Quarter 3 2022 InnovationsPump Industry News Applications Expert Opinion Embracing hydroelectric power with pumps as turbines insightindustryPumpfrom To andaffinitybeyondFOCUSON:Chemical& pharmaceutical
New E-SPD+ Our new generation air-cooled inverter, ESPD+, can be installed on the pump motor terminal board and it significantly extends the range of applications and functionalities. • Highly flexible • Versatility of design • Innovative LCD display • System protection against overcurrents • Easy installation and programming • Connectivity provided by 4 configurable digital inputs, 2 configurable digital outputs, 2 analogue 4-20 mA inputs, 1 0-10V input, and 1 input for PTC. www.ebaraeurope.co.ukScantheQRcodetofindoutmore!
In the following pages you will find many examples of how the sector’s response is reaping rewards, despite the hurdles it has faced. Companies are expanding and investing in their facilities while others are hiring to deal with increased demand. New products and solutions continue to be developed to tackle existing and emerging issues. Technology advances are supporting the global need to tackle climate change. And throughout this, the membership of the BPMA has continued to grow, now standing at its highest ever level.
It has been a pleasure to work with my colleagues on the council and the team managing the association – Steve Scofield, Steve Smith and Gary Wilde – as we shaped the direction of the association to ensure it supported the interests of its members while championing this important industrial sector.
please email circulation@flowmag.co.ukThecontentofflowmagazine 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.
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Editor
Quarter 3 2022www.bpma.org.uk CONTENTS 3
It’s fair to say the last four years have been challenging. Whether you support it or not, Brexit has brought with it many tests for businesses. Then there was a global pandemic which nobody could have prepared for. And more recently, we have the impacts of the conflict in Ukraine. But as President, I have seen how the liquid pump sector has responded. It hasn’t been easy, far from it, but the association’s members have risen to the challenges – demonstrating resilience, adaptability and innovation. Something we should all be very proud of.
Publisher
Accounts Touchwave Media Ltd accounts@flowmag.co.uk
So, as I step away from my role, I feel confident that the sector, and the association that represents and supports it, have a bright future ahead, and I wish those who will continue to drive the association forward all the best.
his is my last welcome letter for Flow magazine as President of the British Pump Manufacturers’ Association (BPMA). With my four-year term of office drawing to a close, I will pass the baton to KSB’s Dale Croker at the association’s AGM in November.
Contributing
Suzanne Gill suzanne@flowmag.co.uk Andrew Castle andrew@flowmag.co.uk 07785 290034
Production G and C Media Ltd production@flowmag.co.uk over three-quarters of a century the British Manufacturers’
Richard Harden, President, BPMA
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
Chris Callander chris@flowmag.co.uk 01732 671123
Editor
Pump
Association (BPMA) has been serving the interests of UK and Irish suppliers of liquid pumps and pumping equipment. BPMA National Metalforming Centre 47 Birmingham Road WestB70Bromwich6PY www.bpma.org.uk BPMA Update PUMP INDUSTRY NEWS Features Chemical pharmaceutical&OPINION PRODUCT NEWS 34 Ensure a quality motor repair 8 New compact boosting system 9 Two new products from KSB 6 New members, new venues and more 4 WEG builds new factory in Europe 5 Calpeda joins Wateralia 16 Saving the higher cost of hire costs 18 The year the earth stood still 20 To affinity and beyond 22 Embracing hydroelectric power with pumps as turbines 24 Supporting hydrogen production for decarbonisationlong-termstrategies 28 Ex Repairs: the knowledge and skills required 30 Improve tanker unloading 32 Pump retrofit eliminates annual maintenance cost Twitter @bpmapumps Projects 12 Peristaltic pump upgrade delivers savings Awards update 10 Nominate your winners PEFC/16-33-254 PEFC Certified This product is from managedsustainablyforests and controlled sources www.pefc.org
For
Now, WEG is constructing an additional 22,680m2 factory at the Santo Tirso site to support the manufacture of MV/HV motors and drives, LV electrical panels and the provision of the corresponding servicing activities on the shop floor as well as on site. The project will see the transfer of the Maia factory to the new plant in Santo Tirso, centralising all operations to a single site.
Mark Abbott, Technical Account Manager, commented: “For me, Houghton International was the obvious organisation to join. The depth of experience and capability of the team and facility is complemented by a clear record of continual innovation. Coupled with a mission statement to ‘be the best in the world at what we do,’ it’s clear that Houghton International is a market leader in the electromechanical services field.”
Among the additions at the new factory is a substantial investment in a new testing laboratory. The space will be suitable for full-load testing to meet the new portfolio of products from WEG, and will continue to enable customers to remotely monitor tests in real time.
From his many years of working with virtually all sectors of the South African and sub-Saharan industrial landscape, Mark’s career has given him in-depth knowledge of a wide range of sectors, including rail, mining, industrial, manufacturing, utilities and power generation. Mark will now be applying his experience as part of the Houghton International team to help owners and operators of motors, generators, pumps and all rotating machines to improve the efficiency and reliability of their assets.
INDUSTRY NEWS4 Quarter 3 2022 www.bpma.org.uk
“Our plans are based on the WEG Manufacturing System (WMS), a programme WEG follows to continually improve the way we manufacture,” continued António. “This philosophy helps us to eliminate waste and achieve the best possible efficiency. In fact, we employ the WMS model throughout our entire business, including our offices. The upcoming investments in Santo Tirso follow this way of thinking and will make us more resilient for decades to come.”
The investment will also increase production capacity to IEC 1400 frame size
electric motors and equivalent MV/HV drives. This is in addition to specialist flameproof, smoke extraction and marine motors, engineered automation solutions, as well as the range of WEG digital and automation tools such as Motion Fleet Management (MFM).
WEG builds new factory in Europe
GLOBAL MOTOR MANUFACTURER, WEG, is undergoing a substantial project to expand the size and capabilities of its European production facility. New investment will see WEG double the size of the manufacturing site in Portugal, hire 100 new employees and create what it believes will be Europe’s most complete testing laboratory for medium voltage (MV) and high voltage (HV) motion drives (electric motors and drives).
robots, and the creation of an automated vertical warehouse for the picking of smaller parts and products.
WEG Portugal, registered as WEGeuroIndústria Eléctrica, S.A., has been the heart of the company’s European production of electric motors and MV/HV drives since its inception 20 years ago. Currently split across two sites in Maia and Santo Tirso in Portugal, the facilities manufacture over 10,000 motors annually, deliver to over 50 countries on five continents and employ over 750 people.
The construction of the second factory in Santo Tirso is currently underway and is expected to be fully operational by 2024. The transfer will be initiated during 2023 and will be gradual, ensuring no impact on production or deliveries.
ELECTRO MECHANICAL ENGINEERING specialist, Houghton International has appointed Mark Abbott as its new Technical Account Manager. With over 30 years experience, Mark will be expanding Houghton International’s presence across the UK, helping to support customers in the south of England with their needs related to the maintenance, repair and life extension of their electromechanical equipment.
“WEG has long believed in the importance of manufacturing products locally to the market where they will be sold,” explained António Duarte, Managing Director of WEG Portugal. “The new investment will significantly improve the site’s manufacturing capabilities, our flexibility and time-to-market, and reinforces our continued commitment to the European market.”Thenew factory will also see WEG intensify its use of robotics and automation, with planned incremental investments for years to come. These technologies include automated guided vehicles (AGVs), six-axis
HOUGHTON INTERNATIONAL APPOINTS TECHNICAL ACCOUNT MANAGER
Chris Robson, Sales Director at Houghton International, commented: “As industries return to full capacity and confidence grows post-covid, we are seeing rapidly increasing demand for our services. As this demand continues to grow, Mark is the perfect fit to help increase our reach across the UK. He draws on a wealth of knowledge and experience to help customers find the right solutions to their problems and keep their machines running better, for longer. I am confident Mark will be a real asset to our business and our customers.”
Through this synergic acquisition, Wateralia will further expand its product range and commercial reach and operate in a large global market, estimated to be worth over €21 billion. With an integrated business model and almost 1,000 employees, Wateralia will count 24 international subsidiaries with a direct presence in 19 countries, a comprehensive product range of around 7,000 SKUs and almost 10,000 customers in various sectors, among water infrastructure, industry, agriculture, domestic and residential, and building services.
Quarter 3 2022 INDUSTRY NEWS 5
MONTHS2
Calpeda joins Wateralia
After a tough two years for the events sector, the 2022 staging of the event saw 2,811 visitors (excluding exhibitor staff) attend over the two days, representing a 15% increase from CHEMUK 2021. Recognising the substantial internal marketplace characteristic of the industry, the combined two-day attendance, including exhibitors, was recorded at 4,044.
Commenting on this year’s hugely successful CHEMUK 2022, Ian Stone, MD of UK Industry Events, said: “With attendance numbers significantly up again, and with such an incredibly diverse attendance of industry professionals spanning the broad chemicals, chemical products & chemical user-industries, CHEM UK 2022 further reinforced its position as the must-attend event for the sector.”
Visitor registration will open in January 2023 when further details of the conference progamme will also be announced.
