We offer a wide range of solutions to improve performance, efficiency and reliability for your pump applications.
• WEG Sync+ Ultra, with an IE6 efficiency rating, this is the most efficient industrial motor on the market.
• Pump Genius, a customisable feature of WEG drives that enables your standard VSD to become dedicated for pumping systems ensuring accurate pressure / flow control throughout the process
• Motion Fleet Management, scans and monitors the performance of assets using cloud based technology for preventative and predictive maintenance.
• WEG SEE +, new efficiency calculator enables you to calculate energy savings, return on investment and ultimately reduce GHG emissions.
Learn more at www.weg.net
Editor Chris Callander chris@flowmag.co.uk 01732 671123
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.
Metalforming Centre 47 Birmingham Road West Bromwich B70 6PY www.bpma.org.uk
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.
Welcome to our third issue of Flow magazine for 2024. In this edition we have a focus on the water and waste treatment sector. While the water utilities in particular are facing growing scrutiny and challenging questions, for reasons we won’t go into here, their supply chain is working tirelessly to support the sector and rise to the many challenges it faces.
Examples of this include the use of submersible mixers that employ permanent magnet motors which are at the heart of denitrification operations in one of Europe’s largest wastewater treatment plants (page 26). The use of innovative motor technology is enabling the operator to meet its operational obligations while saving tens of thousands of Euros in energy costs.
We also look at new technology that is enabling teams searching water supply networks for leaks to cover ground twice as fast as was previously typical (page 36). This is not only enabling engineers trained in the analysis to spend more time working on the aspects they are best qualified to support, but is also helping to tackle the growing issue of a lack of engineers with the skills necessary to carry out the task.
And, with a renewed focus on home building across the UK, reliant on already strained wastewater infrastructure, we also examine how packaged pump stations can meet the standards set by the utilities (page 30).
This is just a small taste of what we have in this issue, with a selection of other feature articles, opinion, industry and product news, project updates and news from the BPMA.
I hope you enjoy the issue.
Dale Croker, President, BPMA
Tucson pumps now available in the UK
TUCSON PUMPS, PART OF THE Sanbra Group, and a sister company to Instantor, is one of Ireland’s leading pump brands for domestic dwellings and light commercial pumping applications. Offering an extensive range of pumping products such as shower pumps, coldwater booster systems, submersible pumps, and central heating circulation pumps, Tucson announced an expansion into the UK market at the InstallerSHOW held in June this year.
Instantor, which manufactures plumbing products and is the market leader in press solutions in Ireland, has also recently introduced its products to the UK. As part of this expansion, Instantor has recruited a new sales team, which includes Dan Wild as UK Sales Manager and Thomas Dickson as Territory Manager for Scotland and Northern Ireland. Dan and Thomas will be responsible for developing business for both the Instantor and Tucson Pumps portfolios and bring with them extensive expertise within the plumbing products market.
In addition, state-of-the-art UK
warehousing and logistical capabilities underpinned by a dedicated customer support team will enable service to be provided to UK plumbers and builders merchants.
Alan Hogan, Heating & Plumbing Divisional Managing Director at Sanbara, said: “Tucson Pumps are now available to plumbers, installers and merchants nationwide. Having already earned the trust of countless trade professionals in Ireland, we’re anticipating a positive
reaction in the UK, as Tucson Pumps have been engineered by a team dedicated to exceeding industry standards, ensuring reliability, efficiency, and longevity.
“We are committed to quality and have recently opened a new laboratory equipped with 20 machines that ensures all pumps undergo rigorous testing before being made available to customers. We also have strong growth plans in place, which include the development of the UK market.”
SCOTTISH WATER MONITORING PROJECT WINS AWARD FOR XYLEM
A GROUND-BREAKING PROJECT THAT is enabling continuous remote monitoring of a 16km trunk main has been recognised at the Water Industry Awards.
The Blairlinnans SoundPrint Acoustic Fibre Optic System, a joint project between Xylem and Scottish Water –and a European first, was named Asset Management Initiative of the Year at the awards ceremony on 4 July 2024.
The Blairlinnans water main is a 42in (1,067mm) pre-stressed concrete (PSC) pipeline that runs from the Blairlinnans Water Treatment Works to a service reservoir in West Dunbartonshire, Scotland. The pipeline was installed in 1974 and is critical to the ongoing operation of Scottish Water’s supply network.
lose its structural integrity, with a risk of failure.
In the first project of its kind in Europe, Scottish Water selected Xylem’s SoundPrint Acoustic Fibre Optic (AFO) system to continually monitor sections of the pipeline. SoundPrint AFO detects breaks in the pre-stressing wire that holds PSC pipelines together.
The system set-up comprises bundled, reinforced fibre-optic cable fed through the water main, which is connected to a data acquisition system to monitor the acoustic activity in near real-time. If a wire break occurs, it is detected by the AFO system, which is connected to Xylem’s AFO analysts via the cellular network.
Scottish Water identified the main as a high-risk asset, which prompted a complete engineering assessment to understand its true condition and prevent an unexpected burst.
Inspections using Xylem’s SmartBall and PipeDiver technologies provided the data necessary to conduct a thorough engineering analysis. The insights showed that while most of the pipeline was in good condition, several sections had broken pre-stressed wires, which are critical to support operational pressures. If the wires break, a trunk main can
Wire break events are investigated by the analysts, and with the help of machine learning, the break location is pinpointed. An email notification is sent to the customer, and the results are posted on a cloud-based system, which displays the pipeline status on colour-coded dashboards.
The monitoring, combined with further analysis by Xylem’s engineering service, enables utilities to make proactive decisions about which sections of pipe need to be replaced or repaired as deterioration continues over time.
FLOWMETERS WITH ETHERNET-APL AWARDED FIELDCOMM GROUP CERTIFICATION
FOLLOWING A COMPREHENSIVE series of tests, FieldComm Group, the global standards-based organisation, has awarded Ethernet-APL physical-layer conformity certification to ABB’s first vortex flowmeter (VortexMaster FSV400) and swirl flowmeter (SwirlMaster FSS400) with Ethernet-APL communication interface. Vortex and Swirl flowmeters are among the most widely used flowmeters in process industries.
Ethernet-APL provides full Ethernet and TCP/IP connectivity in hazardous environments such as in chemical factories, oil and gas operations, and hydrogen plants. Up until now, the application of Ethernet in most process industries has remained minimal due to concerns around safety, cost and limitations on cable length which have made it difficult to establish communication networks across large industrial facilities.
“For ABB, this certificate is an important milestone on our journey towards a fully
digitalised instrumentation and networkcentric architecture,” said Tilo Merlin, Platform Manager for Instrumentation and Head of APL Development Program at ABB Measurement & Analytics. “Getting this certificate means we can be quick in rolling out APL technology to other instruments based on the same platform. More specifically, Ethernet-APL-enabled pressure and temperature instrumentation is expected in 2025.”
“Product certification is key for assuring product quality and interoperability in industrial communication networks,” said Paul Sereiko, Director of Marketing and Product Strategy at FieldComm Group.
In June 2024, ABB announced that it was bringing the benefits of Ethernet communications to flow measurement with the integration of Ethernet-APL connectivity in its flowmeters for the first time. The new FSS400 Swirl and FSV400 Vortex
GRUNDFOS MARKS 60 SUCCESSFUL YEARS IN THE UK
GRUNDFOS, A GLOBAL LEADER IN PUMP SOLUTIONS and water technologies, is celebrating 60 years in the UK. Since 1964, when the UK sales company was established, Grundfos has grown to become one of the leading suppliers of pump solutions in the UK.
The Denmark-based company has experienced strong growth in the UK in recent years, doubling its revenue from 2005-2023 with a strong focus on commercial buildings as well as the food and beverage industry.
During the past 60 years, the UK has remained a significant part of Grundfos’ global business and is one of the company’s largest markets globally. As part of its commitment to the UK, Grundfos has continually invested in and expanded its business over the years.
Commenting on the milestone, Glynn Williams, UK Managing Director at Grundfos since 2020, said: “Our longstanding success in the UK is a result of always working closely together with our customers to come up with tailor-made solutions that make a real difference for them, diligently focusing on sustainability in everything we do.”
He added: “We have also been fortunate and skilled to have a loyal customer base that ranges from independent partners to national, multi-branch businesses. Many of whom have been with us for several years.”
flowmeters offer possibilities for simplified connectivity and high-speed collection and analysis of a wealth of process and diagnostic data in the field.
As a global standards-based organisation, FieldComm Group comprises leading process automation organisations, manufacturers, universities, and research organisations that work together to direct the development, incorporation, and implementation of new and overlapping technologies and serves as the source for FDI (Field Device Integration) technology.
2 WEEKS
TOP UK MANUFACTURING APPRENTICE EMPLOYER 2024
AESSEAL IS THE TOP UK apprentice employer in the manufacturing sector for the second time, according to the Department of Education’s annual rankings.
