pumpaction - · pdf filejulian lowe grundfos pumps ... wilo-emu fa submersible pumps are...

Dosing pumpswith integratedflow control.seepex progressive cavity dosing pumps are used in all industriesfor precise metering without the need for pulsation dampenersor control valves. For viscous and non-viscous products, aggressivechemicals and high pressure applications seepex pumps provideaccurate and reliable metering with rapid turndown whereneeded. • reduce chemical costs - accurate linear flow independent of viscosity and pressure• reduce system costs - no pulsation dampeners, strainers, or non return valves needed• does not vapour lock• integrated digital flow control directly linked to pump speed• dry run protection• profibus enabled for fully automated control

seepex UK Ltd.Tel [email protected]

PumPActionSePtember 2013

In thIS ISSue:

edItor’S Column P3 & CounCIl newS

welCome to our P4 lateSt memberS

SCottISh mInI P6 ConferenCe PrevIew

memberS newS P6

ConferenCe & P14 exhIbItIon revIew

talkIng teChnICal P17

PumP Centre P18 manager John howarth lookS at Some CauSeS of PumP Shaft faIlure

newS from the P22 ImeChe

CallIng all P22 Young engIneerS

traInIng & P23 awareneSS daY Programme 2013/14

ContaCt detaIlS:

tel: 01925 843512fax: 01925 843500

emaIl:

[email protected]

the offICIal newSletter of the PumP Centre

www.PumPCentre.Com

www.pumpcentre.comSeptember 2013

Pump Centre manager: Mr. J. HowarthTel: 01925 843506Fax: 01925 [email protected]

Publishing:Imedia Marketing Consultants Ltd1 Norton Place, The Lakeside Centre,180 Lifford Lane, Kings Norton,Birmingham B30 3NUTel: 0121 451 [email protected],.uk

advertisement sales:Jon [email protected]: 0121 451 2156

design and artwork:Marc PittawayAdvertising Matters [email protected]

disclaimer

This newsletter is designed to provide information of a general nature and is not intended as a substitute for professional advice in a particular matter. You should always seek appropriate advice from a suitably qualified professional before taking, or refraining from taking, any action. The opinions and interpretations expressed within this newsletter are those of the contributors/authors only and may not reflect those of other parties. No representation or warranty, express or implied, is made as to the accuracy or completeness of the information contained in this newsletter and therefore the information should not be relied upon. The contents of this newsletter should not be construed as professional advice and ESR Technology Limited and the Pump Centre disclaim liability for any loss, howsoever caused, arising directly or indirectly from reliance on the information contained within this newsletter.

Contents editor’s ColumnDear Reader

I am very pleased with the positive feedback we have received from our annual Conference & Exhibition which we held at the International Centre, Telford at the end of May. The event was well supported by exhibitors and delegates alike and its success gives us a great platform for next year. We have signed a three year deal with the International Centre to host the Conference up to 2016. It is a nice sized venue which can allow the event to grow, but is not so big as to make the event impersonal.

The long awaited upgrade to the Pump Centre website is now underway and should be completed within the next few months. The aim is that the new website will provide a better user experience and be more functional. All members will be notified shortly before the launch about the new site and the new features.

The Pump Centre Members Council election has just finished and the new Council Members take up their seat at the next council meeting in mid-September. The Council now comprises the following people:

USERS: Mike Rush United Utilities Brian Spence Scottish Water Simon Whatley Thames Water Mike Ward Yorkshire Water Keith Solts Environment Agency Mark Keen Southern Water

MANUFACTURERS: Julian Lowe Grundfos Pumps Derek Jackson Hidrostal Limited Stuart Lumsden KSB Ltd Bob Went Xylem Water Solutions

SUPPLIERS: Mark Scally ABB Brian Conway Boulting Group Alistair Mackinnon Pulsar Process Measurement Andrew Reeks Siemens Philip Hall WEG

Any members who wish to put an item on the council agenda can do so by either contacting myself, or any of the council members listed above.

