Flow Magazine: Quarter 4, 2021 - Focus on Building Services

Quarter 4 2021

Pump industry insight from

FOCUS ON: Building services

Embedding intelligence in pumps

Are your bearings protected?

Pump Industry News

Innovations

Applications

Expert Opinion

CONTENTS 3 Editor Chris Callander chris@flowmag.co.uk 01732 671123 Contributing Editor Suzanne Gill suzanne@flowmag.co.uk Publisher Andrew Castle andrew@flowmag.co.uk 07785 290034 Accounts Touchwave Media Ltd accounts@flowmag.co.uk Production G and C Media Ltd production@flowmag.co.uk

For over three-quarters of a century the British Pump Manufacturers’ Association (BPMA) has been serving the interests of UK and Irish suppliers of liquid pumps and pumping equipment.

I

n the last issue of Flow, I mentioned with anticipation that we were just a week away from the Pump Industry Awards. I can now report that the evening was a huge success with what I believe to be the largest turnout in the event’s 20-year history. There was an unbelievable buzz in the air as an industry came back together for the first time in two years, and it was clear that everyone who attended was more than ready to make new connections and re-engage with existing colleagues. The awards themselves were exceptionally well received, with all those recognised being worthy winners. In our report in this issue (page 12), you will find details of the winners in each of the categories covered.

We have also taken the opportunity to look in some depth at the finalists in the Project of the Year category (page 14). There was a truly diverse selection of projects across the five finalists, reflecting the breadth of activity the pump sector is involved in.

Also in this issue, we give a brief overview of the Association’s AGM, held in November this year (page 8). For those who attend, it is an opportunity to see the scale of delivery and support the Association offers its members and associates. In addition to the involved and detailed work on technical standards mentioned in the piece there has been much activity to support members. Training has been delivered to around 400 delegates with courses now CPD accredited, almost 200 briefing notes have been issued on topics ranging from BREXIT updates to Government briefings, partnership opportunities and much more. Plus, nearly 120 enquiries for the supply of pumps and pumping systems have been forwarded to the membership during the last 12 months. So when I reflect on 2021 as we near its close, for all the challenges we have faced, it is truly encouraging to see the industry coming back together and to understand how much our Association is doing to support it.

Until next year.

Richard Harden, President, BPMA

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

4

6

flow is a controlled circulation journal published quarterly on behalf of the BPMA by Touchwave Media Ltd and G and C Media Ltd. For a copy of the magazine’s terms of control and to request a copy please email circulation@flowmag.co.uk The content of flow magazine does not necessarily reflect the views of the editor, publishers or the BPMA. The publishers accept no legal responsibility for loss arising from information in this publication and do not endorse any products or processes mentioned within it. No part of this publication may be reproduced or stored in a retrieval system without the publisher’s written consent. © BPMA. All rights reserved.

www.bpma.org.uk

Sectors come together

18 After the flood

Wilo and Schneider Electric intensify collaboration

20 What level control

solution should I use?

BPMA NEWS

Twitter @bpmapumps 8

Features

BPMA wraps up a hectic year

22 Sewage pump systems for

leisure sites 24 Eliminate grease and

reduce O-ring friction

PRODUCT NEWS 10 SPP Pumps expands

product portfolio

Industry Awards 12 The pump sector enjoys its

long-awaited awards

Projects 14 A look at the finalists in the

PIA Project of the Year Award

Building Services 26 Embedding intelligence

in pumps 28 Pulse circulators offer

energy savings

Challenges of moving to low carbon heating solutions

OPINION 30 The answer to your skills gaps

could be closer than you think Quarter 4 2021

4 INDUSTRY NEWS

WESSEX WATER TO DEPLOY AI ACROSS WASTEWATER NETWORK UK WATER COMPANY WESSEX WATER is joining forces with artificial intelligence (AI) company StormHarvester, to expand the use of AI to detect blockages across its entire wastewater network.

The deployment follows a successful trial in May 2020 and is said to be the most extensive to be rolled out in any wastewater network in the world.

Following the trial, Wessex Water has confirmed it will deploy StormHarvester’s AI technology across its entire network over the next three years, as part of its commitment to continue providing high standards of sewerage services to its customers and the environment. The expansion will cover nearly 35,000 km of sewers and wastewater generated by 2.8 million people.

“We are very pleased to win the network rollout,” said Brian Moloney, Managing Director at StormHarvester. “This is the biggest commitment ever to deploy AI in wastewater networks, not just in the UK but also globally.

The trial in the city of Bath tested the scope of AI to see whether it was possible to use machine learning to identify

early-forming sewer blockages, mute unnecessary control room alarms and establish an operational basis for a shift towards condition-based maintenance.

During the trial, StormHarvester’s Intelligent Sewer Suite detected over 60 early blockage formations in real-time.

“Our pilot showed 92% accuracy in identifying early forming blockages with zero missed and control room alarm rationalisation of 97%. Our technology also identified at least two incidents that we are fairly confident would have resulted in Category 3 spillages or worse.

Numbers like these make for a strong

business case for utilities,” said Brian.

Sewer blockages can lead to costly service failures, including pollution and flooding events, but they can be quickly remedied if spotted early enough. Wet weather makes it difficult to differentiate expected high sewer levels caused by heavy rainfall volumes from those arising from restrictions, such as partial or total blockages.

By deploying AI with the capacity to differentiate between these different events, both an improvement in alarm quality and alarm rationalisation is possible.

PUMP, VALVE AND COMPRESSOR SECTORS COME TOGETHER FOLLOWING THE COVID INDUCED POSTPONEMENT OF the co-located events scheduled for both 2020 and 2021, Europump (the European Pump Association) has announced that it is again partnering with CEIR (the European Valve Association) and Pneurop (the European Compressed Air Association) to stage their respective Annual Meetings next year in Brussels. Running across three days, from 9th to 11th May 2022, at the Hotel NH Collection Brussels Grand Sablon, the three organisations will also deliver a Joint EU Policy Conference.

Enjoying similar levels of longevity and heritage within the sectors they serve, the three organisations have shared many similar public policy interests over the years, and increasingly so around international standards and energy use reduction measures. Furthermore, having developed vast experience in their respective disciplines, by forging closer links and a more collaborative approach to certain activities, it was agreed they could better harvest that expertise for greater mutual benefit.

In updating its New Industrial Strategy proposed in 2020, the European Commission has further indicated that it relies on industry to deliver on the major challenges faced by our economies and societies in Europe – sustainability, digital transformation, and global competitiveness – as well as the need to overcome the crisis provoked by the COVID-19 pandemic.

The EU Recovery and Resilience Plan launched in Spring 2021 is largely building on the capability of European industry to design and produce the building blocks of the twin green and digital Quarter 4 2021

transition. At the same time, the EU is shaping a dense regulatory framework that does not always support the freedom and flexibility needed for companies to grow and compete globally.

For a long time, European technology industries, and in particular the pumps, valves, and compressors sectors, have considered the enhancement of their global competitiveness within the framework of societal and environmental challenges, notably by contributing to the preparation of energy efficiency and circular economy regulations. In parallel, digitalisation has provided increased opportunities as well as new challenges, including regulatory debates on the sharing of industrial data, artificial intelligence, and cybersecurity. These developments, amidst fierce international competition where public authorities and the private sector are increasingly working closer together to design and deploy strategies that promote national value chains, require an overarching Europe-wide positioning.

In support of the new EU legislative cycle, Europump, CEIR and Pneurop will gather in Brussels on 10th May to address all these aspects. The Joint Conference will consist of a policy panel debate between industry executives and EU officials and MEPs, and three technical parallel sessions addressing topics of relevance for the three industry sectors. Specifically, these sessions will cover the ‘Circular economy and Eco-design’, ‘Industry’s Digitalisation and Innovation’, and ‘The restriction of use of materials and substances of concern’.