The South Yorkshire-based company, which supplies mechanical seals and reliability services to global industry, was one of 700 major UK businesses assessed, drawn from the public and private sectors.
While the company’s apprentice intake during 2023-24 was significantly lower than many of the other entrants (number one was the British Army), AESSEAL was in the top 7% of all of those assessed, based on criteria including diversity and apprentice completions.
AESSEAL Managing Director, Chris
Rea, said: “Getting and keeping great people is a key part of our formula for business success, and this accolade shows the Department of Education rankings are not purely a numbers game. Congratulations to all the other manufacturing and engineering companies and every other UK business that is investing in the future.”
Overall, 14% of AESSEAL employees started as apprentices and 39 new apprentices were taken on in 2023-24. With an overall placing of 50th out of
700, the company was the top-ranked manufacturer for the second time, after a similar placing in 2022.
AESSEAL offers apprenticeship opportunities ranging from Level 2 to Level 6.
SELWOOD CHOOSES CATERPILLAR AS ITS PREFERRED SUPPLIER OF INDUSTRIAL DIESEL ENGINES
SELWOOD HAS ENTERED INTO A new preferred supplier partnership with Finning CAT, which will see greener, more cost-efficient and easier to maintain engines used across its market-leading pump range.
Pumps manufactured at Selwood headquarters in Chandlers Ford, Hampshire, for international sale and use across its UK-wide rental fleet, will now be fitted with Cat engines, including its C1.7 and C2.2 models in Selwood’s popular 4in and 6in pumps.
Cat engines were chosen by Selwood for their performance, lower engine lifecycle and service costs, fuel efficiency, and ability to run for long periods without requiring maintenance. This reduces the total life cost of pump ownership for customers, cuts emissions and simplifies maintenance.
Cat engines meet EU Stage 5 and EPA Tier 4 Final requirements, supporting Selwood customers to meet environmental standards in Europe, the UK, and the USA.
Dan Whitehouse, Production and Engineering Director at Selwood, said: “As part of an ongoing product development and manufacturing improvement programme, we wanted to simplify our manufacturing process and make it
easier and more cost-effective for our customers to own and maintain our pumps.
“For every engine supplier there is a different control system, spares, servicing regimes, monitoring system and diagnostic tools. Our customers often manage several pumps with different engines. Having Caterpillar as our preferred supplier means this ongoing servicing regime will be simplified across our customer’s fleet of Selwood pumps.
“Caterpillar’s global presence, its engines’ lower lifecycle costs and complete product range from 18kW are just some of the reasons why we chose
them as our preferred partner. Its engines are also well recognised for their tough construction applications and use in rugged environments, which is essential for our pumps.
“Additionally, Caterpillar’s long-term vision to make its products more sustainable aligns with our own commitment to reducing the impact of our operations on the environment.”
The engines come with Caterpillar’s VisionLink Telematics as standard, which provides insights into operating run times, fuel levels, equipment health and more, to help customers manage their Selwood pumps.
FOUR NEW ADDITIONS TO SANIFLO’S PRODUCT PORTFOLIO
SANIFLO HAS INTRODUCED FOUR new products to its product range. The additions include new models of the Sanifos 610 and 1300 lifting stations with radar technology, new Sanisub 800 and Sanisub 800 Rainkit submersible pumps, and a new version of the Saniwall Pro UP featuring a choice of Carrara marble or concrete grey wall panel.
The Sanifos 610 and 1300 underground lifting stations are designed to remove black, grey or rainwater from houses and commercial premises. They are also perfect when adding a garden room, changing the use of a building, or adding an extension, as they can deal with multiple toilets, basins, showers, sinks and washing machines.
The company’s newest solution for this all-in-one underground pump is radar technology, which allows for accurate water level measurements up to 2mm. The new radar technology means that there is no contact with water, so there are no issues with waste or limescale affecting the device.
The new Sanisub 800 can be a stationary or portable submersible pump designed for flooding in domestic and commercial environments. It can discharge up to a
maximum head of 11m and has a flow rate of 15m3/hr. It comes with an integrated non-return valve and has an automatic float arm.
Designed to remove flood water from domestic or commercial properties. This pump is said to be perfect for professionals called to deal with a flood situation.
Automatically triggered by an integrated lever float, this versatile pump can be easily
converted into a low-suction pump for residual water. It features a removable drain and a float lock for continuous operation.
The Sanisub 800 Rainkit is designed to remove flood water from basements, car parks, etc. The kit comprises two Sanisub 800 submersible pumps mounted on a stainless steel frame. These pumps operate alternately and come preassembled.
Ideal for both domestic and commercial environments, the pump kit can raise water up to 11m with a particle size of 20mm without the drain by placing the pumps on the feet provided.
With a Grohe frame with a built-in macerator, the Saniwall Pro UP helps create a contemporary bathroom with a wall-hung WC (not included).
The new Saniwall Pro UP Style comes with the same features but with a new wall covering in either Carrara marble or concrete grey design. The wall panels are only 3mm thick and are made with two layers of aluminium and a polyethene core.
www.saniflo.co.uk
NEWLY AVAILABLE TURBINE PUMP SUITS LIMITED SUCTION HEAD APPLICATIONS
MICHAEL SMITH ENGINEERS HAS added the TPM magnetic coupled peripheral pump, engineered by Dickow Pumpen, to the range of pumps for liquids and chemicals it supplies to UK industry.
The pump is designed to meet the demanding requirements of various industries, including oil & gas, chemical, petrochemical, aviation, and renewable energy.
The TPM peripheral pump, also known as a turbine pump, shares operational similarities with centrifugal and sidechannel pumps, offering the best of both worlds. With its low net positive suction head (NPSH) requirements, the TPM pump is suited for applications with limited suction head.
The TPM range can deliver flow rates
of up to 17 m³/hr and a maximum differential head of 400m. With a design pressure of 40 bar and a maximum operating temperature of 300°C, the range is built to ensure reliable performance even under the most challenging conditions.
One of the standout features of this peripheral pump is its ability to handle liquids with entrained gas, enabling continuous operation even during gas release or temporary air ingress. Additionally, its hermetically sealed design makes it an excellent choice for handling toxic, explosive, or environmentally hazardous fluids, ensuring safety and compliance with stringent environmental standards.
Michael Smith Engineers, Dickow’s
offering underscores its commitment to providing cutting-edge solutions that meet the evolving needs of its customers across diverse industries.
www.michael-smith-engineers.co.uk
The new Sanisub 800 submersible pump
NEW SERVICE OFFERS QUICK TURNAROUND ON BOOSTER SETS
EFFICIENCY-FIRST MANUFACTURER, WILO UK HAS launched a service aimed at delivering a three-to-five working day turnaround on selected booster sets.
With a growing number of properties seeing their taps reduced to a trickle, despite running without issue for decades on end, Wilo has recognised the need for a solution sooner rather than later. The manufacturer’s range of smart cold water booster sets are on hand to deliver constant pressure at every extraction point throughout a building, be it a high-rise block of flats, or a semi-detached house.
The service includes a selection of Wilo’s latest offerings, including the SiBoost range. This heavy-duty system ensures an efficient operation while offering ease-of-use through its smart LCD display, making it perfect for large commercial applications. The Isar MODH1 and the Wilo-Centrum ranges are also covered and, thanks to their compact design, can be used across a variety of smaller commercial operations.
Wilo offers an end-to-end service to ensure that suitable boosters are selected, commissioned and, post-installation, serviced correctly so that they perform at their very best for years to come. Each booster set is assembled locally in the heart of Burton-on-Trent, meaning that it won’t be long before properties are once again receiving adequate pressure.
SEAMLESS INTEGRATION AND MAXIMUM BUILDING COMFORT
NIDEC DRIVES’ NEW CONTROL TECHNIQUES
SI-BACnet IP option module provides enhanced control and maximum efficiency in building automation systems, ensuring accurate and co-ordinated operation to boost occupant comfort.
The new module provides high speed Ethernet-based communication for its flexible Commander C and Specialist Pump Drive F600 & HVAC Drive H300 families. This offers a scalable range of feature sets and performance levels to meet a wide range of fan, pump and compressor application needs. As a result, multiple applications controlled by Control Techniques drives throughout a building can be integrated together for simple and convenient centralised control.
Dual Ethernet ports on the module and plug-and-play integration ensure robust and reliable communications.
SI-BACnet IP enables user commands and provides motor data references to the drive, as well as supplying process values or setpoints to the drive’s PID controller. Drive status information can also be retrieved, while analogue and digital I/O can be easily monitored and controlled. Resetting drive faults is also possible, along with drive commissioning. www.ControlTechniques.com
Wilo’s new service guarantees a turnaround of selected models in just three to five days, making it perfect for those in need of a booster set in a hurry.
