Quarter 4 2022

Pump
industry
insight from

FOCUS AREAS:
Mining and quarrying
Building services

VSDs' role in decarbonising

the water industry

Keep your dewatering

project afloat

Pump Industry News Innovations Applications Expert Opinion

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
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STUART-TURNER.CO.UK
 CONTENTS 3

I
’m delighted to be writing this, my first introduction to Flow magazine
Editor
as the newly appointed President of the British Pump Manufacturers
Chris Callander
Association (BPMA).
chris@flowmag.co.uk
Being appointed as President of the BPMA is a privilege, and I look
01732 671123
forward to working with the BPMA staff and members as we navigate
our way through a very strange and challenging time here in the UK.
Contributing Editor
It’s no surprise that ongoing economic and political turmoil continues
Suzanne Gill
to present obstacles and uncertainty in the pump market, making the
suzanne@flowmag.co.uk
BPMA’s role as a support for its members more relevant than ever.
We have a number of uncertainties affecting the pump sector, from supply-chain
Publisher
issues and ongoing skills shortages to the rising cost of energy, the changing legislative
Andrew Castle
landscape, and the onset of a recession.
andrew@flowmag.co.uk
Through these times of change, the Association will continue its mission to influence
07785 290034
the pump sector business environment in the interests of members’ competitiveness and
sustainability and to increase sector awareness by providing technical support and pump
Accounts
technology training to members, operators and purchasers of pumping equipment. All of
Touchwave Media Ltd
which will go on to benefit you, our member’s customers.
accounts@flowmag.co.uk
Having spent the last two years as Vice President of the Association, I have worked
closely with outgoing President, Richard Harden. I have seen the dedication and
Production
commitment he has given to the role and I am determined to carry on his good work.
G and C Media Ltd
I am enormously grateful to Richard for all that he has done for the BPMA during his
production@flowmag.co.uk
Presidency and am delighted that he will continue to support the Association as a
Member of its Council.
For over three-quarters of a century This issue of Flow is packed with news and insights, many addressing the challenges
the British Pump Manufacturers’
I have already outlined. If there are any topics you would like to see in future issues of the
Association (BPMA) has been serving
the interests of UK and Irish suppliers of magazine, please let us know; you can email the editor at chris@flowmag.co.uk.
liquid pumps and pumping equipment.
Dale Croker, President, BPMA

PUMP INDUSTRY NEWS Features

BPMA 4 Service team goes electric 16 Seal solution saves
National Metalforming Centre £182k in just 10 months
47 Birmingham Road 5 Stuart Turner continues
West Bromwich expansion 18 Meeting marine SWRO
B70 6PY
www.bpma.org.uk challenges

Twitter @bpmapumps
BPMA Update 22 High lift pump replacement
project offers energy saving
6 New members, new President
solution
flow is a controlled circulation journal and more
published quarterly on behalf of
28 Trialling and scaling
the BPMA by Touchwave Media Ltd
and G and C Media Ltd. For a copy
of the magazine’s terms of control
Project Updates up production

and to request a copy please email

circulation@flowmag.co.uk
The content of flow magazine does
8 Ultrasonic flowmeters
optimise pump station
Building services
not necessarily reflect the views of the
editor, publishers or the BPMA. The operation 30 Booster sets: fixed or variable?
publishers accept no legal responsibility
for loss arising from information in this
publication and do not endorse any
products or processes mentioned within Awards update Mining & Quarrying
it. No part of this publication may be
reproduced or stored in a retrieval system
without the publisher’s written consent. 10 Awards entry deadline 32 Keep your dewatering
is fast approaching project afloat
© BPMA. All rights reserved.

PEFC Certified

This product is
Skills OPINION
from sustainably
managed forests and
controlled sources
12 Industry calls for action 34 Optimise your pump
systems to save energy
PEFC/16-33-254 www.pefc.org

on skills

www.bpma.org.uk Quarter 4 2022

4 INDUSTRY NEWS

Businesses to be given UK product marking flexibility

BUSINESS SECRETARY, GRANT SHAPPS
has announced that businesses will be
given an additional two years to apply new
product safety marking, giving thousands
of businesses the freedom to focus on
growth.
The UK Conformity Assessed (UKCA)
marking has been introduced as part of
the UK’s own robust regulatory framework.
It shows that products comply with our
product safety regulations which are
designed to protect consumers.
However, given the difficult economic
conditions created by post-pandemic
shifts in demand and supply, alongside
Putin’s war in Ukraine and the associated
high energy prices, the government says it
does not want to burden businesses with
the requirement to meet the original (31
December 2022) deadline.
The government will continue to
recognise the CE marking for two years,
therefore allowing businesses until 31
December 2024 to prepare for the UKCA
marking. Businesses can also use the
UKCA marking, giving them flexibility to
choose which marking to apply.
Commenting on the announcement,
Shapps, said: The government is
determined to remove barriers to
businesses so they can get on with
their top priorities, like providing quality
customer service, enabling growth and
supporting their staff.
“This move will give businesses the
breathing space and flexibility they need
at this crucial time and ensure that our
future system for product safety marking
is fit for purpose, providing the highest
standard for consumers without harming
businesses.
“To support manufacturers, the
government is also reviewing the wider
product safety framework, ensuring we
minimise the burdens on business while
keeping our system up to date with new
innovative methods such as e-labelling.
“As part of this, the government will
make it easier than ever for businesses to
apply product markings.”
The government says that this package
will give thousands of businesses
additional time to focus on delivering
growth and creating jobs while giving
them flexibility in how they meet their legal
obligations.
There will be different rules for medical
devices, construction products, cableways,
transportable pressure equipment,
unmanned aircraft systems, rail products,
and marine equipment. Government
departments responsible for these sectors
are making sector-specific arrangements.

SERVICE TEAM GOES ELECTRIC

PACKAGED PUMPS SYSTEMS HAS LAUNCHED AN
E-Team of engineers who will travel to service call outs on e-bikes.
The team is made up of two engineers who will travel around
London’s Zone 1 on their e-bikes, supported by an engineering
supervisor in an electric van who will deliver additional parts, but
also be on hand to support on certain jobs.
The initiative means that the engineers will be able to undertake
approximately 50% more jobs in a day by reducing the amount
of time they spend travelling, leading to an even better customer
experience.
The introduction of e-cargo bikes will have an immediate
impact on reducing carbon emissions, as well as a reduction in
congestion and noise. Mark Underwood, Managing Director, said: “I’m thrilled that we
It’s estimated that the project will save over £15,000 a year in have officially launched E-Team – a sustainable solution which
fuel costs per engineer, as the e-cargo bikes replace diesel vans. will bring a host of benefits for our customers, engineers and the
That means each E-Team engineer will be using 8,000 fewer environment.
litres of fuel per year (160 litres every week) – giving a significant “Feedback from tests for this project has been excellent so
reduction in emissions. The engineers have also completed a we’re glad we can put it into action and get some of our engineers
course on how to use the bikes safely. onto two wheels instead of four.”

AESSEAL charitable giving tops £2.3 million

YORKSHIRE-BASED ENGINEERING
and reliability company, AESSEAL has
created a new £500,000 AESSEAL
Lieutenancy Fund, which will be
administered by the South Yorkshire
Community Foundation.
The new fund adds to the £1.8 million
already committed by AESSEAL plc to
support charities in South Yorkshire,
bringing the company’s support for the
Foundation to £2.3 million.
The company, which has its global
headquarters in Rotherham, says that
during the pandemic it was able to target
support to local charities who were in
great need, based upon feedback from the
unique network of local Deputy Lieutenants,
who assist the region’s Lord-Lieutenant in
representing His Majesty the King.
Chris Rea, the Managing Director of
AESSEAL plc said: “The purpose of the fund
is to reach into the community and support
local organisations that do not have a
national voice and many of which are run
by a large number of unpaid volunteers.
Deputy Lieutenants, who are all also
volunteers, often have in-depth knowledge
of local needs that would otherwise go
unnoticed.”
This is the third charitable fund
administered by the South Yorkshire
Community Foundation on behalf of
AESSEAL plc.

Quarter 4 2022 www.bpma.org.uk

 INDUSTRY NEWS 5

STUART TURNER AWARD FOR

CONTINUES EXPANSION
THE LATEST IN A SERIES OF
acquisitions for Stuart Turner, a
manufacturer of residential and
commercial pumps and water-boosting
products, sees the company acquire
Aquatronic Group Management (AGM), a
provider of cold-water boosting installation
and maintenance equipment and services
in the UK.
Stuart Turner supplies water-boosting
products that manage water pressure
in residential and commercial/industrial
applications. These range from domestic
shower pumps, where the company’s
Monsoon product is the UK market leader,
to bespoke systems that combine cold-
water boosting, pressurisation units and
circulators to manage hot and cold water
supply in commercial buildings and for
industrial purposes.
Based in Colchester, AGM designs and
manufactures pressurisation and water
booster units and installs and maintains
fresh and waste-water pump systems.
The company offers a nationwide service
from its Manchester, Colchester and
Southampton centres.
This complementary acquisition not
only expands the overall product range
offered by Stuart Turner but also brings a
hugely important servicing capability into
the business. It supports the strategy to
transform the company into the leading
provider of water-boosting solutions and
services in the UK.
Commenting on this latest purchase,
Richard Harden, Stuart Turner’s Chief
Executive, said: “AGM is a great fit for our
product portfolio and gives us immediate
access to the services market, which is
seen as a significant area of growth for
the company. The team at AGM have
established a fantastic reputation for both
service and technical capability, and we look
forward to welcoming them into the Stuart
Turner family.”
WILO FACTORY
WILO’S SMART FACTORY AT THE
company’s headquarters in Dortmund
has been awarded ‘Factory of the Year
2022’.
The award’s organisers, A.T. Kearney
and SV Veranstaltungen, recognise
specifically used digitalisation solutions
that have significantly increased the
efficiency of the new production within a
very short period of time.
According to the jury, the new factory
in Dortmund is setting standards in
digitalisation and sustainability. Among
other things, the jury also recognised the
company’s hydrogen strategy.