CHEMUK 2022 RECORDS A 15% INCREASE IN ATTENDANCE AS 2023 DATES CONFIRMED
www.chemcialukexpo.com
THE DATES FOR CHEMUK 2023 HAVE been confirmed, with the event set to take place at the NEC in Birmingham on May 10 and 11 next year.
Exhibitor stands are available to book now, via the event website. However, space is selling quickly, so anyone interested in exhibiting is advised to book soon.
The BPMA is one of the headline industry partners to the CHEMUK event, supporting the Chemical, Process & Plant Engineering Show Zone. Many BPMA members exhibited and sponsored the show, including ABB, AESSEAL, Apex Pumps, Atlas Copco, AVT Pump, Crest Pumps, Flowserve, Grundfos Pumps, Tomlinson Hall, and Watson Marlow.
Ambienta, one of Europe’s largest asset managers focused on environmental sustainability, has announced that Calpeda, a global manufacturer of pumps, motors and systems for the integrated water cycle, is joining its platform company Wateralia. With the industrial integration between Calpeda and Caprari, whose acquisition was completed in 2021, Wateralia aims to become one of the largest independent European players in the electric pumps and pumping systems industry.
Founded in 1959, Calpeda has a broad product portfolio, mainly focusing on centrifugal pumps, multistage pumps, submersible and borehole lines, as well as self-priming and peripheral pumps. With two Italian production sites, 14 international subsidiaries and almost 500 employees, Calpeda is a global water pumps and systems brand selling its products in more than 100 countries. The company, with its strong commitment to research and development, has a leading role in promoting a sustainable growth of the water industry.
Looking forward, a new venue has been secured for the 2023 Pump Industry Awards, which will take place at the Hilton at St George’s Park in Burton on Trent on March 16. Situated on the edge of the National Forest, the impressive hotel is part of St. George’s Park – the training ground for all 28 English national football teams – and is recognised the World over as the home of English football. Nominations are being sought for the award’s eight open categories, with the entry deadline set for Friday, January 6, 2023. Details can be found on the award’s dedicated website, www.pumpindustryawards.com
Finally, the association’s AGM will be held on November 10 this year at the Wychwood Park Hotel, Crewe. Alongside
NEW MEMBERS, NEW VENUES AND MORE
The association recently published its 2022/23 buyers’ guide and directory. The annual publication contains information about BPMA activities, useful articles, UK pump market data, and details of products and services that its members offer. It is an invaluable resource for anyone looking to source equipment for pumps and pumping
Regal Rexnord offers a wide-ranging product portfolio of expertly engineered components and systems, including couplings, bearings, motors, gears and chain, with many historic brands making up this extensive product offering.
Founded in 2003, Lincoln Crankshaft & Machine manufactures precision heavyduty rotating parts, including industrial crankshafts and rotor shafts for missioncritical applications in oil, gas, energy, transport and industrial applications.
The company’s submersible pumps can be used for clean or dirty water pumping projects and can be applied underwater and in various demanding environments, such as mines, quarries and tunnels.
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systems, and a copy can be ordered, free of charge, via the BPMA website at bit.ly/BPMABG
The popular BPMA annual golf day took place in September. Held at the stunning Vale Resort in Glamorgan, the Welsh National course produced a challenge for the teams. A team from Grundfos took the overall prize, pipping a team from Stuart Turner to the top spot. The association’s own Steve Schofield won the nearest the pin competition while ABB’s Dave Hawley achieved the longest drive of the day.
FEATURE6 www.bpma.org.ukQuarter 3 2022 BPMA Update6
hree new members have joined the British Pump Manufacturers’ Association since the last issue of Flow magazine, achieving the largest membership in the association’s history.
UPCOMING TRAINING FROM THE BPMA Date Course title Duration Location 14-15 September 2022 BPMA Pump Repair & Maintenance 2 days West Bromwich 15 September 2022 ATEX Workshop 1 day West Bromwich 24 October 2022 Pumping Fundamentals 1 day Online 25 October 2022 Pump Systems 1 day Online 26 October 2022 Pump Selection 1 day Online 7-10 November 2022 Certified Pump Systems Auditor (CPSA) 4 days West Bromwich For more information or to book any of the courses listed please visit www.bpma.org.uk/lectures *All classroom-based training is scheduled subject to the COVID-19 restrictions in place at the time.
and a presentation on the issues affecting industry post Brexit from BEIS, there will be a report on BPMA’s 2021/22 activities. Also at the AGM, Richard Harden of Stuart Turner, the association’s current president, will be retiring after four years in the role, and Dale Croker of KSB will be appointed the new BPMA President
Kent-based Euroflo Fluid Handling has provided expert industrial drainage, dredging and sewage pump services throughout the UK & Ireland since 1996.
YEARS6.5 +353 (0)44 934 company/patterson-pump-ireland-ltd7078www.ie.pattersonpumps.comsales@ie.pattersonpumps.com
Patterson
Pump Ireland is a complete pump manufacturer, offering our customers some of the most reliable pumping solutions available. Our fire pumps stand over life and property throughout the world. Reduce on-site labor time, engineering and installation time and associated costs. Choose a system that arrives on-site in a fully enclosed ready for use pump house. This pre-engineered pumping system saves time and money for our customers. warr anty guara2nteed y e a r
FIRE
HORIZONTALPUMP SPLIT CASE (HSC) FIRE END-SUCTIONPUMP FIRE IN-LINEVERTICALPUMP FIRE TURBINEVERTICALPUMP
When the pressure is restored, the flow sensor will detect the lack of water flow and stop the pump until the next system start. The Wilo-Isar BOOST5 also provides protection against dry running, thermal protection against motor and inverter overheating and electrical protection against sudden changes in voltage and current.
Designed for use where accurate, low flow dosing or transfer pumps are required for either intermittent or continuous dosing, the pump has a high tolerance to aggressive chemicals (0-14PH).
controls, supporting low power consumption and operating costs.
Fully sealed joints maximise life and minimise downtime, while packing, single, and double mechanical seals are available in various materials to support the most corrosive applications.
Water pressure can also be affected by extended pipe runs within larger properties, or the location of a building, such as being situated on top of a hill. Buildings in busy cities also experience issues with water pressure due to higher water usage and
www.wilo.co.uk
The new booster system is an energy and cost-efficient option, thanks to its smart sensors, efficient hydraulics and demand-sensing technology. This means the system automatically adjusts its speed to the requirements within the property, only providing an extra water boost when required.
When the pressure sensor detects a drop in the system, the electronics start
Thanks to its efficient hydraulic design and insulated casing, the system runs smoothly and quietly.
The simple and intuitive control panel also means users can easily manage the pressure output and monitor the operating status, including error messages.
www.nov.com
NEW COMPACT BOOSTING SYSTEM
The Low Flow Metering Range Pump includes enhanced element offerings with improved precision metering control technology, reduced break-out torque, and good slow-speed performance. These elements help to expand the scope of metering applications while still supplying each fluid with a smooth, pulsation-free flow.
The advantages of the Low Flow Metering Range Pump include the ability to handle abrasives, corrosives, solids in suspension, and viscous fluids. The pump can work with pressures up to 300 psi or 24 bar, and the pressure capability is independent of speed. It is self-priming and has a high suction lift capability with a low shear pumping action and no valves to clog, stick, or vapour lock. The design is also compatible with integral variable frequency drives and motor
Quarter 3 2022 www.bpma.org.uk Product News8
Constructed of the most dependable materials, most of the pump components are supplied in stainless steel. The suction chamber is manufactured in high-density polyethylene, while the end cover and mechanical seal housing are made of polyvinylidene fluoride. For severe chemical environments, internal pump components can be supplied in Hastelloy.
increased flow demand, often with insufficient infrastructure to deliver the required flow and pressure.
The use of different stator materials enables the pump to be used for a wide range of applications and products, including acids and alkalis, wastewater chemical injection, chemical processing for various industries and the pharmaceutical industry.
Gearbox and motor options include close coupled, long coupled, synchronous speed motor, fixed speed gearbox, and frequency inverter.
WATER PUMPS AND PUMP SYSTEMS manufacturer, Wilo UK, has announced the addition of a new compact water boosting system to its residential and light commercial product portfolio: The Wilo-Isar BOOST5.Thenew Wilo-Isar BOOST5 is a compact, plug-and-play solution that uses multistage, self-priming and automatic pressureboosting technology to offer a solution to combat fluctuating or insufficient water pressure. The system guarantees constant pressure for domestic water supply in large domestic settings, as well as smaller nonresidential amenities, businesses and small sports
Wilo’s solution to this is the Wilo-Isar BOOST5, a new pressure-boosting system that provides buildings with the ideal water pressure at every outlet at all times.
the pump to restore the set-point pressure. The inbuilt inverter varies the speed of the pump, regulating the hydraulic performance according to the specific demands.
ACCURATE, LOW FLOW DOSING AND TRANSFER
Manyfacilities.factors can have a negative effect on the water pressure within a property, including using a lot of water at the same time. Running things like a shower, a garden hose and a washing machine can all decrease the pressure in a property as a result of combined higher flow demands.
NOV HAS EXPANDED THE AVAILABILITY OF ITS LOW FLOW Metering Range Pump, which offers optimised process times, lower operations costs, and minimised downtime.
