Flow Magazine: Quarter 3, 2021 - Focus on Petrol, Oil & Gas

Quarter 3 2021

Pump industry insight from

FOCUS ON: Petrol, oil & gas Keeping the world in motion - sustainably

Are your bearings protected?

Pump Industry News

Innovations

Applications

Expert Opinion

haywardtyler.com luton@haywardtyler.com

+44 (0)1582 731144

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.

W

hen this issue of flow magazine starts to land on the industry’s desks and bounce into its inboxes, it will be just a week until the long-awaited Pump Industry Awards gala ceremony, initially scheduled for March 2020, finally takes place. The need to postpone the event, twice, was a real blow, particularly as it was due to celebrate its 20th anniversary.

So, to finally see it just days away is much welcomed.

The fact that the event can take place at all reflects an incredible level of support over the past 18 months from everyone involved. This includes the sponsors, the companies that have entered, those planning to attend, and everyone involved in its organisation. And I would particularly like to thank Andrew and Hannah from the event organisers, Touchwave Media, for all their hard work making, undoing and re-making the arrangements that go into staging the awards.

COVID is, of course, still with us, and the need for caution will be reflected in the event this year. But I believe, as do many people I speak to, that the business community is ready to come back together face-to-face. To that end, on page 14 of this issue, you will see that we have already released details of the 2022 Pump Industry Awards, which will move back to its original spring timing, set to take place on March 24 in Kenilworth.

For the 2022 event we plan to recognise the outstanding efforts companies in our sector went to, to ensure they were able to help essential businesses keep operating under extreme pressures. There have been some amazing stories of companies quickly developing innovative solutions to the many challenges the coronavirus pandemic presented, including those with supply chains, remote operations, staff safety and more. So, we believe these should be recognised and will be sharing details of this new addition in due course.

If we don’t see you at the Pump Industry Awards this year, maybe you can join us in 2022.

And, if you think your company has done something worthy of recognition, why not enter?

Richard Harden, President, BPMA

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

4 Engineering company

offers free Net Zero training

7 Wilo honoured with design award

BPMA NEWS

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.

Cover image courtesy of John Crane

www.bpma.org.uk

8

BPMA and AEMT sign Mutual Co-operation Agreement

PRODUCT NEWS 10 Service-friendly short

shaft coupling

12 New borehole pump cooling shrouds

Industry Awards 14 PIA 2022 announced

Projects

Q&A 18 PMFC’s Philip Clarke

answers readers’ questions

Features 20 Choose the right O-ring 24 Selecting booster pumps

for irrigation 30 Are your bearings protected 32 Keeping London’s water

supply running

Focus on Petrol, Oil & Gas 34 Reliable sealing for carbon capture 38 Repairing water injection pumps

OPINION

16 Isolating gate valves for Wigan 42 Keeping the world in

motion – sustainably

wastewater treatment works Quarter 3 2021

4 INDUSTRY NEWS

ALFA LAVAL APPOINTS WHP AS AUTHORISED INTEGRATOR HYGIENIC FLUID HANDLING technology specialist Alfa Laval has appointed WHP as its latest authorised integrator, helping enhance the sustainability of the engineering solutions provider’s operations.

The new partnership is the latest in a long relationship between the two companies, with knowledge being shared to manage customers’ environmental impact. By working with Alfa Laval, WHP’s clean room, clean manufacturing solutions and complex process systems will gain further visibility with the organisation’s target audiences.

“This development is the latest in our strategy to expand our distribution and integration operations within the UK market,” said Leonardo Morabito, Business Unit Manager, Hygienic Fluid Handling at Alfa Laval UK and Ireland. “WHP has a sterling reputation as a world-class leader in supply and design services across a number of industries, standing out for its ability to offer ‘clean room’ managed environments and turnkey process packages. As the only authorised Alfa Laval partner within key markets, we look forward to offering WHP support

providing their clients with comprehensive engineering solutions, and further strengthening our ongoing relationship.”

A specialist in the modular design and turnkey projects for cleanroom construction, laboratories, R&D and suites or facilities for containment and evaluation, Gateshead-based WHP provides end-to-end design-and-build services for clients varying from bluechips to start-ups.

Ian Lichfield, CEO of WHP, added:

“WHP has a long trading history with Alfa Laval and I am delighted that we are now the Alfa Laval Authorised Partner for the pharma and healthcare markets we serve. We are thrilled to be aligned with such an internationally recognised brand that stands for quality, and I am looking forward to working closely with the Alfa Laval team to enable WHP to offer customers the best engineering solutions and the highest levels of technical support.”

ENGINEERING COMPANY OFFERS FREE NET ZERO TRAINING THE UK ENGINEERING COMPANY, AESSEAL, IS offering free training to help other businesses on the journey to Net Zero.

AESSEAL plc, whose global headquarters are in Rotherham, is promoting the Betterworld.Solutions campaign to encourage businesses to adopt an Investment Policy to Prevent Global Warming. Based on the company’s Net Zero achievements it has developed an online training course. This is now being offered free of charge via the Betterworld.Solutions project to any business that adopts a policy based on the template provided.

AESSEAL MD, Chris Rea, explained: “Adopting an easy to understand policy is a public statement of intent that the company is committed to listening to its own experts, and making sensible investment decisions that help the environment in a timely manner.

“This goes beyond ISO commitments which are often complex and hard to understand. It tells staff, and the society in which we operate, in plain language that we mean business, and that we are on the journey to Net Zero together”.

Chris believes that with Net Zero and green policies on everyone’s lips, what is really needed is urgent action. However, companies that want to join in may lack knowledge about what is Quarter 3 2021

involved and how they can make a difference The free training course covers understanding sustainability concepts (e.g. three pillars of sustainability, defining sustainability, sustainability strategies, UN17 Goals); learning how to combat climate change (defining global warming, climate change); understanding the concepts of Net Zero (defining Net Zero, scope 1, 2 and 3, residual emissions/offsetting, carbon capture, Net Zero targets and the Paris Agreement); learning how businesses can be profitable and Net Zero (emission reduction projects businesses can undertake, real life examples, verification); the business case and how businesses can drive effective change; and verifying the approach to Net Zero and the data.

The course takes between one hour and one hour 30 minutes to complete, but participants can break it up into bite-sized modules. There are also multiple-choice questions to confirm understanding.

The course contains real-life example projects that can reduce greenhouse gas emissions, often with a short payback that makes them a sound investment choice by any standards.

Companies interested in the course can find more details at the website: https://betterworld.solutions www.bpma.org.uk

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Keeping industry turning every second... every day...every year With over 110 years of technical and design expertise, Brook Crompton offers leading edge energy efficient electric motors across global markets. As the original innovator in electric motor development, Brook Crompton are trusted to power limitless industrial processes and its robust motor design drives fans, pumps, compressors, conveyors and more.

Driven by technology and innovation, Brook Crompton has one of the widest available ranges of electric motors for operation in safe areas, hazardous atmospheres and hostile environments.

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.

Contact us at: T: +44 (0)1484 557200 E: sales@brookcrompton.com

6 INDUSTRY NEWS

AVT RELIABILITY SEALS PARTNERSHIP WITH TELEDYNE FLIR

AVT RELIABILITY HAS ANNOUNCED a partnership with world-leading thermal imaging camera manufacturer, Teledyne FLIR. The partnership with the Oregon, USA, headquartered company, will enable AVT Reliability to offer industrial clients stateof-the-art cameras and software for the condition monitoring of assets, further enhancing its UK and Ireland thermal imaging offer.

Lee McFarlane, Group Technical Director at AVT Reliability, which is part of the AES Engineering Reliability Group, said: “The quality of a thermal imaging camera is crucial to the safe collection of detailed and accurate data to inform a proactive maintenance plan.

“Teledyne FLIR is world-renowned for the innovation of its design and the quality of its thermal imaging equipment, which we have utilised for decades in our service business.

“It was a natural fit for both parties that AVT Reliability UK and Ireland become a channel partner in the condition monitoring sector.

We’re confident that their range of advanced products will bring enormous benefits to our clients.”

Handheld thermal imaging cameras can be used as part of a condition based maintenance programme on electrical, static and rotating equipment.

Lee McFarlane added: “The range of cameras available is extensive,

depending on their application and budget. Additionally, AVT Reliability’s certified consultants can offer practical and technical guidance to clients, to ensure they apply the technology for optimum benefit.”

Musk Process Services to deliver CEMB HOFMANN a turnkey project at BASF Pharma UK AWARDED

ISO9001-2015 REACCREDITATION

EJ MUSK PROCESS SERVICES HAS been awarded a contract to deliver a seven-figure improvement at BASF Pharma’s Callanish plant on the Isle of Lewis. The investment includes the building of a new permanent tank farm and operational improvements to purification systems.

The turnkey project includes design, manufacturing, installation and commissioning. Musk, part of the Edwin James Group, will manage the whole project. Fabrication will be managed at the Swadlincote plant, and installation will be undertaken using Musk teams supported by local contractors.

“As one of the area’s biggest privatesector employers, this investment underpins our commitment to the region. The new tank farm and other improvements will ensure that we can continue to deliver world-class pharmaceutical ingredients to our customers. Our relationship with Musk spans several years, and we know Quarter 3 2021

from experience that they deliver a level of engineering and service that we can trust to get the job done,” said Angus Morrison, Site Manager at BASF Callanish.

BASF Callanish manufactures highly-concentrated omega-3 fatty acids for pharmaceutical and nutritional applications. The company employs more than 80 people at its dedicated lipid development plant on the Isle of Lewis and is part of the Pharma Ingredients & Services of BASF’s Nutrition & Health division.

