Flow Magazine: Quarter 4, 2023 - Focus on Mining & Quarrying

Quarter 4 2023

Pump industry insight from

SECTOR FOCUS: Mining & Quarrying

Managing the changing tides of cybersecurity

Investing in the future of dewatering

Pump Industry News

Innovations

Applications

Expert Opinion

Solutions for

INDUSTRY MFM

X2000

WEGscan App

X1000

MOTION FLEET MANAGEMENT Online monitoring and intelligent management of the equipment and assset fleet.

The ideal solution for monitoring and increasing the availability of your fleet equipment and assets.

Based on cloud computing technology, motors, drives, gearboxes, pumps and compressors can be tracked and monitored at any time and from anywhere in the world. This allows planned and predictive maintenance avoiding costly downtime and ensuring the efficiency and performance of equipment.

www.weg.net

CONTENTS 3

A

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.

s we come to the end of 2023, flow magazine’s fourth year, thoughts start to turn towards what we can expect in 2024.

A highlight of the year for the pump industry is, of course, the Pump Industry Awards. Due to be held in March, this annual event always offers a superb opportunity to showcase and celebrate the breadth of excellent work across the sector and to recognise the contribution we collectively make to so many aspects of everybody’s day-to-day lives.

In this issue of flow you can find out more about what to expect on the night and I would encourage anyone in the industry to join this fantastic evening.

You can also find out about the award categories and how you can enter them.

There is still time, but you have to be quick as the entry deadline is in the first week of January.

As a previous winner of a Pump Industry Award, I can attest to the value it can bring, both within a business when staff see the recognition of their hard work, and outside of the organisation as customers and suppliers see the industry’s recognition.

The process of entering also provides an opportunity to step back and reflect on achievements and successes. With the constant pressures we all face today, the chance to do this, can often pass us by. But it is a valuable and rewarding exercise that we should try and make the time to do.

So, before you turn the page and dive into another excellent issue of flow , why not take a moment to consider what you and your business should be celebrating. Who knows, 2024 could be a winning year for you.

PUMP INDUSTRY NEWS

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

4

2000 reasons for success

5

The end of an era for one industry figure

BPMA Update 6

Product News

Twitter @bpmapumps flow is a controlled circulation journal

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

8

Pump motor with brush- lifting device

9

New hybrid motor line

PEFC/16-33-254

www.bpma.org.uk

www.pefc.org

12

Plant upgrades to intelligent electric actuators

Features 18

The future of water sustainability

22

Managing the changing tides of cybersecurity

28 Pump compatibility is key with challenging media 30 Pumping solutions for corn ethanol plant

Mining & Quarrying 34 Investing in the future of dewatering 36 Water treatment plant to enable tin mine reopening

22

Awards update

PEFC Certified This product is from sustainably managed forests and controlled sources

AGM highlights achievements

Project Updates

10

Awards entry deadline approaches

OPINION 38 Will WEG’s acquisition be a game changer?

Quarter 4 2023

4 INDUSTRY NEWS

Europump unveils New user-friendly website EUROPUMP, THE EUROPEAN Association for Pump Manufacturers, has announced the launch of its new and improved website, europump.net.

The redesigned site offers a modern and intuitive interface, providing an enhanced user experience for members, partners, associates, and other pump industry professionals.

Europump members represent more than 450 companies with a collective production value of over €10 billion and an employee count of 100,000 people throughout Europe.

The new website serves to improve communication regarding the vital role Europump and its National Association members play in the regulatory and standardisation framework that now exists internationally.

Key features of the new Europump website include a focus on user-friendly exploration, making it easier for visitors to find the information they need quickly

and efficiently. While a responsive layout ensures seamless viewing across various devices, including desktops, tablets, and smartphones.

Visitors to the site can explore Europump’s extensive range of pump-related information, from industry profiles to policy documents, position papers to membership benefits, and efficiency guides to pump types; a valuable resource for engineers,

project managers, company executives, stakeholders and anyone seeking reliable pump technology information and guidance.

A highlight of the new design is the Energy Saving Dashboard, which provides a real-time illustration of the energy savings being made under the Ecopump initiative, designed to be the cornerstone of the European pump sector’s energy and environmental policy.

ERIKS WELCOMES ITS FIRST APPRENTICES ERIKS HAS WELCOMED THE FIRST apprentices to its newly designed apprenticeship programme. The new programme demonstrates its commitment to fostering a new generation of engineers and bridging the engineering skills gap.

Thirteen apprentices aged between 17 and 27 will pursue Level 3 Engineering qualifications across different ERIKS locations throughout the United Kingdom. In stark contrast to the persistent concerns around a lack of enthusiasm for engineering careers in the United Kingdom, ERIKS experienced a strong interest in its apprenticeship programme, with 500 individuals applying for the initiative.

Created from the ground up by Lori Broadhurst, Talent Development Partner at ERIKS, the programme represents an

investment of £30,000 per apprentice. According to Lori: “The aim is to futureproof the company’s workforce by not only nurturing career-specific skills but also fostering a sense of community among apprentices”.

While the apprentices will primarily hone their skills at their respective sites, they will gather every 4-6 weeks for ‘block release learning’ at SMB College in Leicester, ensuring a well-rounded formal engineering education as well as a practical, hands-on one.

While this inaugural year focuses on engineering apprenticeships, ERIKS plans to expand the programme into other areas in the future, including sales, service, supply chain management, finance, and human resources.

2000 REASONS FOR SUCCESS THE AES ENGINEERING GROUP, including AESSEAL and AVT Reliability, has taken on its 2,000th employee worldwide as its global expansion continues.

Over the past few years, the group has accelerated its growth by investing in people as well as in the latest robotic and AI-powered technology at AESSEAL’s recently completed ‘Factory for the

Quarter 4 2023

Future in Rotherham, South Yorkshire, and through global acquisitions and partnerships.

Managing Director, Chris Rea, acknowledging that the global workforce had now passed 2,000, said the company goal was not to be the biggest, but to be the best: “We welcome all the new members of the AES ‘family’, as we need the best

possible people to give the exceptional customer service that drives our success.”

The group, headquartered in Rotherham in the UK, is one of the world’s largest manufacturers of mechanical seals used in all types of industry and is a leading advocate of environmentally friendly investment to reduce pollution, lower carbon emissions, and cut water use.

www.bpma.org.uk

INDUSTRY NEWS 5

THE END OF AN ERA FOR INDUSTRY FIGURE AFTER A LONG AND DISTINGUISHED career, Reflex Winkelmann’s Dave Cannon has taken the decision to retire from the industry after 60 years, almost 14 of which have been spent with the heating and hot water specialist.

Dave began his career in 1963 at the age of 15, initially as a trainee welder/ fitter. Unfortunately, this was short-lived, and after a period in which he worked in various roles, including van boy and bricklayer, he eventually started working for a UK pump company called Pullen Pumps in 1964. Dave had various roles throughout his time at Pullen Pumps.

From the initial role as a stores labourer, Dave progressed through the business and, although he had spells at other companies, continued to be asked to return and spent a significant portion of his life travelling the world as a service engineer and finally as the technical manager for Pullen Pumps.

As part of the service team, Dave worked closely with Reflex Winkelmann and became recognised as Pullen Pumps’

in-house expert working on multiple sites, including Heathrow Airport, BBC Manchester and many others.

During a planned commissioning visit to the BBC studios in Manchester in 2009 Dave was accompanied by Dan Tester, who was responsible for the Reflex operation in the UK at the time. After an informal conversation during the visit regarding the plans for Reflex in the UK, a meeting in Germany soon followed and in 2010, he started work for Reflex Winkelmann as Technical Manager.

Dave’s career includes many highlights, but one that stands out is his involvement in the successful design, construction, supply, and commissioning of four packaged skid assemblies to serve the new Lloyds data centre in Northamptonshire a little over ten years ago. The equipment has been closely monitored via routine maintenance, and the client has enjoyed uninterrupted operation since, thanks to a resilient design.

Asked what he would like to pass on

to those coming into the industry to follow in his footsteps, Dave said: “Don’t forget that every day is a school day.

Grab every opportunity to learn, as there is always something new and exciting to understand.”

Dave’s colleagues at Reflex Winkelmann and those he has worked with over his distinguished career wish him a long and happy retirement.

WEG ACQUIRES ELECTRIC MOTORS AND GENERATORS BUSINESS FROM REGAL REXNORD THROUGH ITS INDIRECT subsidiaries abroad, WEG has announced the acquisition of the industrial electric motors and generators business of Regal Rexnord Corporation, a global manufacturer of electromechanical equipment. The acquisition value is $400 million, subject to standard price adjustments for this type of transaction.

This transaction focuses on the industrial electric motors and generators businesses of the Marathon, Cemp, and Rotor brands within the Industrial Systems operational segment of Regal Rexnord, a company headquartered in the United States and listed on the New York Stock Exchange.

WEG will also integrate a team of approximately 2,800 employees operating in ten factories in seven countries (United States, Mexico, China, India, Italy, the Netherlands, and Canada) and commercial subsidiaries in 11 countries.

The net operating revenue of these businesses in 2022 was approximately R$ 2.8 billion (US$ 541.5 million), with an adjusted EBITDA margin of 9.5%.

Quarter 4 2023

WEEKS

2

BPMA Update 6 FEATURE

ACHIEVEMENTS HIGHLIGHTED AT AGM

E

arly in November, the British Pump Manufacturers’ Association’s (BPMA) officers and members gathered in person and virtually for the annual Association AGM. Held for those attending at the Wychwood Park Hotel in Crewe, the meeting was chaired by the newly appointed BPMA board member Andrew Simpson of Apex Pumps.

Among the formalities required by the Association’s Articles of Association, 12 Council members whose two-year term had concluded were duly re-elected.

Three members who had retired from Council since the last AGM, Richard Harden and Morgan Warren-Ross, both ex of Stuart Turner Pumps, and Calpeda’s Ken Hall, were thanked for their loyal service to the BPMA. Three recent additions to the Council, who had been co-opted since the last AGM, Nicki Cox of Armstrong Fluid Technology, Patrick Tantum of Caprari and Nick Yeomans from Weir Minerals, were formally elected along with Aaron Chung of ESPA Pumps UK, who was nominated at the meeting.