The Wilo-Isar BOOST5 system offers easy installation thanks to its plug-in design, and its LED display and simple button controls make it simple to operate for the end-user. Comprehensive built-in protection features guarantee safe operation and peace of mind. The system is also made of a corrosion-resistant technopolymer, guaranteeing a long service life.
Designed using the latest numerical software and proven by extensive testing, the volute casing incorporates the optimum shape and cutwater clearances whilst the impeller has the perfect combination of number, depth and shape of vane for maximum efficiency. All components are machined from solid thermoplastics such as polypropylene or PVDF for added strength and consistency.
The booster set is fitted with two fully redundant pumps, each with its own power and control circuit. The redundant control systems continuously monitor pressure switches and limit switches for broken wires and short circuits. Motor and dry running protection are disabled in the event of a fire, making sure the pumps do not stop before fire fighting ends. The master switch and valves are secured against unauthorised operation. If one of the pumps fails, the redundant control system takes over and starts up the second pump. This provides a high level of safety for the operator, the buildings to be protected and the infrastructure.
Product News 9 Quarter 3 2022
TWO NEW PRODUCTS FROM KSB
The open impeller design allows for some passage of solids, while the improved hydraulic design ensures excellent performance in low NPSH applications as well as minimal mechanical vibrations, ensuring a longer life between service intervals.
PUMPS, VALVES AND SERVICES specialist KSB has recently launched two new product series.
The break tank ensures that drinking and fire-fighting water are hygienically separated to EN 1717 type AB. The net tank volume meets the 3% rule stipulated in the standard.
www.ksb.com
The body is made of EN 1.4409 stainless steel, a material that is particularly resistant to chlorinated water and suitable for drinking water. To keep the fluid handled clean, the body is designed without dead volume, preventing deposits in the valve. Nominal sizes range from Rp 1/2in- 3in.
The EOV features an enhanced vane design that improves efficiencies by up to 35%, so that flow rates and discharge pressures are improved on each model.
The new corrosionresistant EOV centrifugal pump range from Crest Pumps gives users a performance increase of up to 15% whilst consuming up to 20% less power when compared to the previous ECC range.
Through its subsidiary, SISTO Armaturen, KSB has launched the SISTO-16RGAMaXX diaphragm valve type series, featuring threaded sockets, a stainless steel body and a special drinking water diaphragm.
The Hya-Duo D FL-R pressure booster system has been designed to conform with DIN 14462 and uses only one main fire-
The confined and supported diaphragm maximises service life and is designed for a pressure of 16 bar. It is made of high-quality elastomer (EPDM/W270) and meets the German Environment Agency’s requirements on plastics suitable for drinking water applications (KTW-BWGL). The valves cover a temperature range from
fighting pump to supply hydrants installed above floor or under floor with up to 192 cubic metres of fire-fighting water per hour.
The first addition from the company is a series of future-proofed diaphragm valves for drinking water.
Corrosion resistant pumps
The second new launch is a fully automatic break tank package booster set for fire fighting applications.
Since the threaded stems for actuating the valves are not in contact with the fluid handled, they will continue to deliver smooth operation, even after many years of use.
-10 to +90°C. This means the type series is also highly suitable for thermal disinfection.
www.crestpumps.co.uk
Once again, we have secured support and backing from a host of leading brands, all of whom recognise the value and importance of promoting excellence across the sector. In addition to our main category sponsors, other sponsorship options are available to help support specific elements of the 2023 presentation evening. Several opportunities still exist, so please get in touch if you would like your brand aligned to outstanding engineering achievement.
Long-time supporter, Marek Lukasczcyk, European & Middle East Marketing Manager at WEG (UK) Ltd, added: “It has always been a pleasure to support the BPMA and the wider pump industry by sponsoring this long-standing and prestigious event, which helps promote engineering excellence. The evening is always a great success and thoroughly enjoyed by everyone, and we look forward to another superb event in March next year.” chevron-circle-right
He continued:” Business and professional excellence deserve to be acknowledged and celebrated, and the Pump Industry Awards do just that. So, I would again encourage all those involved in the pump sector to prepare and submit their entries for the 2023 awards programme.”
• Project of the Year - Sponsored by Stuart Turner
This recognition and acknowledgement will be represented by nine award categories that collectively honour the full breadth of product and service delivery by the pump industry:
• Contribution to Skills & Training –Sponsored by Crest Pumps
The online entry forms, which seek submissions for activities and achievements that took place in the 18 months up to December 2022, are now available on the dedicated awards website –compumpindustryawards.www.–withtheentry
Steve Schofield, Director and CEO at the British Pump Manufacturers Association,
• Manufacturer of the Year - Sponsored by WEG UK
deadline set for Friday, January 6, 2023. Please note this important date, and begin considering which key developments, initiatives, projects, staff, and successes you will put forward for industry recognition and reward.
commented: “This year’s awards ceremony – the 21st such event – was as good as any I can remember. The atmosphere was fantastic, and the competition was intense. The quality of entries was extremely high, which echoes the creativity and engineering skill within this key sector. Our congratulations go to all the winners for their excellent achievements, but our acknowledgment and appreciation must also go to every nominee and finalist.”
www.pumpindustryawards.com
• Environmental Contribution of the Year - Sponsored by SPP Pumps
• Product of the Year - Sponsored by Process Engineering
www.bpma.org.ukQuarter 3 2022 Awards Update10
NOMINATE YOUR WINNERS
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aintaining the early Spring timeline, the next Gala Dinner and Presentation Ceremony will take place on Thursday, March 16, at our fantastic new venue – the Hilton at St George’s Park in Burton on Trent.
Having returned the annual Pump Industry Awards to its usual March slot following the disruption caused by the pandemic, it is now time to seek the all-important nominations for the 2023 Pump Industry Awards.
The pump sector continues to play a crucial role in ensuring our food production, manufacturingutilities,processes, transportation and other essential services are maintained, and for the 2023 award programme, special recognition will again go to those companies and individuals who have gone that extra mile to meet, and more often exceed, the demands and challenges presented by the sectors served.
• Distributor of the Year – Sponsored by Stuart Turner
• Supplier of the Year - Sponsored by Wilo
Situated on the edge of the National Forest, this impressive hotel is part of St. George’s Park – the training ground for all 28 English national football teams – and is recognised the World over as the Home of English Football. Sporting excellence is synonymous with this venue, and early next year it will also become the location for heralding engineering excellence across the pump sector.
• Rising Star Award - Sponsored by World Pumps
• Lifetime Contribution - Sponsored by BPMA
BPS Pumps W: www.bpspumps.co.uk T: 0121 503 3000 M: 07388 570267 E: julian@bpspumps.co.uk/beth@bpspumps.co.uk The small range of pumps is suitable for many applications, including water, fuel oil and chemicals We also offer pumps and spares for other manufacturers along with mechanical seals and seal kits from stock BPS PUMPS PRODUCES THE BERESFORD RANGE OF PUMPS MANUFACTURED IN THE 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. E: jonathan.price@kiwa.comW: www.kiwa.co.uk/water T: +44(0)1495 308185
With aluminium oxide, a peristaltic pump is the only real choice. However, to overcome the issues present, the new replacement pump features a roller shoe design, silicon
Specifically, the SAER XS-151 has cast impellers and diffusers that offer excellent wear resistance, together with the standard counter thrust ring and guide bushings. It is suitable for immersion at depths of up to 300m under liquid level and has a maximum working pressure of 45 bar.
The pump would form part of a pipework system to transfer pressurised seawater to remotely clean the turbine’s walkways, making them safe and suitable for operatives to walk on.
Peristaltic pumps are a great choice for slurries, sludges and highly viscous fluids – commonly able to handle between 15% and 80% solids (depending on the solution) – without issue. The solution doesn’t make contact with the moving parts of the pump, there’s no need for the pump to be primed with a service liquid, and dry-running is not a problem either.
T-T PUMPS HAS SUPPLIED A HIGH-PERFORMANCE
lubrication and the ability to change the ‘pinch’ level of the roller. This new solution has delivered savings on replacement parts, lower maintenance costs and downtime.less
pumping solutions. The unit’s high specification gives the customer a fit-for-purpose solution that will provide reliable operation long into the future.
www.ttpumps.com
SUBMERSIBLE PUMP FOR OFFSHORE WIND FARM WALKWAYS
NEWS12 www.bpma.org.ukQuarter 3 2022
In addition, the pump’s control system was re-engineered so the pump could be run in reverse to clear any blockages.
Recently, CDR Pumps’ engineering team upgraded a customer’s peristaltic pump as its existing solution wasn’t reliable and was regularly failing.
T-T’s client, one of the world’s leading renewable energy companies, approached the company with a need to specify a submersible pump for use at an offshore wind turbine farm.
Constructed with a full stainless steel outer body and wetted parts suitable for life in seawater, the unit is a 6in stainless steel semi-axial submersible pump complete with an integral non-return valve, designed to deliver the highest levels of performance even in the harshest conditions, such as those encountered in offshore environments.
Given the application, the pump needed to be constructed from materials suitable for life in seawater. T-T has extensive experience in specifying and supplying pumps for many specialist environments.