Becker UK announces
new partnerships
BECKER UK HAS ANNOUNCED A PARTNERSHIP WITH
Samoa, offering its customers access to a wide range
of high-quality, pneumatically driven air-operated double
diaphragm pumps
(AODD) for fluid
handling applications.
Samoa’s air-operated
pumps offer high levels
of air efficiency, wear-
free valve technology
and ATEX certification
alongside a range of
additional features.
The pumps can also
be connected with local PLC/SCADA/U-Pump systems for S
automatic and real-time pump remote control, monitoring MONTH
and feedback.
Becker UK has also announced a partnership with NITTO
KOHKI, which sees the Japanese manufacturer’s liquid
2
diaphragm pumps added to the Yorkshire-based company’s
portfolio, alongside a range of air compressors and vacuum
pumps.
Both Samoa and NITTO KOHKI are family-run and owned
businesses, as is Becker UK. The three organisations’ shared
values make the partnerships an ideal fit.

Quarter 4 2022
6 FEATURE
BPMA Update
NEW MEMBERS, NEW PRESIDENT AND MORE
NOVEMBER THIS YEAR SAW THE
BPMA’s annual AGM take place at
Wychwood Park Hotel in Crewe. The event
was well attended, with the many delegates
at the hotel joined by several who accessed
the AGM virtually.
In accordance with the BPMA’s Articles
of Association, members of the BPMA
Council are elected at the AGM. They hold
office for two years but are eligible for
re-election for successive periods of two
years. Several Council members did indeed
offer themselves for re-election, including
Richard Harden from Stuart Turner, Ken Hall
of Calpeda, Stephen Shaw from AESSEAL,
KSB’s Dale Croker, Adam Ferneyhough from
DAB Pumps, Glynn Williams of Grundfos,
Dan McClusky from NOV, David Noble of
SPX Flow, and Jim Wall representing Sulzer
Pumps. Two Council members had been
co-opted during the year preceding the AGM
– Morgan Warren-Ross from Stuart Turner
and Muhammad Haroon of Siemens – and
both also offered themselves for re-election.
In addition, Tony Lawson and Julijana Ristov
had retired from Council during the time
leading up to the AGM. All those who had
been and were serving on the Council were
thanked for their continued support of, and
service to, the BPMA.
Also at the AGM, the president’s report
shared details of 160 meetings which had
been held with BPMA representation, six
CEN, ISO and API standards that are currently
UPCOMING TRAINING FROM THE BPMA
Date Course title
24 January 2023 Pumping Fundamentals
25 January 2023 Pump Selection
26 January 2023 Pump Systems
21 March 2023 Pumping Fundamentals
22 March 2023 BPMA Pump Repair & Maintenance
9 May 2023 Certified Pump Systems Auditor (CPSA)
For more information or to book any of the courses listed please visit www.bpma.org.uk/lectures
*All classroom-based training is scheduled subject to the COVID-19 restrictions in place at the time.
Quarter 4 2022
active and are being monitored by the BPMA,
and over 24 European pieces of legislation,
be they Directives or Regulations, which are
currently active and also being monitored by
the Association.
Alongside the formal business of the AGM,
those attending were given a presentation
on the World Pump Report by Jeremy
Leonard from the report’s producer, Oxford
Economics. The report is a benefit of
membership circulated free of charge each
year and covers pump market forecasts
across 71 countries, 16 end-use sectors
and five pump categories. A post-Brexit
update was also presented by Terry Boniface,
Assistant Director, Electronics and Machinery,
from the Department for Business, Energy & Richard Harden (left), CEO of Stuart Turner,
Industrial Strategy (BEIS). hands over the BPMA’s presidency to
The final piece of business at the AGM Dale Croker, MD of KSB UK.
was the appointment of the Association’s
president. Richard Harden, CEO of Stuart part of ITT’s Industrial Process business,
Turner, had completed his tenure as BPMA one of the largest suppliers of pumping
President and Dale Croker, MD of KSB UK, equipment and aftermarket services in the
was proposed as president for the next world. Its portfolio includes Goulds Pumps,
two years. Mr Harden was duly thanked for Rheinhutte, Bornemann, i-Alert, PumpSmart,
his service, which, because of the COVID ProCast and Plant Performance Services.
pandemic, had been four years rather than From six regional depots in the North East,
the normal two-year period. new member, the CHC Group, is a specialist
supplier of heating equipment, components
NEW MEMBERS and spares from a wide range of brands.
Three new members have joined the BPMA And the latest member, KGN Pillinger, is
since the last issue of flow, bringing the total a specialist in the design, manufacture
membership to 114. ITT Industries UK is and service of bespoke water pumping
a wholly owned subsidiary of ITT Inc and equipment.
Duration Location
1 day Online
1 day Online
1 day Online
1 day West Bromwich
2 days West Bromwich
4 days West Bromwich
www.bpma.org.uk
 Product News 7

DEWATERING PUMPS FOR SMALLER TASKS

USED THROUGHOUT MINING AND
civil engineering schemes,
dewatering pumps are vital to
keeping projects running to time.
For the day-to-day removal of water,
Sulzer has completed its lineup of
dewatering pumps with the launch
of five new models for drainage and
sludge applications.
Designated as ‘J’ for drainage and
‘JS’ for sludge, the new J4, J7, JS4,
JS7 and JS8 models offer flow rates
from 5.5 l/sec with heads up to 16m.
Their slim design and low weight of
construction make the pumps easy
to transport between locations and
set up for work.
Drainage applications are always
challenging, and for pumps that need to
operate round-the-clock, reliability and
efficiency are essential. Stainless steel
construction ensures long-term reliability
against erosion and corrosion.
The pumps are designed for safe and
effective operation without supervision.
A float switch provides automatic level
control and ensures water levels are
maintained reliably while built-in sensors
protect the motor from overheating. The
natural cooling provided by the double
outer casing enables the pumps to run
continuously at low levels and even run
dry without damaging the electric
motor.
In these applications, the impeller
must withstand the harsh pumping
environment, and Sulzer’s design
includes adjustable wear parts
and a nitrile rubber coating for
maximum abrasion resistance. The
JS models are equipped with an
agitator at the base of the pump
to ensure the continuous flow of
sludge and to prevent airlocks in
the pump, minimising the risk of
clogging.
Available with hose or threaded
connections for ease of installation
in either temporary or fixed
applications, the pumps are
suited to a range of dewatering tasks.
Maintenance is easy to manage with
inspection ports to assess seal integrity
and simple spare part management
thanks to the modular design of the pump.
www.sulzer.com

Flanged pumps for

diesel engines
CAPRARI’S RANGE OF FLANGED PUMPS HAS BEEN
extended with the addition of new MEC-AG65, MEC-MG65
models.
The new pumps, with modular support, offer installation
flexibility and the possibility of pump coupling with diesel motors
with SAE3, SAE4 and SAE5 flanges. The version with SAE3
monobloc support, is still available.
The hydraulic performance and the exclusive technical
solutions are designed to
ensure high energy saving
and operational reliability.
The multistage and
single-stage centrifugal
horizontal shaft pumps
are ideal for irrigation and
water supply, thanks to their robust structure, they can be used in YEARS
heavy duty conditions ensuring long term durability.
A new Easy Fit stuffing box is also available for the MEC-MG
and MEC-AG pump series, allowing the removal of the stuffing 6.5
box with the pump in place, giving access to the packing seal
for replacement directly in the field. The Easy Fit geometry and
materials make the device practical, lightweight and sturdy. At
the same time its cataphoresis-treated components provide
resistance to oxidation.

www.caprari.com

Quarter 4 2022
8 Project Updates

PHOSPHORUS REMOVAL PROMPTS MAJOR DOSING PUMP ORDER

TIGHTENING REGULATORY
requirements on phosphorus removal
have resulted in the largest ever order of
Qdos ReNu chemical metering pumps for
Watson-Marlow Fluid Technology Solutions
(WMFTS).
The 240 pumps are required by process
specialist Colloide Engineering Systems
which has built 115 chemical dosing skids
for site upgrades by Severn Trent Water
(STW). Colloide says four or five versions
of each chemical dosing rig and multiple
setups may be required at a single site. In
addition, Colloide placed a further order
for 40 Watson-Marlow 630 series process
pumps for the skid packages.
The skids are being used to deliver the UK
utility’s phosphorous removal programme
for AMP7, the regulatory asset management
period 2020-25.
Phosphorus is a normal part of domestic
sewage and new legislation in the European
Water Framework Directive requires
water utilities to meet much tighter
environmental discharge limits to
reduce the amount entering rivers
and streams. The minimum total
phosphorus consent level has
been tightened to 0.25mg/litre,
which means introducing a range
of processes and techniques, and
investing in new equipment.
Chemical dosing is one approach
being used by water companies rates – Qdos 30, 60 and 120. These dosing
to meet the new phosphorus consent, pumps offer repeatable flow up to 120l/hr
and equipment needs to be flexible and and a maximum operating pressure of 7 bar,
multi-chemical compatible. This means whilst metering accuracy is assured to ±1%.
a range of dosing pumps able to handle Unlike traditional diaphragm metering
different chemicals used in flocculation and pumps, the flow remains the same whatever
coagulation – including ferric, aluminium the pressure value which provides greater
chloride and polymers – may be required for dosing control leading to tangible chemical
each skid. savings.
The order from Colloide includes Qdos
peristaltic pumps with three different flow www.wmfts.com