The President’s report, which followed the Council election, then highlighted key elements of the Association’s work over the preceding 12 months. It was reported that Association representatives had held and attended over 150 meetings within the BPMA and with the European umbrella Association, Europump, the British Standards Institute, and the standards bodies CEN and ISO. It was noted that the Association’s Technical meetings were regularly attended by

over 20 member representatives with the Association monitoring and reporting on developments with six active CEN, ISO and API standards and over 29 pieces of European legislation.

An update on training activity explained that 363 delegates had been through BPMA training in person across 40 separate presentations, while a further 130 students had registered for the introductory e-learning course and 14 for the more advanced e-learning programme. The development of a new course covering variable speed drives was also mentioned.

There were 12 new members joining the BPMA during the last year, with the total membership standing at 116 at the time of the AGM. Additional achievements highlighted in the report included over 250 guests at the Pump Industry Awards dinner and 50 participants at the annual golf day, plus 16 press releases and feature articles

which were produced and distributed to the media.

Following the President’s report, attendees were given two guest presentations. Kiran Ahmed from Oxford Economics gave an overview of the World Pump Report, a detailed analysis of the global pump market provided to members as part of their benefits. This presentation covered the economic backdrop, key developments in industry markets and the implications for pump market demand.

The second guest presentation came from Terry Boniface, Assistant Director – Electronics and Machinery at the Department for Business & Trade. Terry gave those at the meeting a legislative update, offering an overview of his department’s responsibilities and the ministerial priorities, including those related to regulation, supply chains, trade agreements, business investment and digital technology.

UPCOMING TRAINING FROM THE BPMA Date

Course title

Duration Location

08 April 2024

Virtual Pumping Fundamentals

1 day

Online

09 April 2024

Virtual Pump Selection

1 day

Online

10 April 2024

Virtual Pump Systems

1 day

Online

6-9 May 2024

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

Quarter 4 2023

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

WELCOME TO THE TH FAMILY > SteriTecTM The new range of DEPA® 316L Stainless Steel Pumps

YEARS

6.5

For more information call 01642 379500

www.tomlinson-hall.co.uk

8 Product News

HIGH-PRESSURE PUMPS FOR BIOMASS POWER PLANTS IN RESPONSE TO THE TRANSITION in power generation from large power stations fired by coal and gas to smaller power stations incinerating biomass or refuse, the KSB Group has developed a new variant of its HGM high-pressure pump that has been tried and tested for 30 years.

The designers of the new variant, called HGM-S, placed a particular focus on it being highly reliable, service-friendly and economical. Examples are its internal, product-lubricated plain bearings that do not require any external supply systems.

The small spacing of bearings lowers the vibration level of the pump, which markedly

reduces wear. The combination of suction stage impeller and axial inlet results in a very low Net Positive Suction Head (NPSH) and good suction characteristics. With its axial inlet, the new pump set is very compact and space-saving.

The shaft sealing is provided by a

mechanical seal at the drive end that is easy to access from the outside. Given the seal design and smart arrangement in the pump, no external piping is needed for cooling and lubrication circuits. Spare parts stock and servicing are kept simple that way.

The largest flow rate of the new pumps is 390m3/hr. The maximum head is 1000m.

The electric drive ratings range from 10kW to 1300kW. The materials for the casings are either steel or stainless steel. All impellers are cast of high-quality stainless steel.

www.ksb.com

PUMP MOTOR WITH BRUSH-LIFTING DEVICE HIGH-OUTPUT ELECTRIC MOTOR specialist, Menzel Elektromotoren has built, installed and commissioned a pump motor equipped with a shortcircuiting and brush-lifting device.

The three-phase slip-ring induction motor drives the peak load pump for Baden-Württemberg state water supply, a German special-purpose association. Due to the brush-lifting device, the motor carbon brushes are only used during motor startup and then lifted off the slip rings. This minimises wear and tear and allows significantly longer maintenance intervals because the brushes no longer need to be replaced regularly

and the slip ring compartment rarely needs to be cleaned of carbon dust.

In addition to a slip-ring motor with brush lifting, the scope of supply also included a motor base frame, coupling, liquid starter and cabling to the nearest switchgear. The size 800 motor with a

nominal output of 6200kW at 5000V nominal voltage drives the peak load pump in the summer months and is becoming increasingly important due to climate change and higher daily water requirements.

Menzel fully tested the motor in the customer’s presence and then installed it and put it into operation at the waterworks. By replacing the original motor from 1969, the customer has ensured the reliable continued operation of the plant for the future.

tinyurl.com/MenzelPump

FLOW SENSORS WITH IO-LINK SENSOR SPECIALIST EGE HAS expanded its range of IO-Link sensors, launching a new series of flow sensors for smart networking in compact plants and systems.

The new SDNB 552 series is based on a tried and tested special model. Four series sensors measure the flow velocity and temperature of water-based liquids in ranges between 0.5 and 10l/min and 5 and 100l/min with linearised measured value output.

The IO-Link interface allows for convenient remote sensor parameterisation and data readout for maintenance. The analogue output and Quarter 4 2023

switching output are available in SIO mode. Parameterisation with IO-Link via the M12 connection is carried out either via a PLC or an IO-Link master – EGE offers the IOL Master Set V1.1 for this purpose. The sensors featuring G1/2 or

G3/4 connection threads are designed for inline mounting in hoses and pipes.

Based on the calorimetric measuring principle, the sensors introduce no moving parts or deflectors into the stream. The wetted parts are made of 1.4571 stainless steel.

The sensors are IP65-rated, pressureresistant up to 10 bar and are designed for media temperatures from 0 to 60°C. Due to their rugged design, EGE flow sensors can withstand moisture and vibrations.

www.ege-elektronik.com

www.bpma.org.uk

Product News 9

WEG UNVEILS NEW HYBRID MOTOR LINE MOTOR MANUFACTURER, WEG, HAS launched a new motor line, the W23 Sync+, a hybrid innovation that combines permanent magnet (PM), ferrite or neodymium magnets and synchronous reluctance (SynRM) motor technologies, providing higher efficiency across all speeds when compared with conventional induction motors.

The permanent magnet synchronous reluctance motor (PMSynRM) line is suitable for applications including compressors, pumps, fans, blowers, conveyors and more.

Advantages of the W23 Sync+ motor line include a higher level of efficiency for the entire speed range compared with conventional induction motors, and a higher power factor than synchronous reluctance motors. This results in a lower total cost of ownership (TCO) for plant managers.

“We’re looking to the future with the W23 Sync+,” explained Marek Lukaszczyk, European and Middle East marketing manager at WEG. “The IE5 and IE6 models far surpass the current

European Ecodesign regulation, which currently requires motors to meet the IE3 or IE4 standard.”

The W23 Sync+ is available in frame sizes from IEC 80 to 450 (NEMA 140 to 7,000). Able to operate over a wide speed range at constant torque, without the use of forced ventilation, this multi-platform solution is available in speed ranges from 750 up to 6,000rpm. The motor’s output rating ranges from 0.75 to 1,250kW, while it’s compatible with 220/380V, 230/400V, 240/415V and 400/690V power supplies.

While a conventional induction motor loses over 20% efficiency across its varying speed and load ranges, the W23 Sync+ maintains its higher efficiency, decreasing less than 2% when the load and speed are reduced by 25%.

The W23 Sync+ also benefits from its compact nature with the same power per frame ratio as induction motors. For

example, the IE5 variety is available in the same frame size as an IE3 motor, which makes interchangeability with existing installations smooth and hassle-free.

www.weg.net

FLOWMETERS FOR PROCESS INDUSTRIES ABB HAS LAUNCHED CoriolisMaster and ProcessMaster flowmeters that can be powered over the same Ethernet cable used for data transmission, eliminating the need for separate cabling.

One of the key challenges facing customers in process industries is the need to reduce the complexity and cost of installation and operations of field instruments, infrastructure and systems. The new flowmeters featuring ProfiNet with Power Over Ethernet address this challenge by providing a single-cable solution.

Incorporating ProfiNet into ABB’s CoriolisMaster and ProcessMaster flowmeters enables seamless and real-time exchange of data and monitoring of alarms and diagnostics.

It also allows for diverse configurations to ensure reliable and efficient communication between the flowmeters and across both local area and wide area networks (LAN & WAN).

An easy-to-access built-in webserver minimises time spent for set-up and parameterisation of the flowmeters. Users get access to all parameters, such as measurement range, units, IO configuration, verification and diagnostic settings as well as a data-logging function.

go.abb/processautomation

Quarter 4 2023

£100k ($130,000)

10 Awards Update

PUMP INDUSTRY AWARDS ENTRY DEADLINE IS APPROACHING The closing date for entries to the Pump Industry Awards is Friday, 5 January 2024.

Entering is simple, and putting forward a nomination demonstrates confidence and pride in the quality of an organisation’s work, people, products, and projects.

T

he BPMA’s annual 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.

For any pump-related product, system, or service that deserves industry-wide recognition, this is the ideal platform.

Organisations that are proud of a particular pump project, their overall environmental credentials or that wish to recognise staff members who have gone above and beyond or have developed an outstanding commitment to skills development, are encouraged to enter. Whatever the engineering or business successes might be, third-party endorsement of key achievements through this awards process delivers unrivalled promotional opportunities.

Submissions are sought for activities and achievements that took place in the 18-month period up to December 2023, and the online entry forms will remain on the dedicated awards website www.pumpindustryawards.com – until the entry deadline of 5.00pm on Friday, 5 January 2024.

Maintaining the early Spring timeline and following the huge success of the 2023 event, the next Gala Dinner and Presentation Ceremony will take place on Thursday, 14 March 2024, at the Hilton at St George’s Park in Burton on Trent.

Situated on the edge of the National Forest, this impressive hotel is part of St. George’s Park – the training ground for all 28 English national football teams – and is recognised the world over as the home of English football.

This key sector of industry continues to play a crucial role in ensuring our food production, utilities, manufacturing processes, transportation and other essential services are maintained, and the 2024 awards programme will again give

Quarter 4 2023

special recognition to those companies and individuals who have not just met, but exceeded the demands and challenges presented by the sectors served.

This recognition and acknowledgement will be represented by eight award categories that collectively honour the full breadth of product and service delivery by the pump industry.