An XS-151 borehole pump was selected with the support of T-T’s partner, SAER Elettropompe, one of Europe’s leading manufacturers and suppliers of submersible and surface
Having been in situ for almost a year without any problems, this solution has already proved itself to be more reliable than the original pump.
PERISTALTIC PUMP UPGRADE DELIVERS SAVINGS
Project updates12
The existing pump had a fixed shoe design with high levels of friction which reduced the life span of the peristaltic hose pump. Extra friction plus an abrasive material leads to more heat and extra wear and tear on the pump parts, neither of which are good for the long-term lifespan of a pump.
www.cdrpumps.co.uk
PUMPING SANDPAPER GRIT –aluminium oxide – can be challenging for some pumps due to it being highly abrasive.
SAER submersible pump for use as part of a system for remotely cleaning walkways at an offshore wind farm.
UK
The CFW900 variable speed drive is a high tech solution for driving and controlling three-phase induction and permanent magnet motors. It offers excellent static and dynamic performance and precise torque, speed and position control. It can be used across a wide range of applications due to its high overload capacity. Instantly compatible with the new WEG Motion Fleet Management software, the CFW900 is the perfect solution for controlling pump systems.
The WEG Motion Fleet Management system is the ideal solution for monitoring and increasing the uptime of your industrial drive fleet. Based on cloud computing technology, the performance of assets can be monitored at any time from any part of the world.
NEW for 2022
Quarter 3 2022 FEATURE14 www.bpma.org.uk technical solutions
MARTIN RICHARDSON: The presence of harmonics is often only apparent when electrical systems start to malfunction, which is why we refer to it as the silent challenge. You can’t see or hear them, but their effects are observable through erratic operation or overheating of equipment. Complicating matters is the fact that these symptoms can potentially be caused by issues completely unrelated to harmonics, making them difficult to quickly diagnose. Harmonics can affect system efficiency, and result in increased losses. In extreme cases they can even cause equipment like generators to fail, and generators are assets the water industry can ill afford to be without for any length of time.
QUESTION: So, on the basis that there will be harmonics present in our systems, how can they be mitigated?MARTINRICHARDSON: There are steps that can be taken to mitigate the effects of harmonics, like adding cooling or over-dimensioning
bit.ly/ABB-SW
Other non-linear loads include LED lighting, photocopiers, computers, televisions, and the majority of electronics that have a power supply. Solar inverters and electric car chargers are also switching devices, and, as such, will generate harmonics. With more of these devices coming online across the country every day,
it is likely that the issue of harmonics will become more widespread in the near future unless steps are taken to mitigate against harmonics already on the grid and reduce harmonic content in new devices.
QUESTION: How do I know if harmonics are present in my system?
Q&A
QUESTION: We have been advised that some problems we are experiencing with the electrical systems at our water treatment works could be caused by harmonics. What are harmonics, and what causes the phenomenon?
MARTIN RICHARDSON: Harmonics can be a big problem in water treatment applications. They are disruptions to the voltage and current waveforms caused by introducing non-linear loads to the grid, which result in the deviation of the voltage and current sine wave. Non-linear loads are typically devices that do not draw current continuously, so anything that involves switching. This can include switched mode power supplies, variable speed drives (VSDs), UPS systems, and solid-state switches. Many of these devices generate harmonics in only small amounts, but as more of them are introduced to the power network, the amount of harmonic distortion accumulates, and can end up affecting power quality and disrupting equipment operation.
equipment. External filters or multi-pulse drives and transformers can also be added to the supply. However, these measures come with additional costs, and can create space problems in already crowded facilities, as well as adding an additional layer of complexity and power requirements to any installation. In any case, these steps merely address the symptoms of harmonics, rather than the underlying causes.
In this issue of flow, Martin Richardson, Water Framework Manager at ABB, looks at the water industry’s silent challenge, harmonics, what causes them, and how they can be mitigated using ultra-low harmonic variable speed drives (VSDs).
Harmonics cannot ever be entirely avoided within a system, as every device creates them to a greater or lesser extent. As switching devices, VSDs have traditionally been considered part of the problem when it comes to harmonics. However, recent developments in drive technology have meant that they can now be part of the solution. Ultra-low harmonic (ULH) drives have built-in harmonic mitigation, including an active supply unit and integrated line filter, which can help to reduce harmonic content by up to 90% compared to conventional VSDs.
By reducing the harmonic content produced by the drive, losses in other components and equipment can be reduced, improving overall system efficiency. It also eliminates the need for additional equipment and cooling provision, reducing the cost and complexity of drive installations. chevron-circle-right
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realising savings of £204,000 per annum on hire fees and diesel. And in line with the recent fuel price rises, those savings have hugely increased.
Even based on fuel prices at the beginning of 2020, the customer was
As a short-term solution, hiring a pump was better than nothing. But then the short-term lasted for eight years.
required, and ERIKS was tasked with finding a more cost-effective proposal.
REPAIR OR REPLACE?
Adrian Megson, Business Development Manager for Pumps at ERIKS, explains how his company replaced a customer’s hired pump with a new electric alternative, bringing significant savings.
eriks.co.uk
provide a duty pump, a standby, and a spare.With a more reliable electricdriven pump installed, a saving in maintenance costs and downtime was made every day. Electric power meant the customer also saw a saving on diesel fuel costs. And a saving in breakdown and repair costs was made, as the new solution extended the pump service life from six months to between three and four years.
Saving the higher cost of hire costs
The final recommendation was to invest in not one but three of the new Caprarielectric-drivenpumpsto
The unreliability and high repair costs eventually drove the customer to take action. But rather than invest in a replacement pump with more efficient technology, they decided to hire another diesel-driven pump.
In the face of ever-increasing diesel fuel charges, the first recommendation was to change to an electric-driven three-stage Caprari pump for far smoother and more reliable operation. This would not only reduce fuel costs but also eliminate the need for daily refuelling and other maintenance. With no need for daily shutdowns, the flow of effluent to the treatment plant would also be constant, making it easier to manage.
ERIKS always maintains a repair or replace neutrality – carefully and accurately costing both options and giving the customer a choice.
Quarter 3 2022 FEATURE16 www.bpma.org.uk Repair or Replace?
That was before ERIKS’ engineers identified the scale of the annual hire costs and diesel fuel.
RIKS’ customer, which operates in the heavy industry sector, used a diesel-driven pump to transfer effluent from a catchment lagoon to a treatment plant several miles away. The distance, the static head and the inherent frictional losses in the pipework mean that a high head pump is Historically,required.two single-stage vertical Mather & Platt pumps were used: a duty pump and one on permanent standby.Theage of the pumps and parts obsolescence also meant long lead times for replacement parts, which had to be specially manufactured.
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Unfortunately, these pumps required daily routine maintenance (refuelling and checking oil and coolant levels), which required a one- to two-hour shutdown every day. They were also notoriously unreliable. The high vibration levels inherent in a single-stage pump resulted in a short Mean Time Between Failure, as the pump virtually shook itself to death. In fact, the vibration was so bad it was impossible to mount the standby pump next to the duty pump – meaning more downtime whenever the pumps needed to be changed.
solutionanother was
When these figures were presented to the customer, it was obvious
In this case, the cost of replacing the current solution with a new thetheonlymotorCaprarielectric-drivenpumpandtogetherwasthesameascostofrepairingoriginalMather & Platt pump. Taking into account the savings on the hire of the temporary pump and the savings in labour costs for refuelling and other maintenance, the most cost-effective decision was obvious.Thecustomer made the right choice. And the savings compared with the original and the temporary pump are significant – and permanent. chevron-circle-right
The savings compared with the original and the temporary pump are significant – and permanent.
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SMARTERJUSTHEATINGGOT
s COVID 19 spread across the globe, the UK government closed schools, shops and hospitality venues to try to slow the spread of the virus. It seemed that overnight the highways went quiet, aeroplanes did not fly, and the birds became noisy. The effect was disorientating. However, generally speaking, life and the structures that kept us going through that period did not stop.
QUALITY OF WATER IS MAINTAINED
No level of automation has yet negated the requirement for all labour. The instrumentation required must be maintained. However, the investments made by the water industry in automation doubly paid for themselves as they gave the water network resilience in a time of extreme need.
AUTOMATION TO THE RESCUE
The water industry has relied upon automation to maintain consistent and highquality supplies flowing long before 2020 and therefore was less reliant on labour to continue operations as demand changed and workforce movement was restricted.
THEAutomationDewateringYEAR THE EARTH STOOD STILL
Quarter 3 2022 FEATURE18 www.bpma.org.uk
How did those superheroes continue to deliver those basic things that were keeping us sustained?
automation. In the UK, the water services regulation authority, OFWAT, sets targets that the water industry must meet to ensure water is provided to end-users efficiently and at an affordable price. Automated systems, supplied with a wealth of data from measurement instruments and analysers, are widely used for a variety of purposes, including monitoring network performance, maximising potable water quality through accurate dosing and ensuring the safety of water before it reaches our taps by detecting and removing potential contaminants.
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Many stepped out of their homes once a week to ‘clap for carers’, yet there were many key worker heroes in a variety of roles through that period that ensured the continued functioning of society by maintaining the supply of water and energy to our homes and food on the shelves of the supermarket.