ULTRASONIC FLOWMETERS OPTIMISE PUMP STATION OPERATION

ULTRASONIC CLAMP-ON FLOWMETERS CAN OPERATE
wherever contact with the fluid to be measured is not feasible.
They are not subject to the same wear and tear and the
resulting loss of accuracy of traditional wetted meters, and they
can undertake a range of data logging
tasks, delivering the baseline and load
profile evidence necessary to maximise
pump station efficiency and help to reduce
energy use.
A leading metropolitan water authority in
Sydney, Australia, was pumping water from
a wet well into a common manifold, where
wastewater was then diverted to various pipelines for further
treatment or an ocean outfall sewer. But because no flowmeters
monitored the pipelines after the manifold, there was no way to
optimise the duty and standby pumps so that they would operate
in the most efficient configuration. It’s impossible to manage
what isn’t measured, and better management of such an energy-
intensive process is needed to deliver maximum pump station
operation.
High risk and expensive, interrupting the process at a pumping
station that serves such a large population was not an option.
The plant’s process engineers needed an alternative way to equip
a flow measuring device, so FLEXIM undertook an on-site trial
to demonstrate the reliability and stability of ultrasonic clamp-on
technology and build confidence in this
measuring method.
Despite spiral welded steel pipes
presenting a challenge in mounting the
transducers, on-site tests showed that
readings aligned to expected pump
flow curves, but they also detected
an unexplained reverse flow. Further
investigations by engineers found that a faulty valve in the manifold
caused a previously unknown flow diversion.
With confidence in the ultrasonic flowmeter’s capabilities
growing, a permanent system was quickly installed, with no
shutdown of the pumping station necessary. The duty and cycle
pump strategy is now fully optimised, and energy consumption
can be reduced.
www.flexim.co.uk

ABB DRIVE CHOSEN FOR REGENERATIVE DRIVE DEMO RIG

AN ABB ACS880 VARIABLE SPEED
drive has been chosen by Torishima
to provide precision motor control for
the company’s new test bed. A smaller
22kW regenerative drive has also been
specified, specifically to allow Torishima
to demonstrate its regenerative
capabilities.
The state-of-the-art test rig is intended
to support Torishima’s growth in the UK
water and utilities markets, and will be
used for factory acceptance testing of
new products at its facility in Glasgow.
The rig will also be used to provide en-
hanced support to service customers, by
allowing Torishima to optimise the energy
efficiency of refurbished and up-graded
equipment, reflecting an increasing
desire from the company to improve
the sustainability of its products and
operations.
The project, which commenced in
August with assistance from ABB Value
Provider EDC Scotland, is expected to be
completed by the end of 2022.
new.abb.com

Quarter 4 2022 www.bpma.org.uk

 CHEMICAL CENTRIFUGAL CORROSION RESISTANT PUMPS

FIND THE BEST PUMP FOR YOU! CONTACT US:

+44 (0)1425 627700 info@crestpumps.co.uk www.crestpumps.co.uk

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10 Awards Update

AWARDS ENTRY DEADLINE

IS FAST APPROACHING
The Pump Industry Awards has recognised and rewarded pump businesses’
achievements, large and small, for over two decades. And once again, with the deadline
fast approaching, the BPMA’s annual awards programme is calling for your nominations.

I
f you or your company have a
pump related success to shout
about, this awards programme
provides the perfect platform.
But you had better be quick, as the
closing date for all entries is Friday,
January 6, 2023.
Entering is simple, and by putting
forward a nomination you are
demonstrating confidence in the
quality of your work, people, products
and projects.
Maintaining the early Spring
timeline, the next Gala Dinner and
Presentation Ceremony will take
place on Thursday, March 16, at a
fantastic new venue – 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. Sporting
excellence is synonymous with this
venue, and early next year it will also
become the location for heralding
engineering excellence across the
pump sector.
The online entry forms, which
seek submissions for activities
and achievements that took
place in the 18 months up to
December 2022, will remain on the
dedicated awards website – www.
pumpindustryawards.com – until
the entry deadline of 5.00pm on
Friday, January 6, 2023. Please
note this important date, and begin
considering which key developments,
initiatives, staff, and successes you
will be putting forward for industry-
wide recognition.
The recognition of those
companies and individuals that have
gone that extra mile to meet, and
more often exceed, the demands
and challenges sector. In addition to
presented by the our main category
sectors served by “The quality of entries was sponsors, there
the pump sector
will be represented
extremely high, which are also other
sponsorship
by eight award echoes the creativity and options to help
categories:
• Product of the
engineering skill that exists support specific
elements of the
Year - Sponsored within this key sector.” 2023 presentation
by Process evening. Several
Engineering opportunities
• Project of the Year - Sponsored by still exist, so please get in touch if
Stuart Turner you would like your brand aligned
• Environmental Contribution of the with outstanding engineering
Year - Sponsored by SPP Pumps achievement.
• Manufacturer of the Year - Steve Schofield, Director and CEO
Sponsored by WEG UK at the British Pump Manufacturers
• Distributor of the Year – Association, commented: “This
Sponsored by Stuart Turner year’s awards ceremony – the 21st
• Supplier of the Year - Sponsored such event – was as good as any
by Wilo I can remember. The atmosphere
• Contribution to Skills & Training – was fantastic, and the competition
Crest Pumps intense. The quality of entries was
• Rising Star Award - Sponsored by extremely high, which echoes the
World Pumps creativity and engineering skill that
exists within this key sector.
Once again, we have secured For further information and to
support and backing from a host submit your entry(s), please visit the
of leading brands, all of whom event’s website. chevron-circle-right
recognise the value and importance
of promoting excellence across the www.pumpindustryawards.com

Quarter 4 2022 www.bpma.org.uk

 HEATING
JUST GOT
SMARTER

Discover the new Calio Pro glandless pump - the simple and smart circulator for
heating large buildings. One pump for all three pressure classes, PN6/PN10/PN16.
Now featuring Dynamic Control as standard: smart controlling that saves you about
40% in energy. Makes installation easy and savings fast!

Flow - 210 x 145mm - Fourth Quarter - 2022.indd 1 07/09/2022 11:53:46

12 Skills
NEWS

Industry calls for action on skills

EURIS, an organisation with 12 UK trade association members, including the British
Pump Manufacturers Association, represents industrial product suppliers with a
combined turnover of over £148 billion. Recognising that skills shortages across the
advanced manufacturing sector are a growing issue for its members, the organisation
initiated a membership survey to gather data about skills gaps and
vacancies. The survey received 171 responses, with 133 from SMEs and 38 from large
companies, and highlighted key actions that need to be taken.

T
he research carried out by
EURIS sought to ascertain how
widespread skills shortages are
and where the impact is most
acute. It is clear from the results that a
lack of suitable candidates with skill and
experience is reducing the output and
potential of UK technology industries. Too
many vacancies remain open for too long,
and the problem is getting worse.
The results showed that 40% of
respondents have vacancies of 5-10% of
their workforce, while 20% of respondents
said these vacancies take, on average, five to
six months to fill. Some 75% of respondents
have witnessed an increase in vacancies in
the last three years, with over 55% having
vacancies for R&D staff, engineers and
scientists. Over 60% of those completing the
survey reported that vacancies are causing
issues with day-to-day operations, and
over 40% said that vacancies had reduced
business capacity and turnover.
Over 80% believe skills shortages
are due to a lack of local labour – not
enough suitable candidates are available.
Responders reported that a requirement
for skilled engineers with degrees that take
years of training and a lack of in-house
training resources across many SMEs
meant that many of the 3-5 million currently
unemployed and underemployed people
in the UK could not be trained to fill the
vacancies. This was also reflected in almost
60% reporting lengthy training periods for
new staff – between 6 and 24 months
– due to the highly technical and industry-
specific requirements.
Overall, these statistics give a worrying
picture of the breadth and depth of
skills shortages across the advanced
manufacturing sector – shortages are
significantly impacting the day-to-day
operations of businesses across the UK.
ADDRESSING THE SKILLS GAP
As part of regular meetings with ministers
from the Department for Business, Energy
& Industrial Strategy (BEIS),
EURIS wants to work with
the government to address
skills shortages in the
advanced manufacturing
sector and used the survey
to try and understand how
best to tackle the issue.
EURIS members believe
that the government has
a role to play in seeking
solutions to the issues
of skills shortages, and
EURIS would like to work
in partnership with the
government to address skills shortages.
This would benefit the whole UK economy
and the organisation believes success
can only be achieved by industry and
government working hand-in-hand on this
important issue.
EURIS, therefore, believes It is clear from
the survey that the following initiatives
would help to resolve the current skills
shortages that exist in the UK in the
advanced manufacturing sector.
SHORT TERM RECOMMENDATIONS
Apprenticeships – The government
needs to work with industry to make
apprenticeships easier to manage and to
incentivise SMEs to set up apprenticeships
and recruit trainees. The introduction of
apprenticeships for mature workers would
also allow for retraining.
Higher education – There should be
the creation of more work placement
opportunities within Higher education
degrees. While the government needs to
work with industry and colleges to ensure
the introduction of more T Level courses
focused on engineering – including work
placements – and to raise awareness of
these courses to encourage take up.
Training resources – Additional
training resources for small companies,
including grants and incentives, need to be
provided, and training providers should be
encouraged to work with sectors with acute
skills shortages to attract more recruits
through apprenticeships and T Levels.
Overseas labour – The government
should consider short-term skilled visas for
Commonwealth countries and minimise
obstacles for skilled workers from Europe to
work in the UK.
LONG TERM RECOMMENDATIONS
Education and career choices –
Training and education programmes
should be created to raise awareness of
apprenticeship options for school leavers.
Closer links between industry and schools
and colleges should be made to provide a
route straight into industry for those who
don’t wish to go to university. Engineering
should be included in the school curriculum
so, from an early age, it becomes a career
young people are aware of and can aspire
to. The government and industry need to
work together to ensure careers advisers
at schools and colleges are fully briefed
on the opportunities of working in the
manufacturing sector and the opportunities
available through apprenticeships and
T Levels. And the government should
introduce more STEM initiatives to
target women who are still hugely under
represented in engineering. chevron-circle-right
www.euristaskforce.org

Quarter 4 2022 www.bpma.org.uk

 Motors
Automation
Energy

Efficiency and Transmission &

Distribution
Coatings

Reliability for the

Water Industry

Motion Fleet Management

The WEG Motion Fleet Management allows operators to
check the status of low and medium voltage motors and
drives (VSDs and soft-starters), gearboxes, gearmotors,
pumps, compressors and other assets installed in any type
of industry or facility. Through periodic data collection and
advanced data processing, both on the edge and in the
cloud, valuable insights are obtained. Thus, it is possible to
establish predictive maintenance plans taking into account
the operating condition of the fleet (condition-based
maintenance) whether on site or working from a remote
location. The result is increased uptime and a reduction of
the drive fleet TCO (total cost of ownership).