6.5 YEARS
bit.ly/WiloBoosting
BPMA WELCOMES NEW MEMBERS
The British Pump Manufacturers Association (BPMA) is delighted to announce the addition of three companies to its membership roster: Innomotics Motors and Large Drives Limited, Bruynseels Ltd, and UK Flowtechnik. These new members bring a wealth of expertise and innovation, further strengthening the BPMA’s commitment to excellence in the pump manufacturing industry.
Innomotics is a leader in the design and manufacture of high-performance motors and large drive systems. Focusing on delivering reliable and efficient solutions, Innomotics has established a reputation for excellence in product quality and customer service. Headquartered in Manchester, its advanced technologies and commitment to sustainability align perfectly with the BPMA’s mission to promote best practices in the industry.
Suffolk-based Bruynseels specialises in the manufacturing and logistics of finished metal castings for pressurebearing applications. The company prides itself on adherence to the highest standards, demonstrated by its ISO 9001:2015 Quality Management System and PED certifications. Its dedication to customer satisfaction makes it a
valuable addition to the BPMA, where it will contribute to advancing industry standards and practices.
UK Flowtechnik is a prominent supplier of flow control and measurement solutions. With a broad product portfolio that includes pumps, valves, and flow meters, UK Flowtechnik serves a diverse range of industries from its base in Nottingham, ensuring optimal performance and efficiency in fluid handling systems. Its expertise in flow technology and commitment to customer care will enhance the BPMA’s collective knowledge base and support the association’s efforts to drive engineering progress.
Wayne Rose, Director and Chief Executive of the BPMA, welcomed the
new members, stating: “We are thrilled to welcome Innomotics, Bruynseels, and UK Flowtechnik into the BPMA. Each of these companies brings unique strengths and capabilities that will undoubtedly enrich our association. We look forward to their active participation and contributions as we continue to promote excellence and innovation within the pump manufacturing industry.”
The BPMA remains dedicated to supporting its members through advocacy, education, and promoting best practices. The addition of these new members reflects the association’s ongoing commitment to fostering a collaborative and progressive industry environment.
UPCOMING TRAINING AND EVENTS FROM THE
Celebrating excellence: The role of awards programmes in industry
Andrew Castle, Director of Touchwave Media, the organisers of the British Pump Manufacturers’ Pump Industry Awards, explores the wide-reaching benefits of engaging with a well-established industry award programme.
In the busy world of modern industry, where competition is fierce, and innovation is the lifeblood of progress, the significance of annual awards programmes cannot be overstated. These programmes serve as beacons of recognition, illuminating the achievements, fresh approaches, and exemplary practices that propel industries forward. From fostering a culture of excellence to inspiring future advancements, annual awards programmes play a pivotal role in shaping the trajectory of industries worldwide. At the heart of annual awards programmes lies the celebration of excellence. By honouring individuals, organisations, and initiatives that demonstrate outstanding performance and innovation, these programmes recognise industry leaders' hard work and dedication and inspire others to reach greater heights. The spotlight cast by awards serves as a powerful motivator, encouraging individuals and teams to strive for excellence in their endeavours.
Moreover, annual awards programmes provide invaluable opportunities for networking and knowledge sharing within industries. As nominees and winners gather, they can exchange ideas, forge partnerships, and learn from one another's successes and challenges. This collaborative spirit fosters a culture of continuous improvement and drives innovation by facilitating the crosspollination of ideas and best practices. Beyond individual recognition, annual awards programmes also serve as a barometer of industry trends and priorities. By examining the criteria and categories of awards, industry stakeholders gain insights into emerging technologies, market demands, and areas of opportunity. This awareness enables businesses to align their strategies and investments with industry trends, ensuring they remain competitive and relevant in a rapidly evolving landscape.
Furthermore, annual awards programmes are crucial in building trust
and credibility within industries. Winning prestigious awards enhances the reputation of individuals and organisations and instils confidence among customers, investors, and stakeholders. The stamp of approval conferred by awards is a testament to the quality, integrity, and excellence of products, services, and initiatives, fostering loyalty and driving business growth.
Importantly, annual awards programmes contribute to developing talent and leadership within industries. These programmes inspire the next generation of industry leaders and innovators by highlighting exemplary achievements and novel approaches. The recognition bestowed upon award winners not only rewards their efforts but also serves as a platform for mentorship and career advancement, empowering individuals to make meaningful contributions to their fields.
In conclusion, annual awards programmes are indispensable assets that enrich, inspire, and propel industries forward. By celebrating excellence, fostering collaboration, and driving innovation, these programmes recognise today's achievements and lay the groundwork for tomorrow's advancements. As industries continue to evolve and face
new challenges, the importance and value of annual awards programmes will only continue to grow, serving as beacons of inspiration and catalysts for progress.
The pump industry is extremely fortunate to have just such an awards programme. Backed by the British Pump Manufacturers' Association since its launch 25 years ago, the annual Pump Industry Awards continues to recognise, celebrate and reward professional and engineering excellence across the pump manufacturing, distribution, and installation arena.
The next presentation evening takes place on the evening of Thursday, 13 March 2025, at the Hilton Hotel, St Georges Park, Burton On Trent – the home of English Football.
If you and your colleagues would like to play your part in celebrating excellence, be sure to book your table for what will undoubtedly be another wonderful evening of success. And if your company has something or someone to shout about, the closing date for entries is Friday, 29 November 2024. chevron-circle-right
www.PumpIndustryAwards.com
MAINS WATER CONVERSION TO BOOSTED SUPPLY
AN EIGHT-STOREY BUILDING IN Trafford Park recently ran out of water in its top two floors due to ever-decreasing mains pressure. This caused large-scale operational issues on site, and as such, a permanent solution to boost the water to the property was needed quickly.
Working with its customer Equans and their site team, Pressboost was able to locate a room on site that could be utilised for tanks and a booster set and quickly sourced the equipment needed.
Over the course of two days, a team member attended to modify the incoming mains to feed two new storage tanks and installed a Lowara GHV20 Hydrovar
X Booster Set to boost the supply to the property.
The entire property now has a boosted supply and a future-proof solution for its water distribution.
A highly practical installation, the two tanks allow for future maintenance without disruption, the new booster set benefits from highly efficient IE5 rated motors, a flow through expansion vessel and valve and Hydrovar X inverters.
Thanks also to the enabling works undertaken by Equans, the combined installation provided a smart and swift solution for this site.
INLINE PUMP BOOSTS DOMESTIC WATER PRESSURE
A HOMEOWNER IN A NEW BUILD house suffered from poor mains water pressure and flow. The mains delivered 1.5 bar water pressure, and when only one tap was on, the pressure dropped down to 1 bar. This was on the first outlet (the kitchen tap) coming straight from the mains system. A flow test showed that on this tap, the householder was getting 9l/min.
However, the main problem area was upstairs, where the flow was so bad that they couldn’t even have a shower. The cold and hot water flow from the basin
was around 3-4l/min, while in the bath, the cold water flow was just 3l/min, and the shower was dripping.
As the householder had a mains-fed combi-boiler system and such a low water flow, a Salamander Pumps’ Technical Advisor recommended the installation of a HomeBoost pump.
HomeBoost is an intelligent inline pump that will quietly boost mains water flow via a combination boiler up to 12l/min.
The installer had already fitted HomeBoost pumps before and was impressed by how good they were; he had
IMPROVING WATER PRESSURE ON A
MAWDSLEYS PUMP SERVICES WAS recently contacted by a local nightclub that had issues with water pressure and supply during peak times.
On busy nights, the water at the top of the boat becomes non-existent and eventually, this leads to the whole nightclub being without water.
Having no access to water during busy times was not acceptable and would potentially result in the venue having to close early.
During an initial on-site inspection, Mawdsley’s engineers encountered an immediate challenge in finding a suitable location to install a booster set and tank as almost every inch of the boat was in use.
With no space on site, the engineers determined the best course of action would be to mount a cold water tank with booster
pumps on either the deck area or on the harbourside itself.
After further investigation, an ideal external location was found, which was close to the incoming main on the boat and within adequate proximity of an electrical source.
no doubts that this pump would be the perfect solution to low water flow to this property.
The HomeBoost installation boosted water flow up to 12l/min to the kitchen tap. The HomeBoost pump also increased water flow to 12l/min from the bath tap, and the shower’s performance was significantly improved.
www.salamanderpumps.co.uk
FLOATING NIGHTCLUB
A Pedrollo Flow V Twin Booster Set, an above-ground, single-piece, self-contained pump station which features a 2000l tank compartment, was installed.
The tank is fully WRAS-approved with a dry compartment that houses the booster set and electrics. The dimensions of the unit are 3192mm x 1192mm x 1123mm high and therefore, the location chosen provided
adequate space.
The tank was mounted over the railings to avoid any damage from vehicles and ensure it didn’t stop access to and from the boat.
The invertercontrolled pumps mean at low demand, the energy consumption is kept to a minimum, and at peak demand, the pressure is constant, making sure the boat doesn’t run dry. www.pressboost.co.uk
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ENSURING THE POWER OF TOMORROW WITH EUROPEAN ENERGY
EUROPEAN ENERGY IS constructing the largest E-methanol plant in the world. With an array of DESMI centrifugal pumps, it is able to provide ships around the world with about 32,000 tons of E-methanol every year while also forwarding the excess heat for over 3,300 local households. All with renewable energy.