And finally, I hope you like the “New Look” Pump Action newsletter. We have made a few changes which hopefully freshen up the publication with the objective to increase the visibility of the Pump Centre and its members, while also providing a more interesting and informative newsletter for the reader. If you have any ideas for articles please drop me a line.

John Howarth

Pump Centre Manager

[email protected]

© ESR Technology LtdPump Centre, ESR Technology Ltd, Whittle House,410 The Quadrant, Birchwood Park, Warrington, WA3 6FW

Editor’s Column & Council News ...........................page 3

Welcome to our Latest Members ..........................page 4

Scottish Mini Conference Preview .........................page 6

Members News ...........................................................page 6

Conference & Exhibition Review ......................... page 14

Talking Technical ...................................................... page 17

Pump Centre Manager John Howarth looks at some causes of pump shaft failure .................... page 18

News from the IMechE .......................................... page 22

Calling all Young Engineers ................................... page 22

Training & Awareness Day Programme 2013/14 ...................................................................... page 23

edItor’S Column & CounCIl newS

The aim of the Pump Centre is to provide its members with cost effective help and support via events, training, consultancy and projects. The Centre strives to promote innovation and raise awareness of new technical development which benefits the technology transfer within the whole supply chain.

Brian Spence of Scottish Water (2nd from the left) with the Pump Centre team (from left to right: Jim, Karen & John) at the Scottish Technical Awareness Day 2012. See page 6 for news of

this year’s Scottish Mini Conference – Pumps & Pumping

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www.pumpcentre.com September 2013

William Hackett Chains Limited have been manufacturing and distributing chain and chain products since 1892 and is the UK’s leading provider of solutions to:

• The Construction and Utility markets providing the industry’s premier chain sling system, hoisting and stainless steel products.

• The Oil & Gas industries specialising in lifting solutions to the offshore and subsea industry.

• The Agricultural industry, where Hackett Harrows have a worldwide reputation for excellence, product design and construction, using the latest technology together with years of manufacturing knowledge that has helped make Hackett the No. 1 chain harrow in the world.

At our West Midlands site, we manufacture and supply Pump Lifting Chains in Gr.50 316L, 316 Stainless Steel and Gr.40 Galvanized Steel to pump manufacturers and indirectly supplying many UK & Ireland Utility companies through our comprehensive distributor network. We can manufacture up to 10t capacity and can supply individual assemblies to meet specific requirements.

William Hackett Chains is renowned for its ethos of integrity and dependability, which is built on its world-class service in design, assembly, certification, compliance and distribution capabilities.

www.williamhackett.co.uk

william hackett Chains limited

A.W. Chesterton Company is one of the largest international manufacturers of industrial fluid sealing devices, hydraulic pneumatic and maintenance chemical products. The company works with customers to provide the solutions that help industry run more reliably, safely, efficiently and economically. Chesterton is a family owned company and has been in business for nearly 130 years.

With a strong commitment to technology and innovation, Chesterton has always focused on delivering value added customer solutions. Chesterton is committed to the chemical, pulp and paper, power, water and waste water process and manufacturing industries, with cross-fertilization of expertise that is supporting many industries and OEM customers.

Chesterton products include mechanical seals, compression packing hydraulic seals, composite coatings, industrial lubrication as well as a range of specialty MRO chemical products.