The balancing act of supplying the right amount of power to the grid when it is needed is tested during more normal times. As a nation of tea drinkers, the UK has a unique pattern of power requirements that the National Grid managers are well used to dealing with. The energy demand of several million kettles being switched on for a brew simultaneously requires the grid to be on standby for half time of big football matches, or the closing sequence on Strictly Come Dancing. Negotiating the spike in
There may have been the odd panic induced shelf stripping of pasta and toilet rolls from the shops; but, the automation of processes at water utilities, energy companies and food manufacturers allowed the services on which we all rely to remain unaffected. Indeed, there was such little disruption that there was no ripple or murmur amongst customers or news outlets of what a feat this was. There may have been an absence of toilet roll, which was well documented, but the taps kept running, the electricity continued to flow, and the internet kept returning our search results on the virus.
The past few years have seen the water industry investing in high levels of
The geography of reservoirs miles from the point of use has accelerated automation in the water industry. With a network of reservoirs and water towers distributed over several hundred miles, automation reduces the requirement to transport operatives to remote locations. It would be inefficient to send an individual to monitor the water quality or water withdrawal when instruments such as level transmitters, flowmeters and continuous water analysers can be used to ensure that levels are topped up and quality is within specified boundaries.
The first lockdown in the UK almost perfectly coincided with the sunniest and
Alan Hunt, Product Manager at ABB Measurement & Analytics in the UK, looks at the role that instrumentation and automation played in keeping the lights on, the taps running, and our supermarket shelves stocked during the pandemic that took hold in 2020.
driest April on record and the hottest for 361 years. This was a perfect storm for the water industry, placing an enormous increase in demand for water just as restrictions were placed on the workforce.
KEEPING THE POWER ON
There is a continued debate for and against automation, with some believing that automated systems take away from the roles traditionally carried out by human workers. However, well applied automation does not do away with jobs for humans but allows both the human to do tasks where they can genuinely add value and the automation to do tasks when people can’t be there to do them.
LEARNING WE APPLY
to be the ultimate problem solvers and complete the kinds of tasks that humans are uniquely capable of doing.
Pump Arrangements
automation. It has also been revealed that whilst automation can deliver better repeatability, better productivity and better quality, humans still need to manage and maintain the system; to complete tasks that humans are uniquely capable of doing, such asInvestmentproblem-solving.inprocess automation can, of course, allow systems to remain up and running in the event of unforeseen circumstances such as a pandemic, but in some cases the automation is also delivering process efficiencies, reducing energy use, reducing chemical use, and delivering a more sustainable process.
The challenge now will be to keep humans doing what they are uniquely capable of doing and allow automation to do the rest.
The key learning for energy providers and the water industry is the great benefit of appropriate investment in process
Custom
Automation 19 Engineered Design Multistage Pumps Vertical Configuration RANGEHS RANGEHP RANGEISF RANGEAPI ISO 5199 Pumps in Custom Alloys Coatings API 610 12th Edition
The real benefit of automation is that it allows humans to use their superpowers
If ten million kettles being turned on simultaneously causes a bump in the road for power supply, the complete change in power consumption patterns caused by a national lockdown is unimaginable. Without power, our water supply is in peril. Artificial Intelligence is playing a greater role in coordinating the supply and demand of electrical power, and smart cities capable of dimming lights rather than inducing a power outage are transforming the power supply network.
bit.ly/ABBMandA
The pandemic proved the resilience of automated infrastructure. It clearly demonstrated the need for planning for enhanced resilience in the future. It is important to reflect on what went well through this period of turbulence – let’s plan for more of that, please. chevron-circle-right
A manufacturers association in Wales (Manufacturing Wales) has said its members and other businesses across the country are adopting automation faster than expected because of the pandemic. The pandemic has been a catalyst for embracing the fourth industrial age not just in Wales but globally, and in order to remain competitive and safeguard business, manufacturers are looking to further increase efficiency using automation.
The pandemic proved the resilience of infrastructure.automated
Those that carry out maintenance for the utilities deserve a nod of appreciation. For the water and energy utilities companies to have faultlessly maintained service such that the general population witnessed no noticeable alterations in supply was not by accident, it was by design. It was down to the systems in place to manage supply and demand and, of course, the extraordinary efforts of the normal staff of maintenance teams ready to fix the networks when faults occur.
demand and avoiding outages requires hydroelectric plants roaring into action at just the right time.
Crest Pumps explains the three pump affinity laws, outlining how they affect the performance of a pump, and demonstrating how they can be used in estimating the impact of making changes to a pump’s shaft speed or impeller diameter.
To Affinity and Beyond
As shaft speed or impeller diameter changes, flow is changed by the same proportional amount. In other words, if shaft speed increases by 10%, then flow at the same head will also increase by 10%. This law is expressed with the following formula:
H1/H2 = (N1/N2)² or (D1/D2)²
Where H is equal to head, N is equal to shaft speed, and D is equal to impeller diameter.
There are three affinity laws:
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
The affinity laws will produce highly accurate results in predicting the impact of changes in speed. However, as an impeller’s diameter changes, the impeller’s efficiency will also change; therefore, applying the affinity laws to calculate the impact on pump performance as a result of a change in impeller diameter is helpful but not always highly accurate. chevron-circle-right
www.crestpumps.co.uk
LAW 3 – POWER IS PROPORTIONAL TO THE CUBE OF SHAFT SPEED OR IMPELLER DIAMETER
As the shaft speed or impeller diameter changes, power changes in proportion to the cube of the change in shaft speed or impeller diameter. In other words, if shaft speed increases by 10%, then pressure at the same
Pump performance20
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flow will increase by 33.1% (1.10³). This law is expressed with the following formula:
Q1Q2= (N1/N2) or (D1/D2)
LAW 1 – FLOW IS PROPORTIONAL TO SHAFT SPEED OR IMPELLER DIAMETER
Where Q is equal to flow, N is equal to shaft speed, and D is equal to impeller diameter.
LAW 2 – PRESSURE IS PROPORTIONAL TO THE SQUARE OF SHAFT SPEED OR IMPELLER DIAMETER
As the shaft speed or impeller diameter changes, pressure changes in proportion to the square of the
he pump affinity laws are a set of formulas that help predict flow, head and power absorbed at different shaft speeds. If you know the shape of a pump performance curve at a certain speed or with a certain impeller diameter, you can use the affinity laws to predict the performance of the same pump at a different speed or with a different diameter impeller with a high degree of accuracy.
change in shaft speed or impeller diameter. In other words, if shaft speed increases by 10%, then pressure at the same flow will increase by 21% (1.10²). This law is expressed with the following formula:
P1/P2 = (N1/N2)³ or (D1/D2)³
Where P is equal to power, N is equal to shaft speed, and D is equal to impeller diameter.
USE OF THE AFFINITY LAWS
To find out more search: ABB Silent Challenge
We have the solution.
Technologies you use in water treatment can introduce disruptive harmonic distortion into electrical systems, causing a variety of complications like premature failure of vital equipment, unstable operation of backup generators and disturbances in sensors.
ACQ580 ultra-low harmonic drive technology from ABB mitigates harmonics while saving energy in water treatment processes, providing a simple solution to a silent problem.
Harmonic— distortion is the water industry’s silent challenge.
Working with a specialist with experience in designing and delivering highly efficient PAT solutions capable of a rapid return on investment, field-proven, affordable, lowmaintenance products and energy-efficient solutions are available, based on simple, readily-available components and spares. This opens up the opportunity to make a change for the better and benefit both the environment and your business. chevron-circle-right
WHY USE A PUMP AS A TURBINE?
Using a PAT system is almost the perfect solution when considering using hydropower as an alternative to conventional thermal power for cleaner energy technologies.
THE CONCEPT
Schemes and initiatives are actively being developed and implemented in industries and commercial sectors to make renewable energy more appealing and a viable alternative to conventional thermal power. SPP Pumps offers a solution and plans to contribute to renewable technologies in the global energy mix by using micro hydropower systems that use energy from flowing water to produce electrical or mechanical energy via pumps working as turbines, known as PAT systems.
Historically, however, there have been challenges associated with micro-hydropower schemes. The non-availability of standardised equipment, typically Francis or Kaplan turbines, is one issue, while the turbines need to be designed according to the site specification making each application unique. And so, as standardised equipment is not available, the usage of electromechanical equipment becomes costly.
They can be installed in various locations with no requirement for large infrastructure. The efficiency generated by a pump in turbine mode is equal to or slightly higher than those in pump mode. Pumps are robust and spare parts are more readily accessible than they are for turbines.
SPP Pumps explains the importance of renewable energies in relation to pumps as turbines (PATs), outlining their function and, most importantly, how these PATs can benefit industry in the future.
than turbines. When pumps are suitably selected, they offer a great alternative to traditional hydro turbines with a substantial economic advantage. It is an efficient and cost-effective method of generating power as well as recovering energy, as you can potentially see a return on investment in as little as three years.
APPLICATIONS
basins. They can be used for pressure control in closed-loop systems, for the pressure drop of head and on a wide range of other plant processes, including outfalls.
ooking at how the world plans to tackle climate change, specific standards were agreed upon at COP26 in November 2021, with one goal to secure a global net zero by 2050 and keep 1.5°C within reach. The main standards agreed upon at COP26 were accelerating the phase-out of coal, curtailing deforestation, speeding up the switch to electric vehicles and encouraging investment in renewables.