Commenting on the project Charlie Price, Operations Director at Musk Process Services, said: “This turnkey project is a perfect example of the type of work we undertake delivering everything from project design to fabrication and installation and commissioning. We’ve built a good relationship with the team at Callanish, and it’s great to work in partnership with them to deliver this key investment.”

CEMB HOFMANN UK’S ISO9001:2015 accreditation has been reissued following a successful assessment of business procedures and an audit of the company’s Quality Management System.

First awarded to the company in 2000, ISO9001-2015 is an internationallyrecognised standard for quality management and acts as a clear blueprint for CEMB Hofmann UK’s internal efficiency and effectiveness.

The news of the re-accreditation follows the award of SafeContractor status, recognising the company’s commitment to Health & Safety in the workplace.

Procedures and processes, driven from the senior management team down throughout the business, support CEMB Hofmann UK’s commitment to not only quality but also safety and environmental management. The company’s Quality Management System provides the framework to drive quality in the business.

Rob Jeffery, Managing Director at CEMB Hofmann UK, commented: “The accreditation is based on strong quality management principles, including a clear focus on the customer, and we take our commitment and responsibilities very seriously. www.bpma.org.uk

Industry NEWS 7

WILO-REXA MINI3 HONOURED WITH IF DESIGN AWARD THE WILO-REXA MINI3 HAS BEEN awarded the renowned iF Design Award. In its statement, the jury praised the good and functional design of technology specialist Wilo’s submersible motor pump and its technical advantages, especially in times of increasing water shortage.

“In times of water shortage, the treatment and reuse of wastewater is an important topic. The Wilo-Rexa MINI3 is the ideal standard submersible sewage pump for house and site drainage,” reads the jury statement of the iF Industrie Forum Design e. V. Association. “In addition to the technical advantages, the sewage pump also sets new accents in design. In contrast to the competition, an asymmetrical housing, a clear alignment of the operating elements and a distinct colour scheme make it easier to use.”

Wilo Product Manager Olivier Armbruster was delighted with the iF Award, which he sees as both an

award and an incentive: “We made no compromises in the development of the Wilo-Rexa MINI3 – not in efficiency, not in performance and certainly not in reliability.

“Rainwater, ground water and sewage occur all the time in houses and on sites. With the Wilo-Rexa MINI3, this can be reliably and efficiently drained.”

In addition, the pump is also suitable for stationary use as well as for mobile

installation. “The Wilo-Rexa MINI3 is one of the industry’s best examples of how functionality and design do not have to be opposites,” explained Georg Weber, Wilo Chief Technology Officer (CTO). “We therefore also understand the iF Award not as a beauty prize but as recognition of a well-thoughtout industrial design that meets the demands of contemporary sustainability at the very highest technological level.”

BRITISH WATER AND THE WATER INDUSTRY FORUM CONFIRM MERGER PLANS THE BOARDS OF BRITISH WATER AND THE WATER Industry Forum have confirmed that the proposed merger of their two organisations is to go ahead and detailed plans and an agreed timetable are being prepared for the merger later this year.

In June this year, the two boards reaffirmed their recommendation to move forward together, first announced in May, following feedback by members that demonstrated clear support for the merger.

The two organisations say that their combined influence will enable them to deliver enhanced value for members and respond most effectively to the unique challenges facing the UK water sector – and the many opportunities these challenges present.

In a joint statement issued today, chairs Chris Loughlin and Mark Fletcher of British Water and the Water Industry Forum

respectively, said: “We are delighted that the merger of British Water and the Water Industry Forum has the backing of our combined membership and that we are now able to finalise our detailed plans.

“We would like to thank members for their clear and positive feedback. Their support means we are now able to move forward together and build a stronger and more influential organisation, providing new and enhanced opportunities for members.”

A proposed operating model and governance framework has been developed to support the activities and priorities of the merged organisation, and importantly to preserve the Water Industry Forum’s integrity and independence, enabling it to maintain the trust and respect that it enjoys throughout the sector.

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

8 BPMA News

BPMA AND AEMT SIGN MUTUAL CO-OPERATION AGREEMENT

THE BRITISH PUMP MANUFACTURERS’ Association (BPMA) and The Association of Electrical and Mechanical Trades (AEMT) have announced the recent signing of a Mutual Co-operation Agreement.

The agreement covers a range of collaborative ideas and opportunities, primarily geared around the development of improved skills and enhanced technology understanding across the industrial and engineering arena. It will allow both parties to explore additional content to strengthen their existing range of training courses. Working on possible compliance and legislative related issues and other factors within the repair and maintenance of pumps and motors will also form a key part of the arrangement.

Commenting on the agreement, Dave Dave Hawley, AEMT President (left) and Richard Harden, BPMA President, Hawley, AEMT President, said: “There are clear sign a Mutual Co-operation Agreement. synergies between our two organisations, including some cross-over of membership, and so I am thrilled to have this agreement in place and excited engineering arena for many years and have developed vast by the potential activities that the collaboration could deliver.” experience in their respective disciplines. But by forging closer Echoing this viewpoint, Richard Harden, BPMA President links and a more collaborative approach to certain activities, we added: “Our two associations, have been serving the can better harvest that expertise for mutual benefit and reward.”

MORE COMPANIES BENEFIT FROM MEMBERSHIP THE BRITISH PUMP MANUFACTURERS’ Association (BPMA) continues to expand its membership, with another three companies joining the association.

One of the companies is Devon-based Rauschert, an independent pioneer of innovative industrial solutions in the technical ceramics and plastics market for more than 120 years.

With its comprehensive industry knowhow and the continuous development of its production process and material range, this business has established itself in several key sectors. Its service portfolio covers all stages of product development, from initial concept to series production (material development, tool design and construction, prototype production, series production and module assembly).

For the pump industry, Rauschert offers an extensive standard range as well as customised pump components, plungers and pistons, seal rings and bearings in a wide range of moulding processes and materials.

Another company to secure its BPMA Quarter 3 2021

membership is Roto Pumps (RPUK). From its assembly and warehouse facility in Denton, Manchester, the company has successfully supplied over 20,000 positive displacement pumps, including pump packages and retrofit spare parts.

Since its formation in 2004, RPUK has demonstrated its expertise in application engineering through its understanding of complex pumping requirements, handling critical media and optimising pump lifecycle costs. Solutions the company can offer cover complete pump assemblies inclusive of the motor, gearbox, base plate, coupling, and guard, as well as special seals. The business has established an extensive network of distributors and channel partners across the entire European region.

Metro Mechanical Services, a specialist in commercial and industrial drainage and pumping solutions, has also recognised the value of joining the BPMA. With expertise across internals, externals, pumps, civils, and plumbing, the company can address the root causes of issues on site and ensure high-quality solutions are delivered.

Supporting the engineers in the field are two offices: the company’s headquarters based just outside London and a northern office in Greater Manchester.

In welcoming these companies into BPMA membership, Gary Wilde, Technical Services Office at the BPMA, said: “The pump sector has not been immune to the huge societal and commercial challenges brought about by the pandemic, and so against this backdrop, it is encouraging to know that the business benefits associated with membership are still valued by a growing number of pump related businesses.”

He added: “We are delighted to have these diverse companies join the BPMA and look forward to providing them with all the support at our disposal.”

Details of the benefits gained by membership of the BPMA can be found on the BPMA website, or by contacting Steve Smith at s.smith@bpma.org.uk www.bpma.org.uk 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

Product News 10 NEWS 10

NEW SERVICE-FRIENDLY SHORT SHAFT COUPLING KTR HAS LAUNCHED A NEW SHAFT coupling, the ROFLEX, meeting DIN 740 with a design which is both short and service friendly.

The ROFLEX is a short shaft coupling in which the input and output shafts can be pushed together between 3 and 6 mm, depending on the size. The torque is transmitted via elastomer packages, which at the same time compensate for misalignments and dampen shocks and torsional vibrations. Should the elastomers fail, due to extreme loads, the fail-safe coupling continues to hold the torque.

The ROFLEX is made of grey cast iron and is available in two types: In type N, both the pocket and the cam part consist of standard hubs. In the SH SPLIT design the cam hub is split. Here, the hub is specifically and mechanically separated into two halves by ‘fracture cutting’, or ‘cracking’. The resulting fracture surfaces centre both hub halves precisely with each other, which makes incorrect assembly almost impossible. The hub halves can be mounted on block, and the fit of the bore remains unchanged. Depending on accessibility, the hub can be pushed on for assembly, or the two hub halves can be joined around the shaft; thus the split

hub can be radially installed and removed without dismantling the adjacent units.

“As a rule, we recommend that our customers fit the SH-SPLIT hub onto the motor shaft. This makes the coupling easier to assemble overall and in case of service there is more space available, for example to exchange the elastomer packs”, said Michael Brüning, Product Manager at KTR. “In addition, it allows the user to carry out the direction of rotation check on the engine without the coupling hub.”

The ROFLEX has been assessed and

confirmed according to the European ATEX product directive 2014/34/EU and is suitable for use in potentially explosive atmospheres. Core industries are pumps and compressors; other areas of application in general mechanical engineering are gearboxes, fans and belt drives.

Both types are currently available in seven sizes for torques from 65 to 790 Nm. Five more sizes in the power range up to 5,000 Nm are to be added by mid-2022. www.ktr.com

Booster set launched to coincide with new ErP regulations WILO UK, HAS ANNOUNCED the launch of a cold-water booster set, the ‘Wilo-ISAR MODH/SCe’, which aligns with changes to the Energy related Products (ErP) regulations.

The new Wilo-ISAR MODH/ SCe cold water booster set range was launched to coincide with the latest changes to ErP regulations and motor efficiency.

The regulations ensure products meet specific measures relating to their energy usage to reduce environmental impact, improve energy efficiency and cut greenhouse gas emissions.