Chesterton’s local service is delivered by a dense sales and service network providing local inventory and technical assistance. Engineering and manufacturing hubs are located in the United States, Mexico, Brazil, China, Sweden, Hungary and Germany. All Chesterton manufacturing sites are ISO 9001/9002 and ISO 14001certified.

www.chesterton.com

Chesterton joins the Pump Centre

Eaton is a diversified industrial manufacturer that is positioned through its global solutions to answer the water industry’s most critical power management challenges. Eaton provides energy-efficient solutions to help its customers effectively manage electrical, hydraulic and mechanical power. Present in over 175 countries, with approximately 103,000 employees, Eaton is uniquely placed to tackle an extensive range of energy-saving problems. The company’s products and services help improve efficiency and ensure against environmental damage. Many of Eaton’s products are used to simplify and increase efficiency within the water and waste water industries, whilst cutting installation times and reducing the impact on the environment. Eaton’s power solutions provide increased safety and reliability to ensure critical operations continue to run. By providing universal connections, certain Eaton products can be integrated into a range of non-Eaton products.

www.eaton.eu

eaton Come on board

This is an exciting period for us at the Pump Centre as we accelerate our plans to grow our organisation.

We are especially pleased to welcome three more new members again this month, taking the total number of new members that have joined in 2013 to 13. This continues the upward trend and compares favourably with the number of new members who joined last year. It is seen as a sign that our strategy to make sure we deliver excellent value continues to reap rewards.

To our new members, we hope you will derive the maximum benefit from joining and wish you a long and mutually beneficial association with us. Our team are always available for help and advice and welcome your call.

welCome to our lateSt memberSPumPAction

4


• DN65 – DN600, in various material options

• IE3 High Efficiency Motors & Efficient Hydraulics

• 1 & 2 Stage low pressure Impellors

• Easy Maintenance Access to all wear parts

• CERAMIC internal options

t:+44 (0) 1283 523000www.wilo.co.uke:[email protected] f:+44 (0) 1283 523099

Strength and power

(but only one has abrasion & corrosion resistant CERAMIC protection options)

WILO Split Case

5


All buildings have pumps operating as part of the heartbeat of their operation – providing heating, cooling, air conditioning and moving sewage and greywater.

Palm Papers – a German company - has recently built a new plant in Kings Lynn. It’s one of the world’s largest and most efficient newsprint paper mills producing 400,000 tonnes of newsprint a year, at 2,000 metres of paper per minute.

The new building sits on a 50 acre site in north Norfolk. It represents a huge investment in environmentally friendly technologies and it’s a building that sets new standards when it comes to environmental performance.

The total pump infrastructure in the building has been supplied by Wilo, in a project valued to them at around €400,000.

A paper mill is responsible for a serious amount of wastewater so a dedicated private sewage facility was built as part of the project. From this, approximately 96% of the wastewater can be recycled, meaning very little water needs to be sourced from the nearby River Ouse and the water that is put back into the river is actually cleaner than the water taken from the river originally.

Wastewater from the plant is dealt with by five Wilo-EMU FA08 submersible pumps and two Wilo-EMU FA10 pumps. These are specially designed to pump waste water containing solids and for sewage plants and pumping stations for water management and industrial applications.

Wilo-EMU FA submersible pumps are also used for rainwater collection and drainage on the site - a total of twelve pumps – Wilo-EMU FA20s and 30s each pumping up to 900m3/h. Four relays control three pumps each and are connected by MODBUS to the building automation system.

In the building, the air conditioning and process cooling use Wilo pumps as well. The 2.3MW cooling requirements are dealt with by two

quantum refrigeration compressors. Wilo-Veroline IPL and IPE in line pumps are utilised for chilled water distribution. In the laboratories cold water distribution is controlled by two Wilo-Stratos CAN pumps – integrated via an IF module lined to the building automation system. These pumps are based on the ECM – electronically commutated motors – which offer double the efficiency of an electronically controlled pump with a conventional drive. Wilo-Stratos high efficiency pumps have been optimised to the operating conditions of the air conditioning refrigeration area. They are capable of operating happily under a wide range of liquid temperatures – from -10°C to +110°C, protected by a cataphoretic coating to guard against corrosion.

Only the most energy efficient pumps were considered for the project with Wilo-Stratos and Wilo-Stratos ECO installed. The heating system comprises five sub-divisions - a total of 13 circuits which are also controlled by the building automation system.