• Product of the Year - Sponsored by DFA Media Group • Project of the Year - Sponsored by AESSEAL • Environmental Contribution of the Year Sponsored by SPP Pumps • Manufacturer of the Year - Sponsored by WEG UK • Distributor of the Year – Sponsored by Caprari / Calpeda • Supplier of the Year - Sponsored by Wilo • Contribution to Skills & Training – Sponsored by Crest Pumps • Rising Star Award - Sponsored by World Pumps Once again, the event has secured support and backing from a host of leading brands, all of whom recognise the value and importance of promoting excellence across

the sector. In addition to the main category sponsors, there are also other sponsorship options to help support specific elements of the 2024 presentation evening. Several opportunities to have brands aligned to outstanding engineering achievement still exist.

Wayne Rose, Director and CEO at the British Pump Manufacturers Association, commented: “This year’s awards ceremony – the 22nd such event – was as good as any I can remember. The atmosphere was fantastic, and the competition was intense.

Business and professional excellence deserves to be acknowledged and celebrated, and these awards do just that for this most important of sectors. I would therefore encourage all those involved in the pump industry to prepare and submit their entries for the 2024 awards programme.”

Those looking for further information on the 2024 Pump Industry Awards or to submit entries are encouraged to visit the website. chevron-circle-right

www.pumpindustryawards.com

www.bpma.org.uk

Ensure machine reliability and reduce waste Want to achieve a significant reduction in unforeseen downtime, optimise your maintenance practices and tasks, and avoid significant production losses? With a cloud-based AI-driven machine learning solution for predictive maintenance of your rotating equipment, you can: •

Detect faults and anomalies

•

Get real-time perspective outcomes

•

Extend asset lifetime

•

Improve the efficiency and longevity of rotating assets

•

Shift from time-based maintenance to predictive maintenance

Let us show you how Grundfos Machine Health ensures machine reliability in your industrial production or utility, reduces downtime, increases longevity of assets and optimises production across operations.

Get in touch and find out more: Cathy Mathiesen, +4552327739, cmathiesen@grundfos.com product-selection.grundfos.com/products/grundfos-machine-health

Don't let this be your last copy of flow!

To make sure you continue to receive your free copy of flow register online at: flowmag.co.uk Choose flow, in print or digital format, and stay up to date with the latest products, technical insights, news and innovations, for the design, specification, installation and management of pumps in:

z Manufacturing z Construction z HVAC z Building services z Mining z Utilities

Quarter 4 2023

Pump industry insight from

SECTOR FOCU S: Mining & Qu arrying

Managing th e changing tides of cybe rsecurity Investing in the of dewatering future

REGISTER NOW AT flowmag.co.uk Pum p Indu

stry New s

Innovati ons

App lica tion

s

Exp ert Opi

nion

SCAN ME

© Grundfos Holding A/S 08.2023

Grundfos Machine Health:

12 Project Updates

WASTEWATER TREATMENT PLANT UPGRADES TO INTELLIGENT ELECTRIC ACTUATORS ROTORK IQ ACTUATORS HAVE BEEN installed at a wastewater pumping plant in Hong Kong. They were upgraded from older manually-operated valves to electric actuators with intelligent functionality built in.

This project included the construction of an underground wastewater balancing tank with a capacity of 16,000m3, a plant house with a ventilation system and improved deodourising facilities. These changes will increase the amount of sewage and wastewater that the site can process, as well as ensure there is no excess flow of treated water.

Nearly 50 actuators have been installed to operate the valves; IB multi-turn gearboxes combined with IQ actuators are being used on penstocks and gate valves on site. IQM actuators from the IQ3 range have been installed on the balancing tank system and sewage gas system. The IQM is the modulating duty version of the IQ 3-phase electric actuator, which features a solid-state reversing starter in place of the electromechanical contactors to allow faster response to changing position signals. To

optimise positional control, the solid-state starter also adds an electronic motor ‘brake’ feature.

The intelligent IQ actuators are well suited to pumping station applications due to their robust environmental sealing.

They have a double-sealed enclosure (IP66/68) making them suited for water applications. Featuring highly reliable

absolute position sensors and an intuitive user interface, the IQ actuators were selected to provide intelligent, automated valve operation.

rotork.com

WATER REDUCTION OF UP TO 80% FOR KEY INDUSTRIAL PROCESS FOR A JUST-IN-TIME SUPPLIER TO the automotive industry, a wastewater recycling system from Membracon has created annual savings of more than £63,000 by reducing water usage from 108,000 litres to just 21,000 litres per day.

Without site space restrictions, which limited installation to a single-pass system, Membracon could have reduced wastewater discharge to just 5,400 litres per day, an annual cost-saving of over £75,000. However, in time, the newly created savings will enable the wastewater plant to be moved to a different part of the premises, allowing a secondary filtration system to be added.

This will increase savings from 80% to 95%.

Matt Williams, Managing Director of Membracon, said: “Nobody wants Quarter 4 2023

downtime and a loss in production, especially in the pressurised automotive industry. Our customer had to run its pretreatment process lines at full capacity, constantly topping up the rinse tanks, which required pure water production to keep everything clean. In addition to tackling increasing costs, the company was also determined for us to help them reduce their environmental impact.”

Membracon had conducted a fullspectrum analysis of the just-in-time supplier’s wastewater. By understanding the precise levels of contaminants, the most cost-effective and easy-to-maintain solution was then custom-designed to suit the customer’s specific needs.

Ultimately, the wastewater recycling system that Membracon introduced has not only cleaned up the wastewater

and reduced discharge but also enabled clean water to be reintroduced upstream.

This has significantly reduced the cost of fresh water being brought into the process.

www.membracon.co.uk

www.bpma.org.uk

cl N os om e 5 t iNa h t ja ioN Nu s ar y2 02 4

PUMP INDUSTRY AWARDS 2024

Here’s your chance to shine!

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 14th March 2024.

Venue: Hilton at St George’s Park, Burton upon Trent Date: Thursday 14th March 2024

The 2024 entry forms CLOSE on the 5TH JANUARY 2024, so be sure to visit the Pump Industry Awards website TODAY and review the award categories and decide which ones you will be entering!

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.”

Event Calendar Nominations Close: 5th January 2024 Judging Session: Mid-January 2024 Voting: 12 th-16th February 2024 Winners Announced: 14th March 2024

www.pumpindustryawards.com Award Programme Partners

Organised by

on behalf of

14 Project Updates

REMOTE PUMP MONITORING HELPS AQUACULTURE FARMER WORK MORE EFFECTIVELY NLN FARMS, LOCATED IN THE US state of North Carolina, needed to transfer water from four aquaculture ponds to a nearby reservoir. The farm selected Xylem’s Godwin CD100 dewatering pump for the job, with Field Smart Technology, which enables real-time monitoring and control of the pump from a smartphone.

Nick Dotson, a fourth-generation farmer and co-owner of NLN Farms, stays busy managing his family’s farm and working a separate, full-time job. The Dotson farm has evolved over the years, switching from cattle to farm-raised catfish in the early 1990s and starting with freshwater crawfish in 2019.

Every summer, Nick needs to drain the crawfish ponds to provide the right conditions for decaying vegetation, the food source for crawfish. Transferring water from the farm’s four ponds to a nearby reservoir requires careful planning and an efficient pumping system.

Nick selected Xylem’s Godwin CD100 pump with Field Smart Technology for dewatering the ponds, because enables him to remotely manage the pump from his smartphone – even while he is at his other job.

The cloud-based Field Smart

Technology solution means that Nick can precisely control water levels in the ponds, 24/7, to ensure the best conditions for the crawfish.

“With Field Smart Technology, I don’t have to babysit my ponds,” commented Nick. “I can set specific alarms to alert me if something needs to be checked, or if my pump shuts down unexpectedly. I can manage the farm on my schedule.”

Field Smart Technology keeps a record of all pump activity, including run status, fuel usage, oil pressure and general engine health. The remote solution provides alarms for engine and pump maintenance, and real-time alerts that enable optimal operation and rapid response to outages or flooding.

“We’re now in the process of closing the crawfish season for the year, but over the last few weeks, I’ve been transferring the pond water to our main reservoir pond, and the Godwin pump with Field Smart Technology has done an amazing job during this process,” Nick added.

As part of a generation that grew up with

digital technology, Nick looks for smart solutions to solve his business needs. By leveraging Xylem’s Field Smart Technology, NLN Farms has minimised human resource requirements by automating maintenance and service. This gives Nick the freedom and flexibility to pursue expansion opportunities.

“I am impressed with the capabilities I have with both the pump and Field Smart,” Nick concluded. “We are already looking into expanding in the industry over the next few years, and we look forward to working with Xylem as we continue to grow.”

www.xylem.com

NO TIME TO WASTE WHEN THE GIBBONS TEAM WAS recently dispatched to the Anglian Water Stambourne site to fine-tune and enhance the performance of the balance tank filling pump, there was no time to waste. This task was no ordinary maintenance job; it required the implementation of advanced speed control measures aimed at reducing the flow rate, ultimately leading to significant energy savings.

In this intricate operation, the Gibbons team used an in-built timer within the ABB ACQ580. The Gibbons engineer employed this timer to delay the start of the pump, aligning perfectly with the specific requirements outlined by the process managers.

After an initial survey, the team meticulously planned and executed

Quarter 4 2023

the modifications, ensuring that the balance tank filling pump operated at peak efficiency, all while reducing energy consumption.

The ABB ACQ580 Variable Speed Drive (VSD) is a versatile motor control solution designed to optimise the performance of electric motors in various industrial applications.

The ACQ580 enables precise control of motor speed and torque, allowing for enhanced efficiency and productivity.

It boasts advanced features, including integrated safety functions, built-in timers, and extensive connectivity options. With its user-friendly interface and intuitive programming, the ACQ580 is well suited to use in industries seeking to improve energy efficiency, reduce maintenance costs, and achieve precise

control over their processes, whether they are used in pumps, fans, conveyors, or other machinery.

www.gibbonsgroup.co.uk

www.bpma.org.uk

The market-leading, domestic variable speed pump and tank system

Plug & Play

CAT 5 Options Available Single or Twin Mèta Pump Options Super Quiet Operation

Always In Stock

UK Production Centre Wedgwood Road Industrial Estate Bicester Oxfordshire OX26 4UL

technical@calpeda.co.uk 01869 241 441

UK Customer Services Centre Frairwood Lane Pontefract West Yorkshire WF8 1UA

Find us on social media and sign up to our mailing list!