The new booster set is an evolution of the Wilo-COR MHI/ SCe booster set range. The evolved product incorporates Wilo’s new Medana range of stainless steel horizontal multistage pumps and now offers a captive nut connection.

This new feature will improve the ease of maintenance, as well as reducing the number of connection points between Quarter 3 2021

the pump and the manifolds, giving the booster set a reduced footprint on site.

Key advantages also include an increased range of flows from 2-72 m3/hour able to deliver pressures up to 7bar. The booster set also comes complete with fully automated controls via variable speed drives and with standard features for BMS connectivity included. Approved to the latest Drinking Water Regulation 4 requirements, the ISAR MODH1/ SCe has been designed to maximise required hydraulic efficiency with the added benefit of a compact design.

Designed for light commercial applications, the Wilo-ISAR MODH1/SCe also features an increased temperature range allowing for installation in a wider range of projects, as well as a new housing and commercial building design. wilo.com/gb/en/ www.bpma.org.uk

Motors | Automation | Energy | Transmission & Distribution | Painting

PUMP GENIUS MULTIPUMP CONTROL TWO OR MORE PUMPS WITH ONE VARIABLE SPEED DRIVE

WEG’s Pump Genius Multipump allows you to control two or more pumps in parallel using one variable speed drive. The drive selects which pumps will operate in order to control the process of the pumping system and allows you to increase or decrease supply according to demand. Pumps can be used alternately or in sequence to ensure even use and prevent excessive wear on one pump. In addition pumps can be isolated for maintenance removing the need to shut down the system.

WEG variable speed drives all comply with EU 2019/1781 effective from July 1st 2021

Transforming energy into solutions

www.weg.net

Product News 12 NEWS 12

OUTDOOR PUMPS WITH PERMANENT MAGNET MOTORS UP TO 10HP ARMSTRONG FLUID TECHNOLOGY has announced that Design Envelope pumps with permanent magnet motors are now available NEMA 4X/IP66 rated, for outdoor installation.

Featuring advanced performance mapping technology and load-limiting logic, the new pumps reduce energy consumption by as much as 30% compared to pumps supplied with a loose variable speed drive. Together with new, more efficient pump hydraulics, the new 1 to 10hp pumps can save an additional 20% compared to competing integrated products with induction motors.

Other features of the new Design Envelope outdoor pumps include a cover to protect the touchscreen user interface

from dirt and sunlight, an overhead weather shield that protects the motor fan from ice seizures, and factory-tested NEMA 4X rated controls which are TL approved.

The optional Parallel Sensorless control provides additional energy savings through best-efficiency staging, while the Pump Manager service provides pump performance tracking along with alerts, alarms and data storage.

“The conventional approach to rooftop and outdoor pumps is to install VFDs in a central, outdoor-rated control panel, separate from the pumps. This adds unnecessary costs and requires a larger footprint,” said Zeljko Terzic, Global Offering Manager, Pumps at Armstrong Fluid Technology. “Our new Design

Envelope pumps feature integrated controls for a reduced footprint and substantially reduced installation costs.” www.armstrongfluidtechnology.com

ONLINE ASSET MONITORING THE NEW WEG MOTION FLEET MANAGEMENT solution provides online asset monitoring to allow predictive maintenance and total cost of ownership (TCO) reduction.

One of the main factors that affects the productivity and profitability of a company is unplanned production downtime.

Most corrective maintenance events could be avoided if machine and equipment parts were being continuously monitored.

Aware of this issue, WEG has developed a software solution that enables users to check the operating status of low and medium voltage motors and drives (VSDs and soft-starters), gearboxes, gearmotors and other assets installed in any industry or facility.

Through periodic data collection and advanced data processing, valuable insights can be obtained at the edge and in the cloud.

From this information, it is possible to establish predictive maintenance plans taking into account the operating condition of the fleet.

The WEG Motion Fleet Management system helps simplify and speed up the operation, maintenance and management of industrial plants. Based on cloud computing technology, the performance of assets can be monitored at any time, from any

part of the world. This approach reduces unplanned downtime, optimises repair actions and speeds up the decision-making of the operations and maintenance team. The result is increased uptime and reduced drive fleet TCO. WEG Motion Fleet Management includes dedicated and robust hardware for data acquisition, data processing on the edge and in the cloud, periodic fleet reports, maintenance order creation and management, asset prioritisation tools. Also included are an Exchange module for data integration (via REST API) and a Specialist module with analytics and artificial intelligence for failure diagnosis and consumption analysis. bit.ly/MoFeMa

NEW BOREHOLE PUMP COOLING SHROUDS DEEP WATER PUMPING SPECIALIST, CAPRARI, has introduced a new range of cooling shrouds for borehole units. Compared to more traditional models, these ‘light versions’ are set to offer users more competitive (and simultaneously more robust) water system solutions.

Quarter 3 2021

Thanks to their optimised design, the light cooling shrouds will ensure correct water speed around the motor, giving perfect cooling and durability over time. They also represent the best solution for vertical installation of borehole electric pumps – in a tank or well – even at high temperatures.

The shrouds are made of AISI 304 stainless steel, further ensuring high levels of corrosion resistance, and they can be certified for use in drinking water systems, according to D.M 174, ACS, WRAS and KTW standards. www.caprari.com www.bpma.org.uk

Coupling & Drive Solutions Now available in the United Kingdom Contact ’s industry experts today for design & drive selections to suit your application. is a global manufacturer you can trust with quality, service and value. martinsprocket.com EMEASales@martinsprocket.com +44 (0) 1926 962161

launch

flowcare

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AFTER SALES SERVICE

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MEMBERS AREA

14 Industry Awards

EXCELLENCE REWARDED AT LONG AWAITED PIA CEREMONY

A

s you read this, there is a good chance that the winners of the latest Pump Industry Awards will be busy polishing their trophies ready for display in their boardrooms or reception areas. The all-important press releases and social media announcements will be no doubt be under way too.

A full review of the BPMA’s gala awards ceremony will be carried in the next edition of Flow (published in December), detailing the winners and all the key moments of what has been a long-awaited and much-anticipated presentation evening.

As one of the first industrial sector events to be postponed due to the pandemic, this long-established and highly regarded awards ceremony was moved from its original date in March 2020 to this September. In addition to celebrating its 20th anniversary, the awards programme received a record number of entries, so it was doubly disappointing to endure such a long postponement – despite the obvious reasons for doing so. But, on the evening of Thursday 23rd September, the extended wait was over, allowing the pump industry to re-connect, re-unite, and celebrate its business, professional, and engineering prowess.

However, despite the delay in announcing the latest set of awards winners, for achievements that took place in the 18 months preceding December 2019, time does not stand still, and so we are now seeking nominations and entries for the 2022 Pump Industry Awards. Returning to our usual spring dateline for the gala dinner and presentation ceremony, the event will take place on Thursday 24th March, with the Chesford Grange Hotel in Kenilworth again being the chosen venue.

The call for nominations, which will cover activities in the two years up to December 2021, will open on Monday 27th September this year – directly after the 2020/21 awards presentation.

The entry deadline has been set for Quarter 3 2021

Friday 7th January 2022, so please make a note of this important date, and begin considering which key developments, activities, and successes you will be putting forward for industry recognition and reward.

Throughout the pandemic, and especially through lockdown, the pump sector played a crucial role in ensuring our utilities, manufacturing processes and essential services were maintained, and so for the 2022 award programme, special recognition will go to those companies and individuals who have gone that extra mile to meet any additional demands and challenges brought about by Covid-19.

This additional acknowledgement will go hand-in-hand with the following nine award categories that collectively honour the full breadth of product and service offerings across the pump industry.

• Product of the Year sponsored by Process Engineering • Project of the Year sponsored by Stuart Turner • Environmental Contribution of the Year sponsored by SPP Pumps • Manufacturer of the Year sponsored

by WEG UK • Distributor of the Year sponsored by EMIR Software • Supplier of the Year sponsored by Wilo • Contribution to Skills & Training sponsored by Tomlinson Hall • Rising Star Award sponsored by World Pumps • Lifetime Contribution sponsored by BPMA Steve Schofield, CEO, British Pump Manufacturers Association, commented: “No-one could have foreseen the disruption caused by the pandemic, and the pump sector has not been immune to its impact. However, despite the many challenges, or maybe because of them, business and professional excellence still deserves to be acknowledged and celebrated. The Pump Industry Awards do just that, and so I would offer my heartfelt congratulations to our latest set of finalists and winners and encourage all those involved in this important sector of ours to prepare and submit their entries for the fast-approaching 2022 awards programme.” www.pumpindustryawards.com www.bpma.org.uk

POLYMERIC MATERIAL FAILURE CONSULTANTS

RESOLVE FLUID LEAKAGE CAUSED BY SEAL FAILURE SPECIALIST INVESTIGATORS OF POLYMERIC AND ELASTOMERIC COMPONENT FAILURE IN FLUID CONTAINING HARDWARE

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END-SUCTION

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NEWS 16 Projects

ISOLATING GATE VALVES FOR WIGAN WASTEWATER TREATMENT WORKS

W

hen a critical water treatment works in Wigan required an overhaul, T-T Flow was brought in to supply two large diameter gate valves to help ensure the continued efficient supply of potable water in the northwest of England.

Wigan Wastewater Treatment Works is an important facility operated by United Utilities, which is responsible for the delivery of potable water and the capture and treatment of wastewater throughout the region.

To ensure the continued efficient delivery and treatment of water, there was a requirement for two new large diameter gate valves to meet the required specification and facilitate safe, easy and reliable operation.