www.weg.net
14 technical
FEATURE solutions
Q&A In this issue of flow, Matthew Taylor, National Internal Sales &
Marketing Manager at KSB, answers a selection of reader questions.
Question: What information do I
need to give to a pump supplier/
manufacturer to get an accurate a
quote?
Matthew Taylor: Typically, a pump
manufacturer will need the flow
required along with the units of
measure, and the head needed, again
with the units of measure.
To get an accurate selection, as
much of the information below as
possible must be supplied.
What medium is being pumped
and at what temperature? If it is not
water being pumped, then as much
information about the medium as
possible should be sent, such as
specific gravity and viscosity.
Any pipework details are also
useful (suction and discharge).
The supplier will need details
of the application (boiler
feed, circulation, submersible
waste water, central heating,
pressurisation, pressure booster
etc.).
The power supply available is an
important consideration. Is 415V
available? A 3-phase supply? And
what is the frequency; 50Hz?
The supplier will also need to
know if the pump needs to be
in a specific material or requires
any special coatings, plus what
certification is needed.
How you want to control the key
parameters of the pumps (on/off,
pressure, flow) is also important to
understand alongside whether you
want the pumps to be fixed speed
or variable speed.
The minimum information
required though is flow rate, head,
the medium being pumped and its
temperature.
Question: Is there a limit on how
many times you can stop and start
a pump?
Matthew Taylor: Yes. All
manufacturers will detail the
maximum stop/starts per hour in
their documentation. Remember,
if you have more than one pump
Quarter 4 2022
operating on duty/
standby, you can increase
the stop/starts by that
amount, so long as you
have an auto changeover
system.
Question: Should you
maximise or minimise the
number of stops/starts?
Matthew Taylor:
This depends on the
application. On pressure
boosting clean water, you
would look to minimise
the number of stop/starts
by fitting an accumulator
to the system or booster.
On wastewater, you do not want the
solids within the medium settling at
the base of the tank, therefore the
idea is to pump it away from the
chamber as quickly as possible. Here
you would maximise the stop/starts.
Question: On start-up I noticed a
leak from the mechanical seal on
one of our pumps. Is this normal?
Matthew Taylor: It is normal for
a mechanical seal to allow some
leakage. The way the mechanical
seal works is to allow some of the
pumped medium to get between the
faces to lubricate the seal and prevent
heat build-up. On start-up, there can
be some leakage while the seal faces
bed in, but this should stop after a
short period. Again, there will always
be some leakage, but if selected
correctly the leakage would normally
not be seen as it would vaporise into
atmosphere.
Question: Can you run a centrifugal
pump with no liquid in it?
Matthew Taylor: One of the most
common forms of failure is the
mechanical seal where the pump has
been run without any medium being
pumped. This is called dry-running.
The mechanical seal needs the
pumped medium to lubricate the seal
faces and keep them cool. If the pump
is operated with no medium, the heat
will build up causing the seal to fail.
In addition, if this is over a prolonged
period, it can result in the shaft getting
hot and causing bearings to fail. It is
generally acceptable to do a quick
direction of rotation test, but the pump
should not be operated without being
primed or vented where appropriate.
Question: Can a submersible pump
be operated un-submerged?
Matthew Taylor: This depends on the
design. Typically, submersible pumps
rely on the medium surrounding the
pump to cool the motor, as these
motors cannot have fans fitted to
them due to the fact that they are
submerged. All manufacturers will
specify the minimum submergence
level needed to allow the pump to
cool. In applications where you need
the pump to operate unsubmerged,
manufacturers have solutions such
as jacketed pumps, or dry well pumps
that can be installed in a separate
chamber. Speaking to the pump’s
manufacturer for advice is always
advisable.
www.ksb.com
If you have questions you’d like to
put to a pumping systems expert,
email them to flow's editor at
chris@flowmag.co.uk
www.bpma.org.uk
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16 Seal
FEATURE
Technology
Seal solution saves
£182k in just 10 months
Issues with seals can cause costly downtime and expensive repairs. When
problems caused by failing seals were identified at Nestlé Purina’s plant in
Poland, AESSEAL was able to offer a solution, as Arkadiusz Jurzak, the
company’s Strategic Project Manager, explains.
T
he installation of DMSC
seals and MagTecta
bearing protectors at its
European plants has led to
significant savings for the pet food
manufacturer Nestlé Purina. The
company asked AESSEAL to provide
a solution to two persistent problems.
One problem was at a meat
processing plant and was caused
by a leaking and unreliable seal on
a mixing machine. The water-based
barrier fluid system could not cope
with pressure fluctuations inside the
mixer, so when the pressure in the
mixer exceeded that of the barrier
system, product began to penetrate
the gland packing. This resulted in
shaft wear and contamination of the
barrier fluid system, resulting in mixer
downtime and high maintenance
costs.
The solution suggested by
AESSEAL was to replace the
gland packing with a DMSC dual
mechanical seal, which is resistant
to temperature and pressure
fluctuations.
Just ten months after its
installation, the DMSC seal was
working continuously, maintenance-
free, and had saved the company
more than £182,000, with payback
achieved in just three months. The
company also estimated that it would
save an additional £200,000 per
line per year as a result of increased
mixer uptime.
These savings, resulting from
the performance and reliability of
the AESSEAL DMSC seal, led to the
decision by Nestlé Purina to install
them in its plants across Europe.
The second problem that AESSEAL
was asked to solve was how to
remedy the persistent leakage from
the lip seals on the rotary valves in the
Quarter 4 2022
product packaging line
at Nestlé Purina’s plant
in Poland. This was
causing damage to
the valve housing and
shaft sleeve, resulting
in the seals needing to
be replaced every four
weeks. This process
took around 33 hours,
with the parts alone
costing £68,000 a year
per line.
AESSEAL
recommended
replacing the lip seals with MagTecta Cargill, Poland. We had worked
bearing protectors, which use together for many years and had
mechanical seal technology to already co-operated on several
prevent leakage. The product’s non- important projects at the Cargill
contacting design also prevents wear plant.”
on the shaft or housing. The result The crucial factor which finally
was an immediate improvement convinced Nestlé Purina to install the
in the meantime between failure AESSEAL products was their long life.
(MTBF) to three months. Subsequent The first 85mm DMSC mechanical
upgrades to the bearings and seal installed on the Siefer Trigonal
housing sleeves Mixer in 2015 was
have increased tested for more
this to six months. The company also than a year before
The success of the being adopted as
MagTecta at its estimated that it would standard in the rest
facility in Poland
led Nestlé Purina to
save an additional £200,000 of Nestlé Purina
plants.
implement similar per line per year as a result Arkadiusz
upgrades at its
plants in Hungary,
of increased mixer uptime. continues to have
regular contact
Russia, France, and with Nestlé Purina
the UK. Poland and visits the plant at least
Arkadiusz Jurzak, Strategic Project once every two weeks. As a result,
Manager at AESSEAL Poland, AESSEAL now has the status of
explained how the relationship with ‘Strategic Mechanical Seal Supplier’
Nestlé Purina came about: “The story for the entire Nestlé Purina group. Any
started in 2015 when Nestlé Purina new equipment supplied to Nestlé
set up its plant in Poland. Until then, Purina should have an AESSEAL
the company knew nothing about mechanical seal or bearing protection
AESSEAL. My first contact in Nestlé installed. chevron-circle-right
Purina, Poland, was a reliability
engineer who had transferred from www.aesseal.com
www.bpma.org.uk
 PUMPS AS TURBINES - HARNESSING
WATER POWER TO ITS FULL POTENTIAL

FOR WHERE IT REALLY MATTERS

SPP PUMPS LIMITED, 1420 LAKEVIEW, ARLINGTON BUSINESS PARK, THEALE, READING, RG7 4SA
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BPMA HP 190x135mm 0722 ENG.indd 1 04/07/2022 18:10
18 MArine
FEATURESWRO
Dewatering

MEETING MARINE SWRO CHALLENGES

Philip Aude Skeldrup, Sales Manager, North Europe Region, at Danfoss, explains
the role pumping systems play in ensuring a growing global demand for
farmed salmon can be met.

A
s the global population grows
in number and wealth, we
continue to add more animal
protein to our diets. In fact,
the global per capita supply of animal
protein has more than doubled since 1960.
Seafood leads the trend: fish is the fastest-
growing animal-based food group, and
we’re eating more than ever.
Increasingly, however, the fish we eat is
farmed, not wild. The supply of wild-caught
fish is stagnating while that of farmed
fish continues to grow. In 2020, the world
harvested 86 million tons of fish for direct
human consumption and caught 76 million
tons of wild fish.