16 Project Updates

LIFTING STATIONS SUPPORT NEW DENTAL SCHOOL A NEW, STATE-OF-THE-ART DENTAL school in Bristol will enable students to put theory into practice using the most modern equipment available in a renovated building in the heart of the city. Bristol University is one of the UK’s leading dental teaching institutions. Its move to a new, purpose-built school will enable the expansion of student places, the availability of new courses, and the creation of new jobs. Some three years in the making, the new facility, formerly the site of a leading bank, opened in September 2023 with numerous clinics and 119 dental chairs.

The three-year project was awarded to Kier Construction, who appointed Briggs and Forrester Engineering Services to complete the building’s fit-out. To support the discharge of grey water waste at certain points, two of Saniflo’s Sanifos underground lifting stations were specified

by Briggs and installed in the basement, along with a Sanivite grey water pump.

The first of the Sanifos 610 lifting stations takes the water from a 20,000-litre booster tank in an adjacent plant room during routine maintenance and cleaning. It also provides an overflow for excess water. This is pumped up to street-level drainage directly above the

unit.

The second Sanifos 610 is situated directly beneath the clinical rooms and takes waste from compressed air and suction drainage tools used by the trainee dentists.

The condensate waste from several air handling units installed in the same section of the basement, but on a higher elevation, is also discharged into this Sanifos, which again pumps the waste up to the mains drains.

The use of the large, 610-litre Sanifos underground pumping stations was recommended by a Saniflo pump specialist following a visit to the site, where the job was scoped out. The units were ordered from a local builders’ merchant, Bristol Building Supplies, who organised a swift delivery for installation by the Briggs team.

A third unit, a compact Sanivite+ grey water lifting station, was specified to take wastewater samples once per week from side stream filters that monitor the heating and chilling systems throughout the whole building. Water is frequently tested, and

the resulting wastewater is pumped out through the Sanivite+ to mains drains.

This automatic operation is designed to ensure there is no rust contamination in the pipework to maintain the optimum efficiency of the temperature controls.

www.saniflo.co.uk

TURNING FARM SLURRY INTO HYGIENIC BEDDING GOODWIN’S FARM IN SUSSEX, AN 800-acre unit that is home to 700 cows, wanted a cattle bedding alternative that would utilise its slurry and reduce the amount held in on-site storage. This would not only free up space on the farm but also reduce the risk of any environmental damage occurring from leaks or the production of harmful ammonia gases.

An HBC Biocell, a complete solution that turns slurry into a hygienic bedding alternative for cattle, was installed on the farm by T-T Pumps. Complete with all of the equipment needed for effective slurry handling – chopper pumps, separators, hoses, level control, control panel, and more – the biocell separates and pasteurises the solid part of slurry, meaning it is mainly liquid slurry being sent to storage.

This slurry separation reduces the need for on-site storage and increases

Quarter 4 2023

the quality of both the solid and liquid slurry content – the solids are utilised as a hygienic bedding alternative, and the liquids can be used as an environmentally friendly fertiliser, recycling the slurry’s nutrient-content for crop growth.

Commenting on the installation, a representative from Goodwin’s Farm said: “We thought that the principle of pasteurised bedding was a very positive one, with 60% of our cubicles on sawdust and mattresses and the other 40% deep lying sand cubicles. We liked the idea of

pasteurised bedding and the benefits it can bring as well as the cost savings.

“It has been a constant learning process from day one, in terms of how long to run the machine, the importance of using only freshly produced bedding for that day, how often to bed up, how much lime to use and how often to sweep the cubicles. We finally feel that we have the right routine for the bedding.

“What goes into the tower is now far more liquid and easier to pump. We have saved directly in bedding costs as well.”

As well as the cost-saving benefits and environmental improvements to its slurry handling, the farm also saw a 30% reduction in slurry entering its slurry tower.

www.ttpumps.com

www.bpma.org.uk

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.

VOGELSANG – LEADING IN TECHNOLOGY For more information: sales.uk@vogelsang.info | 01270 216 600 vogelsang.co.uk

Utilities, water & waste 18 FEATURE

The future of water sustainability Brett Mernin, Bruce Grobler and Jose Giacomoni are long-time specialists in the use of variable speed drives in pumping applications at Control Techniques. Together, they look at the challenges facing the modern water and wastewater industries as well as the importance of VSDs in reducing operating costs and improving sustainability.

P

umps are at the heart of every water installation, and variable speed drive (VSDs) manufacturers are continuously innovating to support the industry and help reduce operating costs as well as improve efficiency. Energy and water have several characteristics in common; they are both essential to modern life, they are diminishing resources which pose a global challenge, and sustainability can be improved by reducing the consumption of both.

Addressing these issues together can benefit consumers, operators and the environment.

Traditional energy sources are being supplemented by renewables, and some water treatment plants are taking advantage of anaerobic digestion to support their business.

At the same time, reducing energy usage is equally important from a cost perspective as well as an environmental position. Furthermore, when energy costs have such a significant impact on water prices for the consumer, making the most efficient use of these resources benefits everyone.

INCREASED URBANISATION A number of major global trends are directly affecting the water sector. Urbanisation is placing much greater pressure on the existing infrastructure, which means utilities need to make the most of the current installed base of equipment and extend its service life. Adding to this, most national water assets have been in place for decades, and historically, utilities have a reactive approach to maintenance, only taking action when a failure occurs.

In many cases, built-in redundancy ensures an uninterrupted supply of water, but the ageing infrastructure needs significant investment.

This can be supported with a proactive maintenance strategy Quarter 4 2023

that uses modern data collection and analysis to optimise repair schedules. Looking at the scale of urban growth, this often necessitates the construction of new treatment and water distribution sites. In this scenario, there is the opportunity to incorporate the latest technology in terms of process and energy efficiency from the outset.

CLIMATE CHANGES Environmental challenges, primarily droughts and flooding, also affect water demand and treatment volumes. Adapting the existing infrastructure to meet the current demands on the water system is ever more difficult. Increasing volumes of drinking water need to be delivered from a diminishing resource, while increased rainfall poses a significant risk of flooding, which can lead to environmental contamination from raw sewage.

Coupled with greater local regulation and compliance, which are essential for high water quality, the challenges

facing the water industry are numerous.

Access to water for drinking and irrigation in areas where water is becoming scarce means extraction rates need to be carefully monitored to ensure water resources are maintained. In countries experiencing significant water shortages, desalination plants may be installed, but they need to operate as efficiently as possible to minimise operating expenses and water costs to the consumer.

Conversely, in regions that are seeing significant increases in rainfall, sufficient to require new pumping stations to be built, large water volumes require large pumps, so achieving optimum hydraulic and electrical efficiency is key to minimising running costs.

REDUCING OPERATIONAL EXPENDITURE The major pain point that utilities have to battle with is rising costs while delivering a basic human www.bpma.org.uk

> 20

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

FEATURE water & waste 20 Utilities, requirement as cost-effectively as possible. Water prices are typically governed by a fixed charge, which covers infrastructure and sewage, as well as a volumetric charge for the water consumed. Water supply is a monopoly; there is no competition in the market, so in some countries, government subsidies are used to reduce the price of water, while others have independent pricing regulators.

In all cases, maintenance costs are a constant challenge, and the art lies in minimising them wherever possible. Of course, prevention is better than cure; taking preemptive action, based on good data, enables planned maintenance to be completed, avoiding unexpected breakdowns.

The ability to detect rag build-up on a pump impeller, for example, enables the controller to briefly run the pump in reverse to dislodge the rag before continuing to operate normally. This feature alone significantly reduces the number of call-outs for technicians, saving their time and fuel.

In addition, the risk of flooding due to blocked pumps is also minimised, which reduces the opportunity for environmental fines. Drives can also detect dry-running and prevent overheating, as well as ensuring non-return valves don’t slam shut, reducing the opportunity for water hammer, which can cause pipe fractures.

IMPROVING INFRASTRUCTURE The global water industry depends on reliable equipment and has historically used built-in redundancy to mitigate the effects of any breakdown. The introduction of modern control systems that can drive preventative maintenance as well as reducing operating costs should be considered across the board. VSDs that have been specifically configured for the water sector also offer several advantages that go beyond the well-documented energy savings.

In the US, a national infrastructure bill has released US $55 billion to support the renewal of pipework and improvements to pumping stations Quarter 4 2023

that include optimising energy efficiency. This is where variable speed drives offer numerous clear benefits by providing specific pump data as well as optimised efficiency.

Improvements to pumping stations can also include upgrades to pumps with revised hydraulics and drive motors. Incorporating permanent magnet technology to achieve IE4 or IE5 classifications needs to be matched with a suitable drive. Careful attention should be paid to the drive because simply upgrading the pump may not be the answer. Some drives do not have field orientated control (FOC) and are incapable of working with permanent magnet systems.

MODERN TECHNOLOGY BENEFITS Standing out as a major benefit, retrofit solutions are relatively easy to implement because modern electronics packages are much smaller than the legacy controls, making a replacement in an existing motor control centre a reasonably simple task. Well-designed control systems are intuitive, and commissioning is straightforward, making life easier for contractors and operators looking to achieve the ideal setup.

In some markets, water pricing can be slightly opaque, with penalties for using more than twice the expected monthly consumption. Modern pump data analysis can mitigate these penalties by raising the alarm before the trigger point.

Looking at solutions that are available to the market, Control Techniques has developed a range of VSDs specifically for the water industry. The F600 offers many benefits in terms of improved

efficiency, data collection, advanced warnings and a five-year warranty, which is attractive to both operators and suppliers/installers. It contains a function block that is specifically designed for pumping applications, simplifying configuration and operation.

UNIVERSAL CHALLENGES Among the challenges faced by the water sector, some are common across the globe, while others are more regional. Universally, energy prices have risen, and this has a direct impact on operating costs, which affects the price of clean water and wastewater charges. At the same time, inflation is driving labour costs, and the number of technical maintenance personnel is reducing.

All of these issues can be positively influenced by tackling inefficiencies and minimising maintenance costs. Upgrading controls offers opportunities for increased remote management and automated maintenance, as well as reduced energy consumption.

Collectively, benefits can be achieved for operators and customers alike, along with the environmental advantages of improved sustainability. chevron-circle-right

Maintenance costs are a constant challenge, and the art lies in minimising them wherever possible.

www.ControlTechniques.com www.bpma.org.uk

Introducing SUBMAT The latest variable speed pump and tank innovation from Calpeda

Turnkey Solution

Bespoke Options Single or Twin MXS Pump Options Ease of Maintenance

Perfect for environments where a conventional cold water booster set and tank are not possible due to size constraints!