T-T Flow, the specialist valve division of T-T Pumps, was engaged to supply a pair of DN500 MSGV isolating wedge gate valves measuring 500mm in diameter. These are rated to withstand

16 Bar pressure and come with customised operating equipment utilising intelligent actuation.

As the valves would be installed beneath steel grating, each one was supplied with an extension spindle bringing the operating element (electric actuator) to an ergonomic position for safe and easy operation.

T-T was selected due to its ability to project manage the whole supply, offering an efficient single point of contact for the client. T-T Flow holds extensive stocks of Aquaflow metal seated wedge gate valves, which for

this size feature superior weld deposit seating faces. Furthermore, T-T’s in-house fully equipped workshops permitted the fabrication of site-specific extension spindles and the mechanical and electrical functional testing of electric actuators. www.ttpumps.com

UK’S FIRST LARGE SCALE AMMONIA HEAT PUMP USES ABB DRIVES AND MOTORS

T

wo ABB low voltage motors and low harmonic variable speed drives (VSDs) are driving the compressors for a new high-tech heating system set to transform the way homes, businesses and public buildings in Clydebank, Scotland, are heated.

The District Heating Network is the first and largest high temperature (80° C) water source heat pump (WSHP) system in the UK. The WSHP works by extracting water from the River Clyde to generate heat for buildings on the site of the former John Brown Shipyard, now known as Queens Quay.

The two 2.65 MW WSHPs are designed, manufactured and installed

by Star Refrigeration in Glasgow and are part of the company’s Neatpump range. The renewable energy heat pump extracts heat from the river’s water by compressing the ammonia refrigerant in a high-efficiency screw compressor. ABB’s motors and drives are used to power the ammonia compressors, each rated at 836kW. Applying variable speed control makes it possible to increase screw compressor capacity by over-speeding up to 60Hz. The compression process raises the water’s temperature before releasing the heat via a heat exchanger to a district heating loop at up to 80° C. Pumping water through a network of

Quarter 3 2021

underground pipes provides heating for several hundred homes and businesses in the area.

Most usefully, the VSDs reduce the starting current. Low harmonic VSDs were chosen to minimise harmonic interference on the mains supply. The VSDs exceed the requirements of EN 61000-3-12 and IEEE519 and offer genuine unity power factor with no compensation needed, thereby avoiding reactive power penalties. The standalone design of the VSD gives it a small footprint, minimising space requirements in the control panel. www.abb.com www.bpma.org.uk

Projects NEWS 17

O-RINGS INCREASE PUMP LIFETIME FROM WEEKS TO ALMOST FOUR YEARS

W

hen one of the world‘s leading chemical companies was looking for a superior perfluoroelastomer (FFKM) sealing solution, it approached sealing solutions specialist Green Tweed. The company’s goal was to increase the MTBF (mean time between failure) of its screw spindle pump from several weeks to several years. In addition, the company wanted to improve safety at all of the pump installations in its EO/PO (ethylene oxide, propylene oxide) plant.

The rotary pump was used as a reactor pump carrying EO/PO media. EO/PO is a very reactive, dangerous medium. In general, EO/PO users or manufacturers will not change o-ring specifications without thorough proof of compatibility.

The faces of the pump‘s mechanical seal had been statically sealed against the housing and the shaft by a variety of FFKM O-ring seals.

Previously installed perfluoro elastomers swelled and lacked sealing force. Since MTBF was only a few weeks, which was not acceptable for the customer, Greene Tweed had been contacted to provide a solution.

Based on Greene Tweed’s recommendation, the customer employed Chemraz 505 seals. This material is one of the few recommended for service in corrosive EO media.

Following the change to Chemraz 505, which reduces the risk of seal swell in EO/ PO service, the O-rings have increased pump lifetime from several weeks to almost four years. The pump continues to run without problems with scheduled maintenance now set for every five years, and it appears this goal will be met without a challenge. www.gtweed.com

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18 technical solutions

Q&A

In this issue of flow, Philip Clarke, Managing Director of Polymeric Material Failure Consultants, answers readers’ questions related to O-ring failures.

QUESTION: Body to adapter O-ring seals, removed from a gas export line ball valve, show widespread through thickness fracture damage that aligns with the direction of squeeze and yet the valve showed no leakage prior to shut down. Why would this be the case?

PHILIP CLARK: Surprisingly it is often the case that elastomeric sealing components can continue to function effectively despite the presence of considerable material damage (extrusion, RGD, compression set, thermal/chemical ageing). The O-ring damage that you describe is likely to be due to rapid gas decompression (RGD) where high pressure gas absorbed by the seal cannot escape sufficiently quickly when system pressure is reduced, the expanding trapped gas causing internal fracture damage. The phenomenon is often seen as concentric oval fracture features on blisters when opened.

Seal damage can often remain hidden while operating conditions remain static. When temperature, pressure or mechanical loading conditions change during maintenance activities or unintentional plant stoppage, the seal that is no longer pressure energised is disturbed and then challenged when pressure is reapplied.

Steps that can be taken to mitigate the threat of RGD fracture damage in gas valves include careful material selection to match thermal and chemical compatibility requirements with high material tear strength. Optimising seal support using for example higher groove fill, reducing seal section diameter (where design allows) and control of rate and temperature of any controlled blow down event will all help.

QUESTION: How can material identification for O-rings from my used valve be verified against the design/service specification?

PHILIP CLARK: A range of techniques are used for elastomer compound ID. Simple quick measurement of density will help ID generic compound type (e.g. nitriles typically being 1.2-1.3g/cm3 while fluoropolymers tend to be 1.8-1.9g/cm³). Solvent swell response can support initial indications from density with swell response for selected elastomer/solvent combinations being different (e.g. rapid high level swell of nitriles in aromatic hydrocarbon; variable swell of FKM grades in methanol). Air oven ageing can quickly distinguish between NBR and HNBR through subjective stiffness increase).

More complex analytical techniques, such as DSC and TGA, characterise glass transition temperature and thermal decomposition profile while FTIR will use fingerprint identification of chemical functional Quarter 3 2021

groups to indicate polymer type. These techniques and others can also be useful when studying material change from service use by comparing used seal condition with a known new reference.

QUESTION: Where seal failure occurs, what information will be required to support an independent failure investigation?

PHILIP CLARK: Seal failure investigation generally involves confirmation of elastomer material type, documentation and characterisation of damage features, gathering of supporting information from the operator with available evidence being bought together to propose a probable root cause.

Seal material condition alone is unlikely to reliably identify the cause of failure. Consideration of the associated engineering hardware and its function is also required.

Requirements from the end user for a typical study include: • Failed components ideally traceable to original location/orientation from planned documented disassembly.

• Manufacturers material data sheets.

• Unused reference seals.

• Process operating conditions (temperature, pressure, fluid, duration).

• Historical failure occurrence.

• Failure scenario and consequences.

A rigorous investigation is an exercise that can require considerable input from the client to ensure that all possible influences on failure are included. www.pmfconsultants.com To pose your questions, or to see more technical solutions to pump user’s challenges and engage in the 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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20 Sealing

Choosing the right O-rings Selecting the correct O-ring for an application can be critical, but to achieve this many factors need to be considered. To help users make the right choice, fluid sealing product specialist, M Barnwell Services, looks at key aspects of an O-ring’s design.

E

lastomers are different compared to any other material used by engineers. For example, plastic or metal components are most likely to be failing when they are visibly deformed. When it comes to an O-ring, for it to function correctly, it must be deformed. An O-ring that is not stretched and squeezed is the wrong O-ring for an application.

An O-ring is a doughnut-shaped article; a closed circle usually made of elastomeric rubber. The O-ring seal’s purpose is to prevent an unwanted leakage or loss of gas or fluid, and it is the most popular form of a seal.

The opposite faces of an O-ring are compressed between the faces of the gland. The consequent zero clearance within the gland guarantees an efficient seal, preventing the fluid or gas from flowing through the gland.

O-RING MANUFACTURING There are two standard processes for the manufacture of rubber O-rings.

In the compression moulding process, the material is manually placed into a mould before the upper and lower parts of the mould are closed. This process is particularly suitable for larger dimensions and smaller quantities due to it being very time-consuming.

With the injection moulding process, the material is automatically injected into a mould (otherwise known as a tool), which has various O-ring cavities. Injection moulding is a process suitable for small dimensions and large quantities.

ELASTOMERS Elastomers are polymers, which are described as large molecules (or macromolecules) formed of Quarter 3 2021

an O-ring retains its shape; if it were stretched too much, it would cause the bonds to break.

many sub units. In Greek, polymer means ‘many parts (poly, ‘many’ + mer, ‘parts’). The polymers are linked to each other to compose a network with cross-connections.

Consequently, they demonstrate the typical elastic and rubbery

A properly designed sealing system includes some level of initial O-ring squeeze. features. The raw product is rubber and is either acquired from plants that produce the substance or developed synthetically.

When applied to an elastomer, vulcanisation leads to the formation of chemical crosslinks of polymer chains. This is to ensure that after the force is removed, the molecules return to their original shape. This is how

HOW AN O-RING WORKS A properly designed sealing system includes some level of initial O-ring squeeze. Only the elasticity of the squeezed O-ring ensures the seal at atmospheric pressure.

Nevertheless, the O-ring is pressed against the low-pressure side of the gland as system stress activates the seal. The O-ring fills the diametrical clearance and prevents any additional leakage.

Pressure and many other considerations determine the efficiency of a seal.

O-Ring ID =

Groove Diameter % of stretch wanted +1 (Between 1% and 5%)

Formula for calculating the optimal O-ring internal diameter (ID)

www.bpma.org.uk

> 22

22 Sealing

[

Maximum O-ring CS =

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Min bore diameter - max groove diameter 2 1-

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Max % compression 100

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Formula for calculating the maximum O-ring cross-section (CS)

DIMENSIONAL CONSIDERATIONS An O-ring’s inside diameter (ID) must be smaller than the piston groove diameter to offer an efficient seal.