To provide the required levels of water pressure around the buildings, Wilo Comfort-Vario pumps are installed, which with four pumps provides a flow of 25m3/h at a head of 80 metres. Once again this system is monitored and controlled by the building automation system.

This integrated pumping system illustrates the energy efficiency benefits of utilising high efficiency pumps, delivering significant operational benefits and savings – not just in the lower energy bills they deliver but in the lower maintenance costs associated with them because of their high reliability levels and in-built protection – this ensures the pumps run with minimal interference and maintenance. The lower life cycle costs associated with selecting Wilo pumps is a vital benefit to any major organisation looking to incorporate this number of pumps in an integrated system that needs to operate constantly with the minimum of fuss.

www.wilo.co.uk

In conjunction with Scottish Water the Pump Centre is running a mini one day conference on the subject of “Pumps & Pumping”. The event is being held on Thursday 10th October 2013 at a venue close to the new Scottish Water Control and Operation Centre at Stepps on the outskirts of Glasgow.

We are expecting around 40 delegates from Scottish Water plus many others from local companies who have an interest in pumps and pumping.

The majority of the presentations will be given by two independent experts, Steve Broadfoot and Brian Nesbitt who will introduce and

discuss a range of pump related topics, such as:

• Pump types and classification• Pump performance, curves and selection• Centrifugal & Positive Displacement Pumps• Variable Speed Drives• Problems and troubleshooting

There will also be a small exhibition of products and services provided by suppliers and manufacturers who are members of the Pump Centre.

If you require more details please contact Jim eaves on 07968 707753 or email [email protected]

Scottish mini Conference – Pumps & Pumping

memberS newS

energy efficient pumps in the news…

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memberS newS

The Environment Agency (EA) has awarded Hidrostal Ltd a three year, exclusive contract worth around £3m to supply pumps and pumping equipment.

Following a comprehensive tendering exercise, SuperHawk mobile, diesel-driven pumps from Hidrostal met the rigorous quality and pricing criteria laid down in the EA’s framework for the contract.

Hidrostal’s SuperHawk diesel pumps provide enhanced fuel efficiency, thereby reducing environmental impact and leading to an average saving of £500 per week for Hidrostal customers across the range of 3” to 12” pumps. In addition, SuperHawk pumps operate as quietly as 53 dB(A) – a huge environmental benefit where work is carried out in residential areas or where wildlife may be sensitive to noise.

Kirsty Browning, Contracts Manager, Environment Agency, commented on the decision, saying, “The Hidrostal SuperHawk is specifically designed with efficiency and environment in mind and has lower CO

2

emissions than its competitors, giving a 30% CO

2 reduction across the range. It continues

to benefit the Environment Agency as it offers low fuel consumption. Hidrostal has also confirmed the possibility of running the pumps

on sustainable bio-diesel which we will be actively looking into. All of this will contribute to meeting our carbon reduction targets.”

Hidrostal MD, Steve Blakemore, commented, “We are delighted to be working so closely with the Environment Agency and consider this a welcome endorsement of the engineering superiority of our SuperHawk diesel-driven, mobile pumping solutions, which serve to maximise performance and to lower financial and environmental costs for our customers.”

www.superhawk.co.uk

SAFE, SOLID &

RELIABLEOur extensive range of products includes:

Magnetic Drive Self Priming Mag Drive Submersible Mag Drive

Flow to 100m3/hr + Flow to 75m3/hr Flow to 20m3/hrHead to 40 metres Head to 28 metres Head to 12 metres

Air Operated Drum & Barrel Control Valves

Flow to 48m3/hr A wide range of Plastic Control Pressure to 16 bar materials and drives Valves

Metering / Dosing Level Controls Bespoke

Flow to 1.1m3/hr Ultrasonic Level Bespoke Design &Pressure to 276 bar Measurement Manufacture

Chem Resist Fluid Transfer are leading suppliers of a wide range ofpumps for aggressive and corrosive applications