UK Production Centre Wedgwood Road Industrial Estate Bicester Oxfordshire OX26 4UL

technical@calpeda.co.uk 01869 241 441

UK Customer Services Centre Frairwood Lane Pontefract West Yorkshire WF8 1UA

Accoustic Dampening

Find us on social media and sign up to our mailing list!

FEATURE 22 Cybersecurity

Managing the changing tides of cybersecurity Amid the digitisation of the water sector, the risks posed by cyber threats are growing.

Nick Nedostup, Chief Information Security Officer at Xylem, discusses how utilities can modernise while staying secure.

E

very day, utilities harness digital tools to deliver efficient services for their communities while solving complex water and resource challenges. Increasingly connected and integrated solutions require increasingly strong defences. We need to embed cybersecurity into our digital approach.

Previously, attacks mainly focused on data breaches and stealing sensitive information, but the rise of ransomware has changed the way that bad actors seek to gain financially by denying a user or organisation access Quarter 4 2023

to files. While financial services companies may have been a prime target, many have invested heavily in cybersecurity, making them less appealing.

The business model is now to disrupt an essential service, put providers under extreme pressure, and get a quick payment – putting water firmly in the crosshairs.

While in the US, for example, the Environmental Protection Agency (EPA) is stepping up to issue guidance, including direction on cybersecurity audits and sanitary survey completion, developing a coordinated industry response

is vital. Organisations such as the Water Information Sharing & Analysis Center (WaterISAC), also in the US, are bringing utilities together to bolster security and ensure water is not a soft mark.

FROM CYBER STRATEGY TO DAY-TO-DAY ACTION So, how can utilities act? The first step for utilities is checking what supports are available. The US and many other jurisdictions provide state-supported funding options that can help address security.

An individual utility may not have the bandwidth to stay across www.bpma.org.uk

Cybersecurity 23 events throughout the sector.

As the tech world moves more to a software-as-a-service or infrastructure-as-a-service model, utilities can save on upfront costs and share the security burden with providers.

Choosing the right vendor by embedding cybersecurity into procurement can build trust that a provider is taking the right security steps.

For businesses such as Xylem, security is the foundation of our ability to be successful in the market. If utilities can develop these trusted relationships, they can also lean on providers to upgrade the system in the background, allowing a utility to get on with serving its community.

LAYERS OF DEFENCE Secure technology is a vital layer of defence, but some layers don't require significant capital or operational investments. One is mapping and understanding a utility's assets for gaps or risks. Simply put, if you don't

know you have it, you can't protect it. Regular security and technology audits can ensure necessary controls are in place. This is not a one-anddone; it needs to be a continuing practice.

And, as threats evolve, we need to keep on top of them.

A key question in that inventory is asking if any devices in a utility are out of date. Another vital layer is education. So many attacks happen through social engineering that trick employees into making security mistakes or giving away sensitive information.

The first line of defence is often the simplest: Arming employees with a basic knowledge of how to take security precautions that can stop many of these attacks at source.

Make your employees aware that it is okay to question things – ask if an email makes sense,

pause to consider if you can trust the person contacting you.

Make time for awareness and education, from online vigilance to showing how to create a strong password.

These simple steps have an impact.

When it comes to cybersecurity, the environment will constantly evolve. We are never really done with security. We must focus on identifying key risks and take steps to address them. Then, we stay vigilant and work together to keep evolving as an industry, one that can get all the benefits of digital technology while staying secure. chevron-circle-right

The first line of defence is often the simplest: Arming employees with a basic knowledge of how to take security precautions.

www.xylem.com

15th & 16th May 2024 The NEC, Birmingham, UK GROUP OF EVENTS

CHEMICALS SUPPLY SHOW

CHEMICALS MANAGEMENT SHOW

PROCESS & CHEMICAL ENGINEERING SHOW

CHEMICAL LABORATORY SHOW

PROCESS & CHEMICAL ENGINEERING SHOW

Running as part of the CHEMUK 2024 Group of Events

Headline Industry Partner

2 Packed Days Hundreds of Exhibitors Valve & Actuator Suppliers Plant & Process Instrumentation Control & Instrumentation Digitisation & Automation Plant & Process Safety Flow & Thermal Solutions Thousands of Specialist Products… plus more

PRE-REGISTER FOR FREE ENTRY! 15TH & 16TH MAY 2024 REGISTER FREE AT WWW.CHEMICALUKEXPO.COM

24 Pump Technology

There is more to circumferential piston pumps than meets the eye It’s not uncommon for there to be confusion when telling lobe pumps and circumferential piston pumps apart. Chad Wunderlich, Distributor Development Manager at Viking Pump, looks at the differences and outlines the advantages of circumferential piston pump technology.

A

circumferential piston pump (CPP) is a type of positive displacement pump that uses rotating pistons to move fluid through the pump housing.

This technology has many benefits and makes circumferential piston pumps an ideal solution for hygienic applications. Unlike other types of positive displacement pumps, such as rotary lobe pumps, circumferential piston pumps can handle a wide range of viscosities and deliver high discharge pressures. Additionally, the pump’s design includes various seal types, such as mechanical seals and O-ring seals, to prevent leakage and subsequent pump damage. With its ability to handle high pressures, viscosity products, and hygienic applications, the circumferential piston pump is widely used in industries such as food processing, where maintaining product integrity and preventing contamination is crucial.

COMPARING DESIGNS It’s not surprising that circumferential piston pumps are often confused with rotary lobe pumps. With the front cover on, both pumps look similar, with a rotor case in the front and a gearbox with timing gears in the back.

Both are rotary positive displacement pumps with non-contacting rotors.

Both are commonly used for food and beverage applications where the pumps require frequent cleaning or need to meet third-party sanitary standards.

So why is a CPP not a lobe pump?

What’s so different?

The difference is in the pumping elements, called rotors.

Quarter 4 2023

A rotary lobe pump (left) compared to a circumferential piston pump, both from Viking’s Revolution Series.

IT’S IN THE ROTORS In a lobe pump, the clearances between rotors and the rotor case wall are very close. In a circumferential piston pump, the rotors run in close clearance to the rotor case wall and to hubs in the rotor case or front cover.

But what advantages does a circumferential piston pump bring, and what pump applications would such a pump be favoured for?

ADVANTAGES AND APPLICATIONS First, many circumferential piston pump models, like Viking Pump’s TRA 10 series, for example, are designed to be easily disassembled for cleaning. Applications like meat processing and other facilities commonly require this type of cleaning to facilitate thorough sanitation and ease of inspection. Circumferential piston pumps are easier to disassemble and reassemble than lobe pump designs.

Secondly, CPPs have higher pressure

capabilities than their lobe counterparts.

Viking Pump offers models with differential pressures up to 500 PSI. Higher pressures are often needed for high-viscosity liquids (like corn syrup) or when pushing liquids through downstream filters.

Lastly, the large carrying cavities and scoop-shaped wings on each rotor help make CPPs better for handling large solids like those found in salsa, fruit preserves, or cookie dough, just to name a few.

So yes, there are more similarities than differences between lobe and circumferential piston pumps, but those differences mean you should never overlook the circumferential piston pump as a positive displacement solution and understand where to apply each design. chevron-circle-right

www.vikingpump.com www.bpma.org.uk

A mobile application enabling paperless service and repair Why is Smart Site right for you?

07:49 Mon 27 Feb

Job List 51676

Service centre

27/02/2023 08:00 10:00

Smart Site reduces the waiting time of documents in transit. All job information is visible at the office as it happens.

Overhaul of Sewage Pump United Performance Ltd LOOSE PAPER MILL B TONN ROAD LIVERPOOL MERSEYSIDE L34 9JB

Lead Engineer: GARYD 27/02/2023 10:30 11:30

60498

Site work Motor repair United Performance Ltd LOOSE PAPER MILL B TONN ROAD LIVERPOOL MERSEYSIDE L34 9JB

Lead Engineer: GARYD 27/02/2023 12:30 13:30

60484

Site work Borehole pump United Performance Ltd LOOSE PAPER MILL B TONN ROAD LIVERPOOL MERSEYSIDE L34 9JB

Lead Engineer: GARYD 27/02/2023 14:30 16:30

61239

Site work

Smart Site is easy to use on any smartphone or tablet device and requires very little training.

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.

Service of 2 x ac motors United Performance Ltd LOOSE PAPER MILL B TONN ROAD LIVERPOOL MERSEYSIDE L34 9JB

Lead Engineer: GARYD

See Smart Site in action!

Scan the QR Code to find out more

5 Steps to Service Success

Empower your engineers with an app that can:

Job (61239) Lead Engineer: GARYD

1

Create new jobs

Job Info Documents Assets

2

View the details of the job

Scheduled Labour Record Time Record Materials Record Expenses

3

Record the work detail undertaken

Engineer Report Record Activities Job Notes Links

4

Adhere to ISO standards, site safety and services

Photographs Health & Safety Checklists Service Checklists Obtain Customer Signature

COMPLETE JOB

5

Review the work and gain customer sign-off

EMiR Software have nearly thirty years’ experience in providing job management solutions for the Electrical & Mechanical Industry, in fact 47% of the AEMT UK Membership have purchased EMiR Software.

Call us today and see how EMiR can help you – 0845 009 4588 Visit www.emirsoftware.com to book a demonstration

26 Hazardous Areas

IE5 ultra-premium motor efficiency in explosive environments ABB has extended its award-winning IE5 SynRM (synchronous reluctance motor) series with a brand-new addition: the IE5 SynRM Increased Safety motor.

I

n what ABB is saying is a worldfirst, customers operating in hazardous area industries can now ensure safety and boost their energy efficiency by deploying motors that offer up to 40% lower energy losses compared to commonly used IE3 motors.

The new version of the IE5 SynRM motor has been developed for use in potentially explosive atmospheres across a wide range of demanding variable-speed industrial applications.

It offers accurate control and high efficiency throughout the whole speed range, even at partial loads.

This makes it the ideal upgrade choice for standard induction motors in pumps, fans and compressors for industries where explosive gas, vapour or dust might be present, such as oil and gas, chemicals, wood processing and flour milling.