This is because an O-ring needs to be slightly stretched so it closely fits the groove. The stretch mentioned above needs to be between 1–5%, with an ideal stretch of 2% in most installations. A stretch of more than 5% is not recommended; the consequent pressure on the seal will reduce the cross-section and contribute to early ageing. In installations where less friction is required and some leakage is allowed, O-rings can sit or ‘float’ in the grooves freely.

To calculate the cross-section (CS) of an O-ring, the size of the gland and the amount of compression must be considered to achieve an effective seal.

Diametrical clearance is a gap between two mating surfaces of a gland. Practically all glands have diametrical clearance; therefore, an O-ring’s cross-section must be larger than the gland height. As a result, the compressed O-ring blocks the diametrical gap, consequently preventing leakage.

MATERIAL CONSIDERATIONS Following the calculation of the correct O-ring size, the correct material must be chosen.

Numerous elastomer materials are available with a wide variety of characteristics, including their chemical resistance, temperature

Quarter 3 2021

Minimum O-ring CS =

[

(

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Max bore diameter - min groove diameter 2 1-

(

Min % compression 100

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+ O-ring CS tolerance

Formula for calculating the minimum O-ring cross-section (CS)

suitability and material hardness.

All of these factors must be considered before purchasing a seal, and a manufacturer or supplier should be able to advise on the best choice if required.

Resistance of particular rubbers to degradation by exposure to various chemicals is a major consideration for O-ring material selection. It is crucial to match the O-ring material with application chemicals to ensure the best resistance. This should be the first step when choosing an O-ring material.

The temperature range encountered throughout the process/operation must also be taken into account. Measuring temperature in the adjacent O-ring environment, rather than the system temperature, is especially important.

Also, the duration of exposure to any high temperature must be considered, regardless of whether it entails short (intermittent) or long (constant) exposure.

Shore A hardness is a measurement of the hardness of a rubber element. The numerical measurements for Shore A hardness go from softer materials (lower-numbered, less than 70) to harder materials (highernumbered, greater than 70). For instance, the standard FKM/FPM (Fluoroelastomer) compound has a hardness of 75 Shore A. This grading technique is intended to operate in the range of ±5 points.

In dynamic (moving) installations,

two types of friction can be observed. When experiencing breakout friction – the force needed to start a motion – the intermittent motion of the component can cause excessively high pressures; these pressures can tear sections of the seal that stick to the gland wall, consequently leading to seal failure.

With ongoing running friction, the constant motion of the component can lead to heat building up in the seal material. This results in swelling, which causes even more heat to build up and leads to extrusion and failure.

Different materials will react differently to friction, and so this should also be factored into the selection.

SUMMARY Correct selection of an O-ring is a direct result of many design considerations to obtain optimal sealing performance. These involve size, compression, stretch, chemical compatibility, and resistance to pressure, temperature and friction. Frequently, various materials could be appropriate for a particular application, therefore it is important to consider a full selection of price and environmental factors. The ultimate choice will be a balance between all of the considerations mentioned above. Of course, if you are in any doubt, you should contact a reputable supplier for advice. chevron-circle-right www.barnwell.co.uk

www.bpma.org.uk

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24 Irrigation

Selecting booster pumps for irrigation The sizing of pumping systems for irrigation needs careful consideration to achieve optimum performance, efficiency and long-term reliability. Based on the application and environment, T-T Pumps looks at the primary factors and requirements to consider when choosing booster pumps for irrigation.

H

ead and flow are the main requirements for any irrigation system; however, a lot of information is required to get the best efficiency and reliability.

Head is seen as the highest point of discharge from the pumps, but we need to understand the total amount of static head and other head losses in the system to define the total head. Pipework costs may push installers towards using less costly small-bore mains to the discharge points, only to undermine the long-term energy cost and system performance.

Unfortunately, the friction loss within a small-bore irrigation system will demand more energy, escalating the running costs where energy is concerned. With this in mind, the greater the flow, the larger the bore pipework needs to be, especially for the main distribution pipework. Other losses are found in any pipework system and should be accounted for when calculating the total head. Sprinklers, irrigators, fittings and valves will have an identified head loss value, and by careful selection and design, some of these losses can be reduced.

Once the total head and flow have been determined, the process of selecting the pumping system can begin. Most facilities, such as golf clubs, sports grounds, parks and large gardens, will require a system using two or more pumps with a ‘jockey’ pump to cope with small fluctuations in pressure demands.

PUMP CONTROL SYSTEMS The control of these pumps is via an electrical control system which will monitor the pressure with the

Quarter 3 2021

discharge water main and start the pumps as demand increases. One pump may be required initially, but an additional pump will be deployed to maintain pressure as demand increases.

A reliable and efficient control system will have a myriad of additional built-in protection features.

In some cases, the control systems may be as simple as using mechanical pressure switches to activate the motors via crude ‘direct online’ starting methods, but more commonly, variable speed drives are being used to match performance with demand, giving better overall performance and economy.

A reliable and efficient control system will have a myriad of additional built-in protection features, supplementary to the

expected motor overload protection; dry running protection is essential to avoid damaging the pumps due to lack of incoming water. Equally, under pressure protection may be provided to shut the system down if there is a delivery main bursts or an unplanned discharge beyond normal planned flows occurs.

POWER SUPPLY The power supply is a very important consideration when specifying an irrigation system.

It is important to ensure that there is sufficient supply to meet the demand of a new system. In addition, the location of a system is important. A system needs to be positioned to optimise the irrigation obligations. However, greater distances from the power source need larger power cabling to avoid voltage drop, which will otherwise undermine the system, and this can have a significant cost implication.

Recent examples of booster pump installations for irrigation www.bpma.org.uk

Irrigation 25 show how different applications can be applied successfully.

GOLF COURSE As part of a broader water management scheme on a Hertfordshire golf course, a booster set was needed to improve water distribution around the expansive course, where the water was extracted from a lake.

A dual booster set was sized and selected, complete with 2 x 5.5kW vertical multistage pumps, motor mounted variable speed drives and a bespoke control panel to Irritech specification, which included a fail-safe backup system via digital pressure controllers. In a duty/ assist configuration, the pump set achieves a performance of 20m³/hr at 8.8 bar pressure.

employed. It included dual 132kW multistage pumps with a 45kW jockey pump – all controlled by a variable speed drive – a triple 30kW set with a 5.5kW jockey pump and two single 55kW boosters, each with an 11kW feeder pump, operating on a dual redundancy basis with mirrored PLC and software.

LARGE IRRIGATION SCHEMES A recently commissioned largescale system indicates the scale and sophistication that can be

FOOTBALL STADIUM A booster set is used daily to water the main pitch at the bet365 stadium.

As with all major sporting

grounds, the home of Stoke City FC requires watering daily to keep the pitch in a premium condition.

So the club needed an efficient and economical product that could provide reliable irrigation with automatic control. The system chosen, which comprised of fixed and variable speed clean water multistage pumps, was designed and manufactured to provide both the flow and water pressure required for the football ground. chevron-circle-right www.ttpumps.com

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26 Water Supply

A new water pump station for Calgary flow magazine found out how technology from the specialist pump manufacturer, KSB, was used in the development of a new pump station in the Canadian city of Calgary, and the refit of another pump station in the same area.

C

algary is one of Canada’s fastest growing metropolitan cities and is the major urban centre for the southern half of the province of Alberta. Calgary is located in the foothills of the Canadian Rocky Mountains, at the confluence of the Bow and Elbow Rivers. Originally founded around agriculture, the city is now the heart of Canada’s energy sector, with much of the current economy driven by oil and gas production.

With an expanding population of over three million and the continued diversification of industry and commerce, the ever-growing demand from Calgarians for potable water has to be met. To satisfy both current and future demands for safe and reliable drinking water, The City of Calgary has recently embarked on a $35M CAD project to replace the most critical water pump station in the city. The existing Shaganappi Pump Station, originally constructed in 1978, supplies drinking water to over 200,000 residents of Calgary and surrounding communities.

Shaganappi Pump Station is the area’s largest pump station. It is a vital component of the city’s water transmission network, which consists of 41 pump stations and 23 storage reservoirs connected by over 4,500km of underground piping. This large number of pump stations and reservoirs is required due to the region’s varying and often rugged topography, which divides the city into many smaller water pressure zones based on elevation.

THE PROJECT The City of Calgary owns and operates two water treatment plants: the Bearspaw Water Treatment Plant and the Glenmore

Quarter 3 2021

Water Treatment Plant. These state-of-the-art treatment facilities draw their source water from the Bow River and the Elbow River, respectively. Both treatment plants combined can produce a total of 950ML of clean drinking water per

The existing Shaganappi Pump Station is over 40 years old and is past its useful life expectancy. day. Treated water is stored on site at the treatment plants before being pumped into the transmission network for distribution throughout the city. The Bearspaw plant, located in the city’s northwest quadrant, pumps water into three separate underground feeder mains. One of these feeder mains is the 1950mm diameter South Feeder, Calgary’s largest and most critical feeder main. Shaganappi Pump Station draws water directly from the South Feeder and then effectively splits the flow, adds

hydraulic energy via pumping and redirects the water to north and south Calgary.

The existing Shaganappi Pump Station is over 40 years old and is past its useful life expectancy.

Many of the mechanical and electrical components within the existing pump station are now obsolete, creating operational and maintenance challenges.

Given the critical nature of this pump station and the extensive upgrades required to ensure efficiency and reliability, the decision was made to replace the existing pump station.