At the heart of European Energy’s Power-to-X plant in Kassoe, Denmark, are 11 Balance-of-plant pumps. By leveraging power from the region’s largest solar park to split water into hydrogen and oxygen, these pumps have been specifically engineered to maintain the correct temperature for the electrolysis needed in the process. The effort not only optimises performance, but also safeguards the longevity and efficiency of the plant.
As CO2 is added to hydrogen, the plant produces E-methanol, which is a versatile
fuel that holds promise for myriad applications, from powering methanol-fuelled ships to supporting production processes for industry giants.
DESMI’s involvement in the project extends beyond pump installation; the company has been there throughout the project’s journey, from the design of the pilot plant to the commercialised facility. During the design phase, DESMI collaborated closely with the engineering company to optimise the cooling system.
at European Energy. “The pumps were chosen based on their balance of cost-effectiveness and quality. They lived up to expectations.”
The integration of DESMI’s pumping solutions ensures seamless fluid handling throughout the Powerto-X conversion process. From precise temperature control to efficient energy conversion, the pumps enable European Energy to achieve optimal performance in their flow processes.
“DESMI has been a trusted partner through the building of the plant in Kassoe,” said Ricki Refstrup, the Maintenance Lead
www.desmi.com
NEW SCREENS FIRMLY IN PLACE DESPITE UNPRECIDENTED STORMS
AT A CRUCIAL STAGE of a £43M upgrade, including a critical inlet screen and screen handling replacement, the last thing a contractor would want is for not one, not two, but three back-toback storm events.
Yet for one leading solution provider to the water industry, it provided the ultimate test for new inlet screens at Hartshill Sewage Treatment Works (STW) near Nuneaton in Warwickshire.
Since July 2022 (through to November 2024), MWH Treatment has been responsible for the design and integration of new inlet screens and screens handling, the expansion of the current primary and secondary treatment, and the addition of a new tertiary treatment and a sludge treatment system at the STW.
This important STW is an all-flowsworks, being upgraded as part of proactive capital maintenance and in readiness for an additional 430l/s, which is to be pumped over from Hinckley in nearby Leicestershire to create a total flow of 1560l/s.
Working to reduce steel and concrete
use where possible, Severn Trent Water and MWH Treatment wanted to reuse the existing inlet structure – removing the need for any new civils, or modifications to the existing assembly, which would have increased the programme of works substantially, adding to costs, environmental impact and health & safety risks. Using 3D digital models to increase on-site productivity, and with the benefit of wastewater handling solutions specialist SPIRAC’s vertical, space-saving screens able to reach 2m down (rather than a restrictive 1m), the inlet was meticulously planned out in the virtual space. This has made it much easier and more economical to fine-tune the design rather than have equipment arrive on site only to be sent away again for modifications.
“From the start, SPIRAC assigned a dedicated team so we could have continuity and clear lines of communication,” said Vince Walker from MWH Treatment. “Leading up to the pressure of the switchovers from old to new equipment we were regularly sharing
our computer screens with SPIRAC’s Projects & Technical team so that the new temporary launder systems would keep us online and that we could be certain that the final screens would be spot on –pre-assembled, tested, ready to slot right in. In the meantime, SPIRAC removed all the redundant equipment and supplied us with a new control philosophy for the new screens and compactors.”
Vince added: “It seems easy to say now, especially with the foul weather after the commissioning works, but this is where planning and collaboration is so important. In a carefully managed, phased approach, we had five separate stages of switching over. SPIRAC ensured that flows were maintained, but with no loss of screening.”
The SPIRAC system has been integrated into the Hartshill treatment works system for the past six months, facing persistent heavy rain. This has proved that the new screens could do their job. Overall, the throughput has been increased by 200 l/s, but they are working as expected and with their self-cleaning design, only basic maintenance is required.
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Capture carbon with side-channel pumps
With the ever-present focus on reducing carbon emissions, CDR Pumps, a specialist in chemical process pumps, looks at the role side-channel pumps play in carbon capture and storage plants and what makes them suitable for the application.
CO2 capture and storage, commonly known as carbon capture and storage (CCS), is a technology used to reduce the release of greenhouse gases and reduce the carbon footprints of a variety of industries. The process involves capturing CO2 from the emissions generated by industrial processes and power plants and storing it in geological formations.
In 2024, builders depend on side-channel pumps to meet the specific requirements of constructing CCS plants. These requirements include low NPSH values, high delivery heads, the ability to withstand extremely low temperatures (down to -60°C), and the ability to handle two-phase flows with up to 50% gas content without damage. Side-channel pumps have been chosen due to their reliability in meeting such demanding criteria.
Capturing and storing CO2 is crucial in the decarbonisation of industrial processes. Today, CCS plants are mainly being constructed in sectors where significant amounts of greenhouse gas are produced, such as power plants that utilise fossil fuels, the chemical industry, oil and gas refineries, the cement industry, iron and steel mills, and the maritime industries. By capturing and storing CO2 in their applications, it is also possible to generate environmentally friendly energy, such as the production of blue hydrogen or the supply of liquefied CO2 for heating purposes, process engineering, or the shipping industry thereby reducing carbon emissions and promoting sustainability.
WHY SIDE-CHANNEL PUMPS?
When using side-channel Pumps in your carboncapturing process, CO2 is captured, and then it goes through a compression stage where it is subjected to high pressure so that it can be transported as a liquid to its destination for use or storage. The biggest benefit of side-channel pumps is that they meet the technical requirements required, but they can also be used in varying stages of the process, from carbon-capturing through to transportation and on to its final destination, whether that be recycled for use in other applications or in solid form and returned to depleted oil fields.
Side-channel pumps have been manufactured to withstand challenging process conditions. These pumps are specifically designed to handle high pressures, reaching up to 100 bar. They are also capable of operating within a wide temperature range, spanning from -60 to +220°C. This versatility allows for the reliable transportation of low-temperature fluids such as CO2 and ammonia, which transition from a gaseous to a liquid state at temperatures around -57°C and -33°C, respectively.
The design of side-channel pumps incorporates various features to accommodate demanding conditions. These include spring assemblies to compensate for thermal expansion and contraction of the hydraulics and elongated inserts which prevent temperature-induced
channel pumps is their ability to perform even when gasses are present in the fluid. When pressurisation changes and the temperature increases, substances like liquid carbon dioxide and ammonia tend to transition into a gaseous state; side-channel pumps have consistently proven to be reliable over extended periods of time – even with two-phase flows with up to 50% gas content – mitigating concerns related to vapour formation and the potential impact on delivery.
The first CCS plant projects are now underway using side-channel pumps, which shows that they are a valuable asset in carbon capture and storage and have been instrumental in reducing carbon dioxide emissions and promoting sustainability. chevron-circle-right
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Creating a bright future for aspiring engineers
Ben Warren, Rising Star award winner at the 2024 Pump Industry Awards, and Team Leader of SPP Pumps’ Future Cell training programme, looks at how considered and wellinvested training programmes can overcome the skills shortage and provide engineering opportunities to both apprentices and existing employees.
The skills shortage in engineering services is very real and is hitting hard in some sectors of the economy. In particular, the Engineering Construction Industry Training Board (ECITB) has highlighted a number of workforce challenges facing the water treatment and oil and gas sectors due to an ageing workforce. An estimated 19.5% of engineers currently working in the UK are expected to retire by 2026. Ensuring that the UK's future engineering needs are met is going to call for significant investment in skills among the next generation of engineers. While industry bodies like Engineering UK and others are calling for clear and properly funded STEM skills plans, many commercial organisations are boosting the skills of their own employees through training programmes.
SPP Pumps is combatting the skills shortage challenges with its 'Future Cell' initiative. This new training area is aimed at both apprentices and existing employees who want to reskill into an engineering role or simply take the opportunity to learn from experienced colleagues.
Designed, planned and implemented by SPP's machine shop team, Future Cell's initial objective was to provide an opportunity to extend knowledge and skills through a series of challenges, working on real-life pumping products and projects.
Investing over half a million pounds in specific equipment and developing learning programmes, the project was designed with a practical focus, ensuring that participants would gain hands-on experience and recognised qualifications through work-based operations in a fully equipped operational machining cell.
Two new CNC machines with remote monitoring and wireless probing help enable trainees to develop key programming and machining skills while producing critical pump components. The success of the initial three-month project
proved the value of such an approach and secured further investment in equipment, with a state-ofthe-art Electric Discharge Machining (EDM) tool recently being added to the programme.
And, with the purchase of three conventional machines, trainees are given the opportunity to become proficient in the underpinning knowledge essential to CNC machining and production engineering. In addition, a bespoke quality area in the machining cell gives apprentices the capability to inspect both their own and others' work to both SPP's and broader industry standards – essential for safe, high-quality operations.
training accordingly, ensuring they gain the necessary knowledge and confidence to make technical decisions to help optimise the process' capacity and productivity.