In addition to energy savings, the new SynRM Increased Safety motors can help customers specify a more cost-effective installation.

For example, in Zone 1, the cooler running design could allow the use of an increased safety motor where a flameproof motor with a special enclosure would be the traditional choice. While in Zone 2, the improved loadability of SynRM motors, that enables more power to be delivered from the same size as an induction motor, is important. This could enable a smaller, and therefore lowercost, motor to fulfil the same duty.

Stefan Floeck, Division President IEC Low Voltage Motors at ABB, said: “We have achieved a significant world-first by bringing the benefits of IE5 ultra-premium efficiency to the hazardous area sector. Adopting best-in-class technology has made our IE5 SynRM motors a gamechanger for operators in a wide range of industries. They see improving energy efficiency as key to achieving their net zero ambitions while optimising their business costs.”

A key benefit of IE5 SynRM Increased Safety motors is that they run cooler than standard designs.

Bearing temperatures are reduced by up to 15°C and winding temperatures by up to 30°C. This provides increased reliability, prolongs the

For details of the full range of training available from the BPMA, scan the QR code to access a digital version of the new and updated training guide.

Or for a copy in the post, email your name and address to: training@bpma.org.uk

motor’s lifetime and reduces maintenance needs.

The SynRM design combines the performance advantages of permanent magnet technology with the simplicity and servicefriendliness of an induction platform. To ensure an environmentally friendly design, the motors don’t contain magnets or rare earth metals.

IE5 SynRM Increased Safety motors are available with output power of 5.5 to 315 kilowatts (kW) in frame sizes IEC 132-315. chevron-circle-right

new.abb.com/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

Challenging Media 28 FEATURE 28

Pump compatibility is key with challenging media When selecting a pump for a specific application, its suitability for the media being pumped is critical, especially if there are properties which make it a challenging application. Castle Pumps outlines some key considerations you need to make when selecting the best pump for a new application.

W

hen it comes to needing a new pump for your process, "What fluid are you handling?" is one of the first questions you should be asked. Everyone understands that ensuring the wetted parts are in materials compatible with your fluid is vital, as failing to do so can cause the impellers, seals and other components to swell, become brittle, erode or even melt.

Castle Pumps often hears customers saying, "Oh, EPDM is fine for my fluid", which is a great starting point. But did you know that the concentration and temperature of a chemical can also impact material selection? For example, Hastelloy C is compatible with hydrochloric acid at 10% concentration at 20°C. However, at 40°C, it has limited resistance.

Not everyone realises that a supplier asking about your fluid is not solely about material selection but also pump selection.

So, what else should you be ready to tell your supplier about your fluid when you have a process requiring a pump?

PRESENCE OF SOLIDS IN THE LIQUID Certain pumping technologies are not suitable for handling even the smallest of particles. Due to the tight tolerances between the casing and the moving parts, vane, gear, and side channel pumps will jam when attempting to pass solids, causing immediate wear. On the other hand, peristaltic and diaphragm pumps can handle solids up to the size of their inlet/ outlet. For that reason, sometimes a larger pump than is needed duty-wise is specified to handle the solid size but run at a lower speed.

It's also important to consider whether the solids are hard and abrasive or soft and malleable. Are they thin and stringy, susceptible to clogging?

Peristaltic pumps have no moving parts that encounter the fluid and, therefore, have no valves, seals or impellers to clog

Quarter 4 2023

or erode. Whereas other pumping technologies could find stringy solids such as fruit juice pulp wrapping around their impellers. For softer solids, flexible impeller pumps are often a lower-cost solution, thanks to their supple rubber impellers being able to bend around them.

VISCOSITY OF THE FLUID Certain designs, such as centrifugal pumps, which are excellent for thin, waterbased chemicals, can struggle with thicker fluids due to frictional losses inside the pump, causing flow rates to decline rapidly, whereas many positive displacement pumps excel. Knowing the viscosity of your fluid is therefore very important to pump specification, but also be aware that this can change with temperature. A pump may be able to handle gear oil at 10°C, but at -10°C, it becomes too thick.

In addition, the presence of solids within a thin liquid such as sand in water is much more abrasive than larger solids in a higher viscosity, lubricating fluid such as oil. The continuous cavities between the rotor and stator of the progressive cavity design and the slight flexibility of the stator means that large solids in thick liquids can be easily handled. However, when an abrasive water-based liquid is pumped, wear can occur more prematurely than a peristaltic pump with limited internal components.

IS THE FLUID SHEAR SENSITIVE? Shear-sensitive fluids are those that, under force, can be damaged or altered, like cream being whipped, shampoo frothing or solids

being crushed like fruit pieces in a yoghurt.

Awareness of the delicate nature of a fluid can impact the specified pump type. While centrifugal pumps apply high shear in operation, shear-sensitive pump designs – such as progressive cavity, flexible impeller, and peristaltic pumps – can keep such fluids intact due to their low internal velocity and the wider tolerances between their pump casing and internal components.

Essentially, it is important to give your pump supplier or system designer full details of the fluid you plan to pump, and where available, providing a material safety data sheet is the most accurate way of ensuring compatibility. When it comes to fuel and oils, users should always specify any additives that may get added afterwards. The liquid's temperature and concentration should also be confirmed if it's a chemical, as this can impact material selection. While the liquid's viscosity is important information to share as well. If you aren't sure about the exact viscosity of your fluid, you can liken it to a more wellknown liquid. chevron-circle-right

www.castlepumps.com

www.bpma.org.uk

THE FLOW MUST GO ON. WITH EFFICIENCY.

Safeguards the availability of your plant: the newly developed Amarex submersible motor pump features non-clogging impellers, operates more energy-efficiently, is easy to service and environmentally friendly.

Find out more at www.ksb.co.uk - 01509 231872 - sales@ksb.com

Flow; 210x145; September 2023.indd 1

16/08/2023 15:10:02

Any queries, please get in contact with charlotte.heath@ksb.com

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

30 Challenging Media

Pumping solutions for ultramodern corn ethanol plant Sulzer explains how its pumps and sealing solutions support reliable and efficient operations in Brazil’s first corn-based ethanol plant.

F

S – Fueling Sustainability, located near Lucas do Rio Verde, Mato Grosso, is Brazil’s first corn-only ethanol plant. Phase one production started in 2017 with an initial capacity of 250 million litres per year. The facility utilises the latest process technologies from ICM, a USA-based company that has become a global expert in biorefining technologies and processes. In addition to bioethanol, some high-value coproducts, such as corn oil and high-protein, high-fibre, dried distiller’s grains, are produced.

The plant also generates electricity from biomass, partly for internal use, with a surplus for sale.

FS – Fueling Sustainability is recognised as the world’s most modern and efficient corn ethanol plant. The production facility has top-class pumping equipment from Sulzer and value-added, patented technologies from ICM. CHALLENGING MEDIA Each step of ethanol production from corn involves pumps that need to cope with some technically demanding applications. The liquids can be complex, have high solids contents, be viscous, corrosive, hot, erosive, or explosive. The right pump materials and optimal sealing systems must be carefully selected to ensure reliable and long-lasting operation. Furthermore, all pumps must be highly efficient in terms of energy and water savings so that the complete plant is operating to its full potential.

In close cooperation with the customer, AHLSTAR and SNS pumps were chosen for all applications – from initial mash slurry transfer to final ethanol truck loading. In total, more than 80 single-stage pumps were installed for phase one. The AHLSTAR pumps in duplex material handle liquids containing solids and Quarter 4 2023

other particles, while the SNS pumps run on clean liquids. Most of the pumps are equipped with double mechanical seals.

In the United States alone, more than 200 corn-based ethanol plants are operating today, and about 70% are equipped with Sulzer pumps.

After careful commissioning and start-up, all pumps have been working well. For the most demanding applications, the AHLSTAR pumps, with adjustable side plates, provide high performance continuously. For clean liquids, the new SNS pumps simply have the highest efficiencies on the market – they exceed the benchmark efficiency index MEI 0.7.

The AHLSTAR and the SNS pumps have open impellers with balancing holes that optimise the shaft seal function. For pumps with double mechanical seals, it was decided after a few months of operation to switch from API piping plan 54 (external pressurised source) to API piping plan 53 (external pressurised reservoir). This change helped to reduce the water consumption and operational costs further. The versatility of the pumps and the dedicated Sulzer service technicians made this upgrade easy and fast.

In 2018, a duplicate of the existing plant was built (phase two). This doubled the production capacity of the Lucas do Rio Verde site.

Satisfied with the collaboration, FS – Fueling Sustainability ordered new similar Sulzer pumps for this extension. The site was further expanded in 2019 (phase three) with additional Sulzer equipment installed. Today, more than 300 AHLSTAR and SNS pumps are running smoothly in the plants.

The corn ethanol site has a total of 307 Sulzer single-stage process pumps in duplex or stainless steel 316 materials. Most AHLSTAR pumps with double seal have the simple and reliable Sulzer thermosiphon SP8 seal pot system.

The AHLSTAR and SNS pump ranges have a wide choice of wet end sizes to cover the required flows (2 to 1,230 m³/hr) and heads (4 to 105m) which allows the pumps to always run at duty points close to the best efficiency points, offering direct and maximised savings in energy costs. chevron-circle-right

www.sulzer.com

www.bpma.org.uk

Pioneering for You

T: 01283 523000

E: sales.uk@

When it comes to reliability, you can count on Wilo. wilo.com We understand how important reliability is to your projects, and that’s why we manufacture quality products that won’t let you down.

You can also count on our expert teams to support you with maintenance and service, technical advice and energy saving solutions that help you to meet your sustainability goals.

Hot Water

Heating

Pressure Boosting

Drainage

Get in touch today and find out how Wilo can help you.

T: 01283 523000 E: sales.uk@wilo.com www.wilo.co.uk

@WiloUK

Flow_Magazine_Half_Page_ Jan22.indd 1

23/08/2022 15:52:12

PRECISION: HORIZONTAL AXIS HARD-BEARING BALANCING MACHINES FOR PUMP MANUFACTURERS The Z series of standard horizontal balancers is our comprehensive range of precision hard bearing machines. All machines can be supplied with either belt, cardan drives or a combination of both.