The new Shaganappi Pump Station, which is currently under construction, will be located approximately 200m west of the existing facility. This will allow the city to reuse much of the existing underground infrastructure, including the original piping connection to the 1950mm diameter South Feeder. This location was chosen to reduce construction costs, minimise disruption of the water system and surrounding communities and facilitate a smooth transition www.bpma.org.uk

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28 Water Supply between the existing and new facilities.

Calgary’s water pump stations are considered critical infrastructure and are designed with redundancy to allow them to continue to operate in an emergency. The existing Shaganappi Pump Station utilises natural gas engines to drive backup pumps in the event of a power outage. The new pump station will utilise a 944kW natural gas generator capable of starting and running one or more pumps in the event of a utility outage. The use of natural gas generators in new pump station installations offers an efficient, flexible and safe solution that meets the city’s critical infrastructure requirements.

THE CHALLENGE Establishing a strong working relationship between KSB Canada and The City of Calgary has been advantageous to both parties. The city issued a Request for Proposal (RFP) in late 2017, in search of a vendor to supply pumps and drivers for existing and new water pump stations. KSB Canada was the successful proponent in this stringent RFP process, which saw the contract awarded in May 2018.

The contract included the supply of pumps and drivers for the new Shaganappi Pump Station project, along with other projects such as the Palliser Drive Pump Station retrofit.

“The Palliser Drive project enabled us to demonstrate to The City of Calgary the capabilities and benefits of our Omega pumps”, reported Pasha Barazandeh, Regional Sales Manager at KSB Canada. “For this project, we supplied two electrically driven pumps and one natural gas engine driven pump to meet a pumping requirement of up to 60ML/d.

The city was pleased with this installation, and 12 months on, it continues to run well.”

While the Palliser Drive Pump Station project was underway, details for the new Shaganappi Pump Station were being finalised, and the pump supply was put into motion. The requirements for Quarter 3 2021

Shaganappi involved the supply of three large KSB RDLO 600-600 pumps rated at 80ML/d and three smaller Omega 300-560 pumps rated at 30ML/d to give a station design capacity of 220ML/d.

This allows for The requirements for Shaganappi involved the supply of three large RDLO 600-600 a total capacity pumps rated at 80ML/d and three smaller Omega 300-560 pumps rated at 30ML/d. of over 300ML/d with all six requirements to satisfy national and pumps in operation. However, such international standards relevant to a situation is not anticipated to the handling of potable water. happen. “For 80% of the time, only one of each pump type might be THE SOLUTION working at the same time, servicing Proven in many water applications two different pressure zones for around the globe, the RDLO and the water supply system,” explained Omega pumps were identified Pasha. as being more than capable of One of the key challenges for KSB meeting the customer’s specific Canada was the size of the natural demands. KSB’s axially split, gas generator at Shaganappi Pump single volute casing RDLO and Station. “The pumps’ configuration Omega pumps feature a doubleand power requirement had to entry radial impeller and are well be modified to meet and exceed suited to the requirement of the water pumping stations. They transport fluids with a minimum of flow resistance, thus lowering the energy and life cycle costs of the systems in which they are installed. CFD optimised hydraulic systems deliver the best duty point and give operating efficiency levels above 86%. The double entry impeller balances the duty condition. To meet this the axial forces, so the load on condition, we needed to modify the maintenance-free bearings the pump hydraulics to maximise is minimal. The combination efficiency for the most frequent of solid bearing brackets, a operating conditions,” continued short and rigid shaft and prePasha. “This led to delivering the loaded bearings guarantees low lowest lifecycle costs and optimum vibration and extended operating operating reliability.” life for the bearings, seals and The City of Calgary specifications coupling. Being axially split case stated that they required betweenpumps simplifies maintenance bearings, axially split case centrifugal procedures, enabling ready pumps. Other specific requirements access to all parts for thorough included suction and discharge inspection. The drive may be nozzles provided with integrally positioned on both the left cast flanges to ANSI/ASME B16.1, and right of the pump without the impeller trim diameter to be additional parts or modifications no more than 98% of the full size to the casing being necessary. chevron-circle-right and removable wearing rings on the impeller and casing. There www.ksb.com were also several specific material

The pumps’ configuration and power requirement had to be modified to meet and exceed the duty condition.

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IMPROVING LIVES.

FEATURE Protection 30 Bearing

Are your bearings protected?

With the ever-present drive to reduce energy use for both environmental and financial benefits, a growing number of pumping systems are employing variable frequency drives. However, their addition can cause issues elsewhere in the systems.

Bearing protection specialist, AEGIS, explains how shaft grounding rings can overcome these issues, allowing the benefits of variable frequency drive use to be realised and costly downtime to be reduced.

P

umps and pumping systems account for 25% of the energy consumed by electric motors in the United States. In pumping-intensive industries, this number is over 50%. And similar figures are seen elsewhere in the world.

To improve the efficiency of pumping systems and reduce their energy consumption, pump users are turning to variable speed or variable frequency drives (VFDs).

Since most pumping systems are designed for maximum service conditions (capacity and differential head), running them at partial load can save considerable energy. So, by precisely matching motor speed to pumping requirements, VFDs can reduce energy costs by as much as 30% or more.

However, while solving one problem, VFD’s can present another.

VFD-induced voltage on motor shafts can discharge through motor

Quarter 3 2021

bearings, causing pitting, frosting, fluting, and total bearing failure in as little as three months.

THE NEED FOR SHAFT GROUNDING Pump motor failures can cost hundreds of thousands to millions of dollars in repairs and lost revenues and can endanger public

Shaft grounding rings protect pump motors and the pumps themselves from VFD-induced bearing damage. health and safety. So, to ensure the reliability of VFD-driven pump motors and systems, bearing protection is needed.

Shaft grounding rings, such as those supplied by AEGIS, ensure the reliable, long-term operation of VFD-driven pumping systems by

dissipating shaft voltage before it discharges through the bearings.

When installed according to AEGIS’ best practices, shaft grounding rings protect pump motors and the pumps themselves from VFD-induced bearing damage and costly downtime.

CASE STUDY When a large midwestern US recreational centre experienced bearing fluting damage to several pump motors, the facility’s manager realised that he needed to install bearing protection on the centre’s VFD-driven motors.

Not sure what product to use, he decided to conduct a head-tohead test on two technologies – common mode chokes and AEGIS shaft grounding rings.

One motor was replaced with a new 7.5 HP 213 T-frame LEESON motor, and common mode chokes were added. A shaft voltage test measured over 10V – still high enough to cause EDM damage.

www.bpma.org.uk

Bearing Protection 31

Oscilloscope voltage profile of a bearing without shaft grounding (left) compared to a bearing with an AEGIS shaft grounding ring (right).

Then an AEGIS uKIT shaft grounding ring was installed, and a shaft voltage measurement was retaken.

The voltage was significantly reduced to less than 1V – too low to cause any EDM damage.

For the second motor, a 7.5 HP Baldor motor, the manager replaced the bearings and only installed an AEGIS ring. Again, the

voltage after the installation was less than a volt.

As the test data showed, there is no change in the shaft voltage by applying a common mode choke, and the motor is still in danger of bearing failure. A common mode choke only lowers the common mode current, which has little if any influence on the

shaft voltage and discharge bearing current.

Based on these results, the facility’s manager insisted that all new or repaired motors be equipped with AEGIS Shaft Grounding Rings before going into service. chevron-circle-right www.est-aegis.com

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FEATURESupply 32 Water

Keeping up with demand

Battersea Shaft Pumping Station serves the Thames Water Ring Main, a critical component in London’s water infrastructure. WEG explains how it supplied motor technology for this colossal vertical turbine pump, with support from Bedford Pumps.

T

he Thames Water Ring Main, formerly known as the London Water Ring Main, plays a critical role in supplying drinking water in the capital. Originally built between 1988 and 1993, the structure forms a 50-mile ring of 2.54m diameter concrete pipe. Primarily, this is used to transfer drinking water from water treatment plants in the Thames and Lea basins into the city.

The main ring lies between ten and 65m below ground level and passes through 21 wells that serve as supply, storage and pumping stations. One of these pumping stations is Battersea Shaft.

Battersea Shaft consists of a large 30-meter-deep vertical shaft containing six pumps that can supply multiple areas of London with drinkable water. However, increasing development in the city has made it necessary to remodel and replan the network to supply this new demand.

Due to rapidly increasing development in London, predictions suggest that there would be a significant shortage of drinking water capacity in the coming years. To accommodate a growing population, the station required additional pumping. This necessitated new equipment in the form of a pump, pump motor and variable speed drive (VSD).

With guidance from a team of experts, it was decided to replace one of the 30 mega-litre per day pumps with a new 45 mega-litre per day option, the maximum limit, due to physical limitations of the environment.

However, the real challenge of this replacement was due to the constant demand for drinking water in the capital. To minimise disruption, the pump needed to be replaced without stopping operations. This necessity had a major influence on the design

Quarter 3 2021

and construction of the pump, and the overall project itself.

It was decided that only the pump that needed to be replaced would be taken offline, enabling the rest of the system to continue operating as usual. However, detailed planning of the pump’s removal, installation, and commissioning was required to achieve this.

Pump supplier Bedford Pumps supported this entire process.

Through the company’s close

Detailed planning of the pump’s removal, installation, and commissioning was required. relationship with motor manufacturer, WEG, the team were able to replace the pump without having to resort to cuts in the supply to the London water network.

For this application, WEG engineers, along with Bedford Pumps, decided the best option was a water-cooled motor design.

The existing pump and motor had extensive fault detection instrumentation and a monitoring system. Therefore, the same range and functionality was installed in the new pump. In addition, due to the uniqueness of the location, the

replacement of any wiring between the electrical equipment and the pump was invasive and required downtime. Because of this, all new instrumentation had to be selected to be compatible with the existing wiring, further complicating the motor selection process.