Future Cell was launched in late 2023, and within its first three months had exceeded its six-month productivity goal.
PEOPLE AT THE HEART
A large part of the programme's success was ensuring that the project leader had personal experience of being an apprentice. Having joined SPP Pumps at 16 as a mechanical engineering apprentice and benefiting from outstanding training to become a multi-skilled machinist, I was selected to lead the Future Cell programme.
As its name suggests, Future Cell has a clear objective of developing the next generation of skilled machinists. With the help of other experienced members of our team, we aim to offer a versatile training environment covering all key machining disciplines while producing high-quality components and reducing sub-contracting costs.
We've created a structured training plan that ensures all apprentices cover the essential skills. We identify individuals' strengths and weaknesses and tailor their
We are keen to raise the aspirations, employability and opportunities among local young people, as well as the wider community. Future Cell provides a golden opportunity for young men and women interested in engineering – and specifically the pumping sector.
The machining team has been engendering excitement and interest in engineering in the local community through primary school visits, secondary school careers events and scouting engagements. Together with other STEM initiatives, the Future Cell initiative is the most recent investment in SPP's wider project to address and hopefully head off the future skills shortage.
With provisions for all ages often featuring discussions around imagining a world without pumps, the team has sought to increase understanding that a career in engineering, and more specifically, the pumping industry, is available and rewarding. chevron-circle-right
www.spppumps.com
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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.
Finding the keys to success in the water and wastewater sector
As pump company Börger celebrates the 20th anniversary of establishing what has become a successful UK operation, Managing Director David Brown reflects on his journey and how the market and the technology he supplies have evolved over the last two decades.
flow: David, how did you come to be at Börger, setting up the UK subsidiary?
David Brown: I was working in sales for a large compressor and pneumatics company, but when they made what I thought was a very unwise change in senior personnel, I believed it was time to get out. I saw a really interesting job in The Daily Telegraph for a sales engineer, but it asked for some ‘basic German language skills’. I didn’t speak German but thought I’d apply anyway – and before I knew it, I was being interviewed by Alois and Anne Börger at Birmingham Airport. And as they say, the rest is history.
f: What were the early days like for Börger UK?
DB: Very busy. I hit the ground running with sales to customers in the industrial sector and, in no time at all, was having an extension built at home as I’d outgrown the dining room table and soon had two colleagues working with me.
f: Although the industrial sales were going well, getting a foothold in the water/wastewater industry must have been an important goal.
was starting to keep a closer eye on power costs before the energy crisis, but now, even more so.
f: How has the technology you supply evolved to meet those changing demands?
DB: Motor efficiencies have changed for the better, moving from ‘Efficiency 2’ motors up to IEC 3 (International Electrical Commission), and now there is an increasing demand for IEC 4. There is also a huge demand for less time-consuming upkeep of equipment; here I think we’ve been way ahead of the game with our long-established maintenance-inplace design.
DB: Yes. We wanted the larger orders to sustain our business and knew we had a good product to sell.
f: When did you manage to break through into the industry?
DB: The most significant moment was back in 2006 when I saw Thames Water at Mogden. I put the cutaway model of my demo Börger pump on the table when I arrived, but after a long journey, I had to dash the loo before we could start the meeting. When I came back, the guys from Thames said: ‘How long have you got?’, ‘Do you want to grab your
high-viz from your car?’, ‘We’ve got some pump jobs for you to look at’.
Unbeknown to me, they’d taken the Börger model apart and put it back together before I got back to the meeting room.
They loved that our rotary lobe pump was so simple and had a ‘maintenancein-place design’, so it would be very easy to service. I put together the quotes that evening in my hotel room, and we won three of the four contracts on offer, one of the orders being for 16 pumps, so that really was our big breakthrough, putting us on an even more solid footing.
f: Over the years since you started Börger UK, how have you seen the demands from the water and wastewater industry evolve?
DB: There is more focus now than ever before on environmental impact. Not surprisingly, we’ve always put evidence forward that rotary lobe pump designs are a far more efficient pumping method. The water and wastewater industry
f: And how do you see the demands of the sector, and the technology that is supplied, developing over the next five, ten or 20 years?
DB: As demand increases to handle various challenging sludges, especially in the growing use of THP (thermal hydrolysis plants) there will be less use of elastomers and more implementation of steel rotors. Due to demand, we’ve just launched our OrbitGrinder, a cutting basket macerator that shreds solids; a completely new technology for the sector.
If the water industry is ever allowed to take in food/organic waste for codigestion with municipal sludge, we could see a big surge in demand for suitable pumps and macerators. We’re ready to go now with our equipment, but because of such very different waste streams, with food waste so contaminated, I can’t see it happening for a very long time, if ever. chevron-circle-right www.boerger.com/en_UK
David Brown brought Börger to the UK 20 years ago.
Ramp up the pressure with cold water booster sets
With the nation facing the task of bridging the gap between demand and supply for water, cold water pressure booster sets are becoming more important in both retrofit and newbuild developments. Jason Cox, Sales Director – Building Services at Wilo UK, outlines how smart water pumps could be the immediate fix to an emerging concern.
The fight for water supply is becoming an increasingly tough battle to win. It’s currently estimated that by 2050, demand for water will outweigh supply by almost five billion litres per day, which is more than a third of the 14 billion litres currently put into public supply.
Once required only for high-rise buildings, cold water pressure boosters are now essential in a variety of properties, both new and existing, that are unable to yield sufficient pressure. But why?
THE REASONS FOR INSUFFICIENT PRESSURE
It’s impossible to lay the blame on a singular factor. With developments cropping up in the nation’s busiest cities, the lack of available supply often results in a pressure reduction to Ofwat’s minimum stipulation of 0.7 bar.
The reality, however, is that certain outlets in high-rise buildings, and even those with two- or three-storeys, won’t even receive this, depending on their geographical position. The issue of outdated, failing water infrastructure in some areas of the country only exacerbates the challenge.
Many homes in London, for example, are served by old water infrastructure that provides a limited flow due to small-diameter pipes. What’s more, some water companies have been forced to reduce the water mains pressure simply to protect pipes from bursting. The culprit? Plastic pipes, which were fitted in the late 1970s
and early 1980s, failing decades earlier than they were designed for. It’s safe to say that neither of these issues can be solved with a quick fix, meaning an alternative solution is required for the building service engineers tasked with boosting pressure effectively and affordably. Cold water booster sets could be that solution, delivering constant pressure at every extraction point throughout a building.
By 2050, demand for water will outweigh supply by almost five billion litres per day.
creating sustainable solutions against the nationwide focus on driving toward Net Zero. Hence, before specifying any solution, performing on-site energy reports can help relevant parties understand the importance of installing or retrofitting the latest pressureboosting technology.
SMART, SUSTAINABLE SOLUTIONS
Besides this, the building industry is also facing the challenge of
Energy reports are a surefire way of demonstrating the potential energy, carbon, and cost savings available from a suggested upgrade. Wilo offers this service as part of an end-toend solution, plus an estimated payback period, so customers
Pressure Boosting
know when to expect these savings to come to fruition. Product selection support is just as important to ensuring the long-term success and reliability of an upgrade. Specifiers and building service engineers who may require assistance with the selection, supply, and commissioning of pump equipment for their projects are encouraged to utilise the help made available by manufacturers like Wilo.
SPECIFYING BOOSTER SETS
When it’s time to replace existing boosters, selecting a smaller motor that can supply that same demand for water pressure will go a long way towards improving energy efficiency. For instance, replacing older, less efficient equipment with booster sets that feature IE5 motors can provide invaluable carbon and energy savings.
Wilo’s SiBoost 2.0 Smart Helix VE is the manufacturer’s most recent booster set for commercial applications. The heavy-duty system ensures efficient operation while being easy to use. This, in part, is made possible by its smart LCD, which is designed to make installation simple. Post-installation, the system notifies end-users of any issues, such as insufficient pressure, before they worsen.
PROGRESS IN PRACTICE
From schools and hotels to hospitals, insufficient water pressure is undeniably a nationwide issue pushing organisations across the country to act. A popular student residence in southwest England is just one example, as the building’s operators initially reached out to Wilo for an on-site energy report.
It was discovered that the building owners could save over £6,000 and more than 46,000kWh a year through efficient, straightforward improvements to the property’s booster set. It was also determined that an upgrade to Wilo’s SiBoost Smart Helix VE would pay for itself in just over three years, all while producing carbon savings of over 10,000kg per year.
This shows the hidden potential for savings that most owners or operators have within touching distance. A simple task like replacing outdated booster sets can make a significant difference, all while adding peace of mind to a building’s residents that their tap won’t be reduced to a trickle anytime soon.