Our full range offers a great deal of flexibility when it comes to your balancing requirements: • Weight of symmetrical motor – from 2kgs to 60,000 kgs • Sensitivity – from 0.02 g.mm to 25 g.mm dependent on machine capacity • Balancing speed (measuring unit) 70-200000 rpm • Type of drive available – belt and cardan shaft • Standard length of bed– 400mm to 7,000 mm • Standard measuring instrument – B11 We have considerable application knowledge gained over many years of operation in pump manufacturing, so that whatever your balancing requirement we’ve got you covered.

Image: our ZB750 horizontal balancer with combined belt and cardan drives

For further information contact us: T: 0161 872 3123 or E: enquiries@cembhofmann.co.uk www.cembhofmann.co.uk

Dredging 32 FEATURE

Simplifying the intricacies of environmental hydraulic dredging

Environmental hydraulic dredging is a key topic in waterway management, integrating technical procedures and environmental mindfulness. Ben Weinrib, CEO of EDDY Pump Corporation, highlights the significant aspects of turbidity and solid-to-water ratios.

E

nvironmental hydraulic dredging is akin to deploying a hefty underwater vacuum cleaner. Its primary objective is to suction up the sediment that accumulates at the bases of rivers, lakes, and other water bodies. But this isn’t about any sediment; the focus often pivots towards contaminated materials, pollutants that, when disturbed, could adversely impact the aquatic ecosystem and water quality.

This slurped-up material, aptly termed ‘slurry,’ is a concoction of water and solids. It is ferried via pipelines to a predefined destination for effective management and treatment, ensuring that contaminants are safely neutralised.

NAVIGATING THROUGH TURBIDITY Engage the anchors momentarily and ponder turbidity, a principal aspect of dredging. Imagine shaking a bottle containing a mix of water and sand. The murky, particle-infused water post-shake illustrates turbidity. In dredging, an excess of this can inadvertently circulate pollutants throughout the water, jeopardising ecological stability.

Herein lie the environmental benefits of hydraulic dredging – its ability to maintain calm waters figuratively by ensuring minimal turbidity. Through confined systems for material transport and meticulous operational protocols, contaminants remain where they should – away from the broader water body. Some dredging technology has taken this to the next level by being able to remove solids without any detectable turbidity and, hence, not hurting the surrounding ecology.

Quarter 4 2023

STRIKING A BALANCE With the foundation laid, let’s delve into a crucial element often overshadowed yet paramount – maintaining an optimal solids-towater ratio in the transported slurry.

Firstly, there is a fiscal vantage point. A slurry richer in solids than water equates to lesser volumes requiring treatment. By sheer quantity, this translates into curtailed processing costs, amplifying economic efficiency. It’s analogous to having less volume of a ‘dirty substance’ to clean, requiring fewer resources. While most hydraulic dredging equipment is capable of up to 20% solids to water ratio by volume, new technology is capable of up to 70% solids, which offers a huge benefit to contractors on environmental dredging projects.

But this isn’t purely a financial conversation; it offers environmental benefits. By minimising the water constituents in the transported slurry, hydraulic dredging champions a philosophy of judicious water usage. This ensures we are not indiscriminately extracting water from ecosystems, reinforcing conservation and resource mindfulness principles.

Having unfurled the sails through the conceptual seas of environmental hydraulic dredging, the benefits of curtailing turbidity, and the necessity of a balanced solids-to-water ratio, we are invariably drawn to a crucial realisation. Environmental hydraulic dredging isn’t merely a procedural activity; it’s a testament to the feasible harmonisation of operational imperatives and

ecological conservation.

It underscores a practical example where our technological and procedural applications can coexist with and enhance our environmental stewardship. By proactively mitigating turbidity and astutely managing our solids-to-water ratio, we are not simply executing a task; we are consciously facilitating a symbiotic relationship between our operational endeavours and the aquatic environment.

In the grand vista of technological progression and ecological challenges, environmental hydraulic dredging stands out as a lighthouse, guiding us towards a pathway where operational pragmatism and environmental custodianship can sail harmoniously. As we navigate the waters of future projects, our practices may perpetually echo a synergy, ensuring that our aquatic territories remain healthful and our methodologies sustainably pragmatic. chevron-circle-right

This isn’t purely a financial conversation; it offers environmental benefits.

eddypump.com www.bpma.org.uk

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 20180629_Anzeige_UK_123x86.indd 1

29.06.18 16:23

How much are your pumps REALLY costing you?

Get ahead of the curve and eliminate unplanned downtime

With the new AVF-X chemical resistant mag drive pumps that exceed Europe’s toughest efficiency requirements ASSEMBLED IN THE UK READY FOR NEXT DAY DELIVERY www.crestpumps.co.uk T: 01425 627700

CONTACT US TODAY!

Mining & Quarrying 34 FEATURE

Investing in the future of dewatering The vast majority of mining involves working below the water table, which means a comprehensive and flexible dewatering plan is essential – particularly as mine workings go deeper to reach diminishing stocks of ore. Weir Minerals looks at how technology enables equipment providers to remove water from a mine and put it to good use afterwards.

M

ines cannot operate without a robust and flexible dewatering strategy. As no two mines are the same, each site’s dewatering requirements will vary, with environmental and geological considerations as well as local climatic variations likely to present unique challenges.

Variations in weather conditions can significantly affect open-pit mining in particular, and even mines operating above the water table can be subject to significant influxes of water caused by environmental changes such as heavy rainfall or, in colder climates, melting snow in the springtime. It is essential, therefore, that the dewatering systems in place have the capacity to handle the maximum potential volume of water inflow to avoid downtime and prevent any risks to safe operation.

A variety of factors dictate the type of dewatering system required for a specific mine. The permeability and porosity of the ground, the amount of surface water, geological features such as underground rivers and seasonal rainfall must all be assessed and factored into a detailed dewatering system before work can begin.

At the forefront of every operator’s requirements from their dewatering equipment are efficiency and reliability, lifetime ownership cost and ease of maintenance.

HOW DOES TECHNOLOGY HELP? There was a higher level of uncertainty in the design of dewatering systems in the past due to the available technology at the time, and equipment was often oversized to deal with a worstcase scenario. Modern geological surveying methods have allowed dewatering systems to be designed with a much higher level of accuracy, and the advances in sophisticated instrumentation and control equipment mean that systems can be optimised with much better control. The obvious

Quarter 4 2023

pitfalls of over or undersized equipment include excessive energy use, high cost of investment and maintenance and risk to equipment and personnel as well as lost production in the case of insufficient capacity.

Today, accurate feasibility studies can map out a dewatering plan over several years, or even the entire lifetime of a project, with pumps located strategically and designed to handle the maximum site requirements, including factoring in unexpected changes to underground water systems and weather conditions.

Flexible technologies allow the use of several types of pumping equipment – from self-primed diesel-driven, submersibles and multistage pumps to high-wall designs for sites that have limited access due to high-sided mine pits. The development of sophisticated pontoon designs also allows equipment to be floated out over water bodies for easier access. The designs are either fixed to banks with access walkways or standalone installations. All designs are rigorously tested and include optimum safety features to help prevent risk

to operators. The pontoons can be constructed from a variety of materials from heavy-duty steel to low-density polyethylene with steel frames, for lighter applications. Each pontoon is designed with a fully tested anchoring system and can also be customised for extreme weather conditions.

Flexibility in dewatering systems is achievable through the latest instrumentation, control and automation technologies, increasing responsiveness to unexpected changes in operating conditions. Technology advancements in instrumentation and equipment controllers allow fully remote and automated control systems to be utilised, reducing the need for personnel to be physically present at remote and sometimes inaccessible sites.

Sophisticated control systems can control the pump operating speed to adapt to changing conditions in the water levels, start up or shut down of equipment in response to other external factors. In addition, mechatronics engineering systems are developing rapidly, enabling monitoring

www.bpma.org.uk

Mining & Quarrying 35

AN INDIVIDUAL SOLUTION All mines are different, and each site’s dewatering plan will be as individual as the operation itself. A ‘one size fits all’ approach is inappropriate when the water flow requirements of each site will be different, not to mention other variations such as operating depths and existing piping systems. Technology is helping both in the planning stage, to draw up comprehensive and reliable dewatering plans, and to optimise the use of the equipment during the process itself. chevron-circle-right

offering our customers some of the most reliable pumping 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

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

r a n t ee

2

year

d

sales@ie.pattersonpumps.com

ua

arr nt a

w

www.ie.pattersonpumps.com

Quarter 4 2023

VERTICAL TURBINE

Reduce on-site labor time, engineering and installation time

company/patterson-pump-ireland-ltd

www.global.weir

FIRE PUMP

VERTICAL IN-LINE

y

WATER WATER EVERYWHERE The composition of the water being moved has a significant effect on the equipment and materials used. The pH range, temperature, corrosive and abrasive content as well as specific gravity of any present solids, all affect what equipment provides the optimum solution to transport the water effectively.

The presence of solids in the water, the specific gravity, size distribution and content percentage will determine the type of pumps required. It may be that slurry pumps are needed to handle a higher content of solids, as traditional dewatering equipment is designed for lower solids contents.

Equally, the pipework and valves are also subject to corrosion and abrasion from the products handled and must be designed accordingly. Burst pipes create a major safety hazard as well as interruption to production.

Dewatering processes also support the ever-increasing emphasis on turning waste into energy as global resources are depleted. Technology is allowing manufacturers to produce equipment that not only dewaters mines to allow safe extraction of ore but which can then be recycled and re-used either within the mining process or, if necessary, by the wider community after necessary processing for commercial or domestic use. This helps to reduce the negative impact on the environment.

The quality of surface and groundwater from a mine is monitored and treatment processes are utilised to ensure it meets the correct standards before being discharged either for disposal to waterways or for use by the wider community.

Patterson Pump Ireland is a complete pump manufacturer,

g

and maintenance to be carried out remotely. Monitoring of equipment and prediction of performance is also being developed to allow better planning for maintenance.

These smart products can be connected via cloud services to provide a live status for any piece of equipment, which safely increases productivity and efficiency.

Fast-moving data acquisition, storage and analysis all play a vital part in the continual process of improving the operating performance of equipment, and ultimately can help restrict environmental impact at the same time as lowering the total cost of ownership of a particular product.

Weir Minerals invests heavily in research and development programmes through its internal resource and is actively involved with a network of academic research partners in universities around the world, working on technologies.