A POPULAR CHOICE
The global salmon market was estimated
at 3.3 million tons in 2021 and is expected
to grow to 4.2 tons by 2027.
Aquaculture plays an important role in
explaining salmon’s worldwide availability
and popularity. Today, people around the
world eat five times more farmed salmon
than wild. The Atlantic salmon is the most
farmed salmonid, but steelhead trout,
cohos, and chinooks are also raised.
Because salmon farms depend on cold
water for productivity and profitability, most
are found in countries such as Norway,
Scotland, Canada, and Chile.
A TINY, BIG PROBLEM
Farmed salmon are usually raised in open-
net pens in coastal areas. The free flow
of seawater through the nets ensures a
constantly replenished natural environment
for the fish but allows parasites to enter the
cages. One of these parasites is particularly
harmful to farm-raised salmon.
Lepeophtheirus salmonis is a parasitic
sea louse whose larvae feed on salmon
skin, mucus, and blood. Less than one
millimetre long, the tiny larvae do find hosts
in the wild, but salmon farms provide high
fish densities that are far more susceptible
to infestation.
Sea lice are highly problematic for
salmon farmers. Infected salmon cannot
be sold; their health deteriorates, and severe
infestations can lead to mass mortality. In
addition, the high concentrations of sea lice
made possible by thousands of salmon in
open pens put wild fish populations near
farms at a higher risk. Delousing infected
salmon is thus an ongoing challenge for
farmers.
DELOUSING SALMON
Farmed salmon is a big business – and
so is salmon delousing. In Norway alone,
where salmon exports totalled more than
€7 billion in 2019, salmon farmers spent an
estimated €500 million fighting lice in 2018.
Worldwide, chemical treatments that
kill sea lice have
been the main
way farmers Salmon farmers spent
delouse penned
salmon for years.
an estimated €500
Hydrogen peroxide, million fighting
cypermethrin,
deltamethrin, and lice in 2018.
azamethiphos have
all been deployed. Hydrogen peroxide
and azamethiphos are now the most
commonly used chemicals.
While effective in delousing farmed
fish, chemical treatments result in other
problems. For one thing, chemically treated
salmon cannot be eaten or sold for weeks
after treatment. Even more critically, the
chemicals kill organisms other than sea
lice: unintended toxicity to non-target
species is a major environmental concern.
Finally, there is a real risk that sea lice will
genetically adapt to the chemicals. Farmers
have thus had good reason to experiment
with a variety of non-chemical delousing
methods.
Trials with everything from lasers to
cleaner fish have narrowed the search for
more sustainable lice treatment to three
mechanical methods. One of these, thermal
treatment, kills lice by briefly transferring
salmon to tanks with seawater heated
to 28-34°C. While effective against lice,
thermal treatments
are associated
with fish injury
and mortality.
Another mechanical
delousing
technology is
flushing salmon with
low-pressure water
jets; again, this is effective against lice but
can result in scale loss, gill bleeding, and
other wounds to the fish.
FRESHWATER TREATMENT
The third mechanical delousing technique
is freshwater treatment. To remove lice,
salmon from open net pens are temporarily
pumped into wellboats filled with fresh
water. Sea lice are sensitive to seawater

Quarter 4 2022 www.bpma.org.uk

 MArine SWRO 19

salinity and cannot survive in fresh water. By comparison, infected

wild salmon typically shed any lice when they return to streams
to spawn. Freshwater treatment has no harmful impact on either
salmon or non-target species. However, freshwater treatments
must be carefully controlled and monitored to ensure that the lice
do not genetically adapt.
This innovative method is effective and efficient but requires
large volumes of fresh water, which may not be readily available
near open-net pens at sea. To avoid hours-long trips to coastal
sources of fresh water in sufficient volumes, some salmon farmers
have recently begun to utilise purpose-built wellboats equipped
with tanks and seawater reverse osmosis (SWRO) plants. The
number of wellboats equipped for SWRO freshwater treatment is
so far limited, but we can expect to see more of them in the future.
Patterson Pump Ireland is a complete pump manufacturer,
MARINE SWRO offering our customers some of the most reliable pumping
Engineers designing marine SWRO plants face several challenges solutions available. Our fire pumps stand over life and
when selecting components such as pumps, variable frequency property throughout the world.
drives (VFDs) and energy recovery devices (ERDs).
Of course, energy efficiency is a priority for any SWRO plant.
However, in a marine application such as a wellboat, where all
electricity is generated by diesel fuel, it is even more important to
specify a design and components that enable the lowest possible
specific energy consumption.
Similarly, reliability and ease of maintenance are always important.
But when a vessel is at sea for much of the year, the greater the
dependability and the longer the service intervals, the better.
Finally, space onboard a vessel is at a premium. Therefore, FIRE PUMP FIRE PUMP FIRE PUMP FIRE PUMP
HORIZONTAL SPLIT END-SUCTION VERTICAL VERTICAL
compact SWRO plants with optimal footprint-output ratios are CASE (HSC) IN-LINE TURBINE
preferred.
With a tank capacity of 7,500 m3, the Gåsø Høvding is the world’s
largest wellboat. Designed specifically for salmon aquaculture,
the high-capacity vessel began operations in Norway at the end
of 2021. The SWRO plant’s designer, Quantum Water, selected
Danfoss APP high-pressure pumps, iSave ERDs, and VFDs for the
SWRO plant to save space, energy, and maintenance.
“Of course, energy efficiency was one of the key criteria,”
explained Nicolás Alberte, General Manager of nb. “However,
even though this is the world’s largest wellboat, space onboard
a vessel is always at a premium. Therefore, maximising capacity
and ensuring easy access to key components while minimising
plant footprint was essential. Finally, operational reliability is critical:
salmon welfare and aquaculture productivity depend directly on
these treatments to mitigate the risks of sea lice infestation and
amoebic gill disease, so reliable performance and long service
intervals are vital.”
To meet these demands, Quantum Water designed a tailormade Reduce on-site labor time, engineering and installation time
SWRO plant that would produce the required water; 5,000 m3/day. and associated costs. Choose a system that arrives on-site in a
Four APP 65/1000 high-pressure pumps and four iSave 70 ERDs
fully enclosed ready for use pump house. This pre-engineered
make up the core of the plant, each connected to a Danfoss VLT
pumping system saves time and money for our customers.
AQUA Drive FC 202 for optimal control and efficiency.
“The combination of Danfoss APP pumps and iSave ERDs
played a significant role in achieving the goals set by our client
for the desalination plant,” Alberte said. “Not only does it provide a
reliable low-energy solution with low maintenance needs, but it also
+353 (0)44 934 7078 r a n t ee
delivers high production capacity in a compact package.” ua
company/patterson-pump-ireland-ltd
2
d
g

“That Danfoss APP pumps use only the pumped medium for
lubrication, thus presenting zero contamination risk, is also a plus,” www.ie.pattersonpumps.com year
concluded Alberte. chevron-circle-right arr nt
y
w

sales@ie.pattersonpumps.com a
bit.ly/DanfossDesal

Quarter 4 2022
20 Pump Maintenance
A straightforward solution
to a complex problem
Pushing older equipment to meet an increased duty requirement can sometimes create
reliability issues down the line. However, achieving this by sourcing newer replacements
can be costly and prohibitively time consuming. To avoid either outcome, one of the largest
oil refineries on the island of Java, Indonesia, relied on the specialist knowledge of Sulzer to
refurbish and modernise eight diesel pumps.
R
ecently, the refinery in Java has
undergone a long-term, facility-
wide upgrade project designed
to maximise production capacity
and meet the future energy demands
of Indonesia. The targeted overhaul
program helped the equipment attain a
new operating point, providing a 50% cost
saving compared to purchasing new units
and a five-month reduction in the overall
lead time.
As part of this initiative, the equipment
identified for modernisation included eight
diesel pumps used to transfer fuel from
the refinery. The pumps used six diesel
drives and two steam turbines for power.
One of the assets dated from 1975, and
no documentation was available on site
for any of the units.
As a result, operators were unsure how
to improve the performance of the pumps
to meet the increased fuel demand while
safeguarding reliability. Consequently,
the engineering contractor approached a
number of pump specialists to see how a
new duty point could be effectively achieved.
Finding a service provider who can work
effectively with older equipment is often
challenging. However, after a rigorous
tender process, the contractor selected
Sulzer.
LOCAL EXPERTISE WITH
GLOBAL SUPPORT
Sulzer’s local service centre in Indonesia
provided access to engineering services
and the company’s wider global network.
This worldwide support proved crucial in
collating all the necessary information and
expertise to deliver this project effectively.
To overcome the lack of documentation,
the Indonesian team contacted Sulzer
Pumps UK. The UK team was able to
source all the documentation and data for
the diesel pumps installed at the refinery.
With this information, the team in
Quarter 4 2022
Indonesia then
collaborated with
the Sulzer Pumps
engineering team
in the USA. Building
upon this, the USA
team also delivered
additional training
to the customer’s
team.
Throughout
the project, the
Singapore service
centre acted as
a central hub for
all the teams to
organise their
findings and recommendations. After the
close international collaboration, it was
clear that the new duty point could be met
without any modifications to the pumps.
GEARING UP
Rather than modifying the pumps, new
gearboxes would be used to increase the
speed of the pumps to reach the new
process requirements, which could be
achieved well within the performance
envelope of the units.
Armed with this information and a plan
of action, Sulzer Indonesia carried out
detailed inspections of the units. The team
then conducted a full refurbishment of the
eight pumps, bringing them back to as-
new standard. New skid frames were fitted
with efficient electric motors connected
to gearboxes to deliver the desired speed
increase, replacing the old diesel drives
and steam turbines. To ensure a complete
drivetrain package, Sulzer also installed
new couplings and lube oil systems. The
rebuilt skids were a plug-and-play solution,
allowing simple reconnection with existing
refinery pipework, unlocking a quick
installation and minimising time on site.
This approach not only ensured a
reduced lead time on the project, but
also meant the retrofit could be carried
out at 50% of the cost of sourcing new
pumps. Furthermore, the retrofit offered
a time saving of five months compared
to delivering replacement units. No
modifications to the pumps themselves
also allowed easy plug-and-play
reintegration into the surrounding process
equipment back at the refinery once work
was complete. What had initially been
a complex problem was solved with a
straightforward solution that saved time
and costs.
MEETING DEMAND RELIABLY
Updating the drive technology for the
pumps ensured that the new duty point
was also met with increased efficiency.
By using the operational data for the
pumps, the complex new performance
requirements could be met with speed-
increasing gearboxes, with future system
reliability assured.
Ultimately, a cost-effective and efficient
solution was provided to the refinery,
ensuring that it could deliver increased fuel
supply while safeguarding availability. chevron-circle-right
www.sulzer.com
www.bpma.org.uk
www.brookcrompton.com
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22 Water Treatment

High Lift Pump Replacement Project

Offers energy saving solution
For half a century, residents and commerce across eight municipalities of the greater
London Area of south western Ontario have received their potable water supply from the
Lake Huron Water Treatment Plant near Grand Bend. In 2017 the Lake Huron Primary
Water Supply System announced an energy audit and pump optimisation study that
identified a significant opportunity for energy savings and the optimisation of pump
operations for the pumping station. flow found out how the savings were realised, with a
solution from KSB.