The event is open to all members of the three organisations as well as those of their respective National Associations. www.bpma.org.uk

Motors | Automation | Energy | Transmission & Distribution | Painting

W22 PERMANENT MAGNET MOTORS THE PERFECT SOLUTION FOR BOOSTER PUMPS WEG’S W22 line of energy efficient electric motors, including the W22 Magnet permanent magnet motor, ensure reductions in energy usage and offer excellent cost benefits with increased performance in continuous or high duty cycle applications particulalrly when matched with WEG’s CFW variable speed drive range.

For more information visit www.weg.net or click on the QR code below.

Transforming energy into solutions

www.weg.net

6 INDUSTRY NEWS

BRAZILIAN WATER UTILITY CUTS ENERGY BILLS BY 25%

SANEAGO, A MAJOR WATER AND wastewater company in Brazil, has adopted ABB smart drives, motors and sensors to improve energy efficiency while boosting reliability at four key pumping stations.

Based in the Brazilian state of Goiás, the water company has deployed an ABB Ability Digital Powertrain solution to improve the energy efficiency and reliability of four key pumping stations.

Installing smart variable speed drives (VSDs) and high-efficiency motors has enabled a 25% saving in the cost of drawing water from several water resources. In addition, remote conditionbased monitoring also ensures a secure supply of drinking water for more than 5.7 million people and thousands of industrial and agricultural users.

The project started with an energy survey that indicated the potential for Saneago to save more than 6,000 MWh per year – worth around US$700k. ABB delivered this saving through its channel partner in Brazil, BEU Engenharia. It installed 15 high-efficiency motors and

15 ACQ580 water-dedicated drives to control the speed and torque of the water pumps.

To help Saneago improve the overall reliability and resilience of its operations, ABB installed smart sensors on the pumps and motors and the NETA21 remote monitoring tool on the drives. The smart sensors and NETA-21 are part of the ABB Ability Digital Powertrain offering that enables remote monitoring of drives, motors, pumps and bearings.

Osmar Qualhato Junior, Energy Management Supervisor at Saneago, said: “One of our biggest operating overheads is the energy for pumping

water. Installing ABB’s Digital Powertrain has achieved our objective of achieving a major increase in energy efficiency. The remote monitoring also gives us powerful new capabilities to get a deeper insight and a better overview of all our water equipment, 24 hours a day. We are now able to act well in advance before any failure occurs.”

Wilo and Schneider Electric intensify collaboration WILO, ONE OF THE WORLD’S LEADING providers of pumps and pump systems for the building services, water management and industrial sectors, and Schneider Electric, a leader in the digital transformation of energy management and automation, have entered into a strategic partnership to jointly develop sustainability and efficiency solutions for the water and buildings industries.

Oliver Hermes, President and CEO of the Wilo Group, said: “With this strategic partnership, we want to fully exploit the joint innovative power of our organisations to develop new digital solutions for the challenges of tomorrow.”

The combination of technologies and services from the two companies will provide complete solutions for energy efficiency and water conservation for sustainable buildings, municipalities, utilities, and industrial water applications.

This partnership is designed to enhance the working relationship Quarter 4 2021

between the two companies in the deployment of unique architectures and digital technologies based on integration and custom developments, including universal automation software technologies. The terms of the strengthened cooperation include the Schneider Electric software-centric automation system, EcoStruxure Automation Expert, as well as analytics capabilities and digital services.

The agreement aims to develop a common value proposition to tackle the existing challenges for water sustainability by defining unique digital solutions for water scarcity, water recycling and infrastructure efficiency,

and then deploy those solutions at scale.

Based on the customer experience developed jointly for Wilopark, Schneider Electric and Wilo will also engage in a collaboration to help industries and buildings of the future reduce their CO2 footprint by addressing operational decarbonisation through innovative technologies and the integration of renewable energy sources and better energy management. www.bpma.org.uk

ABB Ability™ Smart Sensor for low voltage motors Up to

70% reduced unplanned downtimes

Up to

Up to

extended motor lifetime

improved energy efficiency

30%

10%

— Your motors are talking to you Are you listening?

http://bit.ly/ABBSmartSensor

Solutions for systems of all types and sizes

Control Remote

of brand

→ Learn more about our products: visit www.reflex.de/en or contact sales@reflexuk.co.uk

8 BPMA News

BPMA WRAPS UP A HECTIC YEAR ALONGSIDE THE DAY-TO-DAY SUPPORT OF ITS MEMBERS, the British Pump Manufacturers’ Association reported on an extremely busy year at its AGM held in November.

Representatives of the Association have held or attended over 160 meetings – mostly virtually for obvious reasons. For the BPMA, this has included Technical and Marketing Committees sharing updates, best practices and ideas, training sessions on a wide range of pump related topics and governance meetings of the Association’s Council. In addition, the activity has included meetings with European counterparts through its membership of Europump and representation of the pump manufacturing sector at meetings held by standards bodies including the British Standards Institution (BSI), The European Committee for Standardization (CEN) and the International Organization for Standardization (ISO).

Seven standards within the scope of CEN, ISO and the American Petroleum Institute (API) are currently in the process of review or development, and the Association closely monitors their progress and, where appropriate, inputs on behalf of its membership. A further 24 European Directives are also active and are monitored and contributed to by Association representatives.

All this is on top of a whole raft of other activities, including the organisation of networking events such as the Association’s golf day, building relationships with other trade associations, aligning training sessions with the Continuing Professional Development organisation (CPD), working with Oxford Economics on the production of the World Pumps report and of course, publishing Flow magazine.

The AGM saw the existing members of its Council reelected, with Dale Croker from KSB confirmed as the Association’s new Vice President. In addition, Dr Evgeny Polyakov, representing Hayward Tyler Pumps, was elected to

his first term on the Council.

At the AGM it was also reported that the Association had attracted 15 new members in the previous 12 months, resulting in the highest ever membership at 115. Among the most recent to recognise the benefits of joining the Association were a number of Associate Members. The Association of Electrical and Mechanical Trades (AEMT), which is working with the BPMA to develop and deliver pump repair courses, took up membership. Also joining was Testing, Inspection and Certification (TIC) specialist, Kiwa Watertec, which tests and certifies products for compliance against UK Water Regulations, UK Building Regulations, European water labelling and many BS/EN standards. Rustek, which provides specialist Eurasian Conformity mark (EAC) certification services to the oil and gas, energy and industrial sectors has also become an associate member, as has Conexiom Europe, which has developed a document platform for automating its customers’ most critical and complex B2B document transactions.

UPCOMING TRAINING FROM THE BPMA Date

Course title

Duration Location

19-20 January 2022

Virtual Pump Selection

2 x half day

Online

19-20 January 2022

Virtual Pumping Fundamentals

2 x half day

Online

1-2 February 2022

Virtual Pump Systems

2 x half day

Online

1-2 February 2022

Virtual Hydraulic Design of Centrifugal Pumps

2 x half day

Online

7 March 2022

Pumping Fundamentals

1 day

West Bromwich

8-9 March 2022

BPMA Pump Repair & Maintenance

2 days

West Bromwich

16-19 May 2022

Certified Pump Systems Auditor (CPSA)

4 days

West Bromwich

For more information or to book any of the courses listed please visit www.bpma.org.uk/lectures *All classroom-based training is scheduled subject to the COVID-19 restrictions in place at the time.

Quarter 4 2021

www.bpma.org.uk

LOW PRESSURE? NO PROBLEM. AQUABOOST COLD WATER BOOSTING SYSTEMS The NEW Aquaboost iBolt and iMatic range of high flow, high head, cold water pressure and flow boosting solutions.

Designed to optimise space and provide a very quiet, simple to install solution for domestic and commercial applications.

STUART-TURNER.CO.UK

Product News 10 NEWS 10

Product news 11

PUMPPROCESS MOTOR WITH SPECIAL FLANGE FOR CHEMICAL PLANT BIOTECH Y AND PRODUCT QUALITY MENZEL ELEKTROMOTOREN HAS created an unusual motor configuration to help the operator of a large chemical plant that needed a replacement for a failed pump motor.