Mining & Quarrying 36 FEATURE

Water treatment plant to enable tin mine reopening Cornish Metals Inc. is using eight Bredel 40 hose pumps and three Qdos chemical metering and dosing pumps from Watson-Marlow Fluid Technology Solutions in its newly opened water treatment plant at the South Crofty tin mine in Cornwall, England.

S

outh Crofty ceased producing tin in 1998, but Cornish Metals is working to reopen it, aiming to reinstate production by 2026.

Before Cornish Metals can begin extracting tin, it must dewater the flooded mine and treat eight million cubic metres of contaminated water to meet standards set by the Environment Agency. The treated, clean water is then discharged into the nearby Red River at up to 25,000m3/day.

As part of the process to decontaminate water pumped out of the underground tin mine, the Bredel pumps are used for transferring sludge, while the Qdos pumps are dosing hydrogen peroxide to oxidise the contaminated metals in the mine water at the water treatment plant (WTP). Cornish Metals expects the dewatering of South Crofty to take 18 months.

Qdos is accurately dosing hydrogen peroxide during the cleaning of the contaminated mine water, to oxidise the metals and cause iron and arsenic to precipitate out of the solution, in the first of five process steps at the WTP. Bredel hose pumps provide the process with reliable, low maintenance and contained transfer of thick sludge – containing contaminants such as iron, manganese and arsenic – which is separated from the treated water in stages two and four. The Bredel hose pumps transfer sludge from the lamella clarifier into a tank, where the sludge is thickened, and then pump the thickened sludge to another tank, from where it is transported to a nearby site for underground storage.

Steven Kingstone, South Crofty Project Manager at Cornish Metals, said: “We are lucky in Cornwall to have a number of suppliers, such as Watson-Marlow, producing high-quality equipment that we can utilise in the reconstruction of South Crofty mine. This highlights the importance that we place on buying local where we can, ensuring that South Crofty’s reopening benefits the local population and economy

Quarter 4 2023

as much as possible. As the site develops, we look forward to continuing to work with Watson-Marlow.”

Tin is vital to decarbonisation and the energy transition due to its use in (soldering on) printed circuit boards, semiconductors and solar PV and is contained in both lead-acid and lithium-ion batteries.

According to the International Tin Association, the world will need another 50,000 tonnes of tin per year by 2030 to meet a surge in demand. South Crofty has the fourth-highest grade tin mineral resource globally, according to Cornish Metals, and the mining site is strategically well-positioned as there is currently no primary tin production in Europe or North America.

Two Bredel hose pumps transferring sludge at the newly-opened water treatment plant at South Crofty tin mine in Cornwall, England.

Bredel and Qdos pumps, from Watson-Marlow Fluid Technology Solutions, are contributing to Pumps like those in the Bredel range the WTP’s goal of minimising South Crofty’s are virtually maintenance-free as there are impact on the local environment. Before the no impellers, liners or mechanical seals start-up of the WTP in October 2023, the to replace, no check valves to clog and no Red River received untreated mine water as rotors or stators to wear out. The only wear a legacy of past mining activities. part is the hose, which can be replaced in A cleaner and healthier Red River will minutes with no special tools. benefit people, wildlife and the local Qdos pumps are also low maintenance – economy. Also, the water discharged reducing the impact of process downtime from South Crofty powers a hydro-turbine and lowering the overall cost of ownership that generates up to 15% of the power – while providing accurate, linear and consumed by the WTP. repeatable chemical metering across all Bredel hose pumps accommodate process conditions. Chemical costs can be continuous flow rates up to 108 m³/hr and reduced by higher accuracy metering, with are extremely durable (pressures up to 16 flow rates that remain constant from 0.1 to bar). There are no internal universal joints, 2000mL/min at up to 7 bar. chevron-circle-right valves, dead corners or glands to impact flow, and they are reversible for backflushing. Bredel hose pumps can handle undiluted mine water and tailings, and www.wmfts.com thickener underflow with up to 80% solids.

www.bpma.org.uk

PUMPS AS TURBINES - HARNESSING WATER POWER TO ITS FULL POTENTIAL

PROTECTING LIFE. IMPROVING LIVES. SPP PUMPS LIMITED, 1420 LAKEVIEW, ARLINGTON BUSINESS PARK, THEALE, READING, RG7 4SA TEL: +44 (0) 1189 32 31 23 • EMAIL: STUART_WALLIS@SPPPUMPS.COM

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

0121 601 6691

scan code for the training guide or email: training@bpma.org.uk

FEATURE 38 Opinion

Will WEG’s acquisition be a game changer?

As reported in the news section of this issue of flow, the world’s second-largest lowvoltage AC motor manufacturer, WEG, has acquired the industrial electric motors and generators business from Regal Rexnord for $400m. Vanessa Lopez, Research Analyst at Interact Analysis, looks at the impact the move could have on the motor market.

W

EG’s acquisition includes most of Regal Rexnord’s Industrial Systems segment, which comprises the Marathon, Cemp and Rotor brands. While Regal Rexnord will continue to operate its commercial motor business, this move represents a significant divestiture from the low-voltage motor market by the company.

Conversely, WEG, a company that has rapidly expanded its share within the lowvoltage motor market in recent years, will add hundreds of millions in revenue to its motor business through one of the most significant acquisitions the market has seen in a decade.

Under this agreement, WEG will gain around 2,800 employees across ten factories in seven countries: Canada, China, India, Italy, Mexico, the Netherlands and the United States. In 2022, the estimated net operating revenue of the included businesses was $541m, with an adjusted EBITDA margin of 9.5%. The transaction is expected to close in the first half of 2024.

Commenting on the acquisition, WEG’s President, Harry Schmelzer Jr., said: “The geographical distribution of these operations complements WEG’s current presence and will help achieve greater scale and cost efficiency as we integrate the new operations with the existing ones. With a long history in the market and a global presence, this acquisition will support the ongoing growth of the WEG Group in the industrial electric motors and generators markets through the incorporation of recognised brands and a product line that complements the Group’s current portfolio.”

Since the merger of Regal Beloit and Rexnord in 2021, Regal Rexnord has struggled to maintain its competitiveness in the low-voltage motor market, losing market share every year since the merger’s announcement. To Regal’s competition, it quickly became clear that the new company

Quarter 4 2023

was not interested in expanding its industrial motors business and was instead focused on building capabilities more aligned with segments like HVAC/R and material handling.

This led to market share being taken by competitors and ultimately led to an underperforming business unit within Regal Rexnord.

This underperformance is demonstrated by a sale price of just $400mn – a fire sale by all accounts.

This would represent the second major acquisition by WEG for a price under the annual revenue of the entity being acquired.

In 2022, WEG acquired Gefran’s motion control business for a price that was half of the entity’s annual revenue.

Over the past few years, WEG has seen significant growth in its share of the lowvoltage AC market. According to Interact Analysis’ most recent low voltage AC motor market report, WEG has grown its share of the low voltage AC motor market by 2.5% since 2020 – a significant jump for such a large business. This rapid rise can be attributed to the company’s performance amidst post-pandemic supply chain constraints. While every motor vendor faced supply chain issues, WEG’s significant vertical integration allowed it to operate with shorter lead times. This led to WEG capturing market share from those who could not meet the lead-time demands of customers. This jump in market share has narrowed the gap between WEG and leading supplier ABB. Now, with the recent acquisition, WEG has the potential to become number one in the market within the next few years. Outside of the immediate addition to its revenue that WEG will see, this acquisition also

provides significant long-term opportunities.

According to a statement given to Valor International by Alberto Kuba, the managing director of WEG’s Motor Business, the manufacturing plants acquired as part of this deal have the capability to operate at a much higher capacity. During a visit to the plants it was observed that they were only running at 50% of their capacity, with only one assembly shift. In contrast, WEG runs continuously at almost all of its plants. Kuba stated that the production volume could theoretically be doubled within the existing structure.

There are concerns surrounding the possible challenges of integrating the acquired entity within WEG’s business.

Regal Rexnord and WEG have historically been each other’s most significant competition, overlapping heavily in many of their target verticals. As a result of this rivalry, harmoniously merging two direct competitors will be more of a lengthy process than other acquisitions WEG has undertaken. However, regardless of the length of time taken to fully integrate the Regal Rexnord business with WEG, this acquisition can only expand WEG’s presence in the motor market. chevron-circle-right www.bpma.org.uk

li

mi

te

d

pl

ac

Europump Annual Meeting & General Assembly

eS

De Vere Beaumont Estate, Windsor, UK 22nd – 24th May 2024

Save the date & book your place This international event provides a unique opportunity for the European pump industry to come together to discuss and debate the important issues currently impacting this key manufacturing sector. A comprehensive programme of talks and presentations, combined with a wonderful social programme will deliver a highly focussed and productive business experience for all those attending.

For more information, and to secure your place, please visit the website today.

With a limit to the number of delegate and partner places available, it is advisable to book early. And if you are looking to extend your stay, either before or after the main event, to enjoy all that Windsor and the surrounding area has to offer, it is even more important to act promptly.

Presented by

Hosted by

Sponsored by

www.europump2024.com

NEW ELECTRIC MOTOR PLANT FROM JANUARY 2024

24,000 m

SUPPLIER OF LARGE MOTORS FOR ALL UK APPLICATIONS MORE THAN 20.000 MOTORS AVAILABLE FROM STOCK! Motors up to 25 MW and 13.8 kV • Low voltage slip-ring and squirrel cage motors up to 3,000 kW • Medium voltage slip-ring and squirrel cage motors up to 15,000 kW • Direct current motors up to 2,000 kW • Frequency converter-proof drives • In-house load test facility up to 13.800 V, 2.300 kVA, 120 Hz

24/7 EMERGENCY SERVICE CUSTOM SOLUTIONS FOR ELECTRIC MOTORS

Customized special designs • Custom designs for special applications and operating conditions • Optimized motor design for higher efficiency • Mechanically and electrically interchangeable motors • Commissioning worldwide MENZEL Great Britain Ltd. | UK Branch Office 27 Hunt Drive | Melton Mowbray | Leicestershire LE13 1PB Martin Rooney | Tel.: +44 1664 500 844 | Mobil: +44 7957 618046 martin.rooney@menzelgb.co.uk MENZEL Elektromotoren GmbH German Headquarters Neues Ufer 19-25 | D–10553 Berlin | Germany

menzel-motors.com info@menzel-motors.com

2

AROUND THE CLOCK, AGAINST THE CLOCK!