops to 1,500 households across the metropolitan borough, meeting around half of the estimated need in Rotherham. The remaining £100,000 will be used to buy dongles for connecting 10,000 households to the internet, meeting the estimated total need across South Yorkshire. Chris Rea, Managing Director of AESSEAL, said: “We believe in being a good neighbour, partner and useful member of the communities in which we live and work.
Chris Rea, Managing Director, AESSEAL.
“Our donation is an investment in young people across Rotherham and South Yorkshire.”
Mr Rea added that 3i Group, an institutional investor with a significant minority shareholding in AESSEAL, has enthusiastically supported the decision. Technology entrepreneur David Richards, a co-founder of the Laptops for Kids campaign, said: “Huge thanks to AESSEAL for this powerful expression of support, which will help thousands of children to access remote learning during the pandemic. “This should be a clarion call to businesses everywhere to support our campaign and make sure every child has safe access to the internet so they can fulfil their potential.” Any individual or business looking to donate devices or cash can do so by visiting www.LTFK.co.uk
STUART TURNER ACQUIRES HVAC STRONGHOLD MIKROFILL STUART TURNER, AN INTERNATIONAL MANUFACTURER of water boosting pumps and systems, has announced the acquisition of pressurisation and HVAC specialist Mikrofill Systems Ltd (Mikrofill). Stuart Turner has now acquired three complementary businesses. The acquisition of Mikrofill follows its purchases of Fluid Water Solutions in 2019 and GAH Heating in October 2018. Mikrofill brings more than 25 years of innovation and experience producing pressurisation units for sealed system control, commercial-grade boilers and water heaters. With manufacturing based in Britain, its award-winning technical expertise, outstanding customer service, commitment to energy efficiency and reputation for reliable products have
made Mikrofill the go-to brand for specification in its sector. Stuart Turner’s acquisition of Mikrofill will significantly expand its range of products and services so that it can provide its customers with the most comprehensive HVAC and water supply solutions across domestic, commercial and industrial sectors. Following the deal, Mikrofill will continue to operate as an independent entity, but as part of Stuart Turner. Richard Harden, CEO of Stuart Turner, said: “Our ambition takes us far beyond our reputation for high-quality shower pumps. Through acquisitions and continued research and development, we have our sights clearly set on powering water for all applications. Adding pressurisation and hot water generation giant Mikrofill to our armoury makes us a real contender for large scale projects with complex requirements.
MBO FOR APEX PUMPS PUMP MANUFACTURER, APEX PUMPS, has announced a management buyout of the business and assets of Apex Fluid Engineering Ltd and Precision Alloys Ltd, as the founder and principal shareholder Nick Sole steps away from the company. Apex Pumps employs 24 staff at its site in Bristol, where it designs and manufactures centrifugal pumping solutions for water, industrial, energy, brewery, aquaculture, chemical process, oil and gas and many other similar demanding applications. The company will continue to be led by the existing senior management team and will be headed by Andrew Quarter 1 2021
Simpson, Managing Director and Sam Kemp, Sales Director. The whole of the Apex Pumps workforce has been retained, and the business will continue to operate from the existing Bristol premises. The new leadership team has said it is committed to building on the relationships built over the past 33 years with the company’s customers and suppliers and will continue to trade on the same terms as before. Commenting on the buyout, Andrew said: “The strong standing of Apex Pumps as a business and its position at the forefront of centrifugal pumps is testament to the dedication and
Andrew Simpson, Managing Director, Apex Pumps.
commitment of Nick Sole. With an incredibly talented team and an enviable product portfolio, I’m looking forward to steering Apex Pumps into the future.” www.bpma.org.uk
6 INDUSTRY NEWS
HAYWARD TYLER REACTS TO UK SMR OPPORTUNITY PUMP AND MOTOR MANUFACTURER, Hayward Tyler, is collaborating with the Nuclear Advanced Manufacturing Research Centre to develop a new reactor coolant pump (RCP) for small modular reactors (SMRs) and is helping the UK supply chain prepare to produce critical components for the global SMR market. SMRs are advanced power plants that can be largely built-in factories as modules to minimise costly on-site construction, and which allow manufacturers to reduce costs by producing many identical units. More than 70 designs of small modular reactor are in development in 18 countries around the world, mostly based on Gen III+ reactor technologies which are relatively close to commercial readiness. “Although there are different types of SMRs being developed by major players, water-cooled reactors remain very attractive and bring a new dimension to the more reliable, clean and affordable nuclear power,” said Dr Evgeny Polyakov, Sales Director at Hayward Tyler.
The project is funded by the Driving the Electric Revolution programme of the Industrial Strategy Challenge Fund, delivered by Innovate UK, and will span nine months in the initial phase. During this time, key milestones will include concept design, verification and validation, along with an extensive supply chain engagement program. Further projects will be completed on various areas of the design, including detailed CFD analysis, prototype manufacture, quality control and lifecycle testing. “Reactor coolant pumps are safety critical which require a specific coast-down flow rate to ensure the necessary rate of heat removal is maintained during a poweroutage to the pumps,” said Robert Bowen, Lead Design Engineer for the RCP project
at Hayward Tyler. “To remove the complexities of dynamic sealing, the design uses an internal, high-inertia flywheel to achieve the coast-down flow. Reducing the large frictional losses by the large flywheel is a significant technical challenge which has required a combined input from the electrical, hydraulic, and mechanical expertise within our design team.” Pumps for the reactor coolant system will primarily be made from low and zerocobalt metal alloys which have minimal risk of suffering radiation-induced corrosion. Very few UK manufacturers have experience of working with these alloys, so the project will draw on the Nuclear AMRC’s detailed knowledge of the UK supply chain to identify potential suppliers and help them prepare for new opportunities in the SMR market.
BPMA NEWS 7
BPMA MEMBERSHIP GROWS AS TRAINING EVOLVES DUE TO THE CONTINUING DISRUPTION caused by the Coronavirus pandemic, the Association’s Pump Fundamentals training course, originally developed as a one-day classroom-based session, is being conducted online as a live webinar for the foreseeable future. Delivered over a series of three 3-hour sessions, the course is ideal for those who understand pumping basics and are looking to further enhance their technical knowledge and understanding. The Association has also added a new course to its training programme addressing the increasingly important area of pump maintenance and repair. The content was developed with representatives from member companies comprising AESSEAL, Altecnic, Eriks, NOV, Secure Meters, Siemens, WEG, Wilo UK & Xylem UK. The two-day course has been designed to provide attendees with the essential and generic knowledge of pump repairs and maintenance. It examines the implications
of repair and replacing a part with a partial or complete overhaul and covers the importance of building in a scheduled or preventative maintenance routine that will help prolong a system’s life. The course will be CPD approved, and its first delivery is scheduled for 23rd & 24th June 2021. Further information on this and other training from the Association is available from Steve Smith on 0121 601 6691 or by email at s.smith@bpma.org.uk. NEW MEMBERS Four new companies have signed up to become members of the BPMA in recent weeks. Water Automation Technology is a UK based OEM manufacturer, importer, and distributor of innovative automation and IOT (telemetry) solutions designed to make water automation easy and less reliant on technicians. Family-owned Maher is a longestablished steel stockholder and processor specialising in high-strength,
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high-performance alloys. Martin Sprocket and Gear UK manufactures power transmission components, material handling products and industrial hand tools with capabilities in machining, fabrication, forging, casting, powdered metal technology and injection moulded plastic. Croydon-based GMT Electrical Services is a long-established service and repair business working in the key areas of pump repair and installation, motor rewind, single and three-phase electrical motor repair, gearbox repair and installation, along with a wide range of fan repair and installation activities. And finally, the Government’s most recent announcements around the easing of Coronavirus restrictions have forced the postponement of the Association’s annual golf day. This popular event will now take place on September 2nd at the St.Pierre Marriott Hotel & Country Club in Chepstow, with further details available on the BPMA website www.bpma.org.uk.