The challenge was to find a motor able to accommodate an existing oversized pump flange dimension. Only Menzel offered a size 400 motor that matched the performance profile and was light enough. The Berlin-based manufacturer converted a stock IM B3 type foot mounting motor to a type IM V1 for vertical flange mounting. To achieve this, the drive-end bearing seat was altered to allow the installation of a thrust bearing. Menzel also manufactured a special flange in-house and adapted it to the shaft, which could only protrude 120 mm from the on site. By installing both the heater flange. Menzel prepared the motor for PS[IV RSMWI PIZIPW JSV E FIXXIV [SVOMRK IRZMVSRQIRX ERH IEW] and connections in one auxiliary quick installation at the customer’s site, due maintenance with a streamlined spare parts inventory to PT100 the terminal box, Menzel was able to save shifting the main terminal box to the common LKH platform. one terminal box. The motor, which most accessible position and mounting is now successfully operating in the a cable entry that could be readily bit.ly/ALBiotech customer’s plant, has a rated output of adapted to the existing cable diameter

POLYMERIC MATERIAL FAILURE CONSULTANTS

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

,62

‫«ٳ‬XzJ³ GASKETS SEALS HOSES

xƏɎƺȸǣƏǼ ǣƳƺȇɎǣˡƬƏɎǣȒȇ ƏȇƳ ƬȒȇƳǣɎǣȒȇ ƏɀɀƺɀɀȅƺȇɎ Damage documentation and characterisation Forensic information gathering Evidence based root cause analysis

07851 086922 01992 509470

philip.clarke@pmfconsultants.com www.pmfconsultants.com

315kW and a nominal voltage of 5000V. It features the cooling type IC 411 and an IP55 protection rating and weighs 4900kg. www.menzel-motors.com

SPP PUMPS EXPANDS PRODUCT PORTFOLIO IN A BID TO FURTHER SUPPORT ITS customers in the UK & Ireland, SPP has expanded its product portfolio with the addition of Pleuger Industries range of submersible pumps. The addition of submersible pumps to SPP’s portfolio enables the company to offer a comprehensive range of centrifugal pumps, covering almost every application.

With sizes ranging from 4in to 50in, Pleuger Industries’ submersible borehole pumps feature a variety of radial, semi-axial and axial impeller hydraulics and can achieve flow ranges of 1m3h–7000m3h and a discharge head range of 2m–700m. These pumps feature water-filled asynchronous motors as standard, with synchronous permanent magnet motors available on request, and are available in a wide variety of materials, including cast iron, bronze, NiAlBz, 316 stainless steel and Super Duplex stainless steel. In addition to the standard borehole pump configuration, Pleuger Industries offer several other designs to cover an even broader range of applications. These include bottom intake pumps suited to low water level applications, booster pumps which provide an alternative to more conventional pumping systems where either space-saving or IP67 rating or higher is required and flood pumps that can achieve flows of up to 20,000m3h as standard or higher on request. www.spppumps.com Quarter 4 2021

www.bpma.org.uk

PRODUCT NEWS 11

APP GIVES ACCESS TO MOTORS’ TECHNICAL INFORMATION BEFORE THEY ARE SUPPLIED, every WEG electric motor undergoes rigorous quality testing according to the main international standards applicable in the country where it will be used.

Continuously investing in innovation and technology, WEG has developed a mobile application that provides access to technical documents, such as datasheets, performance curves, technical drawings, nameplates, and the results of electrical testing performed on motors.

Available for the Android and iOS platforms, WEG Data Viewer can be accessed by anyone who wants more information about every motor that leaves WEG’s factories.

Using a QR code provided on a label attached to the fan cover, shaft end or the inside of the terminal box, it is possible to obtain, at any time, the motor’s technical information. In motors without the QR code, it is possible to access the

information by entering the serial number available on the nameplate.

Rodrigo Fumo, Director of Engineering and Technological Innovation at WEG, commented: “WEG Data Viewer was designed to simplify routines, comparative analyses and maintenance since it provides quick and easy access to key product information. It is an

application that all WEG customers can use.”

In future updates, the application will gather other technical information, such as operation and installation manuals, catalogues and dimension testing reports. www.weg.net

Kiwa UK Regulation 4 (KUKreg4) The Kiwa UK Regulation 4 Product Approval Scheme (KUKreg4) a robust method for demonstrating compliance with the Water Supply (Water Fittings) Regulations 1999.

W: www.kiwa.co.uk/water

T: +44(0)1495 308185

E: jonathan.price@kiwa.com

12 Industry Awards

THE PUMP SECTOR ENJOYS ITS LONG-AWAITED AWARDS

H

eralded as a great success by all those in attendance, the PIA Awards celebrated business and professional excellence across the pump industry and its own 20th Anniversary. Hosted by Philippa Forrester of Tomorrow’s World and Robot Wars fame, the event provided a wonderful opportunity for the pump industry to reunite and reconnect with friends, colleagues, and clients. The atmosphere was one of real enjoyment and networking, after what has been an extremely challenging time for everyone.

Recognising significant achievements which took place in the 18 months preceding December 2019, nine category winners were announced, as follows: • Product of the Year, sponsored by Process Engineering - Sulzer XJ900 Submersible Dewatering Pump • Project of the Year, sponsored by Stuart Turner - Armstrong Fluid Technology: Upgrade for National Grid • Environmental Contribution of the Year, sponsored by SPP Pumps - Wilo UK / Environment Agency: River Severn Water Management • Manufacturer of the Year, sponsored by WEG UK - Stuart Turner • Distributor of the Year, sponsored by EMIR Software - Campion Pumps • Supplier of the Year, sponsored by Wilo - ABB • Contribution to Skills & Training, sponsored by Tomlinson Hall - SPP Pumps: STEM Ambassadors in

Quarter 4 2021

partnership with Innovation Lab • Rising Star Award, sponsored by World Pumps - Thomas Parker, TEC Electric Motors • Lifetime Contribution, sponsored by BPMA - Peter Reynolds, Grundfos Pumps (retired)

Event Director, Andrew Castle, said after the event: “Our congratulations go to all the winners for their excellent achievements, but our acknowledgement and appreciation must also go to every nominee and finalist. The quality of all entries was again extremely high, and the competition was fierce. It has been an incredibly long wait for all those involved, and I so would like to thank everyone for their continued patience and understanding as we battled to get the awards ceremony staged.

2022 AWARDS PROGRAMME Despite the enforced delay in announcing the latest set of award winners, time does not stand still, and so the event’s organisers are now seeking nominations and entries for the 2022 Pump Industry Awards.

Returning to its usual spring dateline for the gala dinner and presentation ceremony, the event will take place on Thursday 24th March, again at the Chesford Grange Hotel in Kenilworth.

The online entry forms, which seek entries for activities in the two years up to December 2021, are available at www.pumpindustryawards.com, with the entry deadline set for Friday 7th January

2022. Please note this important date, and begin considering which key developments, activities, and successes you will be putting forward for industry recognition and reward.

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

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

Steve Schofield, CEO of the British Pump Manufacturers Association, commented: “No-one could have foreseen the disruption caused by the pandemic, and the pump sector has not been immune to its impact.

However, despite the many challenges, our 20th Anniversary was as good as any I can remember. Business and professional excellence deserves to be acknowledged and celebrated, and the Pump Industry Awards do just that. As such, I would encourage all those involved in this important sector of ours to prepare and submit their entries for the 2022 awards programme.” chevron-circle-right www.pumpindustryawards.com

www.bpma.org.uk

!

U E N

ROTEX® ZS-DKM-SH

ROFLEX®-SH

We’ve cracked it!

Looking for ways to reduce downtime and associated costs? Look no further than KTR’s range of split-hub (SH) coupling solutions. KTR’s “cracked” cast hubs split vertically off the shaft, enabling both pump and motor to remain aligned and in place, resulting in quicker www.ktr.com maintenance turnarounds. Thanks to KTR’s advanced “cracking” process, manufacturing costs are reduced, performance is maintained and ATEX certification is also available. For www.ktr.com/uk more info visit www.ktr.com/uk

EMiR customers are industry leaders, like you, in all of these electro-mechanical products...