Chem Resist Group Limited T: 01924 499466Britannia House, Lockway, F: 01924 490334Ravensthorpe Inustrial Estate E: [email protected], WF13 3SX W: www.chemresistfluidtransfer.com

Chemresist Proof 1.indd 1 29/07/2013 05:00:42

Diaphragm Pumps

Chemresist Proof 2.indd 1 31/07/2013 10:00:51

environment agency awards hidrostal ltd exclusive Contract to Supply its Super Silent, diesel-driven Superhawk Pump range

the Class leading dura 45 Peristaltic Pump

The Verderflex Dura 45 is the pathfinder in a new generation of medium flow, industrial hose pumps. A product of intensive engineering investigation, with genuine class-leading performance, the Verderflex Dura 45 combines a close-coupled pump’s compactness with a long coupled pump’s easy serviceability. Additionally, its innovative, patent pending flange design reduces downtime by speeding up hose changes whilst totally containing the pumped liquid inside the pump’s housing eliminating any risk of workplace contamination.

Ideal for medium flow applications up to 12m³/h, the Verderflex Dura 45 solves pumping problems associated with dry running liquid streams, shear sensitive polymers, high viscosity sludge and pastes, variable speed dosing, abrasive solids in suspension and off-gassing fluids. This makes the Verderflex Dura 45 ideal for use in biogas production, brewing, chemical m a nu fa c t u r i n g , food processing, mining and water treatment.

www.verder.co.uk

verderflex dura 45 Peristaltic hose Pump

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During the third year of my MEng Mechanical Engineering Degree at Lancaster University I was expected to compete a large individual project. The aim of my project was to develop a new way of aerating water in wastewater treatment with a reduced energy cost that could be retrofitted to existing facilities. The new system, called “Persephone”, uses the principles of a siphon to achieve this. The water passing around the downward bend causes a negative pressure difference; which if an inlet is present, will naturally draw air into the system. The goal was to prove whether the concept could be commercially viable.

The aeration process is used to dissolve oxygen into water to provide for the bacteria needed to treat sewage. An aeration system traditionally consists of compressed air being forced through diffusers and currently accounts for 1% of the UK’s total electricity usage. A siphon would naturally flow if there is a head difference between the inlet and outlet; however many aeration tanks are at the same level and therefore a submersible pump was used to create the initial water flow. A GLS-50-24-253-S was very kindly donated by Xylem Lowara as the cost of it was many times the project budget and the project would not have been possible without them.

The test rig was built to allow for testing of the dissolved oxygen level and power usage. The quantitative target that the system needed to achieve was to provide 1.6kg of dissolved oxygen per kilowatt-hour of power used; this was based on information provided by United Utilities. This target was exceeded for at least the first 5 seconds on the majority of tests before saturation occurred.

The basic financial information and expenditure for the aeration process was provided by United Utilities and using these figures it was calculated that with further development the Persephone System could provide a saving of up to 21% in electricity costs for aeration.

Frazer StewartMEng Mechanical Engineering StudentLancaster University

Supervisor:Dr George AggidisDirector of the Lancaster University Renewables Energy Group (LUREG)For more information contact the Pump Centre.

Pump Centre members support third year

project

CSD Sealing Systems UK is celebrating the company’s 20th year anniversary by increasing their workforce to meet the demands of its services.

CSD is pleased to announce the addition of Louise Windham to the administration team. Louise brings over nine year’s customer

CSd celebrates 20 years anniversary by expanding its team

care experience as well as strong organisational skills. Her previous administrative roles involved processing orders for a global company and supporting the new business development team by managing new client accounts.

Louise will be responsible for the day-to-day administration, dealing with customer enquiries, processing orders and providing support to the well-established admin team.

Louise said, “I am delighted to be joining CSD, this is an excellent opportunity for me to use the skills I have learnt over the years and make a positive impact on the business”.