UNDER PRESSURE? NOT ANYMORE
To combat the issue of insufficient water pressure, the industry’s solution providers, like Wilo, guarantee an end-to-end service to ensure that suitable boosters are selected, commissioned, and, post-installation, serviced correctly, so that they perform at their best for years to come. Wilo has worked with the country’s largest housing associations, hospitals, and accommodation providers to gain the necessary experience required to help any business overcome what may be a unique water pressure issue.
Wilo can also select, build, and deliver a booster set within three to five working days, meaning that it won’t be long before tenants are once again receiving sufficient pressure and building owners are making long-term energy savings. chevron-circle-right
wilo.com/gb/en
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Submersible mixers support huge wastewater treatment project
As part of one of the largest investments in Europe for wastewater treatment, a plant near Naples, Italy, was equipped with innovative technologies to improve water quality while minimising energy usage. At the core of effective denitrification operations are Sulzer’s XRW 400 submersible mixers with a permanent magnet motor, which could cut energy costs by up to €45,000.
The large-scale project aims to improve the quality of the coastal environment and the waters around Naples by revamping and upgrading key water and wastewater treatment facilities in the region. This program represents the largest European investment in water purification and decontamination for the past 20 years, supporting the treatment of wastewater from over 4.5 million inhabitant equivalents (900,000m3 of water per day) in the region.
One of the five facilities selected is among the largest in Europe. Established in the 1970s, it gathers wastewater from a large area in the northern part of Naples and has a processing capacity of 240,000m3 of water per day (1.2 million inhabitant equivalents). To continue supporting the region, key improvements were required to optimise the sewage treatment process and energy consumption while ensuring regulatory compliance.
AN INNOVATION TANK
submersible mixers.
To meet the objectives set out for the successful re-functionalisation and modernisation of this infrastructure, a leading water and waste service specialist contacted Sulzer. The companies have a longstanding relationship, and through multiple international collaborations, the specialist has been able to learn more about Sulzer’s state-of-the-art technologies and services, growing its confidence in the ability of its partner to deliver well-suited solutions. In particular, there was enthusiasm to adopt 28 of Sulzer’s highly energyefficient mixers, such as the XRW 300 range of submersible units, for the 14 denitrification tanks within the wastewater treatment plant.
Used to remove nitrogen from wastewater effluents, the tanks installed
These are extremely compact, delivering effective processing of wastewater, and are equipped with Premium Efficiency IE3-equivalent, sensorless, permanent magnet motors that are controlled by variable frequency drives.
“This means that they can adjust their speed to suit the real-time environmental conditions rather than maintaining a set speed at all times. As a result, it is possible to reduce energy use whenever possible, delivering significant benefits when it comes to operational costs and environmental performance.”
DRIVING PERFORMANCE
In practice, the use of conventional solutions with IE3-equivalent, three-phase, squirrel-cage motors could reduce energy costs by €8,000 at the plant.
Conversely, the XRW 400 series could slash such expenditures by more than five times, delivering savings of up to €45,000. Even more, the presence of
activities and their associated costs.
Following the installation, commissioning and startup of Sulzer’s submersible mixers, the plant and its denitrification tanks have been running smoothly. These have efficiently processed large volumes of wastewater daily while meeting environmental standards for effluents.
Elisabetta commented: “We are very happy with our collaboration on this project. The XRW 400 mixers are the first to run via permanent-magnet motors and represent the only solution of this kind that would meet the equipment specifications for the denitrification tanks. We are sure there will be many other treatment plants that will look to collaborate with us and achieve similar benefits.” chevron-circle-right
Aluminium pump proves ideal for pH level adjustment
When fluid circulation specialist Trebles heard that Siltbuster, a water treatment solutions provider, wanted to utilise a submersible pump and experiment with pH level correction in water, it swiftly offered an Atlas Copco WEDA D50 to aid in the experimental setup, as flow found out.
Siltbuster is a leading provider of environmental solutions for responsive water and wastewater treatment. The company sought to develop an extremely efficient method for introducing gas into water through a pH correction system.
By equipping Siltbuster with a WEDA D50 submersible pump, a solution has been devised to adjust the pH level in water. This approach entails attaching a Venturi system to the pump’s discharge, facilitating the injection of CO2 vapours into the water.
The WEDA D50’s lightweight aluminium construction, weighing approximately 55kg, as opposed to its cast iron counterpart weighing 70kg or more, significantly aids with the transportation of the pump, making handling much easier.
PH CORRECTION SYSTEM
When Trebles initially had a discussion with Siltbuster, the company wanted to develop a highly efficient method for gas transfer into the water to ultimately optimise wastewater treatment processes by correcting pH levels.
“The pump is of really high quality; one of the first things we do when we receive a pump is check the weight of the unit. If it’s got good weight and gravity, it obviously has a decent amount of metal in it. The next thing is that we literally tap the side of the pump to ensure there are no hollow spots inside it or that it’s got a good thick casting on it. So, my initial impression was that the stator housing is obviously a decent thickness because it doesn’t sound hollow,” explained Chris Lawless, Siltbuster’s Operations Technical Engineer.
The devised solution involves a sophisticated approach to pH level correction in wastewater treatment processes. By connecting a Venturi system to the discharge of the WEDA D50 pump, the methodology enables precise injection of CO2 vapours into the water. This innovative technique aims to achieve
the desired results in adjusting pH levels, thereby improving the overall efficiency of water treatment operations.
“The predominant application is a gas saturation process. To correct the pH of alkaline water, we’ll be adding CO2 vapour. I’m actually going to add a Venturi system to the discharge of this pump to inject CO2. This pump will be submerged inside a tank, so it’s going to be an extremely efficient way of transferring gas into water and correcting the pH. So, this is ultimately going to be a pH correction system,” added Chris.
A notable advantage of the pump lies in its lightweight aluminium construction, weighing approximately 55kg.
This marks a significant difference from the conventional cast-iron equivalents, which typically surpass 70kg in weight. The substantial weight reduction not only enhanced operational manoeuvrability but also simplified the transportation of the pump, thereby streamlining logistical processes.
Throughout testing, Siltbuster discovered several pointers for optimising the pump’s performance. One notable observation was the importance of clear labelling regarding Direct-On-Line (DOL) operation on the pump casing to prevent damage to internal electronics, particularly when powered by an inverter. Additionally, it was noted that threaded aluminium connections could experience galling and seizing when attached to galvanised flanges. To prevent this, it is recommended that anti-
seize be applied to all aluminium threads before attachment to dissimilar metals.
Additionally, users expressed a desire for a central lifting eye to attach a ‘D’ shackle to the handle to aid in manoeuvrability, and they would recommend exploring the availability of an anode kit for marine environments.
One feature noted by Siltbuster was the use of yellow paint, which notably enhanced the pump’s visibility once it was submerged. This helped to improve safety and allows for easy monitoring during operations. The integration of an overload and rotation relay system also proved highly beneficial. This feature minimises the need for service calls due to issues such as incorrect running or overcurrent, especially when wired DOL. Ultimately, it ensures smoother operation, reduces maintenance requirements and contributes to the overall efficiency and reliability of water treatment processes.
The teamwork between Trebles and Siltbuster demonstrates a shared dedication to pushing the limits of water treatment technologies. Through partnership, creative approaches, and a strong focus on environmental responsibility, this project highlights how it is possible to pave the way for new solutions in water treatment. chevron-circle-right
TOUGH PUMPS, POWERFUL PERFORMANCE
In everything we do, we never lose sight of what it‘s all about for you: economical work and easy handling.
Whether chemical substances, oils or media for the food industry, it is important to fill or empty quickly and precisely. Due to the reversible conveying direction, both processes can be carried out with just one pump.
As a result of their compact yet powerful construction, Vogelsang rotary lobe pumps are among the most frequently ordered pumps in many UK industries. They transport highly viscous or aggressive media of all kinds and even pump liquids with rough solids without blocking.
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For more information: sales.uk@vogelsang.info | 01270 216 600 vogelsang.co.uk
Large housing developments that cannot connect to the main sewer by gravity require packaged pumping stations to perform the vital task of safely removing wastewater. They must be designed to meet water company standards. Helen Wilson, the Industry & Infrastructure UK Manager at Xylem UK, answers the questions developers may ask before selecting a pumping station.
Packaged pumping stations (PPSs) are factory-built systems that pump wastewater and stormwater from a site into the public sewer network for treatment and disposal.
The systems are typically used where a development cannot connect to the public sewer system by gravity. It may be situated below the network, in a remote or inaccessible location, or a considerable distance away from the main sewer, making a traditional gravitybased system unfeasible or not costeffective.
Do I need to liaise with the local water company before installation?
and controls. This means the installation process is simple and can be arranged to suit programmes work, saving onsite buildtime and reducing disruption.
If you are constructing sewers or pumping stations as part of a new development, it is advisable to apply for an S104 connection in the design phase of a new project. This process allows the local water company to adopt the new sewerage system under Section 104 of the Water Industry Act 1991. By doing so, you ensure that your development complies with industry standards and that the sewer network is properly integrated into the existing infrastructure.