COMPRESSORS GEARBOXES PUMPS

CONTROL PANELS GENERATORS

SEALS & BEARINGS

HVAC

CONVEYORS

DRIVES

HYDRAULICS

TRANSFORMERS

ELECTRONICS

MOTORS

FANS/BLOWERS

PLANT MACHINERY

VALVES

EMiR Software has over 25 years experience providing software that manages any and all of these services: DISTRIBUTION

FIELD SERVICE

MANUFACTURE & ASSEMBLY

ELECTRICAL CONTRACTORS REPAIR

SALES

SERVICE

Call us today and see how EMiR can help you 0845 009 4588 Visit www.emirsoftware.com to book a demonstration PLEASE QUOTE “RENEW21” TO RECEIVE A SPECIAL OFFER DISCOUNT FROM THIS ADVERT

Please scan this QR code to find out more

14 Projects

PUMPING PROJECT OF THE YEAR Five companies were shortlisted in the Project of the Year category at the recent Pump Industry Awards, which recognised the most innovative pump project, installation or service, introduced onto the market within the previous 24 months. The competition was strong with the award, sponsored by Stuart Turner, going to Armstrong Fluid Technology. Flow magazine took a look at the projects that made it to the finalist stage.

ARMSTRONG FLUID TECHNOLOGY: UPGRADE FOR NATIONAL GRID Armstrong Fluid Technology’s upgrade for the National Grid’s three-storey commercial office block in Solihull reduced pump energy consumption by more than a third, with additional benefits of rapid installation, which was carried out over a weekend, and the best lifecycle costs.

The new pumps selected for installation were Armstrong Design Envelope models that can respond instantaneously and automatically to system load, adjusting speed and drawing only the power required to meet demand. These pumps reduce costs and improve environmental performance through variable speed, demand-based operation. The performance characteristics of the replacement Armstrong pumps made it possible for legacy 7.5kW to 15kW twin headed pumps to be replaced by smaller 5.5kW to 7.5kW models with integral inverters, reducing the embedded carbon footprint for the project.

Further benefits were gained when the legacy pumps removed from the site were disassembled and the materials separated for recycling. A total of 3.5 tonnes of equipment were removed from the site, and a Certificate of Sustainable Disposal was provided to the National Grid.

Ian Shaw, Technical Energy Manager of CBRE, responsible for identifying and implementing energy savings across the National Grid estate, said: “Upgrading to new Armstrong variable speed DE pumps and Pump Manager active pump management software has not only provided us clear visibility of the Quarter 4 2021

performance of our systems at any time but has also delivered verifiable energy savings.” chevron-circle-right www.armstrongfluidtechnology.com CAMPION PUMPS: CENTER PARCS LONGFORD FOREST PROJECT When Center Parcs opened its first resort in Ireland, Longford Forest, in August 2019, a robust water system was required to accommodate the project’s unique design features.

Campion Pumps designed, supplied and installed a solution to handle the site’s daily water requirements and support its firefighting demands. The solution was unique to any system the client had in other parks, utilising a bespoke five pump Hydrovar online booster set. This fully self-regulating booster set offered four highflow 22kW pumps and one highly efficient 7.5kW pump; all pumps were vertical multistage with IE3 motors, integrated pump controllers and pressure transducers. A network of 14 foul pumping stations was also installed around the park.

A robust water network was required to accommodate the project’s unique design features, including an indoor water park, 3,500m2 pool, a spa and wellness centre and accommodation for up to 2,500 guests during each short break.

The larger five pump Hydrovar controlled booster set with a jockey pump automatically designed into the skid provided water supply at much reduced energy costs while allowing the larger pumps to automatically engage for large volume water supply or a fire situation.

Given the remote location of this site and the forest surroundings, some special considerations were also required. Water tanks had to fill at off-peak intervals by managing inlet valves and parameters to manage the flow. The local fire chief required a dedicated key switch and a series of complex generator controls to allow increased pressure in emergencies.

Plus, as the main park water supply booster set was also being used for firefighting, the skid was designed for both low flows, and large fire demand flows. The fire officer also required that park water pressure of 6 bar be reduced to 3 bar in the event of a fire, and the Hydrovar booster set had to allow both the automatic or manual operation of a fire switch.

The online cloud-based monitoring platform, Campion Connect, give access to a wide range of information

www.bpma.org.uk

NUCLEAR

DEFENCE

OIL & GAS

CHEMICAL

Coupling & Drive Solutions 70+

Years in Business

30+

Global Manufacturing Facilities

focuses on providing value Known for quality and service, no matter the size of the request. From individual components ’s industry experts today for to full package needs, contact design and drive selections to suit your application. martinsprocket.com

EMEASales@martinsprocket.com

+44 (0) 1926 962161

40+

Thousand Square Foot U.K. Facility

FEATURE Dewatering 16 Projects

Using Campion’s online cloud-based monitoring platform, Campion Connect with a mobile application, Center Parcs facilities management has access to an intuitive platform with customised responsive monitoring display, 3D visual display, realtime data, alarm and event notifications, detailed reporting and trends tool.

Since the opening of the village in August 2019, the water network has supported over 40 million litres of water, performed successfully in rigorous health and safety tests and emergency drills, and the Campion Connect management system has averted over 900 potential issues which may have resulted in serious downtime for the site. chevron-circle-right campion.ie BAKER HUGHES: N’GOMA FPSO SHORT-CYCLE PROJECT In 2019 Baker Hughes Nuovo Pignone PVS completed the delivery of two API610 11th edition High-Pressure Pumps (Single Stage OH type - 200 m3/h - 25 bar) as booster pumps to transport produced water to a desander package on the N’Goma Floating Production Storage & Off-loading Unit (FPSO) in Angola.

The N’Goma FPSO is one of the biggest offshore units operating in the production, storage and off-loading of crude oil. This project represented a significant challenge for Baker Hughes with just a six-month project time instead of the standard lead time of 12 months.

These pumps are designed to work for at least 30 consecutive years under severe offshore operating conditions. The process fluid (seawater) with elevated chloride levels is highly corrosive and needs to be transferred continuously in the FPSO process with a high level of reliability. In addition, due to the type of Quarter 4 2021

FLOWROX DIGITAL SERVICES: MALIBU IIOT PLATFORM The Malibu IIoT Platform developed by Flowrox is a remote monitoring solution that helps assess and catch failures of critical assets before they occur. Users of the system can connect and optimise any critical piece of equipment, all driving toward predictive maintenance, increased uptime, increased throughput and increased efficiency.

Data collected by the platform is sent to the cloud for analysis. The data can then create reports, send contextualised alarms, and predict failures.

A key advantage of the Malibu IIoT Platform is that customers don’t need to become IIoT experts themselves. Flowrox guides the system connectivity and manages the solution’s cloud aspects.

The customer gets a simple, intuitive, 3D-image based cloud platform to view the data in real time, get alarms and reports, and access static and dynamic data. Users can see a wide range of parameters based on the sensors employed, including energy usage and the manufacturer’s pump curve. More powerful analytics, such as regressions and AI, can also be used to calculate and predict the failure of wear parts, like bearings. chevron-circle-right

GRUNDFOS PUMPS: GLASTONBURY FESTIVAL For an event on the scale of Glastonbury, many aspects need to be considered, not least of which is the availability and accessibility of sufficient clean water.

With this in mind, the festival’s organisers asked Grundfos Pumps to advise them in relation to the site’s water boosting and delivery requirements, to ensure that their equipment remained fit for purpose and to seek any additional opportunities to optimise their antiquated systems further.

Following a site survey, attention focussed on the control and efficiency of the booster systems, an important aspect as energy and sustainability are high on Glastonbury’s agenda. Attention then concentrated on modernising the pump and dosing systems and introducing a remote monitoring solution to streamline the water demand and delivery whilst giving full system visibility.

The Grundfos solution included upgrading the pump systems to optimise efficiency, incorporating a new precision dosing system, and a remote monitoring system that would mean a significant improvement in data exchange.