David Ripley, Managing Director of CSD UK, said:

“It is fantastic to welcome Louise to our team and I am sure her skills and understanding will be of great value to our clients. We are building on the company’s achievements over the years by strengthening the workforce in order to support our future growth and maintain our high levels of customer service and support.”

CSD UK is celebrating 20 years in business during 2013. From its small beginnings in Blyth the company has expanded its offices but still retained its local roots with offices based in Cramlington. It has experienced significant growth as market leaders over the years and developed relationships with some of the biggest names in the marine, power generation, water, construction & petrochemical industries.

David Ripley added “We are proud to be a UK company with a strong presence within all of our markets. With our very experienced and knowledgeable team, we work hard to deliver what our customers want, when they want it, supporting their high standards in high risk environments and challenging industries. After 20 years we are still growing and innovating and we are looking forward to some exciting times over the next 20 years!”

www.csdsealingsystems.co.uk

memberS newSPumPAction

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The Vikings’ River Splash is a popular attraction at LEGOLAND®. It also consumes more energy than nearly everything else in the amusement park. However, by installing Danfoss VLT® frequency converters, electricity consumption has been reduced by 190,000kWh per annum, and at the same time it has become easier to regulate water flow.

Something within the region of 1,800 litres of water per second are pumped round the channels so that children and adults can have fun. The goal is to use only the necessary amount of water to send the park’s guests on a wild ride in the tub-shaped boats. The ride uses propeller pumps to generate the water flow and create a “rafting effect”.

Circulating large quantities of water requires a lot of energy and energy consumption is now higher on the agenda than ever before. This is why regulating the water flow in the attraction is an important step towards energy reduction.

using only the required water volumes

Previously flow control was carried out using wooden shutters and gates, the surplus water was diverted back to its starting point and the pumps operated at the same speed irrespective of how much water was required.

“By installing Danfoss VLT® frequency converters on the two pumps of the ride we have reduced energy consumption. At the same time it is now easier to regulate the water volume because the frequency converter ensures that the pumps only circulate the necessary volumes of water,” says Anders Christensen, electrical technician at LEGOLAND®.

The added benefit of better flow control is:

• Shorter Waiting Times

Operators are able to send off the boats more regularly - the more boats that can be sent off per hour the shorter the waiting time for the park’s guests.

• A Smoother Ride

Accurate independent control of the two pumps allows for a more pleasant ride for the children.

www.danfoss.com/drives

vlt® drives control energy consumption

at legoland®Customers’ demands for accurate, reliable metering and the option of remote control have been met by the new seepex range of dosing pumps. Linear dosing with accuracy of +/- 0.5% over flow rates of 200ml/hr to 1,500l/hr is enhanced with an integrated flow control unit and profibus dp connectivity. The pumps can be controlled remotely via automation systems or manually using the push button control unit linked to the VSD.

Progressive cavity pumps have many advantages for metering over other positive displacement types. The flow has minimal pulsation due to the action of the rotor and stator pumping elements therefore pulsation dampeners are not needed and calibration is easy. Higher pressures can be achieved, up to 24 bar, and non-return valves and degassing are not needed so systems can be simplified thus reducing installation and maintenance costs. Dry running protection is provided by the flow control unit and level controls can be linked to provide a fully automatic system. Flexible installation including vertical mounting of pumps is possible where space is limited and the inverter control can be either integral to the motor or mounted separately where corrosive chemicals are handled.

seepex pumps can handle abrasive and corrosive chemicals at a range of temperatures and with the help of our engineers pump selection using the correct materials is ensured for reliable and repeatable dosing without corrosion of pump parts.

www.seepex.com

new from seepex – integrated flow control and profibus

connectivity

seepex hygienic dosing pump for accurate control

memberS newS

QUANTUM INTELLIGENT PUMP

CONTROL

Malvern, Worcs WR14 1JJ, UK Tel: +44 (0) 1684 891371

[email protected]

Quantum Controller increases both efficiency andmonitoring flow rate out of a well, via a dedicated 4-20mA.