Quarter 3 2022 www.bpma.org.uk Renewable Energy22
PUMP AS TURBINES
Achieving these inspiring targets globally will require an active transition from conventional thermal power to cleaner energy technologies, with a higher inclusion of renewable technologies in the global energy mix.
With the pressure differential (head) of a water flow providing the opportunity to recover valuable energy, there are multiple applications where PAT systems can be installed.Municipal water companies can integrate them into drinking water supply systems, replacing pressure relief valves and stilling
PAT systems are a well-known concept in the water supply industry. SPP Pumps has been offering this as a solution since 2009. PAT is the perfect model because the pumps are less complicated to operate
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The use of residual water small hydropower stations can also be applied to pumped storage plants, barrages or dams, rivers or streams. In addition, they can be used to retrofit small hydropower systems as a replacement for old or redundant turbines.While, in industrial applications, PATs can be used in areas such as cooling water circulation systems or where the reduction of process water pressure is required.
In 2010, the share of renewable technology in the global energy mix was a modest 8.6%. Cleaner renewable technologies are expected to increase and contribute to the worldwide power sector by 25% by 2025. That is a 17% increase in just over three years. This clearly indicates that renewable energies will play a huge role in achieving a global net zero position by mid-century.
Embracing hydroelectric power with pumps as turbines
bit.ly/SPP-PAT
part from solar power and wind energy, hydrogen is a key energy source in almost all industries. Green hydrogen has more uses than just serving to drive vehicles and store renewable energy. In refineries, previously grey hydrogen used for desulphurising the pre-products of petrol and diesel oil is to be replaced at least partly by green hydrogen. In pilot projects in the steel industry, green hydrogen is already being used for the direct reduction of iron ore as an alternative to the furnace process with high greenhouse gas emissions. The cement, glass and ceramics industries are also looking for new ways of converting their processes into a CO2-neutral production.
However, this change will only be successful if an efficient and economical hydrogen industry is established, including production, import, transport, storage and conversion. This may sound good on paper, but in reality, the details to be considered for decarbonisation strategies are manifold.
Supporting hydrogen production for long-term decarbonisation strategies
KSB has been involved in hydrogen developments for many years. Both its valve and pump portfolios already comprise a broad range of products that can be used in all stages of the hydrogen value creation chain.
Quarter 3 2022 www.bpma.org.uk > 26 24 sustainability
Christof Lindner, who is responsible for hydrogen technology at KSB’s General Industry Market Area, explained the current situation: “A challenge when implementing hydrogen projects is that detailed requirements for the components used still vary greatly,
Change will only be successful if an efficient and economical hydrogen industry is established.
be addressed is the system size. Currently, electrolysers are usually modular designs, which raises the question of what will be more advantageous from an energy point of view in the future. Having each electrolyser fitted with its own cooling system or electrolysersseveralhavingparallel fitted with a common cooling system, which requires more powerful pumps? Looking to the future, what will be more popular, container solutions or large-scale projects? This also directly impacts on the selection of pumps and valves.
for instance, the materials and the surface qualities.”
Next to the metal industry, the basic chemicals industry is the highest energy consuming industry in Germany. Until now, its energy demand has primarily been covered by fossil raw materials, which are anticipated to be at least partly replaced by green hydrogen in the future. In this changeover, pumps and valves play a decisive role, as KSB explains.
PUMPS FOR TODAY’S AND TOMORROW’S PROCESSES
With regard to conversion processes (e.g. ammonia) and blue hydrogen production processes based on fossil fuels (SMR, ATR, and CCS), KSB’s pumps and valves have been operating for many decades. The same forappliesalsotovalveschloralkali
Container solutions would have flow rates of about 10 m³/hr, but large projects (studies only at this stage) may exceed 800 m³/hr. Likewise, the operating pressure
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electrolysis, where diaphragmits and butterfly valves have long been popular choices. Despite this background, Lindner is aware that: “Many questions, such as hydraulic balancing or the duty cycle of pumps in the different hydrogen processes can only be clarified when the development is more advanced.”
Another issue that needs to
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Among the pumps tried and tested in alkaline electrolysis is the Magnochem horizontal volute casing pump with a magnetic drive. The standardised chemical pump is available in close-coupled design or back pull-out design. “This sealless pump has been used for many years in industries whenever toxic, explosive or valuable fluids have to be pumped. It is the ideal match for hydrogen technology,” Lindner added. With its magnetic drive, the pump is hermetically sealed, thereby averting the risk of leakage. This plays a major part in alkaline electrolysis, where atmosphere.contactcrystallisespumpedpotashcausticisandinwiththe
www.ksb.com
Another pump type suitable for hydrogen production is the multi-stage, vertical highpressure centrifugal pump.
Known for more than a century, alkaline electrolysis is certainly among the most highly developed technologies. However, its potential for reducing costs is limited.
may range from 6 to 40 bar. Larger, modular systems may also have higher control requirements for an optimum interaction of components, requiring variable speed pumps and control valves.
Diaphragm valves and seal-less pumps that contribute to making the processes safer are represented by the SISTO-20 or SISTO-16s type series and the ISORIA or the KE type series butterfly valves that are made of corrosion-resistant material or coated accordingly.
FUTURE TASKS
Quarter 3 2022 www.bpma.org.uk
PEM electrolysis is a much more recent technology. Its benefits are safety, ease of use and high flexibility at changing loads. Compared to alkaline electrolysis, this technology offers a lot of potential for technical developments and cost savings, and it does not require the use of any risky chemicals. The electrolytetoxicaside, the ofsimilarpumpsconditionsapplicationforaretothosealkaline electrolysis. The new technology is particularly interesting when looking at the aspect of hydrogen production from renewable energy sources becoming fit for mass production in the future. KSB is contributing to these developments by providing diaphragm valves, butterfly valves, and various pumps for pilot systems.
pumps, or ISORIA and SISTO-20 valves, are frequently employed for cooling heat exchangers. Using PumpDrive variable speed systems to deliver maximum energy efficiency, the pumps’ vertical installation and in-line design mean they are very compact.
“A supplier not only needs a broad product programme to cover a wide field of applications, but also detailed knowledge on systems engineering, duty cycles, materials and energy efficiency,” said Lindner. This is especially relevant since several different technologies for green hydrogen production are available or emerging.
PEM ELECTROLYSIS IS READY TO TAKE OFF
Compliant with ISO 5199, the Magnochem pump, with its broad range of hydraulic sizes, materials and magnetic drives, offers a large number of technically feasible variants. This makes it a good match for the most diverse of tasks in hydrogen production, and the user receives a pump with maximum safety, reliability and economic efficiency.
KSB’s resources cover all main technologies of green hydrogen production, whether it is alkaline electrolysis (AEL), proton exchange membrane electrolysis (PEM) or future technologies, such as anion exchange membrane electrolysis (AEM) or high-temperature electrolysis (HTEL).
Experts see the tasks of future technologies, such as anion exchange membrane electrolysis (AEM) or hightemperature electrolysis (HTE), as being a particular challenge in accommodating the high temperatures that place demanding requirements on materials. Regardless of the method used in the future and what system size will prove more suitable, Lindner sees KSB’s portfolio of valves and pumps providing the technologies that deliver the best efficiency as well as maximum safety and reliability that these future technologies require. chevron-circle-right
It should be noted that hydrogen technology involves more than just hydrogen production. A key process to be considered is the cooling water supply. Etabloc /Etaline type
Another pump type suitable for hydrogen production is the multi-stage, vertical high-pressure centrifugal pump. Typically used for water treatment and pressure generation, it is designed for up to 40 bar and is very flexible, having a number of stages and the option of speed control. The compact design is a perfect match for installation in tight spaces in container solutions. Even at low flow rates it can generate high pressures.
SISTO diaphragm valves, for example, are designed with a completely enclosed and spiralsupported TFM diaphragm, which is provided with flexibility by an EPDM diaphragm fitted at its rear. The diffusion-tight TFM and a PVDF barrier foil in-between the diaphragms reduce gas diffusion, thus protecting the environment and the valve interiors. Valves needed for cryogenic applications, such as the subsequent transport,
are covered by the KSB DANAIS type series. Experience with valves for liquid hydrogen (-253°C) results from optimising the Ariane rocket programme in test facilities.
26 sustainability
PUMPS AND VALVES FOR ALKALINE ELECTROLYSIS
“Since its operation is still more durable and reliable than PEM, operational disadvantages such as the hazardous fluid or the low flexibility regarding a change in load conditions are accepted,” explained Lindner.
The pump’s close-coupled design makes it suitable for tight installation spaces.
Our experience covers a range of pumps including Centrifugal, Submersible, Vacuum, Vane, Stirrer Shafts, Vertical, Sumps, Bilge and Multi-stage.
Our workshop is equipped with a large range of both horizontal and vertical balancing machines to cover a multitude of applications, including shaft and impeller balancing for pump manufacturers and repair and overhaul companies across the UK.