The upgrades improved the stability of the supply and significantly reduced energy demand and leakages, as proportional control significantly reduced system pressures. The new Grundfos dosing solution insured precise and accurate dosing and reduced chemical use, improving the drinking water quality.

The addition of the Grundfos Remote Management system allowed complete network accessibility 24/7, with multiplatform visible alarms advising of any immediate issues. chevron-circle-right

flowrox.com

www.grundfos.com

offshore process and marine environment, the customer required an extremely high level of efficiency. For these reasons, the pumps were designed with innovative materials, including high-grade Super Duplex stainless steel and with a fully integrated system with the pump, electric motor and flushing systems on a single easy to install baseplate. chevron-circle-right www.bakerhughes.com

www.bpma.org.uk

Pioneering for You

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

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

Providing Smart Solutions For: Hot Water:

Heating:

Pressure Boosting:

Drainage:

For more information please contact a member of our sales team.

T: 01283 523000 | www.wilo.com/gb/en | E: sales.uk@wilo.com @wiloUK |

@wiloukltd | @teamwilo |

@WiloUK

Looking for a replacement pump?

Visit the Wilo Pump Exchange!

Flow_Magazine_Half_Page_ Sep21.indd 1

27/08/2021 11:34:32

Pump Portfolio Expansion

SPP Pumps Ltd are pleased to announce that we are the exclusive Pleuger Industries GmbH official UK & Ireland distribution and service partner for submersible pumps for the Water, General Industries and Mining markets.

For more information please contact: tel: 0118 932 3123 or email: water@spppumps.com SPP Pumps Limited, 1420 Lakeview, Arlington Business Park, Theale, Reading, RG7 4SA

PROTECTING LIFE. IMPROVING LIVES.

18 Dewatering

After the flood

When flooding in North Macedonia threatened the country’s electricity supply, the company tasked with draining the mine, Simtech Solution, turned to WEG for support.

A

mong the consequences of a natural disaster, which struck North Macedonia in August 2020, was the flooding of a coal mine beneath a thermal power plant managed by the state company ESM-North Macedonia.

More than 300,000 cubic metres of water had flooded the lower parts of the mine, effectively disabling all of its working operations. This had major ramifications, as ESM’s thermal power plant is integral to North Macedonia’s energy system. It supplies three-times 265MW of power, generating 70% of the country’s overall power requirements.

The mine had to be drained, quickly and effectively. Extra pressure was added by the coming winter season, as North Macedonians’ lives and wellbeing would depend on the plant’s ability to produce electricity from its processed coal.

With such high stakes, ESM turned to its supplier, Simtech Solution, which specialises in devising automation and SCADA systems, and power distribution and management for environments including industrial automation, water treatment and more.

HEAVY-DUTY PUMPS Even with its years of experience, a natural disaster was a first for Simtech Solution. As Igor Novevski, Projects & Business Development at Simtech, explained: “There were several obstacles that had to be overcome if we were going to succeed.

“We only had a couple of days for project planning to devise the technical solution and three weeks to execute the entire project. So, there was a very high pressure to complete the draining project on time and a a quick response from was needed from all our project partners.”

This included the supply of several heavy-duty pumps sourced to pump all the sludge from the mine. Three 110kW pumps, manufactured by Tsurumi of Japan, and three 90kW pumps, from Dragflow of Italy, were delivered by local distributor TETRA DOOEL. All were supplied with electrical equipment, but

Quarter 4 2021

More than 300,000 cubic metres of water had flooded part of ESM-North Macedonia’s thermal power plant, disabling its working operations.

something else was needed: an effective start-stop control system.

Soft-starters would be essential for the fast, safe and reliable use of these pump motors — especially in a project as time-critical as the ESM plant drainage project.

ESM’s requirement to integrate several PT100 thermal protection probes during the project.

However, even with the right systems in place, there was another major challenge that the project would have to overcome: COVID-19.

THE SOFT APPROACH For this, Simtech Solution turned to its partner, WEG. Simtech Solution already had experience with WEG’s SSW06 series soft-starter, designed to accelerate, decelerate and protect three-phase induction motors. This time, it opted for the SSW900 soft-starter from WEG. The SSW900 is designed for energy savings, embedded protection and extended durability of electric motors.

The equipment is fitted with a builtin bypass, which helps to extend the starter lifetime, optimises the electrical installation, and reduces heat dissipation.

Simtech Solution also opted for the SSW900 for its fault history and diagnosis capabilities, troubleshooting with date and time, and network communication interface.

The soft-starter’s compatibility with digital systems and human-machine interfaces was also useful in light of

LONG-DISTANCE WORKING Whereas WEG’s training would typically be held at its facilities in Germany, this time, it turned to online training organised by WEG International Trade, Austria.

“We’ve got colleagues in Brazil that are automation specialists,” explained Kamil Rygiel, Sales Account Manager at WEG. “Every single training session was led by them, accompanied by regular remote communication throughout the project.”

This regular contact for different issues and topics throughout the project helped guarantee a smooth installation, helped further by Simtech Solution’s prior experiences with WEG’s SSW06 series soft-starter.

Despite the challenges of a short time frame and the ongoing pandemic, the drainage project was completed in record time, and the technical solution was delivered to the end client. chevron-circle-right www.weg.net www.bpma.org.uk

HP RANGE API RANGE

ISO 5199 Pumps in Custom Alloys

API 610 12th Edition EMFC RANGE

HS RANGE ISF RANGE

Multistage Pumps

TVL RANGE

Engineered Design

Cantilever Pumps

Mixed Flow Pumps

Custom Pump Arrangements

Vertical Configuration

Coatings

Industrial pumping solutions bespoke to your application designed and built in the UK since 1988

For further information please contact us on: apexpumps.com

0117 9077555 email: sales@apexpumps.com

ENERGY REVOLUTION STARTS AT HOME. Hassle-free installation, operation and maintenance: The Calio S circulator pump replaces most models without the need to change the connector.

For more information, contact KSB UK. 01509 231872 - www.ksb.co.uk

20 Level Control

What level control solution should I use?

A frequently asked question when considering a pump system design is what method of level detection do you need? Jane Delicata, Controls Divisional Manager at fluid solutions provider T-T Pumps, looks at which options suit different applications and budgets.

T

here are many different elements to bear in mind when choosing appropriate level sensors, but the key items are liquid/ medium for the level control to be installed in, the accuracy, criticality and reliability required and lastly, budget.

LIQUID The first thing to consider is what medium the level control is to be installed in or is required to measure.

If it is purely water, consider if this is potable (drinking water) or purely waste/grey water.

Float switches are the most used product for systems in both clean water and wastewater applications as many variants are available to suit different requirements and offer a relatively inexpensive solution.

Conductivity level control systems, such as probes, also lend themselves to largely clean or grey water applications, where the risk of solids adhering to the conductive rods is minimal. However, this would not be preferable for applications where the liquid is particularly viscous, or the solids’ content is high.

For corrosive liquids, for example those used in process control, then ‘non-contact’ forms of level control such as ultrasonic (where an echo is bounced from a datum surface and timed until the signal is received back to determine the level) are most suited.

This type of level control is also suited to very dense viscous mediums where contact with any measurement and control items would prove problematic.

Various other forms of noncontact level control, such as radar, Quarter 4 2021

can offer solutions for applications where establishing a datum via ultrasonic echo would be difficult, such as tidal situations which have to deal with the constant movement of the surface in heavy seas.

Working with powders presents other specific issues, for which tuning fork type level switches are an ideal choice. The level switch incorporates a piezoelectric crystal that vibrates the fork at its natural

Should extremely accurate level readings be required, then ultrasonic level control is the most obvious choice. frequency. When the fork comes in contact with a material, the vibration is dampened, and the switch changes state.

ACCURACY AND RELIABILITY How critical is the level reading required? If it is simply to control an on/off action like turning on a pump or energising a solenoid valve, then floats or conductivity probes would

work well in this scenario.