Thankfully, WEG is an expert in delivering motors for unique pumping applications. For this application, WEG chose a 450kW Master Line water cooled induction motor. These motors stand out for the flexibility of their electrical and mechanical functionalities. What’s more, these designs are easily customised, making them interchangeable with already existing motors.

For the Battersea Shaft Pumping Station, WEG committed to achieving 96% efficiency performance.

Following completion of the project, during testing, this figure was not only achieved but exceeded with a greater margin.

Following completion in January 2020, the pump is now fully commissioned and in full service.

What’s notable is that designing the new equipment to work with existing infrastructure, together with detailed construction planning, massively minimised the installation period for the project. And crucially, avoided pumping station outages. chevron-circle-right www.weg.net www.bpma.org.uk

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

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Quarter 3 20 21

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FEATURE & Gas 34 Oil

Reliable sealing for carbon capture, utilisation and storage As oil and gas companies play their part in the race to meet global net-zero ambitions, an increasing number are working with Carbon Capture, Utilisation and Storage solutions. In this approach, sealing technology has a critical role, as John Crane explains.

A

ccording to the most recent report from the United Nation’s Intergovernmental Panel on Climate Change (IPCC), carbon dioxide (CO2) is the main driver of climate change around the globe. In 2020, global CO2 emissions were estimated by the International Energy Agency (IEA) at 33.4 Gt, and this is forecasted to increase in 2021 as global economies recover from the COVID-19 pandemic. To enable countries to meet their netzero ambitions following the Paris Climate Agreement, large-scale deployment of Carbon Capture, Utilisation and Storage (CCUS) technology and solutions are needed.

For decades, several oil and gas companies have implemented CCUS technology to trap greenhouse gas from natural gas operations, often as pilot or demonstration projects. The captured CO2 can be compressed and reinjected into geological formations or used for enhanced

Quarter 3 2021

oil recovery (EOR). However, since 2017, more than 30 CCUS facilities, most of which are large-scale in size, have been planned. Most of

Oil and gas companies must consider several factors when choosing the right sealing system. these projects are in the United States and Europe, with other projects underway in Australia, China, Korea, the Middle East and New Zealand – all with the potential of capturing more than 130 million tonnes of CO2 annually.

To safely handle and transport CO2 into EOR applications or underground storage, centrifugal compressors with non-contacting dry gas seals are typically used.

However, as interest in CCUS increases, CO2 applications face new challenges. Higher operating pressures, temperatures and faster

rotational speeds result in increased seal leakage, underscoring how essential the correct sealing system is for successful equipment operation and energy efficiency.

As a result, oil and gas companies must consider several factors when choosing the right sealing system for turbomachinery in CO2 applications. Selecting an appropriate sealing system will help reduce maintenance time, reduce energy consumption, lower total lifecycle costs and ensure peak performance.

Further, retrofitting CO2 capture equipment, outlined in the following examples, can extend the lifespans of existing facilities, enhance associated infrastructure and supply chains, and significantly reduce CO2 emissions.

AUSTRALIAN CCUS DESIGN A SUCCESS A 2016 joint venture of international oil and gas companies began a CCUS initiative off the Australian coast to address international www.bpma.org.uk

>36

FEATURE & Gas 36 Oil concerns about greenhouse gases.

The 4 MTPA CO2 injection project would capture CO2 from offshore gas fields and sequester it onshore more than one mile underground.

Project engineers found that reliably capturing and storing the CO2 presented the greenfield project with considerable compressor sealing challenges, including handling supercritical fluids and volatile temperature and pressure conditions.

Partnering with a well-known compressor manufacturer, seal manufacturer John Crane presented recommendations to address the CCUS challenges, including three CO2 compressor trains – each train equipped with two compressor strings driven by an electric motor and two gearboxes. Four non contacting tandem gas seals per compressor were included in the recommendation to handle the supercritical fluid, as well as seal gas panels that included heating units and other support systems.

Proper seal design was critical. A seal failure could shut down the CO2 injection plant, possibly preventing the operation from meeting the greenhouse gas reduction goals promised to the Australian government. The project injects up to four million tonnes of CO2 each year, reducing greenhouse gas emissions by approximately 40% and contributing 4% to Australia’s carbon reduction target.

The three compressor trains were brought online in sequence – the first in 2019. The tandem gas seals were installed in the compressors

by John Crane, and the site’s developers conducted the startup.

Engineers from both the CO2 injection site and the compressor manufacturer were familiar with the spiral groove face pattern of the seals as well as their noncontacting design that has been a turbomachinery standard since the 1970s. The seals were built to handle the supercritical CO2 fluid and the high pressure and speeds of the process.

Site engineers expected a long mean time between repair (MTBR) from the seals — the mating and Quarter 3 2021

primary rings of seals eliminate wear by maintaining sealing gaps of approximately 5μm/0.0002in during dynamic operation.

Since 2019, when the first compressor train went into operation, there have been no seal failures or repairs on any of the three compressor trains.

The LNG operation continues to operate without CO2 seal problems.

The high reliability of the seals is helping the operation keep its 40% greenhouse gas emissions reduction commitment – more than 100 million tonnes over the life of the injection project.

FIRST CCUS GETS SEAL OVERHAUL Operated by a multinational energy company, the world’s first offshore CCUS facility began sequestering CO2 in 1996. The North Sea operation captures and stores approximately one million tonnes of CO2 annually in a sandstone formation one kilometre beneath the

The seals’ 25-year reliability has helped the energy company sequester more than 25 million tonnes of CO2. ocean floor, using two compressors to pump CO2 into the formation.

Developed to reduce greenhouse gas emissions, the facility also helped the energy company use advanced recovery technology to extract natural gas from hardto-reach pockets. The centrifugal compressors operated at relatively low pressures and were equipped with tandem dry-gas seals.

For the next 16 years, the seals operated reliably and met the expectations of the CCUS managers. The non-contacting seals are designed with a patented spiral groove pattern, maintaining the same sealing gap between the mating and primary rings as the Australian example above.

During planned maintenance in 2012, the tandem seals were refurbished at a John Crane facility

to ensure a prolonged working life. The facility was equipped with standardised testing, grooving and spin-test gas seal equipment readily available, including CO2 compression.

Since the overhaul in 2012, the seals have worked without failure or repair – a MTBR record of almost ten years. The seals’ 25-year reliability has helped the energy company sequester more than 25 million tonnes of CO2, the oil and gas platforms work at optimum levels, and the company has avoided millions in potential financial penalties.

CONCLUSION Even though energy companies have performed enhanced oil recovery with carbon dioxide for decades, the oil and gas industry faces new supercritical CO2 application challenges.

However, choosing the right seal technology or retrofitting existing CO2 capture equipment will help reduce maintenance time and costs and ensure peak operational performance.

By accounting for the unique sealing requirements and properties of CO2 at supercritical conditions, oil and gas companies can reliably use CCUS technology to trap millions of tonnes of CO2 from natural gas operations. chevron-circle-right www.johncrane.com www.bpma.org.uk

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FEATURE & Gas 38 Oil

Repair and optimisation of water injection pumps

Offshore oil fields need to optimise productivity to remain profitable, and this often means that water injection pumps are used to increase the speed of oil recovery.

These high energy pumps need to deliver reliable performance from day one, so when a Norwegian offshore platform required expert support to repair two pumps, it called on Sulzer’s design and manufacturing expertise, as flow discovered.

O

il and gas continue to form the building blocks of our essential everyday items. As these resources become more difficult to reach, oil producers need to optimise the efficiency of their processes.

The Scandinavian oil platform has operated two BB5 water injection pumps for over ten years, but they have suffered from rapid wear and high vibration. The original equipment manufacturer had delivered several upgrades, but there was little improvement in either performance or reliability. There were also long periods when there was no water injection capacity, which severely impacted oil recovery rates. To help resolve this, the operators decided to approach Sulzer for a solution.

RETROFIT OF EXISTING PUMPS Initial discussions led to an offer to investigate the spare pump cartridge, which had also exhibited the same symptoms of vibration.

Sulzer took the cartridge to its Stavanger Service Center and dismantled it. The engineers discovered that the main shaft had rotodynamic issues, which caused the vibrations, and that this fault had been an issue from new.

To restore the water injection capability of the platform with minimal delay, Sulzer suggested, in the short term, that the cartridge should be replaced with a hybrid component. This would fit precisely into the existing barrel of the pump on the platform and enable the first pump to operate.

Sulzer did not manufacture

Quarter 3 2021

the pump in question, but this would pose no problems for the project because it can apply its expertise to equipment from any manufacturer.

Over the next six months, the new hybrid cartridge was manufactured.

Together with the onsite maintenance provider, Sulzer engineers installed and commissioned the water injection pump and returned the platform to normal operations.

NEW PUMPING ASSETS In the meantime, Equinor had decided to replace both of the original water injection pumps with new assets designed and manufactured by Sulzer. Sulzer began manufacturing the new injection pumps, which would be installed during separate, planned maintenance windows. The projects were carefully coordinated to ensure the pumps were delivered on time, together with other auxiliary components, to meet the installation program set out by Equinor.

Oddvar Holta, Project Manager for Sulzer, said: “The greatest challenge has been the very short delivery time on the hybrid cartridge, which would normally have taken ten months. We have managed to streamline this process and meet the objectives of our customer, getting the water injection pump up and running on time.”

ADDITIONAL ENERGY SAVINGS However, the story continues; having manufactured the new pumps to match the specifications of the original components, and after the first one had been installed, a change in site conditions prompted the decision to reduce the operational head of the new pumps to reduce energy consumption and CO2 emissions.

This required the pumps to be de-staged, removing four of the original eight impellers in cartridge A and two impellers in cartridge B. The design engineers in Leeds created the necessary drawings for the transition tubes, which were manufactured at the same site.