The station design and installation must comply with the industry’s Sewage Sector Guidance (SSG), a suite of documents that sets out adoption requirements, including location, size, pipework, valve layout, pump types, level and control specifications. The SSG was introduced in April 2020, replacing the Sewers for Adoption guidance.
How long will it take to install a packaged pumping station?
PPSs are pre-assembled units that are delivered to the site fully kitted out with components, including pumps, pipes, valves,
Xylem’s Flygt brand offers a range of packaged pumping stations, which it aims to specify, price and supply within four to six weeks. To avoid any site-specific issues, Xylem engineers will work with the developer to clarify details such as where the station will be situated. Does it have clear access? Has the correct access cover been specified? And, importantly, has a groundwater survey been carried out?
Who will be responsible for the management and maintenance of the pumping station once installed?
Water companies and New Appointments & Variations (NAVs) – limited companies selected to run water and sewerage services in specific geographic areas – are recognised as the most suitable owners of sewerage networks. Once satisfied the pumping station has been completed to the agreed standard, the utility will adopt the asset and take over its management.
Before this can happen, a pre-adoption onsite inspection is usually carried out to ensure all works have been completed as per the design. Representatives from the water company, the developer and, where Xylem is the supplier, a member of its
engineering team are all involved.
As a turnkey service provider, Xylem offers developers a preadoption advisory service and full technical submission to be used to apply for an S104 legal agreement.
Are packaged pumping stations easy to maintain?
The right packaged pumping station will provide efficient and reliable pumping for new housing, from single dwellings through to major developments. Models with high-end pumps will provide decades of service and, in the long term, will be more efficient than alternatives such as septic tanks or onsite treatment units.
Xylem’s engineers advise at least one service visit per year to lift and check the electrical pumps. If the station is found to receive large volumes of unflushable items, such as wet wipes and nappies, they would recommend up to four visits per year.
Are smart pumping stations now available?
As urbanisation increases and developments expand into more remote and inaccessible areas, the need to efficiently pump wastewater to treatment works becomes amore crucial consideration. As such, the technology is becoming more intelligent to meet changing customer needs.
One example is the Flygt Concertor, which was the world’s first wastewater pumping system with integrated intelligence. The smart system is capable of sensing the operating conditions of its environment, adapting performance in real time and providing feedback to operators. chevron-circle-right
www.xylem.com/en-uk
A mobile application enabling paperless service and repair
Why is Smart Site right for you?
Smart Site is easy to use on any smartphone or tablet device and requires very little training.
Smart Site reduces the waiting time of documents in transit. All job information is visible at the office as it happens.
Smart Site delivers accuracy. The app captures information as it happens, meaning there is less chance that something important is missed or recorded incorrectly.
Smart Site streamlines the administrative process ensuring that contracted and chargeable work can be completed in a timely fashion and invoiced with complete confidence.
Smart Site stores the history of an asset’s repair and service, so your engineer has all of the detail they need to do the job right first time.
See Smart Site in action!
Utilities, Water & Waste Treatment
Microbiological analysis for drinking water takes a step forward
Microbiological analysis specialist bNovate Technologies explains how automated flow cytometry, which offers fast, accurate and efficient cell detection, is protecting residents in a Swiss village from the ill effects of a contaminated water supply.
At the foot of the Pierre Avoi Mountain in the Swiss Alps, the village of Saxon has a singular history with water. A spa town in the 1850s, it is an idyllic, natural setting, with most of its drinking water, which is drawn from mountain springs, injected directly into the network without filtration or treatment.
However, it was not so idyllic when in the past, residents of the 7,000 strong community, some in very remote areas, fell ill because of significant bacterial contamination.
Only recently, in one of England’s most popular holiday destinations, Devon, cryptosporidiosis found in the supply from South West Water caused vomiting and diarrhoea, not to mention disruption, distress, anxiety and anger. This incident was closely followed by numerous people falling ill in Beckenham and then a warning in Surrey, also under Thames Water, for the 600 people in the village of Bramley not to drink tap water due to contamination.
Whether in the Swiss Alps, an English tourist county or elsewhere, those responsible for water supply do take action and apologise, but by then, it is always too late for those affected.
SPEEDING UP RESULTS
Monitoring is in place, of course, but gaining results from traditional methods of culturing bacteria can take up to 24 or even 48 hours. Culturing viruses can take weeks. So, it is no wonder that contaminated water can be distributed and consumed before illness from microbial hazards is reported.
But in forward-thinking Saxon, Switzerland, where maintaining the natural purity of their water is
considered vital by its residents, there is now a new, automated system in place that will detect anomalies within just 20 minutes; a system that will switch off the water and chlorinate so that those drinking the water from their taps are always safe.
In England, South West Water blamed a faulty valve for all the issues. There was also talk that heavy agriculture was the reason. But in Saxon, melting ice was the culprit, alongside the problem that so many people now face in today’s fast-changing climate: prolonged, torrential rain.
by detectors.
“After creating a rainfall detection system, the problem remained as to how to automate microlinear detection,” said Sara Ferdi, from bNovate Technologies.
“We see a growing trend in the water industry towards automated and connected water monitoring solutions. However, microbial water quality is not usually surveyed because it is too time-consuming and labour-intensive. Rapid microbial methods are needed to address the problem properly, which is how we came to help Saxon with automated flow cytometry.”
A technology that provides rapid multi-parametric analysis of single cells in solution, flow cytometry utilises lasers as light sources to produce both scattered and fluorescent light signals that are read
In an average year, up to 70% of the water in Saxon and its mountain communities emanates from highaltitude springs. To protect people who live in remote locations from contamination, carrying out urgent monitoring and manually cutting off water supply takes, not surprisingly, a large number of man-hours.
“It’s always the same story,” added Sara. “There is always a lack of resources to get qualified personnel into the places where they are needed. This is why our BactoSense solution, an online flow cytometer, is such a game-changer for microbiological analysis, because it can be connected to a supervisory control and data acquisition (SCADA) system or a mobile GSM network via a small antenna.
“There’s also the benefit that BactoSense functions with a sustainable, hermetically-sealed and refillable cartridge system, which allows you to run tests (depending on the sampling interval of 30 minutes up to six hours), so you don’t need to send anyone out to check it.”
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By analysing real-time meteorological data supplied by MeteoSwiss, the country’s Federal Office for Meteorology and Climatology, on a Cloud application, the BactoSense’s measurement intervals are set via a programmable logic controller (PLC) and SCADA. In the event of poor quality, the water is automatically isolated, and an alarm is transmitted. Power consumption for the entire microbiological contamination risk management system is very low at just a few hundred watts.
MANAGED AUTOMATICALLY
From water catchment to distribution, everything for Saxon is now automated around the clock, swiftly addressing any anomalies, often without manual intervention.
“Compared to time-consuming heterotrophic plate counts (HPC) that are widely used to survey water quality, this is a real breakthrough,” continued Sara.
“Since our automated analyser was introduced, there have been no reports from Saxon residents of illness due to water pollution. Several alerts have been triggered, with most contaminants traced to isolated sources. Actions such as chlorine dosing, reservoir isolation, alternative water supply activation, or reservoir inflow interruption can be initiated. Additionally, real-time alerts can be issued to individual villages in case of contamination risks. In response, all of the actions mentioned above are managed automatically with minimal human intervention. Only 3.5kg of chlorine was used over a year, whereas continuous dosing would have required around 129kg of chlorine, thus supporting Saxon’s wish to maintain the purity of its natural water.”
FLOW CYTOMETRY IN ACTION
During a heavy snowmelt, there was an increase in bacteria at two reservoirs. In an example of affirmative, quick action, water from certain springs was rejected and manually discharged until the cell count normalised, to stop chlorination.
Two months later, an anomaly saw an immediate need to isolate one spring and an inlet to avoid chlorination of a reservoir. Laboratory tests on the area downstream from the spring to the inlet revealed E. coli and Enterococcus spp. contamination. As a result of this pollution, the catchment was completely renovated.
In the autumn, contamination required a valve to be closed automatically, followed by temporary chlorination. Subsequent microbiological sampling showed an increase in mesophilic aerobic germs, E. coli and enterococci in the Vouarde spring. Thanks to the automatic measurements, the offending spring was isolated in time to protect consumers in the downstream networks.
Turbidity was chosen as the parameter of choice, and measurements were taken to decide how best to implement the automatic discharge. With turbidity, bacterial contamination tends to be underestimated. This is to be expected for system-level measurements, but unexpected for raw water. The results of this study agree with previous results obtained with flow cytometry in a large study conducted by Besmer and Hammes in 2016. There, sources were reported to be stable in dry weather and respond quickly to rain events. In addition, different online physical parameters showed responses to rain events, but they differed in terms of response time, sensitivity, and relative variation. They conclude that none of the individual abiotic parameters reliably describes total cell concentration. They also concluded that total cell count is, therefore, a valuable parameter for microbiological impurities in karst springs. Monitoring provides an optimum understanding of the system and its processes. Turbidity cannot, therefore, reliably rule out microbiological contamination.