8 Product News
AQUABOOST RANGE EXPANDED PUMP SPECIALIST STUART TURNER has extended its Aquaboost range of cold-water pressure and flow boosting solutions with the new iBolt and iMatic intelligent variable speed boosting solutions. The Aquaboost iBolt range of variable speed booster pumps and pump sets features horizontal multistage pumps controlled by air-cooled variable speed frequency inverters, designed to deliver a constant water pressure supply where flow demand varies. They are available as a stand-alone single pump or single and twin booster sets. These high performing yet intuitive to commission pumps deliver flow rates from 5 m3/hour to 15 m3/hour and head pressures up to 9.0 bar. With an added buffer of pressurised
cold water to supplement pressure and flow, Aquaboost iBolt booster sets are supplied with a WRAS approved 8l or 24l pressure vessel, combined with either a single or twin pump set mounted on a powder-coated base plate for ease of installation. Twin booster sets offer up to 15 m3/hour per pump with heads up to 7.1 bar. Aquaboost iMatic systems are designed for installation where space is limited, yet despite their size can offer flow rates up to 10 m3/hour (per pump) and produce head pressures of up to 6.6 bar. They are supplied as an integrated system, featuring one or two submersible multistage pumps, controlled by automatic variable speed frequency inverters and packaged with a polypropylene break tank.
Aquaboost iMatic integrated systems utilise WRAS approved materials and include an AC air gap within the tank design for added peace of mind. www.stuart-turner.co.uk
WIRELESS CONDITION MONITOR BOOSTS PROCESS UPTIME NEW FROM ALFA LAVAL, THE COMPANY’S CM SYSTEM monitors the operating condition of rotating equipment such as pumps, mixers and agitators used in hygienic process environments. Compact, easy to use and easy to install, it tracks equipment vibration, temperature and total run-time – three of the most widely used parameters for detecting and diagnosing equipment faults. This enables manufacturers in the dairy, food, beverage, home-personal care and pharmaceutical industries to protect critical assets, ensure process uptime, improve worker safety, reduce maintenance costs and gain a competitive advantage. Powering the Alfa Laval CM are equipment sensors that transmit data to a connected compatible mobile device for predictive maintenance analysis, thereby supporting decisionmaking with advanced diagnostics such as trend monitoring.
Maintenance staff can check equipment vibration and temperature – either by visible notification on an LED indicator on the monitor or through an intuitive mobile app on a connected iOS or Android device within a 20m range during a periodic walkaround. Trend analysis and FFT (Fast Fourier Transform) vibration data assist in diagnosing faults. These also enable operators to use the CM to make informed decisions on scheduling maintenance and process shutdown based on actionable information in addition to actual run-time and time to next service. Initially, the CM has been optimised for use with Alfa Laval SX and SRU positive displacement pumps and, with product adaptation, can monitor other rotating equipment. www.alfalaval.co.uk
PUMP SUPPLIER LAUNCHES NEW FITTINGS AND ACCESSORIES RANGE OBART PUMPS HAS LAUNCHED A range of pump accessories and fittings designed to complement its range of submersible and puddle pumps, surface pumps, engine pumps, hand pumps and flood management products. Said by the company to be manufactured to a high specification and released under the brand name ‘FIT&FLOW’, the range is made up of over 70 different products. Pump hoses are often only available in 50m and 100m lengths, but according to the company, the ‘FIT&FLOW’ range has been designed to Quarter 1 2021
be as user-friendly, accessible and cost-effective as possible with 6m, 10m, 15m, 20m, 30m, 50m and 100m coils available. Accessories and fittings in the range include hose tail, pressure pipe, washers, couplings, nipples, sockets, valves, strainers, clips and clamps. Products can be purchased individually, in packs and in complete kits. www.obartpumps.co.uk www.bpma.org.uk
Are you ready for the New European Efficiency Regulations (EU)2019/1781?
Visit www.weg.net to learn more of our full range of energy efficient motors and drives.
From July 2021 all new 2, 4, 6 and 8 pole motors in the power range 0.75 kW to 1,000 kW for use in the Eurozone will be required to meet IE3 efficiency class ratings. In addition special purpose motors, including those used in hazardous areas entering the supply chain must be rated IE3 or higher.* For the first time variable speed drives are included within the scope of the legislation. *Increased safety motors Ex eb will be required to be at least efficiency rating IE2 from 2023.
Minimum Efficiency of Electric Motors and Variable Speed Drives Regulation scope
Year and minimum efficiency requirements (2015 onwards)
AC induction motors <= 1000 V 0.75-7.5 kW
3 phase, 2/4/6 pole
7.5-375 kW
3 phase, 2/4/6 pole
75-200 kW
3 phase, 2/4/6 pole
2015
2017
2016
2017
2018 - 2020
2021
2022
2023
Onwards
2021
2022
2023
Onwards
0.75kW-1000kW 3 phase 2,4,6,8 pole 0.75-1000 kW
ATEX/Brake all poles
0.12kW-1000kW Ex eb all poles 0.12kW & above 1 phase all poles 0.12-0.75 kW
3 phase/brake all poles
Variable speed drives 0.12kW-1000kW
2018 - 2020
The table above shows the regulation scope and timeline, the boxed area corresponds to the current regulations
(in bold)
www.weg.net
Industry awards 10 FEATURE 10
COVID TIMELINE PUSHES PIA CEREMONY TO SEPTEMBER FOLLOWING THE UK GOVERNMENT’S recently announced ‘roadmap’ to lifting its COVID-19 restrictions, the BPMA and its event organiser, Touchwave Media, have been forced once again to postpone the 2020/21 Pump Industry Awards (PIA) Ceremony, hitherto scheduled for the evening of Thursday 1st July 2021. Having already rescheduled the event several times from its original date in March 2020, it is very much hoped that the proposed timeline mapped out by the Prime Minister will indeed deliver the eagerly anticipated relaxation of the rules. However, with caution being the watchword over the coming months, whilst the vaccine rollout continues apace, and public confidence develops, the event has now been rescheduled to the evening of Thursday September 23, 2021. The Chesford Grange Hotel in Kenilworth will be retained as the venue for this special evening of reward and celebration. Commenting on the decision, Steve Schofield, CEO at the BPMA, said: “Whilst the health and safety of
attendees continues to be our priority, the credibility and delivery of the overall awards presentation for all those involved – members, sponsors, finalists, and winners – remains a key consideration. This is especially so as we look to celebrate the event’s 20th Anniversary in what is the BPMA’s 80th year.” He continued: “Although our hand has once again been forced, with the roadmap now in place and the prospect of a populationwide rollout of the vaccination programme by the Autumn, I’m sure all will support this responsible approach. I would again thank everyone for their continued understanding during these extraordinary times, and on behalf of everyone at the BPMA, I wish you a safe and healthy transition through the next few weeks and months.” With the venue’s unwavering support,
the gala awards dinner will be staged as initially planned. All sponsorships, table bookings, and overnight accommodation are honoured and carried forward to the new date. As already highlighted, this year’s awards programme celebrates its 20th Anniversary, and so we can look forward to a wonderful, and above all safe, evening of reward and celebration. www.pumpindustryawards.com.