T
he outcome of the study
commissioned by the Lake
Huron Primary Water Supply
System (LHPWSS) has been
the modification of the original five-pump
configuration in the pump station and its
replacement with a six-pump configuration.
This has involved removing three of the
original 50-year-old 3000hp (2237kW)
pumps and replacing them with four
high-lift pumps from KSB. With the new
pumps running on their operational curve,
substantial energy savings can be made.
As an electrical transmission-connected
entity, the LHPWSS was eligible under the
Independent Electricity Systems Operator’s
(IESO) Industrial Accelerator Program (IAP)
for financial incentives for eligible energy
efficiency projects.
Four international pump manufacturers
submitted bids, but KSB Canada’s
submission stood out. Despite being
the highest capital expenditure cost by in 1996 and 2014, The Regional Water with the size of the pump. The base plates
a significant amount, KSB’s submission Supply Division of the City of London for each pump were the same size.
actually offered the lowest overall (RWS) partially twinned the 47km main A significant benefit of the proposal was
anticipated lifecycle cost over 25 years. This transmission pipeline to a terminal reservoir that with the smaller pumps using the
was possible due to KSB’s energy efficiency resulting in the pumps no longer running on same size casings and base plates as the
and creative solution offering a single type their curve. two larger pumps, they had engineered
for all four pumps (large and small). This the opportunity to increase the pump size
reduced the spares requirement, in turn PUMP SELECTION by fitting larger impellers and motors at
reducing the lifecycle cost and providing The overriding issues the pump suppliers a future date. This can be done on site
flexibility to easily increase pump capacity in faced were delivering energy savings without any civil works needing to be
the future as demand continues to increase. and ensuring that pumps could be carried out. Thus, if demand grows for
The contract was awarded to KSB Canada, accommodated in the limited amount the water supply to be increased, it can be
which commenced design and consultation of space in the pump hall and that the accommodated with the minimum cost
work in 2019. floor could withstand the weight of the and disruption to the plant.
The LHPWSS plant has a current pumps. In addition, the supplier needed Following a 25-year Life Cycle Cost
treatment capacity of 340 million litres to guarantee a wide operating range with analysis, taking into account the capital
per day and serves the city’s population of low available NPSH, covering multiple cost, energy consumption and maintenance
approximately 420,000 people in the eight duty conditions with pumps operating at costs made by AECOM Canada,
municipalities, including 80% of the city of full speed. consultants for LHPWSS, the contract was
London. KSB’s proposal, using just a single type awarded to KSB.
The pumping station was originally for all four pumps, meant only the impellers “The eventual scope of the project
designed for a single pipeline, but later, and motors were different, in accordance involved the supply of four bottom > 24

Quarter 4 2022 www.bpma.org.uk

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

W: www.kiwa.co.uk/water T: +44(0)1495 308185 E: jonathan.price@kiwa.com

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T: 01283 523000 E: sales.uk@

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solutions that help you to meet your sustainability goals. Hot Water Heating