‘Time to spill’ warning and advanced pumping optionsallow you to prioritise response and minimise use inpeak periods.

l No unnecessary call outs to reset tripped pumpsl Tariff Guard

software overrides usage during peak periods

l Monitors for burst rising main and pump blockage from a wet well

l Removes need for Mag Flow meters

facts

Electricity consumption per season on the Vikings’ River Splash attraction*:

• Prior to installation of the frequency converters: 440,000 kWh.

• After installation: 250,000 kWh.

• Savings: 190,000 kWh per season.

* Two 132 kW Danfoss VLT® 6172 frequency converters connected to two 125 kW propeller pumps control the water flow in the Vikings’ River Splash attraction.

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Following a 12 month trial, rotary lobe pumps made by Borger have been installed by Severn Trent Water at its enhanced Rushmoor STW near Telford, as a way of improving wholelife costs.

Offering lower capital expenditure (CAPEX), as well as reduced energy consumption compared to many other types of pump, a Borger rotary lobe unit was successfully trialled for sludge handling, ragging, wear and ease of maintenance-in-place.

Now installed in two Primary Settlement Tanks (50m long by 20m wide by 3.5m deep), currently undergoing refurbishment, Borger’s rotary lobe pumps are proving that they can handle onerous de-sludging duties.

Manjit Chadha, Programme Manager for the e5 Alliance, who are delivering a £6.5M Growth scheme at Rushmoor STW, commented:

“Whole life costs are very important to us, so we have looked closely at what is best for desludging of Primary Settlement Tanks (PSTs), which across the industry is always one of the most arduous sludge handling applications”.

He added: “Borger’s rotary lobe pumps provide key benefits such as simple installation, easy access for blockage removal, easy overhaul (typically 1 hour), and a bi-directional function that eases blockage clearance. The pumps can also be run dry for short periods”.

www.boerger.com

borger’s pumps get de-sludging at rushmoor

Until recently, turbidity testing at the Pontsticill Water Treatment Works relied on the use of bellows pump technology. However, the inherent introduction of air in the samples was undesirable and led to false readings. Now though, relief has arrived in the shape of Watson-Marlow’s new Qdos 30 metering pumps, which not only provide excellent suction lift, but do so without air locks.

“This is a clean water site and the quality of sample is very important,” states Marek Cegielski, a process scientist and manager. “In the past we’ve tried other types of turbidity monitoring devices, such as dip probes, but without much success. We’ve even used bubble traps in conjunction with our bellows pumps, but we still fell short of 100% reliability. Of course, eliminating the need for bubble traps was one of the attractions of replacing one of our bellows pumps with the new Qdos 30 from Watson-Marlow.”

upstream benefits

The Pontsticill Water Treatment Works draws its water from the Pontsticill Reservoir, a large body of water measuring some 102 hectares in surface area, and holding up to 3400 million gallons of water. With this in mind, successful turbidity testing is vital.

Turbidity is a key test of water quality. It is defined as the cloudiness or haziness of a fluid caused by individual particles (suspended solids) that are generally invisible to the naked eye, similar to smoke in air. Water can contain suspended solid matter consisting of particles of many different sizes. While some suspended material will be large enough and heavy enough to settle rapidly to the bottom of a container if a liquid sample is left to stand (the ‘settleable’ solids), very small particles will only settle slowly or not at all if the sample is regularly agitated or the particles are colloidal. These small solid particles cause the liquid to appear turbid. In drinking water, the higher the turbidity level, the higher the risk that people may develop gastrointestinal problems.

Crystal clear solution

The Qdos 30 metering pump at Pontsticill is taking elutriant from a DAF (dissolved air flotation) filtration plant and lifting it approximately 3 metres before it passes through a turbidity meter and returns by gravity back into the flow. At this point the water has already been subjected to coagulation, flocculation and flotation, and is ready for final filtration processes.