UPCOMING TRAINING FROM THE BPMA Date
Course title
Duration
Format
18 March 2021
CE Marking & You, inc UKCA Mark
3.5 hours
Online
23-24 June 2021
BPMA Pump Repair & Maintenance
2 days
West Bromwich*
14-17 September 2021
Certified Pump Systems Auditor (CPSA)
4 days
West Bromwich*
For more information or to book any of the couses listed please visit www.bpma.org.uk/lectures *All classroom-based training is scheduled subject to the COVID-19 restrictions in place at the time.
For details of the full range of training available from the BPMA, scan the QR code to access a digital version of the new and updated training guide. Or for a copy in the post, email your name and address to: training@bpma.org.uk
Quarter 1 2021
www.bpma.org.uk
LOW PRESSURE? NO PROBLEM. AQUABOOST COLD WATER BOOSTING SYSTEMS The NEW Aquaboost iBolt and iMatic range of high flow, high head, cold water pressure and flow boosting solutions. Designed to optimise space and provide a very quiet, simple to install solution for domestic and commercial applications.
STUART-TURNER.CO.UK www.bpma.org.uk
FEATURE 12 SKILLS
Keep an open mind to develop the best engineering talent
With many businesses in the industrial sector experiencing difficulty recruiting young engineers, maybe the answer to the engineering skills shortage lies elsewhere. James Henson, Operations Manager (Design & Compliance) at Musk Process Services, explains how his company supported his development, and reaped the rewards.
A
sk someone to think of a ‘typical’ engineering career path and they will likely say something along the following lines: Specialised apprenticeship at 16 or 18, qualify, become a team leader, then supervisor, working towards heading up a team or site and possibly eventually becoming the senior leader of the firm. However, what if some of your potentially best engineers did not, or could not follow that path? Are you and your organisation thinking outside the box when it comes to recognising and developing engineering talent and future business leaders? If you are not, my story might help you to see how you can... My current role is as Operations Manager at Musk Process Services. In this position, I lead the Engineering Compliance and Design department; however, my journey to where I am now definitely wasn’t straightforward. I always knew I wanted a job that I could develop into a career for life. I began as a semi-skilled carpenter. I also began an apprenticeship as a car mechanic leading on from this role, but could not support myself on the wage so returned to the previous role to pay bills and save. This allowed me to eventually pursue my ultimate goal, as an apprentice engineer. It was after this that I was first made aware of Musk, (then Peme) and was successful in joining the company as a computer-aided design (CAD) technician. It wasn’t an apprenticeship; however, it offered the opportunity to get into engineering, which was my goal. Although my title was CAD Technician, I was an ‘office lackey’, taking on many jobs and tasks from the engineers. I worked hard, though, starting early and staying late, which caught the Managing Director’s eye. He offered me the opportunity of pursuing an apprenticeship with the company, despite the fact I wasn’t the typical ‘straight out of school’ new recruit. I completed the apprenticeship that I had always wanted and qualified in Mechanical Engineering and Design. I really believe that engineering companies can benefit from having an open mind when it comes to apprenticeships and offering development opportunities to their existing and older staff, as well as taking on recruits directly from education. My opportunities to expand my skills and knowledge continued after my apprenticeship. Once I had qualified through the apprenticeship, I was encouraged to lead design and installation projects which gave me a good grounding in most aspects of our business and my trade.
Quarter 1 2021
After broadening my knowledge, I was offered the opportunity to move into the Reliability Engineering Department, to widen my knowledge of asset care and the business. Under the guidance of Senior Reliability and Condition Monitoring Engineers, I completed an HNC. I also EJ Musk’s James Henson. furthered my skills and gained a qualification in Specialised Condition Based Monitoring Techniques. After this, a colleague and I decided to begin the Professional Registration Programme with the IET. This Professional Registration, which we jointly developed, demonstrates to our clients the high level of engineering skill, experience and expertise within our business. It also provides recognition for our more experienced engineers and key talent within the business. Within the development of this new programme, I was able to offer the opportunity to eight engineers. The areas of specialisms and levels varied hugely, evident in the presence of a Reliability Engineer and also our head of Asset Care. This was a new opportunity for me to provide support not only to my direct reports but to my peers and senior engineers. Currently, half of the initial cohort has been awarded the Chartered Engineering Status CEng, including myself. This is something I would never have considered a possibility at the age of 16 but it has been made possible thanks to the open-mindedness of my engineering colleagues throughout my career. I have learnt so much during my career with Musk, and I am so fortunate to have been given learning opportunities throughout this time. Mentoring by fellow colleagues has been truly life-changing. I feel that apprenticeships are often stereotyped to young, school leavers; however, many others can benefit hugely from them. Every day we are learning, and there is so much more knowledge to acquire. We have recognised that it really doesn’t matter at what stage you are within your career; you can always advance yourself. We have developed learning opportunities which not only benefit colleagues but also our wider business partners. chevron-circle-right www.ejmusk.co.uk www.bpma.org.uk
We design and manufacture a wide range of centrifugal pumps for all types of demanding applications. Manufacturing in the UK with our Precision Alloys Replicast® foundry enabling the design and manufacture of high integrity. Bespoke designs to the your exacting requirements at competitive prices backed by a highly responsive and efficient service.
Industrial pumping solutions bespoke to your application designed and built in the UK since 1988
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14 COMPLIANCE
Post-brexit Pump conformity – what you need to know BPMA’s Steve Schofield looks at what manufacturers and users of pumps and pumping systems need to know about product standards and legislation, following the UK’s exit from the EU.