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www.wilo.co.uk Pressure Boosting Drainage
24 Water Treatment
suction horizontal split case pumps,
vibration monitoring system and flow
straighteners (suction conditioning spools)
for potable water distribution (water
supply),” explained Marcus Henderson,
KSB National Operations Manager. “Also,
part of the contract was to supply two
TECO make 1494kW/2000hp @ 1200rpm,
4160V / 3Ph/60Hz and two TECO make
2611Kw/3500hp @ 1200rpm, 4160V /
3Ph/60Hz electric motors.”
The plant’s pumps are rated for
1,158 l/sec, and each of the pumps’
discharge piping is equipped with a 500mm
diameter tilting disk check valve, along with
a 500mm diameter metal seated ball valve
equipped with a motorised electric actuator.
The water treatment plant has two
hydropneumatic tanks, each with a capacity
of 580m³, for transient protection of the
47km partially twinned 1200mm diameter
water main distribution system.
The pumps specified were 2 x RDLO
500-835 B SC G O BS with a design flow
capacity of 900 l/sec and a design flow
pump head of 125m TDH, along with 2 x
RDLO 500-835 A SC G O BS with a design
flow capacity of 1,300 l/sec and a design
flow pump head of 150m TDH.
RDLO PUMPS
Proven in many water applications
worldwide, the RDLO pumps were
identified as more than capable of
meeting the customer’s specific
demands. KSB’s RDLO axially split, single-
stage volute pumps have been developed
specifically for handling raw water, clean
water, service water and transport fluids
with minimal flow resistance. As a result,
they lower the energy and life cycle costs
of the systems in which they are installed.
They also meet the twin demands of
reliability and high availability. Reliability
results from the casing halves being
sealed by solid casing split flanges at the
upper and lower casing part, and high
availability is attributable to the use of
generously dimensioned bearings and
high-quality shaft seals. Smooth running
is ensured at all times thanks to the
flow-optimised, vortex-free intake elbow
and rigid shaft with a short bearing span.
Because the shaft is completely sealed
without steps/threads in the wetted
area, the RDLO offers reliable power
transmission.
The combination of solid bearing
brackets, a short and rigid shaft and pre-
loaded bearings guarantees low vibration
and extended operating life for the bearings,
Quarter 4 2022
seals and coupling. Being
axially split case pumps
simplifies maintenance
procedures, enabling
ready access to all parts
for thorough inspection.
The drive may be
positioned on both the
left and right of the pump
without additional parts
or modifications to the
casing being necessary.
“Two of the pumps
are connected to 3500
hp motors, and the
other two to 2500 hp
motors. These are the
main pumps supplying
drinking water to the
entire LHPWSS, with
many customers over
50km away, so they
consume a significant
amount of energy. It is
marginal improvements
such as these that can
improve efficiency by
one or two per cent, but they work out to big combination valve and the high-lift pump
dollars when you consider the plant’s overall for maintenance and repair purposes.
size,” added Marcus.
PUMP EFFICIENCY
INSTALLATION A significant element of the project
“Because the pumps were being was the issue of the pumps delivering
retrofitted into the original premises, it energy savings, which involved factory
was necessary to run the plant at half acceptance testing at KSB’s Halle
capacity on one transmission side during facility in Germany. Marcus explained:
installation,” explained Billy. “As there was “Factory testing involved shipping one
a spare bay already in the plant it was motor of each size to our factory and
possible to utilise this for the installation coupling them up to the pumps for string
of the first pump. The procedure then testing and recording the overall pump
involved running pumps one, two and performance. The motors also underwent
three while pumps five and six were being type testing under full load in accordance
installed before switching to running with the IEEE Standard so that they could
pumps four, five and six while pumps one, determine motor efficiency.
two and three were installed.” “There were strict penalties on
The introduction of the new pumps performance guarantees on this project,
also provided the opportunity to retrofit so if we failed to meet the efficiency
isolation valves. Historically the lack of guarantees given, KSB would be required to
isolation valves on the existing pumps pay LHPWSS the difference in energy costs
required the complete isolation of half delivered and those which were guaranteed
of the discharge header board (three over the performance lifetime.
pumps) to facilitate the repair to one “It is worth noting that when the pump
pump, effectively limiting the pump tests were carried out, they had to be on
capacity of the plant to half of its rated bare internals. The coatings were only
capacity. The selection of a combined applied after testing, so it was a true test
control/check valve to replace two of the raw efficiency of the pumps. Given
valves on each pump discharge meant that coating can improve efficiency by
that each pump would have a dedicated one to two per cent, we faced some tough
isolation valve for each pump discharge. conditions.” chevron-circle-right
Isolation valves on each pump discharge
will enable the complete isolation of the www.ksb.com
www.bpma.org.uk
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FOR HIGH VOLUME PRODUCTION
The VEBK500/TFM/TFO is our brand-new machine
designed for the dynamic balancing of pump impellers
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Supplied with either milling correction or industrial belt
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follow the profile of the impeller.
Please contact us for a full technical specification.
We deliver the most comprehensive range of dynamic
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26 sustainability
VSDs’ role in decarbonising
the water industry
Martin Richardson, Water Framework Manager at ABB, explains how variable
speed drives (VSDs) can represent an easy and cost-effective way for the water
industry to progress rapidly to Net Zero.
E
lectric motors account for
a significant proportion of
the water industry’s energy
consumption. Many motors
are run without any kind of speed
control, while some use mechanical
means such as valves and dampers
to modulate flow and pressure.
This is inherently inefficient, as the
motor is still running at full speed,
regardless of demand. A variable
speed drive (VSD) instead controls
the motor electronically, to always
match motor output with actual
demand. As such, the motor only
uses the minimum amount of
energy that it needs, which can save
both energy and money.
Pumps, fans and compressors,
are centrifugal applications, and as
such obey the cube law. This means
that a small decrease in speed results
in a proportionally higher decrease
in energy use. In practice, running a
motor at 80% speed requires 50%
of the energy required to run at full
speed.
HIDDEN FUNCTIONALITY
In most cases, installing a VSD
will lead to improved energy
efficiency almost overnight simply
by reducing the motor’s speed.
However, VSDs are highly complex,
with modern devices boasting
huge amounts of functionality, and
so the real savings come when you
start exploring what else a VSD can
do for you.
For instance, energy tariffs are
generally higher during peak demand
and lower at night (depending on
your supplier). A VSD provides the
flexibility to operate intensive or non-
critical processes at the right point
in time to achieve the lowest cost.
Reservoir controls, for example, can
pump water into a reservoir overnight
when tariffs are lower. And the more
you get into this level of detail, the
Quarter 4 2022
more you can gain control over
processes to uncover other
efficiency savings.
Pumping slower for longer
can also make a big difference.
Consider the example of
using a pump to empty a tank.
Pumping slower may take more
time, but even a small change
in pump speed can lead to a
disproportionately higher energy
saving.
At a basic level, a VSD will
save energy on pumping
applications. But it also provides
the flexibility to rethink control
philosophies for applications driven
by motors in the water industry and
helps to optimise processes so that
they reflect varying changes in costs
upstream and demand downstream.
Modern VSDs are also packed with
sophisticated application-specific
features such as multi-pump control,
which can make a big difference to
the resilience of operations.
IMPROVING RESILIENCE
Reducing leakage and bursts will
be crucial in working towards the
industry’s Net Zero goals. Prevention
clearly is better than cure when it
comes to leakage; however, many
leaks are only detected when roads
start flooding with water. As well
as wasting water and potentially
causing damage to the surroundings,
digging up roads to repair pipes
uses enormous amounts of carbon.
VSDs incorporate internal PID loops,
which, in this context, can ensure
that pressure is maintained at
certain levels regardless of any other
variables in play, as the VSD is able
to constantly adjust motor speed
depending on the circumstances.
The VSD can also provide an early
warning system for any potential
leaks, as issues can be inferred
from the behaviour of the motor
and pump. For instance, if a booster
pump is running with VSD control
and is operating at full speed for
more than, for example, one minute,
then this usually suggests that there
is an issue that needs resolving
somewhere, and the VSD can flag
this up. Running motors at lower
speeds generally will also reduce
strain on pipes and valves.
IN SUMMARY
When people think about how
to save energy, often the first
suggestions are to turn lights off
and reduce the heating. However,
the difference this makes can
be negligible when compared
to reducing the energy usage
of, for instance, a pump at a
pumping station by up to 50%.
Moreover, turning off lights and
reducing temperatures can end
up compromising comfort. A VSD,
on the other hand, allows required
output to be maintained, at a
much higher efficiency, and with
no compromise on productivity
and effectiveness. When looking
for cost-effective ways to save
energy, the VSD could be the key
to unlocking significant progress
on the water industry’s road to Net
Zero. chevron-circle-right
bit.ly/ABBwawa
www.bpma.org.uk
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28 Challenging Fluids
Trialling and scaling
up production
Beginning production of a new formulation batch or liquid product can often bring
difficulties. We found out how North Ridge Pumps recently helped an innovator within
the supplement industry to scale production and perform trials on a new product.
K
nowing which pump
technology to use to
ensure a safe, efficient
process and provide
flexibility for small-scale batches,
whilst undertaking refinements
before commercialisation, can prove
challenging.
Not only are you trying to ensure
accurate, repeatable, traceable
results and avoid transferring fluids
manually, but you also need to ensure
any technology selected will stand
the test of time and ensure cross-
contamination does not skew results.
The client was looking to transfer
one of several highly viscous blends
of chemicals that would not flow
under gravity, and they wanted to
consistently batch set amounts.
HIGH VISCOSITY LIQUIDS
High-viscosity liquids often cause
difficulty in transfer applications.
They do not flow under gravity and
require a specialist pump technology
which, if used, can also pose issues if run
without fluid and can be easily damaged.
Such fluids are sometimes so thick that
when delivered in barrels or containers, if the
incorrect pump technology is chosen, the
fluid is not pumped – holes are made with
the pump within the fluid container rather
than it being completely emptied, with large
amounts of product remaining.
Not only is the product within the centre
of containers a cause for concern, but
also fluids which may remain stuck to the
side of the container. With more expensive
fluids, this can generate costly waste, or
cause problems with fluids which must be
disposed of via waste collection. So, what
factors should be considered when looking
at scale production or conducting trials?
FIVE CONSIDERATIONS
Sensitivity to shear: Some fluids may
be shear sensitive, meaning they must
Quarter 4 2022
be handled gently to avoid adversely
affecting them during transfer.
Solid handling: When solids are
transferred, careful consideration needs to
be given to how they are handled. They can
be transferred with technologies preserving
their shape and consistency, or with designs
which can assist with the next stage of
production, with solids broken down or
partially blended.
Volatile and corrosive liquids: Volatile
and corrosive liquid handling is another
consideration, such as whether an
ATEX-approved design is required or a
sealless pump is needed to ensure the
full containment of fluids. Other options
include the swaging of hose fittings for the
safety and security of leak-free connections,
nozzles for ease of fluid dispensing and
speed control to alter dispensing rates and
prevent splashing.
Accuracy and repeatability: The ability
to repeatedly batch pre-set amounts
with ease, or record the amounts
dispensed with high accuracy, is
crucial to ensuring consistency.
Accreditation: Material choice
can be puzzling. This can include
whether to adopt an accredited
hygienic design, or a stainless-
steel design which can be easily
disassembled and cleaned –
providing peace of mind during
testing – or to simply what is
chemically resistant.
HIGH-VISCOSITY FLUID
DISPENSING
For the supplement project, North
Ridge was tasked with assisting
a client in dispensing a product
being developed which had the
consistency of molten fat.
When cold, the product would
solidify, making it unpumpable and
nearly impossible to remove from
the container.
The equipment needed to be
hygienic, easily cleanable and able to
handle a wide temperature range, yet
consistently transfer differing volumes of
liquid as accurately as possible.
North Ridge supplied, commissioned,
and installed a complete automatic
batching system to dispense the liquid
accurately and repeatedly.
The unit was supplied complete with a
heat-traced hose to ensure the liquid did
not solidify in the hose, with the barrel
also heat-traced to ensure the contents
remained liquid and pumpable. As the fluid
was heated, it became easily pumpable,
enabling the client to trial new processes,
test small-scale batches and trial packing
methods.
Their results are accurate, repeatable
and fully traceable, enabling them to
accelerate production and scaling. chevron-circle-right
www.northridgepumps.com
www.bpma.org.uk
—
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30 Building Services Focus
Booster sets: fixed or variable?
Daryl Williams, the Commercial Specialist at Pumps UK, outlines the differences
between fixed- and variable-speed booster solutions, explaining the applications
where each approach is most appropriate.
O
ne of the solutions
to avoiding supply
interruptions (and
unhappy clients) is to opt
for cold water booster solutions
that are designed with built-in
‘redundancy’, often extra pumps that
can take over during maintenance
cycles or failures.
Some systems rely on a common
controller and run at a fixed speed.
Others are fitted with inverters that
can vary the speed of the pumps.
Both have advantages for certain
applications.
A general definition of a water
pump inverter is a device that
maintains constant and stable
pressure in a water system by
varying the speed of the pump
motor to deliver the pre-set pressure
at the outlet regardless of how many
outlets or appliances are in use, up
to the maximum capability of the
pump. In recent times, booster sets
fitted with inverters have become
increasingly popular.
Naturally, these hi-tech innovations
come at a price. The addition of
inverters to a water-pressure booster
set is not an insignificant cost. That
said, opting for less expensive fixed-
speed sets can, potentially, be more
expensive in the long term for some
applications.
PRECISION CONTROL
Booster sets, such as the PUK VARI
COM range, designed with Nastec
inverters, allow individual pumps
to be isolated and the system to
continue the supply even if a pump
is removed or is offline. These smart
inverters allow for precision control
via the Nastec Now application and
Bluetooth technology.
ENERGY SAVINGS
There are further advantages in
booster sets designed with inverters,
as they can be programmed to
vary the performance of the set
based upon demand, so less power
Quarter 4 2022
is consumed compared with a
similar fixed-speed set. The wider
the operating range of the pumps,
the greater the potential for energy
saving.
While inverters do not directly save
energy, the programmed operational
parameters of the set can offer
substantial energy-use reductions
to the end-user. With some sources
suggesting that reductions between
10% and 40% of the energy
consumed by the industrial and
service sectors in some countries
are possible, the potential for savings
and energy consumption reduction
is a hot topic.
According to the Harvard Business
Review, Dec 2021, nearly all the
world’s largest companies have
annual sustainability reporting
and a sizeable number pledging
to be net zero by 2050. With rising
energy costs, due diligence dictates In addition to the reliability of
weighing higher initial outlay against booster sets with in-built redundancy,
energy consumption, maintenance Nastec inverters can perform another
costs and reliability. rather clever trick, courtesy of their
networking connectivity capability
RELIABILITY AND (via Bluetooth), creating a ‘combined
PERFORMANCE operation’. In practice, one of the
One of the great things about inverters can reassign its pump as
packaged variable speed booster the ‘master’ or duty pump in the
sets, PUK VARI COM, for example, event of the duty pump going offline,
is the flexibility thus maintaining
in configuration. the operational
In a three-pump
set, one pump
The potential for savings program.
Fixed-speed
can be assigned and energy consumption sets still have a
as the ‘duty’
pump, supplying
reduction is a hot topic. place and offer
advantages in
the required certain scenarios,
flow rate most of the time, with a such as operations requiring a
second pump designated ‘assist’ constant flow rate, like an irrigation
to help cope with higher demand system or a factory with machines
cycles. The third pump is used that use a steady flow during
as a standby to replace the duty production. But for water supplies
pump if it is offline, increasing the that have variable demand, variable
overall reliability of the set. Similarly, speed booster sets offer some
twin-pump configurations can significant advantages in energy
have a second pump as standby to saving, water saving, noise reduction
mitigate against interruptions during and reliability. chevron-circle-right
maintenance or in the event of a
failure. www.pumpsukltd.com
www.bpma.org.uk
Independent Pump Training
from
E-learning
Classroom based
“Live” webinars
On-site courses
Tailored options

For more information call

0121 601 6691
scan code for the training guide
or email: training@bpma.org.uk

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32 Mining & Quarrying focus

Keep your dewatering

project afloat
To choose the right floating pump station for a dewatering project, it is important
to understand the factors which affect its environment, deployment, operation and
maintenance. Dewatering specialist, Weir, outlines seven things which need to be
considered when choosing a dewatering barge.

T
hree elements will determine the
type of barge suitable for any
given application: the hydraulic
requirements of dewatering,
the physical conditions on site and the
bathymetry of the water the barge will be
deployed on.