Still, combined with automated flow cytometry, which offers fast, accurate and efficient cell detection, it is a reliable way of automating source rejection.
PREVENTION IS ALWAYS BEST
“Since our automated analyser was introduced, there have been no reports from Saxon residents of illness due to water pollution.”
Sara commented: “Combining real-time monitoring with proactive response mechanisms can ensure consistent access to safe drinking water, even amidst changing environmental dynamics.
“Prevention is always the best measure you can take. We now have the technology to stop people from becoming ill from water they believe to be safe.
“Data-driven decisions from automated solutions can greatly improve drinking water safety at both small and much larger water supply sites.” chevron-circle-right
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Extraction,
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Flowmeter integrated with SCADA software to enhance water conservation efforts
ABB HAS INTEGRATED ITS AquaMaster4 Mobile Comms flowmeter with the Topkapi SCADA system, enhanceing water conservation efforts around the world. AREAL, publisher of the Topkapi software platform, recently released a communication driver which allowed AquaMaster4 Mobile Comms to communicate directly with Topkapi through 4G and the FTP/FTPS protocol.
Topkapi is a modular and integrated solution for the management of automated processes widely used in the water and wastewater industry. The software meets the specific needs of the water industry, supporting the sector with district metering and non-revenue water monitoring.
The integration expands ABB’s support beyond its current systems, such as Symphony Plus SCADA and System 800xA, to help water utilities meet sustainability targets through increased
data access.
“ABB has a massive installed base of AquaMaster4 electromagnetic flowmeters globally,” said Krishna Prashanth, Global Product Line Manager, Electromagnetic Flowmeters, for ABB Measurement & Analytics. “By interfacing AquaMaster4 Mobile Comms with the Topkapi SCADA software, we can make an even bigger difference in the markets we serve.”
transmission, making reports and trend analyses created in Topkapi more detailed and accurate. It enables AquaMaster4 to supply near real-time data for smart and precise water management, including flow measurement, pressure measurement and monitoring of diagnostic alarms.
The AquaMaster4 Mobile Comms flowmeter is a wireless solution for continuous flow measurement. In 2021, it became the world’s first electromagnetic flowmeter with bidirectional connectivity, enabling 60% lower power consumption and identifying leaks faster than other solutions on the market. AquaMaster’s previous generation was interfaced with Topkapi 15 years ago using the 2G SMS protocol.
Faster wide-scale leak detection within reach
OVARRO’S LATEST ADDITION, EnigmaREACH, is a lift-and-shift correlating hub for rapid non-revenue water (NRW) reductions.
It combines either 32 or 64 loggers, a tablet, a single app for logger deployment, retrieval and follow-up, and access to Ovarro’s LeakInsight analytics platform.
EnigmaREACH offers mass logger deployment and expanded network coverage compared to that of traditional lift-and-shift kits. The companion app guides technicians through the logger installation, retrieval and follow-up processes.
Typically, a team taking a lift-and-shift approach – deploying loggers in a specific location and retrieving them usually the next day – will use between 80 and 100 loggers, positioned around 75m apart, for approximately 6km of network coverage. One EnigmaREACH kit comprising 64 loggers can monitor up to 16km of pipe network, depending on how far apart they are positioned – more than double the distance with fewer loggers – and can perform 256 overnight correlations.
Traditionally, once the loggers are
The new 4G connectivity to the FTP/ FTPS server allows for enhanced data retrieved, skilled analysts use a laptop to assess the data themselves to identify an area of interest and to review or assign any points of interest (POIs) to be followed up. A follow-up technician would then deploy additional correlating kits to pinpoint the leak and place the blue mark on the ground.
When the technician retrieves the EnigmaREACH loggers and places them in their associated box, the data gathered is automatically uploaded to the LeakInsight analytics platform via a mobile phone or tablet. LeakInsight will automatically complete the correlation and generate the POIs for the user to view when they log into the system. The POIs can then be assigned to technicians directly through the app.
Having a system that automatically generates POIs, as well as a simple-touse app to guide technicians through their tasks on the ground, frees up skilled analysts and technicians. This means they can spend more time validating – another benefit, given the current recruitment and retention challenges in the leakage field.
The BPMA Member Directory
Full members of the British Pump Manufacturers Association (BPMA) include manufacturers, contractors, distributors, importers, and repairers of industrial pumps, with operations in the UK and Republic of Ireland. Membership is also available to suppliers of pump-specific equipment to pump companies. Associate Membership is available to companies and
individuals who work with or supply services to BPMA members, such as industry journals, technology centres, or consultants. BPMA members have agreed to a code of conduct which states that they must demonstrate the highest degree of professionalism, expertise and ethical standards in every aspect of their operations.
Further information about the association’s members can be found on the BPMA website at www.bpma.org.uk/members.
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Improving infrastructure planning is essential to delivery
The water sector needs to build infrastructure at scale over the coming decades. Ahead of her keynote address at the Water Industry Forum on 25 September, Sharon Darcy, chair of the Linear Infrastructure Planning Panel, argues that competing demands with other sectors over the allocation of resources means a collaborative approach is vital.
The water industry faces a monumental challenge: delivering the vast infrastructure needed to meet future demands while navigating a complex landscape of competing energy, transport and communications projects.
Projects with robust early stakeholder engagement are more likely to succeed, which is why the Linear Infrastructure Planning Panel (LIPP) works across utility sectors, with representatives from community groups, non-governmental organisations and other external stakeholders, to develop a common language and leading practice on infrastructure planning.
At the Water Industry Forum’s annual dinner in Leeds on 25 September, crosssector research and insights from LIPP will be shared, showing how planning consent for infrastructure projects can be achieved, and how critical initiatives can be developed and delivered costeffectively, building community support.
BALANCING NEEDS
Balancing national and local needs in infrastructure planning decisions is notoriously difficult, but it is a challenge that needs to be faced if the water sector is going to deliver on net zero carbon, resilience and other national goals. Founded in 2023, LIPP aims to listen and incorporate the perspectives of key public interest stakeholders, including social and environmental groups, in the development of good practice and ethical approaches to the implementation of new techniques, including algorithms and advanced software tools, in linear infrastructure planning.
LIPP published a white paper in March 2024, ‘Delivering net zero,
resilience and nature recovery: How new tools and approaches can transform infrastructure planning’, which has already fed into the UK Parliament’s Environmental Audit Committee reporting on sustainable electrification. The report draws on intensive engagement with key stakeholders and looks at the social, environmental and economic metrics used in the spatial planning of infrastructure such as electricity transmission lines and major water pipelines.
It highlights new technologies and the changes needed to procurement processes to ensure the successful delivery of infrastructure that is essential in meeting net zero targets and resilience to climate impacts. The paper also explores ways of managing uncertainty when developing metrics in these areas, including the need for robust data and ways of ranking and weighing up different metrics.
challenges in grid development, with public opposition to the expansion of power lines needed to transport renewable energy to population centres.
Projects with robust early stakeholder engagement are more likely to succeed.
INFORMED DECISION-MAKING
England faces a critical land shortage. A growing population needs to be housed, while producing enough food, protecting nature and tackling climate change. Despite the intense competition for land, there is no system in place to manage it effectively.
Attendees at the WIF annual dinner will hear a swathe of insights from other industries, such as energy, which can be drawn on to help the water sector navigate current and future challenges. The energy sector is grappling with
The water sector can learn from these experiences by integrating technical and spatial planning much earlier in the decision-making process. The recent King’s Speech outlining the new Planning & Infrastructure Bill acknowledges the need for advanced spatial planning that considers multiple infrastructure sectors.
By joining up technical planning with spatial planning, learning from other sectors, and through early strategic stakeholder engagement, I believe the water sector will be well-placed to streamline the infrastructure planning process and delivery into the next asset management plan (AMP) period – 2025-30, and beyond. chevron-circle-right
Sharon Darcy is chair of the Linear Infrastructure Planning Panel and an independent non-executive board member at Portsmouth Water. She will address the Water Industry Forum Annual Dinner in Leeds on 25 September 2024. To register, visit: https://bit.ly/BWWIF
PUMP INDUSTRY AWARDS 2025
Rewarding pump industry excellence once more!
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 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 venue - the home of English football - on Thursday 13th March 2025.
Dale Croker, 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.”
Award Programme Partners
The online entry forms will close on Friday 29th November, so be sure to visit the Pump Industry Awards website to review the award categories and decide which ones you will be entering!
Venue: Hilton at St George’s Park, Burton upon Trent
Date: Thursday 13th March 2025
Event Calendar
Nominations Open: 1st July 2024
Nominations Close: 29th November 2024
Judging Session: Mid December 2024
Voting: 13th – 17th January 2025
Winners Announced: 13th March 2025
www.pumpindustryawards.com
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