F
or 47 years, the UK has followed the rules on placing pumps on the European market, subsequently adhering to all the necessary legislation and standards. In 2000 the EU published its ‘Blue Guide’ on implementing EU product rules for the first time. Since then, there have been updated versions to ensure that readers have the correct information to place goods onto the EU market legally. The pump sector has adopted the Blue Guide to ensure the correct interpretation is used. However, now the UK has left the EU, there is no obligation to follow the rules originating from Brussels. It would be crazy to think that UK legislators would or even could write new rules specifically for the UK market, there are too many. So what next? Many EU Directives have already been adopted into UK law. They are known as a Statutory Instrument (SI), and UK legislators have now removed any reference to the EU or EU courts and inserted UK references. Legislators have also confirmed that a UK version of the Blue Guide will be written and circulated during 2021. To conform to EU legislation, the easiest method is to work to a harmonised standard that subsequently offers legislative information and a route to conformity. This is no longer applicable to the UK market, so if industry wishes to follow a similar route, then it now needs to work to UK Designated Standards – a list of which can be found at www.gov.uk/guidance/designatedstandards. The main documentation that should accompany a pump is called the EU Declaration of Conformity in Europe, and for the UK market this will now be called the UK Declaration of Conformity (UK DOC). The information required on the UK DOC is largely the same as is required on an EU Declaration of Conformity. However, this can vary depending on the application legislation, but generally should include: • Name and full business address or that of your authorised representative. • The product’s serial number, model or type identification. • A statement stating the author takes full responsibility for the product’s compliance. • The details of the approved body which carried out the conformity assessment procedure (if applicable). • The relevant legislation with which the product complies. • Your name and signature. • The date the declaration was issued.
Quarter 1 2021
• Any supplementary information (if applicable). The UK DOC will also need to list: • Relevant UK legislation – rather than EU legislation (www.bit.ly/EU2UK). • UK designated standards (www.bit.ly/EU2UK2). The UK standards are currently the same in substance and with the same reference as the EU standards. Finally, any pump placed on the UK market will need to show the UKCA (UK Conformity Assessed) marking, a new UK product marking used for goods being placed on the market in Great Britain (England, Wales and Scotland). It covers most goods that previously required the CE marking. The UKCA marking alone cannot be used for goods placed on the market in Northern Ireland, which require the CE marking or UKNI marking for the foreseeable future. The UKCA marking came into effect on January 1, 2021. However, to allow businesses time to adjust to the new requirements, they can still use the CE marking until January 1, 2022 (in most cases). The CE marking is only valid in Great Britain for areas where GB and EU rules remain the same. If the EU changes its rules and a CE mark is placed on a product based on those new rules, this product cannot be sold in Great Britain, even before December 31, 2021. chevron-circle-right
Any pump placed on the UK market will need to show the UKCA marking.
www.bpma.org.uk
PUMPS AS TURBINES - HARNESSING WATER POWER TO ITS FULL POTENTIAL
FOR WHERE IT REALLY MATTERS SPP PUMPS LIMITED, 1420 LAKEVIEW, ARLINGTON BUSINESS PARK, THEALE, READING, RG7 4SA TEL: +44 (0) 1189 32 31 23 • EMAIL: STUART_WALLIS@SPPPUMPS.COM
16 technical solutions
Q&A
In this issue of flow, Tony Keville, Managing Director of pump specialist, Tomlinson Hall, answers readers’ pump related questions.
QUESTION: Our water system runs on a constant pressure booster set, with a Variable Speed Drive (VSD), and has operated satisfactorily for several years. However, we have recently fitted air actuated ball and butterfly valves and the system is constantly tripping on over pressure activations. What might be causing this, and are there any solutions we could try? TONY KEVILLE: The actual closure time for ball and butterfly valves only takes place over the last 15 to 25 degrees and hence is very short. If you consider the line constant and use the simplified Joucowsky equations you will find that the surge pressures that are being generated may be as much as 30 bar, or even higher, and so will trip the transducers whose response time is very short. You could try and fit signal processing to ensure that the overpressure has to be present for at least 500ms before the VSDs respond. You may also try and fit all air actuated valves with snubbers to increase their actuation time, preferably to several seconds. QUESTION: We pump from a large storage tank to various demand points in our factory using an air driven diaphragm pump. The valves for each demand point are air driven ball valves controlled by level controllers in the reactors. The pipework runs at a high level through the roof space which can be warm. Recently, we have experienced some issues with the discharge valves being jammed in the seats and cannot explain why. Is there something wrong with the pump? TONY KEVILLE: The pump is perfectly OK, as is the system concept, the execution needs some attention though. The supply tank has a large thermal mass so it takes a long time to both heat up and cool down. The pipework has a small volume and is easily heated up. When the demand valve is opened the pump starts automatically and supplies liquid to the demand point, that valve now closes and the pump stalls out as a hydraulic balance is achieved. So far, so good. But the liquid in the pipework can now heat up and consequently expand. However, as the pipework is a sealed container, due to the pump non-return valve and the closed valve at the demand point, where can the excess liquid go? Frequently on air-operated diaphragm pumps it pushes the discharge valve balls back down and through the valve seats. I have seen this many, many times. The solution is very simple. You could fit a hydraulic expansion vessel to accommodate the expanded volume, but an easier option is to fit a small relief valve from the discharge to the suction pipework set at 1 bar Quarter 1 2021
above air pressure. It only needs to be a ¼ inch valve just don’t forget to add it to your relief valve register.
QUESTION: Our boiler feed pumps have a minimum pressure marked on the discharge pressure gauge, but our demand has dropped significantly, and we want to run them at a lower speed on a ariable Speed Drive (VSD). TONY KEVILLE: As boiler feed sizes increase the method of taking out the axial thrust changes. Small pumps use the motor bearings either with deep groove bearings or axial thrust bearings. However, as the pumps get larger the use of rolling element thrust bearings tends to give way to using balance discs or drums at the discharge end of the pump, with a low-pressure balance pipe leading back to the suction. If you then proceed to lower the discharge pressure the forces acting between the balance disc and its seating, or along the length of the balance drum, are too low and clashing occurs resulting in a very rapid destruction of the pump. The typical gap on a balance disc is only 12 thousandths of an inch, so you have little leeway for error. On some larger boiler feed and similar highpressure pumps, and also on large borehole pumps which use a Michell Thrust type bearing, the temptation to use a VSD to save energy is persuasive. However, be very careful as the speed may reach a point at which the tilting pads no longer entrain sufficient lubricant to give adequate cushioning and the bearing can fail very rapidly. Of course, you should always seek guidance from the pump manufacturer. To pose your questions, or to see more technical solutions to pump user’s challenges and engage in their discussion, head over to the BPMA’s new online technical forum. Go to forum.bpma.org.uk or scan the QR code. www.bpma.org.uk
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18 environment
Pumps: Missing in climate action? The potential energy savings and positive impact on global carbon emissions available from improving the energy efficiency of pumps and pumping systems are enormous. According to the Betterworld Solutions initiative, led by AESSEAL and supported by the BPMA, this is a significant opportunity currently being missed by the UK Government.