PHYSICAL CONDITIONS
While some mines enjoy reasonable weather
year-round and are readily accessible by
heavy transport, it’s not uncommon for the
climate to significantly affect the installation
and operation of waterborne dewatering
equipment.
Unsurprisingly, the most common issues
come from areas where temperatures
regularly fall below 0°C for sustained
periods. Not only can the resulting ice
interfere with the dewatering itself, but
surface ice can cause substantial damage
over time to barges and pontoons,
necessitating a de-icing solution to keep an
area around the barge fluid.
Weir Minerals’ Multiflo barges employ de-
icing systems to manage temperatures as
low as -50°C, which have been tested in the
trying conditions of the Canadian tundra, and
other arctic-like environments. They allow
for worry-free, year-round operation when
combined with heat tracing, self-draining
pipes, and other freeze-prevention systems.
Areas prone to seasonal flooding or
extended rainfall experience drastic changes
in water level, which have to be accounted
for in the mooring or anchoring system
used, access to the barge, and bottom-
out protection (filled foam used to protect
against hull breach) for the pump.
For many remote sites, a seasonal
or permanent lack of readily accessible
roads designed for heavy-load traffic will
affect which barges can be deployed. Weir
Minerals’ engineered-to-order dewatering
pump systems have been deployed in a
number of hard-to-access regions around
the world and can accommodate sites
requiring airlift or traffic over ice roads.
Many other site conditions have to be
accounted for when designing a barge
system; wind, snow, and seismic loading
all affect the buoyancy and stability of the
barge.
POND BATHYMETRY
A pond bathymetry survey should be
conducted to map the body of water’s
geotechnical data. This hydro-acoustic
survey produces maps showing the water
depths based on location. This information
is crucial to analyse wave formation, which
is used in the marine analysis to simulate
wave loading on the barge structure,
pipeline, and access walkways.
These factors will determine where the
barge should ideally be placed and how
much mooring or anchoring it will require
to stay in place. This requirement can be
substantial, with some projects requiring
hundreds of tonnes of anchoring to prevent
high winds from forcing the barge to
break free and collide with land or other
equipment, or even capsizing.
DEWATERING AND
HYDRAULIC REQUIREMENTS
The parameters of the pumps needed
for dewatering naturally determine the
style of barge suitable to carry it. Once a
pump has been selected, its type (vertical,
submersible, horizontal), physical size,
weight and geometry will determine how it
can be safely supported on the barge.
Larger horizontal pumps typically
require barges like the WEIR Multiflo
steel hull barges, while smaller vertical
pumps can be mounted on polythene or
fibreglass barges. In addition to the pump
size, the number of pumps on one barge
system also plays a major factor in barge
hull determination, with steel hull barges
typically able to support more than one
pump.
The nature of the substance being
pumped also plays an important role,
especially in brine or acidic applications.
Due to the corrosive effects, the barge
hulls and frames must be fabricated from
special materials or protected with special

Quarter 4 2022 www.bpma.org.uk

 Mining & Quarrying Focus 33

coatings or anti-corrosion systems such MAINTENANCE For most applications, a shore-based

as cathodic protection.
A number of secondary factors, such
as the provisioning of input power, pump
maintenance strategies and barge access,
are key to the ongoing efficiency of the
dewatering operation.
ACCESS TO BARGE
In most cases, a floating walkway is a
preferred method of accessing a barge
– combining economic efficiency with
constant personnel access to the platform.
It also simplifies power distribution, as
cable trays can carry electrical and control
cables.
For platforms which require direct vehicle
access, a suspension bridge or gangway
between the barge and the shore is the
most elegant solution, although they
typically aren’t economically practical over
long distances, particularly in areas prone
to snowfall.
For areas where neither of these are
practical, marine access involving boats or
hovercraft is generally used to access the
barge.
The ideal maintenance strategy generally electrical genset is the ideal solution, as
depends on the type of dewatering being it simplifies management and operates
performed – while all pumps require more efficiently than a diesel engine.
regular maintenance, those deployed in
clear-water applications generally have PORTABILITY
more flexibility in their planning than The last key decision point is how
tailings and slurry dewatering, where portable the barge needs to be. Will
maintenance is one barge be
always a core part of dewatering in
the conversation. multiple locations
Larger, monolithic The last key decision over its lifespan
or pumphouse style point is how portable or deployed in a
barges with space particularly remote
for a monorail or the barge needs to be. location?
crane within the If it’s being
pumphouse allow reused in multiple
pumps to be refurbished and repaired on locations, does it need to be draggable
the barge itself, while other barges need between ponds?
to be pulled to shore for the pumps to be For larger installations, it’s important
extracted. to consider if the operation is likely to be
scaled up or down further on, which could
POWER require modular barges or leaving extra
The provisioning of power is another key space for additional pumps to be added
factor in designing a dewatering solution, down the track. chevron-circle-right
particularly for sites which are too remote
for standard electrical access. www.global.weir
34 Opinion
Optimise your pump
systems to save energy
Steve Schofield, Europump Executive Council Member, offers some basic information
and guidance on purchasing, maintaining and designing pump systems for optimum
energy efficiency, maximum CO₂ reduction and best capital expenditure payback time.
P
ump systems account for 20%
of the world's electrical energy
demand and between 25% - 50%
of the electrical energy usage in
certain applications. Pumps are the single
largest user of electricity within industry
across the European Union, consuming
over 300 TWhpa of electricity, which in
turn accounts for over 65 Mton of CO2
emissions.
It is also well documented that
rotodynamic pumps, which account for
80% of the installed base, are typically
between 20-30% oversized. There is,
therefore, a major potential to save
energy if rotodynamic pumps are properly
sized and operated.
WHERE TO START
To identify if a pumping system is sized
correctly and assess the potential for
savings, make the following checks:
• Are you wasting liquid flow?
• Are you creating additional pressure?
• What is the monitoring & controls
philosophy?
• Are there any oversized pumps
installed for your required duty?
• Are there any significantly old pumps
employed in the system?
• Is there excessive noise in the system?
• Are there any throttling valves installed
in the system?
• Have you the correct size of pipework?
• Inadequate maintenance lowers
pump system efficiency, so what
maintenance procedures are in place?
• Are you adopting a proactive
equipment replacement programme to
current EU legislation
SYSTEM DESIGN
The vast majority of existing pump
systems operating today were not
originally designed with energy
conservation as a major consideration. If
pump systems are initially designed on
an energy-efficient basis and are correctly
applied and sized, the energy savings will
Quarter 4 2022
often exceed 50%.
To design an energy-efficient pump
system, all the following criteria should be
considered:
• Basic plant layout
• Pipe size, configuration and restrictions
to limited pipework losses
• Information on the liquid (viscosity,
density, aggressiveness, temperature)
• System characteristics and pump
selection
• Pump/system control
• Correct sizing of the pump units
• Selecting the most energy-efficient
pumps at the best efficient point
• Selecting the most energy-efficient
motors
• Fitting variable speed drives to match
the system design and demand
Low energy costs are a direct result of
knowing the minimum flow and pressure
that the system requires to operate
successfully (system demand) and then
selecting the correct sized pump and
matching it to the system.
When selecting a pump, it is important
to determine the required flow and
pressure to be generated by the pump.
The flow may be determined by a
process requirement, the heating or
cooling required in the system, or the
peak water demand for utilities. The
pressure required may be to elevate the
liquid within the system or to overcome
the pressure losses created as the liquid
passes through it.
It is important to know as much about
the pump system as possible and to
create a pressure/flow profile for the
system. The energy required to drive
the pump is directly related to the flow
and pressure required. To generate high
pressures generally leads to designs
which may be inefficient, and therefore
neither the flow nor the pressure must be
over specified.
When specifying a new pump, ask for
a high-efficiency motor to be fitted. If
Steve Schofield, Europump Executive
Council Member and BPMA CEO.
you are replacing or rewinding a motor,
then evaluate the cost of fitting a high-
efficiency motor remembering to factor in
the running savings, which will pay back
any increase in cost. The overall cost
associated with operating these essential
pieces of equipment throughout their
entire life span can be broken down as 5%
for the initial purchase/installation costs,
10% for ongoing maintenance and 85%
for the energy used to run them. Clearly,
any reduction in the energy consumed
by electric motors is important, and with
modern designs, that reduction can be as
much as 30%.
It is also evident that many pumps
and motors are constantly operated at
full power, irrespective of process needs,
so across Europe's installed base, there
is the potential for significant energy
savings. These savings can, in turn,
drop to the bottom line and increase
the profitability of any business. Using
an electrical variable speed drive is the
simplest and most economical way of
controlling the pump and matching it to
the pump system. chevron-circle-right
europump.net
www.bpma.org.uk
 NO
MI
NA
TIO
N SN
OW
OP
EN

PUMP INDUSTRY
AWARDS 2023

Here’s your chance to shine!

The BPMA’s annual Pump Industry Awards programme has been
Venue:
recognising and rewarding the achievements of pump businesses, Hilton at St G
large and small for over two decades. Throughout that time it eorge’s Park,
Burton on Tre
has become one of the leading events to serve the industrial and nt
commercial arena. So, if you or your company have a pump related Date:
Thursday 16 th
success to shout about, these awards provide the perfect platform. March
2023
The gala presentation dinner caps off the awards programme in style,
providing excellent networking opportunities, great food and superb The 2023 Call for Nominations is now open,
entertainment. It’s your chance to celebrate with colleagues, interact so be sure to visit the Pump Industry Awards
with peers, entertain customers and be part of the pump industry’s
website to review the award categories and
biggest and best celebration. Manufacturing and distribution prowess,
product development and application, environmental consideration, skills decide which ones you will be entering!
development and customer support will all be acknowledged through this
wide reaching awards programme. So why not consider which of your
engineering successes are deserving of industry wide recognition, and be
sure to join us at our wonderful new venue - the home of English football
- on Thursday 16th March 2023.

Event Calendar
NOMINATIONS OPEN - 1st June 2022
NOMINATIONS CLOSE - 6th January 2023
JUDGING SESSION - Mid-January 2023 Richard Harden, BPMA President, says of the Pump Industry
Awards, “The pump industry continues to be a hotbed of
FINALISTS ANNOUNCED - 30th January 2023 competitiveness, where the constant search for greater
operational performance and improved efficiencies amongst
VOTING - 6th - 10th February 2023 its broad customer base, demands all those operating within
this important sector to be at the top of their game. This BPMA
WINNERS ANNOUNCED - 16th March 2023 backed awards programme allows the pump industry to come
together in celebration of that drive for engineering excellence.”

www.pumpindustryawards.com
Award Programme Partners

Organised by on behalf of
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