Should extremely accurate level readings, or perhaps the calculation of the volume of a tank’s contents be required, then ultrasonic level control is the most obvious choice, with factors such as temperature compensation and intelligence built into the units to cover a wide range of applications and scenarios.

However, all this technology comes at a price, which leads us very nicely to the next point: the economics of purchase.

PRICING Both float switches and conductivity probes are relatively inexpensive in terms of their cost to implement, with floats being the most costeffective as a rule.

The use of conductivity probes will also require a control relay which could be costly to incorporate.

If the budget allows, then ultrasonic ‘non-contact’ level control or tuning fork type level control is the budget-busting but highly effective, all-round choice balancing accuracy, life expectancy, and flexibility of the equipment. chevron-circle-right www.ttpumps.com www.bpma.org.uk

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

armstrongfluidtechnology.com

22 Waste Treatment

Sewage pump systems for leisure sites

With the increasing popularity of camping and caravan parks, particularly with staycations at an all-time high, attention is drawn to sewage treatment and storage requirements.

Submersible pump specialist, Pump Supplies, looks at the options available.

W

ith COVID-19 lockdown restrictions on international travel, it seems that most people still tried to get away in the UK for a well-earned break over the last year. The birth of the ‘staycation’ has seen caravan and camping sites grow exponentially over the last two years, with many of them now staying open all year round.

Equally, many sites have increased their ground space or decreased their pitch sizes to accommodate the growing number of people wanting to holiday with their friends and family in the great outdoors.

This increase in footfall will undoubtedly put pressure on the sites’ water supply, wastewater drainage and sewage pump systems, and sometimes, if increased demand is placed on such systems, they can simply break down. No one wants to use a campsite with blocked toilets, broken showers or flooded fields.

Customers’ expectations wouldn’t be met, which would be extremely detrimental to the site owner’s business.

Campsites and caravan parks are very often set in rural communities away from main sewage networks. Therefore, their owners must be fully up to date with the rules and regulations set by the Environment Agency as they could face significant fines if they don’t comply. There are strict compliance regulations for ammonia, phosphorus, nitrogen and Biochemical oxygen demand (BOD).

It is particularly important for sewage to be treated and stored to avoid treated effluent leaking into the local environment, reservoirs or estuaries. In these examples, there are three options available: Quarter 4 2021

SEWAGE PUMP SYSTEMS This is the best way to handle wastewater by installing an on-site sewage treatment pump system.

These effectively pump the waste and effluent to the main drainage sewers, allowing the site owner to dispose of the effluent without paying for its removal from a septic tank or cesspit.

The systems are enclosed and treat the effluent, which means that treated water from the sewage plant can flow into a running watercourse, groundwater soakaway or in some instances, a storm drain.

Furthermore, sewage treatment pumping systems are by far the most environmentally friendly option for campsites and caravan parks.

Most pump supply companies will survey the site and develop a system that’s appropriate for the size of the ground and the demand placed on its services. After installation, they will manage the system and be on call if, heaven forbid, anything went wrong.

The biggest issue with septic tanks is that they produce a biproduct called hydrogen sulphide, which produces a foul-smelling odour around the tank. So much so that many authorities in the UK and Ireland have prohibited their use.

CESSPITS Cesspits are the worst option of all.

They are pretty basic, comprising of a large holding tank with an inlet but no outlet.

The effluent isn’t treated, and the contents have to be removed by licenced waste carrier companies using a vacuum tanker.

The size of the tank will have to be enormous on a campsite or caravan site because it needs to hold a tremendous amount of effluent as it doesn’t break down.

In conclusion, with the increase in demand as more people are using camping sites and caravan parks, sewage removal systems must be fit for purpose and robust enough to cope with the extra demand. chevron-circle-right

It is particularly important for sewage to be treated and stored to avoid treated effluent leaking into the local environment.

SEPTIC TANKS This type of waste system partially treats the effluent because it only treats the waste at the top of the tank. The process is mainly anaerobic and is much slower than a complete sewage treatment plant to break down the effluent.

www.pumpsupplies.co.uk www.bpma.org.uk

The most comprehensive balancing service for pump manufacturers Our VB15 UG automatic two plane balancer is from our wide range of vertical machines and is suitable for dynamically balancing pump impellers with milling correction.

We deliver the most comprehensive range of dynamic balancing services in the UK and all delivered by our locally-based team of experts. This combined with considerable application knowledge gained over many years of operation and experience in pump manufacturing means that For further whatever your balancing information requirement we’ve got contact us on you covered.

T: 0161 872 3123 or E: enquiries@cembhofmann.co.uk www.cembhofmann.co.uk

24 Sealing Solutions

Eliminate grease and reduce O-ring friction High-performance thermoplastics, composites, and engineered components manufacturer, Greene Tweed, explains how one of its low friction coatings helped a customer overcome challenges with high durometer O-rings.

A

large European petrochemicals company was facing difficulties installing dynamic O-rings made of Chemraz 526, a perfluoroelastomer with a durometer of 95 Shore A – the only grade suitable for their mechanical seal application. The cartridge seal would need to be disassembled, cleaned, and rebuilt using grease lubricant.

Due to the force required to install the high durometer O-rings, the mechanical seal OEM realised it needed a faster and more reliable installation method without the delay a redesign would require.

The challenges being faced weren’t limited to the installation of the mechanical seal into the pump; the OEM also encountered difficulty installing the seal head onto the sleeve because of the high durometer O-ring and found it hard to move the dynamic O-ring and risked hangup of the rotating face.

To address these problems, Greene Tweed recommended a low friction solution to the OEM. Greene Tweed applied Enduro LF10, a low-friction, precision-applied coating to the high durometer perfluoroelastormer O-rings.

Enduro LF10 coating is a proprietary vapour-deposited PTFE-based coating that can be applied to various components within manufacturing equipment, including elastomeric, thermoplastic, or metal components, to enhance their performance.

The proprietary coating – used extensively in the semiconductor industry – succeeds by reducing friction and stiction to improve seal lifetime and drive down costs. The petrochemicals company wasn’t alone. In industries as diverse as pharmaceuticals, hydrocarbons, and chemical processing, many companies experience reliability challenges related to mechanical seals and friction as well as stiction of the O-ring sealing elements.

Quarter 4 2021

TESTING To investigate the performance of this high durometer O-ring coated with Enduro LF10, the OEM tested friction caused by coated and uncoated O-rings before installing the coated O-ring in a test rig.

The test was conducted in a lab, where loading conditions were simulated to compare friction caused by a coated and an uncoated O-ring. The mechanical seal OEM began the test by looking at the performance of uncoated O-rings with and without grease. Next, it conducted the same test on O-rings coated with Enduro LF10.

After the frictional test, the OEM tested the O-rings coated with Enduro LF10 dynamically by installing them into a mechanical seal test rig.

The friction test results were clear: The O-ring coated with Enduro LF10 without grease exhibited the lowest friction. Using O-rings coated with Enduro LF10, the mechanical seal OEM could reduce the friction in ungreased mechanical seals to less than half compared to an uncoated O-ring of the same material.

By reducing friction, Enduro LF10 enables the use of high durometer O-rings for dynamic seal without the need to

grease, preventing hang-up of the dynamic seal faces while improving performance.

For the dynamic test, the Enduro LF10 coated O-rings endured 1800 hours of rigorous testing with exceptionally constant inlet temperature, outlet temperature, inboard (IB) face temperature, pressure, IB leakage, and outboard (OB) leakage. This consistent performance – without any dynamic seal face hang-ups – indicated extended service life of mechanical seals in pumps without the use of grease lubrication on the O-rings.

CONCLUSION Enduro LF10 coating offers conclusive advantages by enabling the use of O-rings made of high durometer materials while lowering friction and eliminating the use of grease lubricants and their associated risks. That’s not all. Coated O-rings ready for installation are supplied by Greene Tweed, eliminating the variability of handapplying grease. Elastomer O-rings coated with Enduro LF10 are easier to install and can endure rigorous operating conditions with minimal leakage, consistent performance, and longer service life. chevron-circle-right www.gtweed.com www.bpma.org.uk

Your Asset Care Partners Working with us to ensure the care of your assets means having an experienced team on hand to help you meet your manufacturing targets cost-effectively.