L
iquid pumps and pumping equipment are the single largest user of electricity in industrial and commercial applications. This amounts to 45TWh annually in the UK, equivalent to the annual electricity use of 12 million homes. The UK Government has announced a ten-point plan for a green industrial revolution covering clean energy, transport, nature and innovative technologies. The blueprint is intended to allow the UK to wipe out its contribution to climate change by 2050. However, the contribution of pumps to global warming is not being addressed in this ambitious plan, despite the UK’s past commitment to tackle the issue. This is a serious oversight, given the high energy use of pumps and their critical role in maintaining our industrial base and standards of living. Since 2015, larger industrial pump users have been required to carry out energy use audits and introduce improvements under the UK’s Energy Saving Opportunity Scheme (ESOS). However, some have taken advantage of a loophole allowing them to opt out if they complied with the ISO 50001 standard aimed at energy management. This has meant they have avoided identifying inefficient pumping systems and subsequently making them more efficient, which would significantly cut their energy use and help the environment. The latest revision of ISO 50001 has closed this loophole, but weak market surveillance and low penalties mean that action in this vital area remains stalled. A ‘carrot and stick’ approach is needed. Fines should be significantly increased to ensure that ‘bad players’ can no longer afford to ignore the problem. In addition, appropriate government support should be provided to make the financial case for change more attractive, and help the drive towards net-zero. MISSING THE POINT The government’s ten points towards a Green Industrial Revolution are diverse, and in some cases, the anticipated savings are some time away. They range from supporting wind power, nuclear energy and zero-emission vehicles, to encouraging green buildings and transport, including advanced aviation. There is a praiseworthy emphasis on securing quality future jobs in these ‘new horizon’ sectors, as well as Quarter 1 2021
helping the environment. However, there is a notable lack of attention to some existing UK industry sectors that also have a future but need to invest in energy savings. We believe the huge savings to be realised by improving the energy efficiency of pumps and pumping systems should become the 11th point in the Government’s plan. The anticipated savings in the 12 years up to 2032, from greening public transport, the shift to zero-emissions vehicles, and green ships, amounts to 7 million tonnes of CO2 equivalent (MtCO2e). However, if we extrapolate the hoped-for 7TWh annual energy savings produced by greening pumps, over the period from 2015 to 2032, this amounts to 119TWh or around 60MtC02e. This is on a much greater scale than the CO2 savings of the three elements of the Government’s ten-point plan. It is almost three times the expected longer-term savings forecast from advancing wind power between 2023 and 2030, which according to government figures, is expected to attract around £20 billion of private investment by 2030 and amounts to about 5% of 2018 UK emissions.
The huge savings to be realised by improving the energy efficiency of pumps and pumping systems should become the 11th point in the Government’s plan.
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20 environment
HOW DID PUMPS GET MISSED? To move a liquid from ‘a’ to ‘b’, a pump is required. Industrial and domestic applications are a vital component of modern life. Given their importance, it is not surprising that they are big energy users. The question has always been, can better engineering improve matters and deliver significant energy savings that can help us on the road to net-zero? Many pumping systems operate inefficiently; however, while the pump is operating successfully, there is no focus or requirement to look at the pump or system. A lot of the installed base of pumps is older technology that is more energy hungry than it needs to be. This is because engineers and plant managers have been trying to ensure that if they need ‘more muscle’ for their processes, there is extra capacity. Older style pumps were typically over-sized and therefore seldom work at their optimum efficiency. Newer pumps are designed to operate efficiently at variable speeds, so they have the built-in flexibility demanded without the energy ‘penalty’. Since a proper energy efficiency policy needs to tackle the issue of the bigger users, the UK Government established the ESOS (Energy Saving Opportunity Scheme) to implement Article 8 (4 to 6) of the EU’s Energy Efficiency Directive (2012/27/EU). A company needs to comply with ESOS if the organisation has over 250 employees, a turnover of over £44.1m, an annual balance sheet of in excess of £37.9m, or is part of a larger organisation that meets any of the above criteria. Non-compliant companies face fines of up to £90,000. Companies that fall within the scope of ESOS are required to undertake an energy audit conducted or overseen by an approved ESOS Lead Assessor. The pump manufacturing and repair industry reacted positively by investing heavily in training qualified auditors and was fully ready to support the policy. However, there was opposition from some major industrial companies who viewed this change to better, more reliable and up-to-date technology as a cost, rather than as an opportunity. As a result of lobbying, they succeeded in getting agreement that organisations fully covered by ISO 50001, which is aimed at energy management, did not need to have a separate ESOS audit. Under UK law, ESOS or ISO 50001 audits must be conducted every four years. The first deadline was December 5, 2015, the second was December 5, 2019, and the next deadline will be December 5, 2023. So, in principle, the larger companies covered by this energy audit requirement should have been busy since 2015, upgrading their pumps to a green standard, as Quarter 1 2021
indicated by the audits. However, those who opted for ISO 50001 saw a convenient loophole since, unlike the ESOS audits, ISO 50001 (2012) did not require the audit recommendations to be put into operation. Despite the challenges of COVID-19, the fate of the planet has been taking increasing prominence. This is demonstrated by the UK government’s commitment to its ten-point plan for a Green Industrial Revolution. It is also reflected in the updated version of ISO 50001 (2018). Within sections 9 and 10 of the 2018 version, the standard now stipulates that energy savings identified must be achieved or certification will be withdrawn. This means that, finally, all companies covered by the legislation must have energy audits and that the audit recommendations should be carried out. WHAT ACTION IS NEEDED? Perhaps it may seem that the problem is solved. The big industrial users of pumps have been given their marching orders, and the Government can concentrate on the new horizon industries in the ten-point plan, putting the potential savings just identified into the carbon bank. Unfortunately, there continues to be strong resistance among some sectors to having meaningful pump audits. Most probably, the debate doesn’t even reach the boardroom, and even where there is a solid investment case, nothing happens. The remedies are two-fold. Despite the convenient assumption that we somehow have the ‘gold standard’ when it comes to following rules, market surveillance in the UK is lamentably absent in this area. Even if a company is identified as being in breach of ESOS, a penalty of £90,000 is not even a slap on the wrist for a big business. Decisive government action is needed to tighten enforcement. Introducing meaningful penalties, perhaps based on a proportion of company turnover, should be considered. In addition, there must be the political will to resist what is often misinformed pressure from big industry. On the other hand, while many of the cases for upgrading pumps will be clearcut, financial assistance to encourage modernisation should also be examined. Not all industries can be ‘new horizon’, so surely the 11th point in the UK Government’s plan must be to ensure that our existing sectors are shown the same attention and encouragement to reduce their energy consumption if we are to reach the net zero target; and pumps can play a significant role in this. chevron-circle-right betterworld.solutions www.bpma.org.uk
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22 water & wastewater
Improving river abstraction efficiency Although there are undeniable environmental concerns over river abstraction, it remains a critical method to ensure an adequate and reliable water supply. ABB’s Martin Richardson outlines how using the latest variable speed drive technology when operating pumps can lower energy costs, reduce abstraction demand and improve the environment.