From our well-equipped workshop facility in Manchester, our knowledge and expertise of designing and manufacturing dynamic balancing machines is available to the pump industry via our contract balancing service.
We provide a quick turnaround service, ideal if you need to cover any capacity or capability constraints and offer a palletised UK wide return service if required.
COMPREHENSIVE CONTRACT BALANCING SERVICE FOR PUMP MANUFACTURERS For further information contact us: T: 0161 872 3123 or E: enquiries@cembhofmann.co.uk www.cembhofmann.co.uk
PUMPS AS TURBINES - HARNESSING WATER POWER TO ITS FULL POTENTIAL FOR WHERE IT REALLY MATTERS SPP PUMPS LIMITED, 1420 LAKEVIEW, ARLINGTON BUSINESS PARK, THEALE, READING, RG7 4SA TEL: +44 (0) 1189 32 31 23 • EMAIL: STUART_WALLIS@SPPPUMPS.COM
Both responsible persons and operatives must be able to provide sufficient evidence that they are up to date with the theory, skills and understanding of the Ex work they are involved with. Their staff should attend regular refreshers every three years on the repair and overhaul aspects of Ex equipment through the AEMT. This means that Ex-registered companies remain up to date on the
practical aspects of repair and any changes in updated standards and ATEX.
Understanding of the general principles of types of protection and marking.
Yes
Familiarity with the particular techniques to be employed in repairs referred to in this standard.
For a company to be on the AEMT Ex-Register, it should have an ISO 9001 quality control system or equivalent; the calibrated tools suitable for the work seen and the required certificates and standards; a minimum of one
Ability to identify replacement parts and components authorised by the manufacturer.
T
Thomas Marks, General Manager and Secretary at the Association for Electrical and Mechanical Trades, explores the requirements placed on the individuals and organisations involved in the repair and service of Ex-rated electromechanical equipment.
Yes
Practical understanding of explosionprotection principles and techniques.
Basic knowledge of quality assurance, including the principles of traceability of measurement and instrument calibration. Yes
Understanding of examination and testing as related to relevant parts of most recent 60079-19 standard.
Familiarity with measurement functions, including practical metrology skills, to measure known quantities.
Yes
Yes
Understanding of those aspects of equipment design which affect the protection concept. Yes
Yes
Competencies apply to each explosion-protection technique for which a company or person is involved. For example, a person can be competent in the repair and overhaul of Ex d motors only and not be fully competent in the repair of Ex d switchgear or Ex e motors.
An Ex Service Centre should have at least one ‘responsible person’, usually the manager or supervisor in charge of the workshop where servicing of Ex or hazardous area equipment is carried out.
General understanding of relevant electrical and mechanical engineering at the craftsperson level or above.
trained and competent operative; as well as a minimum of one responsible person to sign off and supervise Ex repair work completed by workshop technicians.
Working knowledge and understanding of relevant standards in the explosion protection field. Yes
Understanding and ability to read and assess engineering drawings.
Yes
Ex Repairs: the knowledge and skills required
PERSONRESPONSIBLE OPERATIVE
KNOWLEDGE AND SKILLS
Yes
bit.ly/Exregister
he knowledge and skills required to service Ex equipment such as motors, pumps, fans, compressors, gearboxes and other mechanical equipment, rests on two different categories of person, as highlighted in the IEC 60079-19 standard: the ‘responsible person’ and ‘operatives’.
Quarter 3 2022 www.bpma.org.uk Hazardous Areas28
The responsible persons must be trained to fully understand the protection concepts of the equipment, what can and cannot be repaired, and what repair procedures may be used, so that they can fully support the workshop staff and verify any work carried out. The responsible person should be able to ensure that the correct records are kept and that quality control systems are in place for the Ex repairs. They should also be able to ensure that the company has the right tools for the equipment being repaired and the relevant standards andOperativescertificates.are all the engineers and technicians that carry out the service and repair of hazardous area equipment. They should have attended the AEMT Ex Theory and Hands-on courses to fully understand the protection concepts of the equipment they are repairing, and, as above, what can and cannot be repaired, and what repair procedures may be used.
In such cases, the repair facility management should define this in their documentation system. chevron-circle-right
Yes
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ensuring that you have priming processes in place. Using Runsafe SiC bushes gives additional protection and means a pump is more robust against catastrophic failures. Additional protection comes in the form of a digital load monitor. Comprising two trip functions, the digital load monitor has a low power alarm to stop a pump when the tanker empties and a high power alarm to stop the feeder if there’s a blockage. Finally, flexible pipework and cam-lock style fittings can overcome nozzle loads and force issues.
IMPROVED SAFETY AND REDUCED COST
he chemical distribution industry is reported to be worth £190 billion worldwide, so it’s no surprise to learn that global mobility has had a huge impact. Chemicals no longer need to be transported via pipelines to the wider manufacturing community, and it is common for materials to be transported by road, rail, and sea, resulting in a rise in tanker unloading applications.
The three main concerns to assess when looking for unloading solutions are priming the pumps before start-up, the units being run dry when the container empties and nozzle loads and forces.
Improve tanker unloading
The company reviewed its Phenolic tanker unloading applications, where raw material is unloaded and transferred to bulk storage tanks for onward processing. Phenol is a top-tier COMAH (Control of Major Accidents Hazards) regulated material with several handling considerations: the product solidifies at low temperature, is hazardous and flammable.Theprocessing plant’s existing canned type seal-less pump sets, driven by 11kW ATEX
www.cdrpumps.co.uk Pharmaceutical & Chemical Focus30 CMYCYMYCMYMCK
SI Group is a major UK chemical processing plant. The company processes Phenol based products and is constantly looking at energysaving opportunities, alongside improving working practices and reducing hazard opportunities.
The Carriage of Dangerous Goods and Use of Transportable Pressure Equipment Regulations, also known as ADR, International Carriage of Dangerous Goods by Rail (RID) Regulations and International Maritime Dangerous Goods Code all cover the transport chain when moving hazardous fluids by road or rail. One of the positive changes we have seen is the chemical manufacturing industry’s preference to unload tankers and IBCs using pumps over the more dated method of pressurising containers to blow out the contents.
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Overcoming the challenges can be resolved with the correct pump installation and
hazardous area electric motors, had to be kept running constantly. This was to ensure the product was agitated, heat conductivity was spread throughout the entire feedstock, and the pumps were kept warm and moving to make sure the chemical did not solidify as temperatures decreased.
Quarter 3 2022 www.bpma.org.uk
CHOOSING THE RIGHT PUMP Health & safety, and chemical compatibility are important factors when choosing the right pump for unloading applications. Mag drive pumps are the safest choice for toxic and hazardous fluids as they feature zerovapour loss.
Polypropylene or ETFE-lined mag drive pumps are a popular choice for unloading applications as they increase the range of chemical compatibility.
The existing pumps were replaced by UTS-B mag drive centrifugal pumps from CDR, manufactured in stainless steel. Offering a zero-vapour loss, seal-less design meant that the fluids and vapours were contained and presented no hazard to the immediate or wider environment or individuals working in it. Choosing the solution from CDR also meant that the power needed to drive the pump could be significantly reduced. Dropping from an 11kW motor to a 5.5kW motor has reduced the amount of energy being used by the solution whilst not compromising on loading and unloading times or the operational effectiveness and lifespan of the pumps.
In addition, heating jackets were incorporated into the solution so that steam, readily available on site, could be repurposed to maintain the temperatures required.
The UTS-B pumps could also be safely switched off when not in use, further reducing energy consumption, mechanical wear and the inherent risks associated with live process lines when circulating fluids.
The benefits of mag drive pumps in tanker unloading applications include a wide range of chemical compatibility, run dry protection and safer zero-vapour loss configuration. This type of pump also removes the need for fume scrubbers as vapours can be returned to the tanker or container. Flow rates from 1m3/hr up to 320m3/hr are possible using mag drive pumps, and this can be variable with the use of control measures such as inverters.
As a result, the new unloading pumps operate for less than five hours a day rather than constantly. This saves 9,866 kW/hr per year per pump. Installing four pumps, reducing total consumption by 39MWhr per year, saved the company over £31,000 in the first year alongside the other benefits gained. chevron-circle-right
CDR Pumps explains how changes in pump technology and the advancement of compatible materials have made tanker unloading safer and more efficient.
10th & 11th May 2023 The NEC, Birmingham, UK 2 Packed Days 450+ Leading Exhibitors Panel Sessions Plant & Process Intensification Control & PRE-REGISTERplusFlowPlantAssetAutomationCHEMICALInstrumentation4.0–/DigitisationManagement&MaintenanceManagement&ThermalSolutions...more!FORFREEENTRY!Headline Industry Partner The UK Expo for Chemical, Process & Plant Engineering CHEMICAL CENTRIFUGAL CORROSION RESISTANT PUMPS FIND THE BEST PUMP FOR YOU! CONTACT US: www.crestpumps.co.uk+44 (0)1425 627700 info@crestpumps.co.uk Magazine Advert Print.pdf 2 08/06/2022 10:13:41 AM
Sulzer became aware of the issues being experienced with the pumps and offered to provide an engineered solution that would deliver long-term performance and reliability. Having appreciated the benefits that Sulzer could deliver, Sitech Manufacturing Services supplied the spare pump
Pharmaceutical & Chemical Focus32
Flow magazine found out how new pump internals from Sulzer solved reliability issues and improved productivity for a Dutch chemical processing plant.