Ou team will help keep your Our assets safe and achieving their full potential through reliability-centric care and can help deliver fast-track o your entire improvement of plant maintenance regime, reduced costs and increased productivity.

Plant Maintenance Reliability Improvement Condition Monitoring Engineering Compliance For further information and case studies visit www.ejmusk.co.uk

26 BUILDING SERVICES

Embedding intelligence in pumps In the wake of COP26, Chris Callander spoke to Wayne Rose, Product Experience Director at Armstrong Fluid Technology, about pump technology's role in improving the sustainability of building stock in the UK.

T

here is significant potential for energy savings to be made in commercial property and large public sector buildings, particularly in HVAC systems.

However, the technology used in buildings needs to support the collection and delivery of the data necessary to make informed decisions that optimise energy efficiency. So I started by asking Wayne how pumping technology needs to be developed.

flow: How will pump technology need to evolve to meet changing customer requirements?

Wanye Rose: The pressure placed on energy efficiency in commercial properties and large public sector buildings such as hospitals, local and national government office buildings, and educational sites is set to intensify. The level of reporting required by the government will almost certainly increase exponentially, to provide the benchmarking essential for all forms of environmental improvement. The key priority is the usability of the efficiency and performance data, rather than quantity.

Building owners can already collect raw data from meters and dataloggers and often have a Building Management System (BMS) that makes collection easy. What these owners really need, however, is information on system performance that can be acted upon immediately, without endless hours of number crunching.

Pump technology will play a crucial role in translating raw data, on the performance of disparate components of the system, into usable intelligence that can form the basis of an action plan. The pumps have always served as the heart of a HVAC system, and with the latest technology, they can also function as the brain.

Active Performance Management technology for pump systems is expected to become the rule rather than the exception in commercial properties, tall buildings and large public sector sites. This essentially makes the performance of a HVAC system visible in real-time, on a 24/7 basis, with complete remote monitoring capability.

Quarter 4 2021

Without information on fluid flow, across the system, it’s difficult to diagnose and optimise efficiency. With accurate flow information, the picture changes entirely. This level of visibility of system performance integrates with the BMS, but goes one step further, providing an additional layer of reliable information on which estate managers and building owners can base their decisions.

For example, Armstrong’s Active Performance Management solution, Pump Manager, uses the embedded intelligence and connectivity of our Design Envelope pump models to provide performance reports to system operators. With this report information, operators can make changes and address issues to optimise HVAC performance. The reports provide online trending and analysis across multiple parameters on single pumps or on an aggregated basis for multiple pumps. This helps to identify performance degradation and facilitates a predictive and proactive approach. Pump Manager will, for example, report issues such as excessive vibration, pump-in-hand, risk of cavitation or dead-head should they occur.

Reporting options include: • Average flow profile over time • Average energy consumption profile • Current operation conditions relative to design conditions • Flow and head relationships • Three-dimensional pump vibration • Carbon footprint report Recently Armstrong integrated Advanced Performance Management capabilities into every Design Envelope pump model.

So every customer now has the option to employ this level of reporting if they need it. We have also developed a retrofit solution to upgrade pumps already in situ.

f: How can the government best support investment in more sustainable pump technology?

WR: Any financial incentive available to building owners and energy managers to assist in improving the environmental performance of their sites is, of course,

Wayne Rose, Product Experience Director at Armstrong Fluid Technology.

both welcome and much needed.

However, it would be good to see financial incentives aligned with the actual lifetime performance of the equipment, rather than just its theoretical efficiency at the time of installation. The complexity of HVAC systems at the larger end of the scale means that there are inevitable challenges when harnessing the full energy efficiency potential of the equipment installed.

Smart commissioning is key to this, along with HVAC technology capable of providing real-time alerts in advance of problems occurring with the equipment.

In particular, it is essential to address performance drift, where the pump and other HVAC system components begin to stray away from the required operating conditions, resulting in energy wastage due to under-performance. In our experience, addressing performance drift can help owners regain energy efficiency savings of up to 40%.

All of the pump technology necessary to achieve these savings is readily available without the need for costly customisation or BMS programming.

In fact, the Armstrong Pump Manager technology already mentioned carries out these tasks automatically, helping to reduce operating costs by providing continuous optimisation of pump performance. This also increases pump www.bpma.org.uk

BUILDING SERVICES 27

solutions available. Our fire pumps stand over life and property throughout the world.

FIRE PUMP

HORIZONTAL SPLIT CASE (HSC)

FIRE PUMP

END-SUCTION

FIRE PUMP

VERTICAL IN-LINE

VERTICAL TURBINE

and associated costs. Choose a system that arrives on-site in a fully enclosed ready for use pump house. This pre-engineered pumping system saves time and money for our customers.

+353 (0)44 934 7078

www.ie.pattersonpumps.com

ua

r a n t ee

2

year

arr nt a

y

company/patterson-pump-ireland-ltd

d

Quarter 4 2021

FIRE PUMP

Reduce on-site labor time, engineering and installation time

sales@ie.pattersonpumps.com

www.armstrongfluidtechnology.com. www.bpma.org.uk

offering our customers some of the most reliable pumping

w

f: As we work towards zero carbon buildings, which emerging pump technologies do you expect to have the most impact in the future?

WR: In many ways, we have much to gain from the more widespread use of the technology already resident in today’s generation of pumps. But as we look to the future, there are some important developments on the horizon with the potential to fundamentally change the environmental performance of UK buildings.

Digital twin technology, for example, promises to drive down energy consumption by facilitating collaborative benchmarking and simulation of alternative HVAC system scenarios. A digital twin is a virtual representation of a mechanical component that serves as a real-time digital counterpart. Originated in the aerospace industry to improve physical model simulation of spacecraft, digital twinning offers immense potential for the HVAC sector. This approach will enable actual data on the environmental performance of buildings to be used to create a digital duplicate. This replica can then be used to help building owners, estates managers, pump manufacturers, consultants and others to understand, analyse, manipulate, and optimise systems. We will be able to learn from installations worldwide, and will be able to make far more accurate and effective design and operational decisions about systems, because we can simulate scenarios with actual building data rather than hypothetical parameters.

Although this sounds rather space-age, the first pump technologies harnessing digital twin capability are likely to be readily available during 2022. chevron-circle-right

Patterson Pump Ireland is a complete pump manufacturer,

g

availability and reliability and reduces unexpected failures by providing early problem detection. An important point to consider is that performance drift can cause particular problems because it leads to noticeable changes in the comfort conditions of a building.

It is common for occupants of a building to take matters into their own hands, making interventions such as opening windows or plugging in fans or heaters. If this occurs, energy efficiency gains are largely erased, and the estates team loses control. Proper control over the long-term optimisation of pump performance is crucial to prevent this all-too-human response. If government policy can focus on these elements of optimisation of energy efficiency over time, we will see tangible reductions in carbon emissions of UK building stock.

28 Building Services

PULSE CIRCULATORS OFFER ENERGY SAVINGS LAUNCHED EARLIER THIS YEAR, the Stuart Turner Pulse range of domestic and commercial circulators cover a range from single head to twin heads of variable speeds. Designed to constantly monitor and regulate pressure and flow and adjust according to the set operating mode, its makers say that the Pulse range is perfect for any application.

The Pulse range features high-efficiency ErP compliant pumps in various sizes with both single and twin head options for Rp1½ to DN80. The range also contains secondary hot water circulators of bronze construction.

Pulse circulators come loaded with energy-saving features and provide installers and specifiers with versatile options, whatever their requirements might be. The pumps are driven by highefficiency permanent magnet motors with EEI ratings as low as <0.20 and are capable of self-modulating to only deliver

what flow is required, based on demand.

This operating mode offers the greatest energy savings of up to 90%, compared to old style fixed speed pumps.