R
iver abstraction is a necessity for supplying water for drinking, farm irrigation, industry and power generation. Yet, abstraction comes with an environmental cost. By changing the natural flow pattern of lakes and rivers, abstraction can alter the amount of water in the environment, which in turn affects wildlife. Improving the efficiency of abstraction can allow water companies to maintain their green credentials, while still ensuring a healthy water supply. With concerns over the sustainability of current abstraction levels and the licences required, utilities are under increasing pressure to minimise the amount of water they remove. Over-abstraction can have a devasting impact on the environment, as witnessed in the Sonoran Desert in Arizona. Here water is taken for irrigation and urbanisation, which has resulted in land subsidence, water scarcity and loss of wildlife and habitat. In the UK, bodies such as the Environment Agency (EA) and Ofwat issue licenses and schemes to help control the abstraction rate. An example is Ofwat’s Abstraction Incentive Mechanism (AIM), which encourages water companies to help protect environmentally sensitive sites by restricting abstraction when surface water flows are low. Applying to all water companies from April 2020, AIM has sought to improve the sustainability and resilience of water supply networks. MAKING PUMPING MORE EFFICIENT Although pumping systems are used every day by water utilities, they are not always used efficiently. Water is often removed using submersible pumps, which need vast amounts of energy, resulting in a large production of carbon. The main problem is that many pumps are in situ for years and are used either ‘off’ or ‘on’, with their flow rates controlled by partially throttled valves. This is an inefficient way of controlling flow, as the physical restriction causes increased head loss across the partially closed delivery valve, making the pump work harder and using far more energy than necessary. INSTALLING VARIABLE SPEED DRIVES A better method is to fully open the delivery valve and use a variable speed drive (VSD) to control the pump motor’s speed and hence flow. Pump energy
Quarter 1 2021
use can be cut by up to 50%, while even more energy can be saved using the latest high-efficiency motor technology: such as the synchronous reluctance motor (SynRM). For example, Southern Water used a SynRM on a low lift pump that extracts around 25 million litres of water per day from the local river. The highly energyefficient SynRM cut maintenance demands of the pump while improving reliability. The existing 75kW DC motor required maintenance to its brushes every three months, and a recent failure had made it critical to find a more reliable solution. A major consideration for Southern Water was cutting operational and downtime costs as part of the total expenditure (TOTEX) approach adopted by Ofwat’s Asset Management Period. Besides improved reliability, the ABB drive is also expected to produce a 4% increase in motor efficiency. Ten years ago, the EA’s Shropshire Groundwater Scheme replaced fixed speed pump control with VSDs across seven pump sets, cutting daily energy use by
Although pumping systems are used every day by water utilities, they are not always used efficiently.
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water & wastewater 23 over 990kWh. As well as improving reliability, the pumping costs were reduced by £85 per day, with carbon dioxide emissions falling by half-a-tonne per day.
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THE FUTURE Ofwat’s interventions on abstraction are a welcome development, while Defra will also consult about the change in abstraction regulation planned to come into effect in 2023. Yet, as the population grows and the weather becomes increasingly unpredictable, abstraction from lakes, rivers, and other watercourses remains necessary to meet burgeoning demand. This means that abstraction is here to stay, and therefore so is the challenge of making it as sustainable as possible. Well established technological solutions can help ensure that abstraction is carried out sustainably when water flows are healthy, while also helping to improve the resilience of supply and mitigate against risks such as extreme weather events. chevron-circle-right
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TACKLING LEAKAGE As well as making abstraction more energy efficient, there is also scope to use VSDs to reduce the amount of water that needs to be abstracted. This can be achieved by cutting leakage in UK water networks, increasing the security of the country’s supply while cutting the cost and carbon footprint associated with taking water from the environment. Water companies across the country are making sterling efforts to detect and fix leaks, yet the public often has the impression that nothing can be done on a widespread scale to solve this problem on a long-term basis. The main culprit in causing leaks is pressure. Keep this at the right level, and many leaks can be prevented. Again, VSDs and their ability to control motor speed come into play. Many pumping stations run the pumps at a steady, high speed until the pressure gets to the desired level. The pumps will then turn off and turn on again when the pressure drops below this set point. This causes frequent starting and stopping, meaning that more non-return valves need to be activated, resulting in pressure transients that can damage pipe walls and joints. Flow rates can be lowered a lot of the time, and using VSDs to do this can go a long way towards keeping pressure in check. Even a small reduction in pressure of around 20% can cut leakage rates by up to 50%. Getting the best combination of flow and pressure can be achieved by setting the VSDs to run the pumps at the right speed and ramping up the speed slowly to the desired level. This reduces pressures, avoiding forcing water through existing gaps. A steady speed also cuts the need for frequent starts, and when starts and stops are needed, they are more gentle and less damaging. Although the public might have a perception that water utilities merely respond to leaks and fix them when they occur, the industry does, in fact, have the means to prevent many of them from happening, cutting costs and making the industry both more resilient and environmentally responsible.
24 Water & Wastewater
Dealing with changing water demands As demand grows and societal changes impact when and how much water people are consuming, how do water companies prepare for an unexpected surge or drop in demand? Marek Lukaszczyk, European and Middle East Marketing Manager at the motor and drive manufacturer WEG, explores three equipment upgrades that water companies can make, which will increase agility and efficiency.
T
he United Nations World Water Development Report 2020 states that global water usage has increased by a factor of six over the past 100 years. Climate change is undoubtedly a longstanding consideration for water management, but low rainfall, high population density and intensive agricultural or industrial activity may also result in sustainability issues — without throwing a global pandemic into the mix. Faced with these challenges and ageing infrastructure, the European water industry is focussing on rejuvenating its existing assets, building resilient systems, and improving operational and energy efficiency. So, where should a water company start in implementing system upgrades? THE TOTEX BASED APPROACH Firstly, it’s important to build an effective strategy. The totex (total expenditure) approach continues to reshape the water industry. This framework considers total cost throughout a project’s lifecycle, allowing water companies to be assessed against long-term outcome measures. In addition to cutting costs, the framework provides better value to consumers and achieves better efficiency management and operational efficiency. Predictability is therefore high on the optimisation agenda through close integration and collaboration with manufacturers at the design stage. CUTTING DOWN WASTAGE In the form of unnecessary energy usage or pesky pipe leaks, waste can be a real problem, affecting a water company’s maximum output. According to the International Energy Agency, a quarter of the water sector’s electricity is for wastewater collection and treatment. For this reason, companies operating in this space must consider investing in energy-efficient technologies. Reducing energy wastage offers environmental and cost-saving benefits and allows businesses to commit more resources to meet changing demands. Opting for an energy-efficient motor that conforms to IE4 and IE5 standards is an excellent place to start, but it is also important to ensure the motor is matched to the load. For example, at a water pump station in Surrey, UK, WEG supplied three 900kW W50 IE4 super premium efficiency motors with IP55 protection, operating at 96.9% efficiency. With new pump impellers, gearboxes, drives and WEG motors, the facility was upgraded from its existing 400 mega litres per day capacity to 750 mega litres per day, with an efficiency increase from 80% to 86%.