Sulzer was called in to offer its design expertise and provide a retrofit solution.
to cause issues, to the point that the pumps were identified as a major cause for concern in the nitrogen process.
orrectly matching equipment to the application is essential for reliable and efficient operations. When machines fail to deliver the required performance, they can cause a significant bottleneck in the manufacturing process resulting in an ongoing loss of potential revenue. For a chemical plant in the Netherlands, years of maintenance issues with a group of ammonia pumps had incurred considerable expense and downtime despite repeated interventions from the original equipment manufacturer (OEM). All these issues are now a distant memory after Sulzer delivered a retrofit solution that continues to prove reliable and cost-effective.
www.bpma.org.ukQuarter 3 2022
COUNTING THE COST
changed for parts made of Super Duplex stainless steel.
Within the vast array of equipment at the processing facility, three pumps, which were originally installed in 1968, are tasked with the onerous job of pumping the ammonia feedstock for the production of nitrogen fertiliser. Two of the between bearing design, type BB3, twin impeller axial flow pumps are powered by steam
turbines and one by a fixed-speed electric motor. In addition to this, an extra pump is kept as a spare.
As the maintenance group responsible for all assets in the chemical processing plant, Sitech Manufacturing Services has to ensure ongoing productivity and continued operations in a very competitive market. Proactive maintenance schedules and planned upgrades allow the company to deliver reliability and cost-effective production. In a recent project, Sulzer was called in to offer its design expertise and provide a retrofit solution to overhaul three bad actors that continued to present issues that the OEM could not resolve.
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From the outset, the pumps have suffered from poor reliability, with a mean time between failure (MTBF) of around 12 months, which has incurred high maintenance costs for the plant. The engineers had to deal with high vibration, excessive wear and broken impellers, all of which were causing a loss of performance and annual maintenance costs of around €150,000.Overthe years, several design changes and mechanical improvements have been made to the pumps. In 1996, due to the corrosion that was also being experienced, the OEM suggested all the internal components be
Pump retrofit eliminates annual maintenance cost
However, the material change did not address the inherent design issues, and the pumps continued to suffer from jammed wear rings, damaged impellers and excessive wear. The resultant loss of performance and high costsmaintenancecontinued
The retrofits have been a considerable success, and the first has now delivered faultless reliability for over six years.
The first step was to use a laser scanner to create a precision model of the entire pump. Once this was complete, the design work could start on the new impellers and driveshaft. Sulzer’s high-energy pump experts in Leeds, supported the project with their extensive equipment knowledge and application experience.
pump was returned to the chemical plant, where it was installed, commissioned and found to run very smoothly. In all, the whole project was completed in just 20 weeks.”
now only one pump remains to be completed. The retrofits have been a considerable success, and the first has now delivered faultless reliability for over six years, confirming that Sulzer could provide all of improvementsthe that wereFrankpromised.Sleijpen at ServicesManufacturingSitech
The retrofit process was preceded by a root cause analysis to determine the weak points in the existing design and enabled Sulzer to establish the best solution for this application.
IMPROVED RELIABILITY
33Pharmaceutical & Chemical Focus
concluded: “The continued vibration monitoring has shown Sulzer’sthatdesign modifications have not only greatly improved the MTBF, but readings are significantly lower than those for the original pumps. This is a good indication of continued performance and long-term reliability, which will continue to save the company money year on year.” chevron-circle-right
the pump was reassembled with the new components before being tested complete,performance.forOncethe
to the local service centre in the Netherlands as the impeller was broken and the pump needed to be repaired.
www.sulzer.com
required improved durability. Once complete, the plans were sent to the manufacturing site for this project in Germany, which created the new impellers and shaft.
ClassroomE-learning based “Live” On-sitewebinarscourses Tailored options For more information call 0121 601 6691 scan code for the training guide or email: training@bpma.org.uk Independent Pump Training from
Ben Lauwerijssen, Regional Sales theexplained:BeneluxManager,forSulzer,“BackinNetherlands,
Starting with Sulzer’s BBT-D pump design as a reference, the engineers focused on the impeller characteristics as well as the wearing parts, which
Having identified these pumps as a source of concern in the manufacturing process, two more pumps were also scheduled for the same improvements, and
to burn off old windings to prevent damage to the steel laminations. It covers which insulation grades should be used, the approach to rebuilding bearing seats, the selection of replacement bearings and grease, and a range of other factors.
www.bpma.org.ukQuarter 3 2022 Opinion34
here are several ways that a poor-quality motor repair can impact a business. Firstly, there could be issues with the energy efficiency of a badly repaired motor which can lead to unnecessary increases in costs. However, if repaired well, a motor should be at least as efficient as when it was new. This was demonstrated by a study carried out by the Association of Electrical and Mechanical Trades (AEMT) and the US-based Electrical Apparatus Service Association (EASA), which used independent testing facilities to confirm higher efficiency IE3 units are unaffected by a repair that uses good practice procedures.
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terminals, that would be a sign that care has been taken. Other small but notable signs include the fitting of new grease nipple caps. They cost a few pence but can make a big difference. Also, look for mesh wrap or some form of protection on the shaft. While silica gel packs inside the terminal box and anti-corrosion coatings can make a difference, especially if the motor may not go straight into service and is in storage for any time.
With growing financial and supply chain pressures, repairing a motor can be an increasingly viable alternative to replacement. But, for a repaired motor to perform as well as, or in some cases better than, when it was new, it is essential that you get a quality repair from your motor repair partner. Karl Metcalfe, Technical Support at the Association of Electrical and Mechanical Trades, explains what to look for when commissioning a repair.
A good motor repairer should have a repair specification they can give customers, showing what will be done.
IEC60034-23 also sets out what tests should be carried out on a motor before and after it is repaired and how the test
equipment should be maintained and calibrated. In line with the repair standard, a good motor repairer should have a repair specification they can give customers, showing what will be done. And when the motor comes back from repair, there should be an accurate record of what has been done, certificatesincludingcovering aspects such as balancing, tolerances,measurement,vibrationandsurge test results.
Karl Metcalfe, Technical Support at the Association of Electrical and Mechanical Trades.
REPAIRINTERNATIONALSTANDARD
So, to ensure you get levels of reliability and efficiency from your next motor repair, ask your repair provider if they work to the international repair, overhaul and reclamation of rotating equipment standard, IEC 60034-23. chevron-circle-right
A motor that has not been well repaired can also be prone to failure earlier than expected. Winding faults can lead to premature insulation breakdown, while poorly fitted bearings can fail sooner than expected. If these unexpected faults occur, the cost of unintended downtime could be massive for some businesses.
One way to ensure a quality repair is to ask your provider if they follow the international repair standard (IEC 60034-23). The standard establishes the benchmarks for repairing rotating equipment, maintaining efficiency levels, high standards of quality control and improving efficiency in associated pieces of Theequipment.standard covers many other aspects of the repair process. It sets out requirements for the maximum usedtemperaturesinanoven
Ensure you get a quality motor repair
There are ways to identify a good quality repair, and this can start before the repairer even sets eyes on the motor. The repairer should take the time to understand what the client needs. They should talk to the customer to find out about the motor, where and how it is being used, and what the customer wants from the repair.
When inspecting a repaired motor, generally, if the motor looks like it has been well treated on the outside, it is likely that it will have been well treated on the inside. For example, when the motor is returned, are the mounting faces free of paint? If they have been well masked when the motor was painted, the motor will be much easier to mount accurately. Equally, if the terminal box looks nice and clean and there are new nuts and washers on the
The BPMA’s annual Pump Industry Awards programme has been recognising and rewarding the achievements of pump businesses, large and small for over two decades. Throughout that time it has become one of the leading events to serve the industrial and commercial arena. So, if you or your company have a pump related success to shout about, these awards provide the perfect platform.
The 2023 Call for Nominations is now open, so be sure to visit the Pump Industry Awards website to review the award categories and decide which ones you will be entering!
The gala presentation dinner caps off the awards programme in style, providing excellent networking opportunities, great food and superb entertainment. It’s your chance to celebrate with colleagues, interact with peers, entertain customers and be part of the pump industry’s biggest and best celebration. Manufacturing and distribution prowess, product development and application, environmental consideration, skills development and customer support will all be acknowledged through this wide reaching awards programme. So why not consider which of your engineering successes are deserving of industry wide recognition, and be sure to join us at our wonderful new venue - the home of English football - on Thursday 16th March 2023.
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.”
Event NOMINATIONSCalendarOPEN - 1st June 2022 NOMINATIONS CLOSE - 6th January 2023 JUDGING SESSION - Mid-January 2023 FINALISTS ANNOUNCED - 30th January 2023 VOTING - 6th - 10th February 2023 WINNERS ANNOUNCED - 16th March 2023 PUMPAWARDSINDUSTRY2023 NOMINATIONSNOWOPEN www.pumpindustryawards.com Venue: Hilton at St George’s Park,Burton on Trent ThursdayDate:16th March 2023
Award Programme Partners
Here’s your chance to shine!
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