Other operating modes include constant speed, night mode and fully automatic mode.

Dimensionally, they compare well with products already in the market and, in most cases, will act as quick and easy replacements with no pipework modification required. They feature a simple to install electrical connection with no need to remove a terminal box.

The range is set to build on the success of Stuart Turner’s existing ST range of domestic circulators, offering solutions for

single dwelling premises all the way up to more significant commercial properties.

“After the successful launch of our domestic heating and hot water circulators, we have now extended the range into a commercial single, twin, screwed and flanged offering which gives contractors a reliable choice with a brand that is recognised throughout the UK”, said Kevin Moore, Group Sales Director at Stuart Turner. stuart-turner.co.uk

WHITEPAPER ADDRESSES CHALLENGES OF MOVING TO LOW CARBON HEATING SOLUTIONS THE HEATING AND HOTWATER Industry Council (HHIC) is urging the government to consider the suitability of current UK domestic heating systems to facilitate the transition to Net Zero.

Retrofitting homes with low-carbon technologies, like heat pumps and hydrogen boilers, will be key to meeting the UK’s Net Zero targets. However, many of the different heating systems that circulate heat and hot water in properties are not currently appropriate for these emerging technologies, nor are they adequately covered by strategy and policy work.

To outline where improvements need to be made and how different domestic systems can be aligned with the country’s long-term goals, the HHIC has launched a comprehensive whitepaper entitled Heating up to Net Zero. It has been researched and written by members of Quarter 4 2021

HHIC, the Hot Water Association (HWA), and the Manufacturers Association of Radiators and Convectors (MARC). It seeks to clarify what the challenges are and what is required for them to be overcome.

One of the key examples given in Heating up to Net Zero is that many homeowners are currently removing hot water cylinders. However, these are needed for the supply of hot water if a low-temperature heat generator, such as a heat pump, is to be fitted in the future. Replacing old cylinders with better insulated and controlled models, that incorporate high recovery heat exchangers and are suitable for low temperature / low carbon systems, should be incentivised by a simple-to-understand government scheme.

From a practical perspective, mandating system balancing of the heating system

will help to drive innovation. Since this was highlighted in the boiler plus review, many control manufacturers now produce flow controlled TRV’S, which are a simple solution to balancing the heating system.

This will become an important part of the commissioning process for lowtemperature systems.

Aside from focusing on the heating system, the HHIC has also drawn attention to the critical role of installer training.

They are a key part of the jigsaw for decarbonising heating and hot water systems and are the main point of contact with the homeowner. For those entering the industry and individuals who already possess a wealth of experience, getting to grips with new technology will be vital for overall successful implementation.

The whitepaper can be downloaded at: bit.ly/HHICNZ www.bpma.org.uk

Independent Pump Training from E-learning Classroom based “Live” webinars On-site courses Tailored options For more information call

0121 601 6691

or scan code for the training guide

11th & 12th May 2022 The NEC, Birmingham, UK PRE-REGISTER FOR FREE ENTRY!

CHEMUK2022 The Supply Chain Expo for the UK’s Chemical, Pharma & Process Industries

FREE ENTRY

WHEN ERED PRE-REGIST

Supporting Partner

2 Packed Days 300+ Leading Exhibitors Panel Sessions Plant & Process Intensification Control & Instrumentation CHEMICAL 4.0 – Automation / Digitisation Asset Management & Maintenance Plant Management Flow & Thermal Solutions... plus more!

11TH & 12TH MAY 2022 REGISTER FREE AT WWW.CHEMICALUKEXPO.COM

FEATURE 30 Opinion

The answer to your skills gaps could be closer than you think James Henson, Operations Manager (Design & Compliance) at Musk Process Services, explains from first-hand experience how keeping an open mind can open up new talent streams.

M

y current role is as Operations Manager at Musk Process Services.

In this position, I lead the Engineering Compliance and Design department; however, my journey to where I am now definitely wasn’t straightforward. Without other engineers and mentors offering me the opportunities that I couldn’t access on my own, I certainly wouldn’t be where I am today; a professionally registered chartered engineer and leading our Design Department.

I always knew I wanted a job that I could develop into a career for life. I began as a semi-skilled carpenter, and spent time as a motor mechanic before eventually pursuing my ultimate goal, an apprenticeship in engineering. It was after this that I was first made aware of Musk, (then Peme) and was successful in joining the company as a computeraided design (CAD) technician. It wasn’t an apprenticeship; however, it offered the opportunity to get into engineering, which was my goal. The position also came with the potential to develop further and turn it into a lifelong career.

I worked hard, starting early and staying late, which caught the Managing Director’s eye. He offered me the opportunity of pursuing an apprenticeship with the company despite the fact I wasn’t the typical ‘straight out of school’ new recruit. The academic year had already started when I was offered this new and exciting role, which required further hard work, catching up with several weeks of college work. Nonetheless, I finally completed the apprenticeship that I had always wanted, qualifying in Mechanical Engineering and Design.

The opportunities to expand my skills and knowledge continued after my apprenticeship, and much of this can be attributed to the mentorship I received from my managers and more

Quarter 4 2021

senior engineers at the time. Once I had qualified through the apprenticeship, I was encouraged to lead design and installation projects which gave me a good grounding in most aspects of our business and my trade.

After broadening my knowledge, I was offered the opportunity to move into the Reliability Engineering Department, to widen my knowledge of asset care and the business. Under the guidance of Senior Reliability and Condition Monitoring Engineers, I completed an HNC. I also furthered my skills and gained a qualification in Specialised Condition Based Monitoring Techniques, such as Thermography and Ultrasound. Again, without my peers’ support, I would never have had the opportunity to expand my engineering knowledge and develop into the engineer I am today.

The Senior Management Team within Musk really believe in others and make it a priority to encourage and enable other colleagues to develop internally.

I was extremely fortunate to be mentored by an experienced Design Manager, Steve Wiles, and our Operations Director, Darren Martin, who included and supported me in establishing the engineering compliance arm of the business that I currently influence. I recognise the mentorship that I have received, and now I want to give that back. I’m grateful to be in a position where I can support other engineers in the business in developing their careers in the same way as I’ve been supported during mine.

I have learnt so much during my career with Musk, and I am so fortunate to have been given the roles and

James Henson, Operations Manager at Musk Process Services.

learning opportunities throughout this time. I feel that apprenticeships are often stereotyped to young people and school leavers; however, many others can benefit hugely from them.

Every day we are learning, and there is so much more knowledge to acquire.

We have recognised that it really doesn’t matter at what stage you are within your career; you can always learn to advance yourself.

I really believe that engineering companies can benefit from having an open mind when it comes to apprenticeships and offering development opportunities to their existing and older staff, as well as taking on recruits directly from education. chevron-circle-right

“I really believe that engineering companies can benefit from having an open mind.”

www.ejmusk.co.uk www.bpma.org.uk

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

PUMP INDUSTRY AWARDS 2022

EVENT CALENDAR

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

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

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

It’s your chance to celebrate with colleagues, re-connect with peers and be part of the pump industry’s biggest and best celebration; put the Thursday 31st March 2022 in your diary now.

The 2022 Call for Nominations is now open, so be sure to visit the Pump Industry Awards website to review the award categories and decide which ones you will be entering!

NOMINATIONS OPEN

27th SEPT 2021

NOMINATIONS CLOSE

7th JAN 2022

JUDGING SESSION

25th JAN 2022

FINALISTS ANNOUNCED

3rd FEB 2022

WINNERS ANNOUNCED

31st March 2022

at the Chesford Grange Hotel, Warwickshire

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

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

Award Programme Partners

www.pumpindustryawards.com

Organised by

on behalf of

www.brookcrompton.com

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

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

The extensive range of stock can be quickly modified to suit customers’ needs and with a high level of technical support from our knowledgeable team we ensure the correct selection of motors is provided for your application.

Brook Crompton’s focus on product and service development ensures we continue to move forward to improve efficiency, offer lower cost of ownership throughout their lifecycle and to reduce environmental impact.

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