Quarter 1 2021
CONDITION MONITORING To ensure that motors are running optimally, water plant managers can retrofit sensors. By using smart technology such as the Industrial Internet of Things (IIoT), cloud technologies, and the data they make available, water companies can monitor their assets and processes in real-time, allowing them to ensure that their systems are performing optimally and respond quickly to unexpected events. Key metrics such as vibration and temperature changes can be early indicators of more serious system faults. This predictive maintenance approach reduces the risk of downtime and consumer disruption. USING A VARIABLE SPEED DRIVE Pumps consume a large proportion of the energy used by electric motors. Upgrading to a variable speed drive (VSD) instead of a fixed speed motor allows companies to account for varying process load. A VSD can automatically control the speed of the motor and rapidly respond to the required demand. This also allows for a more efficient operation instead of continually operating at a water flow designed for the system’s maximum demand. Going one step further, companies can invest in sophisticated process control software, such as WEG’s Pump Genius. This built-in VSD software enables engineers to increase their process accuracy and protection, while offering system monitoring. The software allows one VSD to control up to five pumps, monitor the operating hours, and add and subtract pumps as demand changes. Automatic broken pipe detection in the VSD can also identify fluid leakage and adjusts motor performance accordingly. By implementing the totex framework, intelligent design decision making can be achieved, which will give water companies of all types added flexibility, better performance and superior cost savings. chevron-circle-right www.weg.net www.bpma.org.uk
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NEWS & Wastewater 26 Water
Demonstrating compliance with the Water supply Regulations Chris Callander spoke to Jonathan Price, Business Development Manager at Kiwa Watertec, to find out about the Kiwa UK Regulation 4 certificate (KUKreg4), an option for demonstrating compliance with the Water Supply (Water Fittings) Regulations.
W
ater installations in the UK need to comply with the Water Supply (Water Fittings) Regulations 1999 England & Wales, 2009 Northern Ireland and 2014 Byelaws Scotland. In respect of water fittings and their requirements, reference should be made to Regulation 4. Regulation 4(1) states that ‘every water fitting should be of an appropriate quality or standard’ and regulation 4(2) provides the options to demonstrate compliance, i.e. CE Marking where applicable, appropriate British or European standards, and also a specification approved by the regulator. Historically, the established voluntary practice has been for ISO17025 accredited laboratories to issue test reports against these specifications and then forward a technical file incorporating these results to WRAS (Water Regulations Advisory Scheme) to issue a certificate of approval. In recent years manufacturers have opted out of getting voluntary WRAS approval and have asked Kiwa to provide an equivalent declaration of compliance, which has been done using a Kiwa UK Regulation 4 certificate (KUKreg4).
flow: What are the Water Supply (Water Fittings) Regulations, and why are they important? Jonathan Price: The regulations set legal requirements for the design, installation, operation and maintenance of water fittings, systems and appliances. They have been designed to prevent drinking water contamination and prevent misuse, waste, undue consumption, and erroneous measurement..
f: Why is it important to have an approval in place to demonstrate compliance with the regulations? JP: This will satisfy water authorities, specifiers and contractors that the product has undertaken the required testing and meets the necessary design requirements for its use. Being able to advertise an Quarter 1 2021
approval mark, such as KUKreg4, also gives a product a competitive advantage over alternatives that do not have any approval or recognised product compliance in place.
f: How does the KUKreg4 scheme achieve assurance that a product complies? JP: KUKreg4 is a robust method for demonstrating compliance with the Water Supply (Water Fittings) Regulations 1999 as the testing is undertaken in an ISO 17025 accredited laboratory and complies with ISO 17065 product certification. During the process of approval, products undertake rigorous testing, and the certification decisions are made by people who have many years’ experience in the industry.
f: Compared to the alternatives, how well recognised is KUKreg4 approval among the water authorities? JP: Historically, WRAS has been the most well-known approval among contractors, specifiers and water authorities. However, recently there have been some changes within WRAS, and the decision making of the approval certificates no longer involves the water authorities. In light of this, water authorities now refer to products having to comply with Regulation 4 rather than specifically to WRAS or any other way of demonstrating product compliance. KUKreg4 has been an accepted way of demonstrating compliance for several years, but the KUKreg4 brand is much more prominent today than it has ever been.
f: Are end users/specifiers/system designers also aware of the alternative, and are they happy to specify products approved to KUKreg4? JP: As we all know, it takes time to change people’s mindset when they have been familiar with one way of doing things for so long. I always use the example of the term ‘Corgi registered’; when that changed, it took people a long time to get used to using the term ‘Gas Safe registered’. This will be the same with KUKreg4; specifiers and contractors will
Jonathan Price, Business Development Manager at Kiwa Watertec.
become more familiar with it the more it is used. With the water authorities now using the terminology that products must be ‘Regulation 4 compliant’, this will undoubtedly increase visibility in the industry of KUKreg4. So in answer to the question, I would say why not? It is one of the recognised ways of doing this.
f: What are some of the advantages of taking the KUKreg4 approach? JP: A key advantage of the KUKreg4 option is that certification decisions are made within Kiwa, so there are no cut-off dates for products to be granted approval. Also, with Kiwa being recognised across Europe, there are opportunities within the approval process to save manufacturers time and money on testing because for certain product groups, the testing and certification process can be cross-referenced. KUKreg4 also offers two levels of compliance – level 3 and level 1+. Level 3 is the equivalent service offering of WRAS (initial testing, no annual audits and a full re-test after five years). Level 1+ involves initial testing, but no full re-test after five years is required – assuming there are no significant changes to the product – as certification is maintained via annual audits of the manufacturing facility. The 1+ system is particularly beneficial to manufacturers with large product groups. chevron-circle-right www.kiwa.co.uk/water www.bpma.org.uk
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28 water & wastewater
TWO PUMPS PROVE BETTER THAN FOUR
REPLACING FOUR FIXED-SPEED pumps with two variable speedcontrolled pumps has increased pumping capacity, improved reliability and significantly reduced noise for Anglian Water’s Kentford Moulton site, near Newmarket. Four 11kW line shaft-driven pumps, first installed in 1992, were running without any form of variable speed control. They have been replaced with two 45kW submersible sewage pumps, with their flow rate controlled by two ABB water drives. The upgrade increases pumping capacity and delivers substantial energy savings, as the ABB drives ensure that the pumps only operate at the speed required. Before the upgrade the average pump running time was 14 hours per day. Following the upgrade, the average
run time reduced to three hours per day. This energy reduction led to an estimated £4,000 annual saving for Anglian Water. The four old pumps ran simultaneously, generating high noise levels and disturbing local residents. The two replacement pumps are run in a duty-standby configuration, meaning only one pump is typically running at a given time, significantly reducing noise levels. The load is shared between the two pumps via switching, spreading wear between the pumps more equally. The project was part of a large pump upgrade at the Kentford Moulton site, carried out by ABB Value Provider, Gibbons Engineering Group. The site needed to remain fully operational while the upgrade took place, so Gibbons connected the new VSDs to temporary pumps while the old pumps were
replaced. This ensured that customers received no interruption in service. new.abb.com
CHOPPER PUMP SOLVES WASTEWATER CHALLENGE
BRUNEL PROJECT TO CUT INDUSTRIAL WASTE
FERRIER PUMPS HAS BROUGHT about a successful solution to a tricky wastewater application at a new chicken processing plant in Scotland. With washdown water containing feathers, faeces and sawdust, achieving the required flow rate was critical, as was the selection of a pump that could cope with the difficult solids. As part of its design, which included two screens, pipework, control panels and flowmeter, Ferrier Pumps brought in a submersible chopper pump from Landia. “Critically, we knew that if the minimum self-cleansing velocity could not be maintained for this packaged pumping station, then the solids in the pumped product would settle out causing blockages”, explained Peter Ramsay, Sales Engineer at Ferrier. “We had also seen from previous experience that the Landia chopper pump is extremely effective and reliable – even when having to deal with very hard-to-handle solids such as feathers. We’ve had no issues at all. It is the best pump for these challenging
applications”. Operating at 1500 rpm, the submersible Landia chopper pump installed by Ferrier Pumps is designed with its classic external knife system that chops solids before they get inside the pump’s casing – continuously reducing particle sizes for the benefit of the process.