Once complete, engineers from Sulzer travelled to the platform, removed the impellers that were no longer required, and installed the new components.

Pump A achieved a power saving of 2MW, which equates to 5,536 tonnes of CO2 per year. Similarly, Pump B’s power consumption was reduced by 1MW, saving 2,768 tonnes of CO2 every year. chevron-circle-right www.sulzer.com www.bpma.org.uk

Pioneering for You

GOING BEYOND THE OBVIOUS Wilo - Going Beyond Pumps Our innovative solutions, smart products and individual services move water in an intelligent, efficient and climate-friendly manner. We are also making an important contribution to climate protection with our sustainability strategy and in conjunction with our partners.

As a result, we’re going beyond pumps and using our cutting-edge technologies, innovative applications and strong expertise to develop products that can be integrated into complex systems. We also help you with analysis, provide individual consultation and recommend tailored and cost-effective solutions.

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NEWS & Gas 40 Oil

Wellbore pump for light and heavy duty LFH ENGINEERING HAS INVESTED £250,000 to develop a specialist pump for the oil and gas industry.

Having successfully met the demands of the world’s leading diesel engine manufacturers for the past ten years, LFH Engineering has now launched a wellbore testing transfer pump system for the oil and gas industry.

The LFH-1000 electric driven centrifugal pump improves flow performance and solids management processes, overcoming many operational difficulties associated with traditional pump systems.

The compact design can be mobilised quickly and takes up less space than olderstyle pumps. Furthermore, the centrifugal design maximises fluid recovery and maintains a constant flow rate. The pumps are designed to cope with a wide range of fluid transfer applications.

Commenting on the new system, Les Hill, CEO of LFH Engineering, said: “Pumps are what we do – and in particular pumps which are designed to safely withstand extreme pressure, temperature and vibration, all of which are seen in the oil and gas environment.

“Our design calculations determine the pumps capability to withstand a 10g shock load which is necessary for the nuclear industry, so we can ensure the

performance we offer is fit for the most demanding working conditions.”

Neil Williamson, Business Development Manager, added: “The LFH-1000 has been under development for several years with input from major well service companies, and we are now in discussion with oil and gas operators and contractors to utilise our pump unit either on or offshore “By working closely with a customer, LFH can make minor adjustments to ensure optimum performance. LFH applies detailed finite element analysis to ensure

pumps are capable of performing at peak productivity.

“This is a very exciting time for LFH as we are confident that we have designed and built a pump system which is truly unique and meets the needs of a wide variety of offshore and onshore situations.”

The Zone 1 electric driven centrifugal pump unit is ATEX and DNV 2.7-1 certified and can handle 11,500 barrels per day (21.2 litres per second) at 33.7 bar. www.lfhengineering.com

EXPLOSION-PROOF AND SMART KSB IS OFFERING ITS CUSTOMERS MONITORING solutions for pumps and other rotating equipment used in potentially explosive atmospheres.

The KSB Guard smart monitoring solution is designed for monitoring already installed pumps and is ideal for retrofitting – regardless of pump make. A sensor unit – comprising a vibration sensor and a temperature sensor – attaches to the pump’s bearing bracket and/or drive lantern or to other rotating equipment to record the relevant data.

The transmission and battery unit wirelessly transmits the measurement data to a gateway which, in turn, transfers the data via encrypted mobile communication to the KSB Cloud.

This is where the data is evaluated and processed. The user can then view the information in the KSB Guard app and on the KSB Guard web portal.

A new feature of the KSB Guard solution is the use of ATEX-certified hardware. The recently launched KSB Guard ATEX gateway is supplied in a flameproof enclosure. The external antennas can be screwed on directly or positioned elsewhere via an extension cable if necessary. The KSB Quarter 3 2021

Guard ATEX sensor unit and KSB Guard ATEX transmission and battery unit are intrinsically safe (Ex-i). Both solutions are also suitable for outdoor installation thanks to robust lithium thionyl chloride batteries with a service life of five to eight years in conjunction with 60-minute measurement intervals. www.ksb.com www.bpma.org.uk

DO YOU MAKE, SELL, INSTALL, REPAIR OR ASSEMBLE PUMPS AND SYSTEMS? BPMA membership offers a wealth of information, advice and opportunities designed to help your business thrive.

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Tender alerts Free commercial, health & Safety and legal advice Free and discounted technical and market insight guides Expert advice on standards, legislation and technical issues Discounted training Energy auditing Discounted insurance UK and EU representation at political and executive levels Exclusive promotional opportunities Valuable networking opportunities

Visit the BPMA website, call or email for more details

www.bpma.org.uk • +44(0)121 601 6692 • g.wilde@bpma.org.uk

FEATURE Protection 42 Bearing

Keeping the world in motion – sustainably

Morten Wierod, President at ABB Motion believes high-efficiency motors and drives are central to the world’s invisible climate solution.

I

n July this year, the EU Ecodesign regulation 2019/1781 for low-voltage induction motors and variable speed drives came into effect, paving the way for millions of motordriven applications to reduce their energy consumption.

Although electric motors consume about 45% of global electricity, they are often not seen while in use. The issue is that too many motor-driven systems in use are inefficient, which is why ABB is working with customers, partners, academia and governments to raise awareness of just how much energy high-efficiency motors and drives can save. Solutions available from ABB today surpass the regulatory demands that recently came into effect and those scheduled for July 2023, when the Ecodesign regulation expands further.

THE INVISIBLE NETWORK AROUND US “Electric motion touches your life several times a day, even though you’re not aware of it,” explains Morten. “Motors and drives are ever-present, from ensuring that clean water reaches your home and running trains, to building, construction and the production of the food you eat.

“So, all around us, and across the world, there are more than 300 million motors, drive systems and sub-systems that are installed, enabling the quality of life that we all want.”

ENERGY EFFICIENCY IN A BOX “The electric motor uses and controls electromagnetic fields to create the movement to make it turn. The variable speed drive is

Quarter 3 2021

probably less well known in the general public, but I call it a box of energy efficiency. Inside the box sits power semiconductors and electronics used together with software to create the correct speeds and torque to control the motor, a much more efficient method than the previously common practice of using brakes to control the speed.

“In that way, you’re able to save from 25 to 40%, even 50% of energy compared to running a motor at full speed as we would do without any speed control.”

WHY THE EU ECODESIGN REGULATION IS IMPORTANT One of the key elements to achieve sustainability goals and targets in cities is energy efficiency, which can be significantly impacted by motor and drive technology.

President of ABB’s Motion business, Morten Wierod.

“I believe industrial energy efficiency has the single greatest capacity for combating the climate emergency” “I’m happy to see good progress with the energy levels of what we call IE3 being valid from July 1st 2021 and moving to IE4, which is the next level of energy efficiency in 2023. But we can do much more because new technologies are already available.” Indeed, ABB has motor and drive solutions that meet the IE5 efficiency class – the highest level of efficiency met by any design to date.

“During 2020, ABB’s installed base of high-efficiency motors

and drives enabled 198 terawatthours of electricity savings, which is more than three times the total annual consumption of Switzerland.

By 2023, it is estimated that the expansion of our installed base of motors and drives will help customers save an additional 78 terawatt-hours of electricity per year – more than the annual consumption of Chile.

“I believe industrial energy efficiency has the single greatest capacity for combating the climate emergency. It is essentially the world’s invisible climate solution.

With high-efficiency motors and drives that power most of the critical process around us, we can keep the world turning while saving energy every day.”

Morten Wierod’s comments were taken from the ABB Decoded podcast titled “How ABB motors and drives help keep the world sustainably in motion”, which can be accessed at bit.ly/ABBDs1e7 www.bpma.org.uk

It’s time to prepare your winning entry for the 2022 Pump Industry Awards!

PUMP INDUSTRY AWARDS 2022

EVENT CALENDAR

Since launching two decades ago, the Pump Industry Awards have grown into one of the leading industrial awards programmes, recognising and rewarding the achievements of pump businesses, large and small. If you or your company have a success to shout about, these awards provide the perfect platform.

Throughout the pandemic the pump sector played a key role in ensuring that utilities, manufacturing processes and essential services were maintained, and so for the 2022 award programme special recognition will go to those companies and individuals who have gone that extra mile to meet any additional demands and challenges brought about by Covid-19. Visit the website for the full list of categories.

The annual gala presentation dinner caps off the awards programme in style, and as always there will be excellent networking opportunities, great food and superb entertainment.

It’s your chance to celebrate with colleagues, re-connect with peers and be part of the pump industry’s biggest and best celebration; put the 24th March 2022 in your diary now.

The 2022 Call for Nominations opens on the 27th September, so be sure to visit the Pump Industry Awards website to review the award categories and decide which ones you will be entering!

NOMINATIONS OPEN

27th SEPT 2021

NOMINATIONS CLOSE

7th JAN 2022

JUDGING SESSION

25th JAN 2022

FINALISTS ANNOUNCED

3rd FEB 2022

WINNERS ANNOUNCED

24th March 2022

at the Chesford Grange Hotel, Warwickshire

Richard Harden, BPMA President, says of the Pump Industry Awards, “The pump industry continues to be a hotbed of competitiveness, where the constant search for greater operational performance and improved efficiencies amongst its broad customer base, demands all those operating within this important sector to be at the top of their game.

This BPMA backed awards programme allows the pump industry to come together in celebration of that drive for engineering excellence.”

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44 FEATURE

great outdoors With an overhead weather shield, an ip66 weatherproof case and ip55 rated motor enclosure, our Outdoor Design Envelope pumps performs at the highest energy efficiency – whatever the weather.

armstrongfluidtechnology.com Quarter 3 2021

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