HELPING ENERGY-HUNGRY industries scoop back and reuse vast volumes of wastewater and heat is the goal of an ambitious new project at Brunel University London. Brunel engineers will develop new water treatment, exhaust condensation and waste valorisation systems that let factories recycle 30% of wastewater and heat. Europe’s Horizon 2020 fund to equip Europe to compete on the world stage is pouring €10,596,775 into the iWAYS project, short for Innovative Water Recovery solutions. The technology, which promises to save billions across several sectors, will first be perfected for Europe’s most energy-intensive industries — chemicals, steel and ceramics — where it will have the biggest impact. The new industrial-scale heat and waste recycling technologies are forecast to cut water use by 30% to 64% and reuse water and heat from humid gases by 30%. They will also sift out acids and tiny particles from run-off gases to cut environmental pollution.
www.ferrierpumps.co.uk
www.brunel.ac.uk
Quarter 1 2021
Ferrier Pumps have brought in a Landia chopper pump to deal with wastewater from chicken processing.
www.bpma.org.uk
UK WATER REGULATION 4
Kiwa UK Regulation 4 (KUKreg4) The Kiwa UK Regulation 4 Product Approval Scheme (KUKreg4) a robust method for demonstrating compliance with the Water Supply (Water Fittings) Regulations 1999.
W: www.kiwa.co.uk/water
T: +44(0)1495 308185
E: jonathan.price@kiwa.com
FEATURE 30 Opinion
We must continue to work with the EU on key standards and directives BPMA’s Steve Schofield explains why it is essential that the pump sector continues its work with EU-based partners to drive the revisions of the Eco-Design Directive.
D
espite the UK’s departure from the European Union, the British Pump Manufacturers’ Association (BPMA) is retaining its membership of Europump, the European Association of Pump Manufacturers. Established in 1960, this influential body represents 16 national pump associations in 12 EU Member States as well as Russia, Switzerland, Turkey, and the UK. Europump members represent more than 450 pump companies with a collective production value of more than €10 Billion and an employee base of some 100,000 people across Europe. As a founding member, the BPMA will continue to play a significant role in the association’s activities, as much of the work undertaken will remain of relevance and importance to the UK. One such area of activity relates to the EU’s ongoing revision of the Eco-Design Directive and its Implementing Measures, which are intended to facilitate a notable reduction in the energy used by a broad range of products and equipment; be they for domestic, commercial, or industrial applications. In essence, the BPMA and its counterparts across Europe want to implement the extended product approach (EPA) for water pumps. This would mean that, in the energy use assessment terms required by the directive, not only should the actual pump be included, but also the associated electric motor and control system, which collectively Quarter 1 2021
comprise the entire pumping unit. Interestingly, and by way of precedence, this approach has already been accepted in heating pumps. TOTAL LIFE CYCLE COST COUNTS This proposal would have a significant impact on energy efficiency. After China and the USA, the continent of Europe has the third largest electricity consumption in the world – around 3,300 terawatt-hours (TWh) per year. More than 300TWh of this is accounted for by electrically operated pumps. That is the equivalent to the generated output of 30 large coal-fired power plants. The Eco-Design Directive aims to improve the environmental impact of energy-intensive products through optimal design. Europump has determined that water pumps can reduce electricity consumption by 35TWh from 137TWh a year. This would make it possible to shut down four coal-fired power stations. However, these enormous energy savings can only be achieved if the narrow ‘product approach’ is abandoned in favour of an ‘extended product approach’, with the aggregated savings being considered over the entire life-cycle of the product and its related system. MAKING THE RIGHT CLIMATE PROTECTION DECISIONS Representations are ongoing, with the pump industry determined to encourage the
legislators to move away from the existing product approach adopted in 2009 for water pumps. Frank Ennenbach, Chairman of the Standards Commission at Europump, said: “We see a real danger that we will not save the 35TWh that we could. We will then miss the opportunity to make a major contribution to sustainability and climate protection. We have everything we need. The legislator just has to make the right decisions.” In concluding, the BPMA, along with all the member organisations within Europump, support the demand of pump manufacturers to move from the ‘narrow’ to the ‘extended’ product approach for water pumps – a key reason why we must remain aligned with the EU on the development of this important directive. chevron-circle-right
The BPMA and its counterparts across Europe want to implement the extended product approach for water pumps.
www.bpma.org.uk
PUMP INDUSTRY AWARDS 2020/21
th 0 2 Anniversa r y Eve nt
Join us at the pump industry’s biggest and best celebration! It’s your chance to network and party with the industry’s best & brightest at this special 20th anniversary event. The PI Awards Gala Dinner is the highlight of the pump industry’s social calendar, celebrating the achievements of both companies and individuals, as finalists and winners are awarded in the charged atmosphere of the presentation ceremony. This event heralds the 20th anniversary and two decades of recognising and rewarding excellence throughout the pump sector. Whether it’s taking a table to host customers or booking a few seats for you, your team and partners, don’t miss this fantastic opportunity to enjoy a wonderful evening of great food, fantastic entertainment and networking until the early hours. Just visit the website www.pumpindustryawards.com and complete the simple online booking form to secure your places at this must-attend event, taking place on Thursday 23rd September at the Chesford Grange Hotel, Warwickshire.
DATE & VENUE Thursday 23rd September 2021 Chesford Grange Hotel, Kenilworth
THE TIMINGS 7.00pm - Drinks Reception
7.45pm - Pump Industry Awards Banquet
9.30pm - Pump Industry Awards Ceremony 10.15pm - Entertainment and Charity Raffle held on behalf of Wateraid 11.00pm - Fun Money Casino and Networking 12.30am - The Survivor’s Breakfast
2020/21 Award Programme Partners
www.pumpindustryawards.com
Organised by
on behalf of
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The extensive range of stock can be quickly modified to suit customers’ needs and with a high level of technical support from our knowledgeable team we ensure the correct selection of motors is provided for your application. Brook Crompton’s focus on product and service development ensures we continue to move forward to improve efficiency, offer lower cost of ownership throughout their lifecycle and to reduce environmental impact.
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