“Our main requirement is for a constant 280ml/min, pulse-free flow,” says Mr Cegielski. “Previously we had tried fitting back valves to bellows pumps to stop the pulsing but in truth we couldn’t properly buffer the effect and still ended up with false readings.”

Plain sailing

Installed in July 2012, the Qdos 30 is working well without any signs of air introduction or flow variation. Watson-Marlow’s innovative new Qdos range has been purposely designed to eliminate ancillary equipment and enhance productivity by delivering more accurate, linear, and repeatable metering than typical solenoid or stepper driven diaphragm pumps.

“So far, so good, as far as we’re concerned – when new technology comes along that has a clear advantage over existing market solutions, then we are always willing to give it a try,” concludes Mr Cegielski.

Featuring all-new hardware and software, other water-related applications for Qdos 30 include disinfection and pH adjustment of drinking water and industrial process water, flocculation, and industrial cooling water preparation to list but a few.

www.watson-marlow.com

Qdos metering pumps solve turbidity testing dilemma for welsh water

memberS newSPumPAction

10

Water is essential for life – for domestic, industrial, commercial and other purposes. Less than one percent of the freshwater is readily accessible and demand for clean water continues to grow. Across the entire water cycle, from drinking water to industrial wastewater, we have the answers for your

www.siemens.co.uk/water

Water and wastewater industry

current and future business needs. Our extensive portfolio includes energy management, water and waste water treatment, automation, control and instrumentation asset management, smart metering, leak detection and infrastructure development. Siemens also offers full service, support, and financial services.

Drink, cook, bathe, irrigate, clean - and drink it again.Siemens solutions ensure that the water quality is always suitable for intended use.


Rising energy prices and limited energy resources call for alternative solutions that save money and are environmentally friendly. KSB have supplied pumps as turbines (PaTs for short) for many years, so it is a well-known concept in the pumping industry. It offers huge advantages such as low investment, service and maintenance costs, with the added benefit of being more straightforward to operate and maintain than conventional turbines.

The principle of a pump as a turbine is to pass water the “wrong way” through a pump, allowing the head (pressure) in the flow to act on the impeller blades, running it in reverse and providing a torque on the output shaft which can be used to drive something. Most commonly, that “something” is an asynchronous generator (a standard induction motor driven in reverse) converting the mechanical energy to electricity, which can be consumed on site and/or fed into the local grid (sold to the local power supply company). But that “something” could equally be another piece of machinery, even a pump.

KSB PaTs can be seen at their best where there is a relatively constant water supply with suitable available head (typically greater than 10m) but where the local electricity supplies are inadequate or unreliable. An example of this is Brazil, where it is almost impossible to find a location that does not feature a small waterway or rapids. At the same time, the country’s geography makes it difficult to supply remote settlements with electricity. It therefore makes sense to use these widely available hydropower sources to produce electricity locally rather than relying on diesel generators for which fuel has to be purchased and with their attendant environmental risks.

PaTs also have their role in locations where power is both available and reliable. The need for cleaner, renewable energy that is cost effective means that PaTs open up the opportunity for water utility companies to look at exploiting smaller flows, previously considered uneconomical, as well as replacing existing conventional hydro turbines. Typical examples of this are compensation flows and spill flows from dams, but other flows such as final effluent from sewage treatment works can be considered. The lower procurement costs of PaTs coupled with high (and increasing) energy prices means that the payback period of KSB PaT systems are usually between 3 and 5 years. The power generated by

these PaTs offsets the overall costs of the infrastructure and puts power back into the grid.

KSB’s PaT’s have been successfully installed in the UK in a number of projects, including Meldon Dam, Morwellham Quay and Avon Dam near Buckfastleigh in Devon. In this case, KSB supplied two PaTs, one for generating power 24/7 from the compensation flow and a larger unit for generating from the spill flow, mainly in the winter months. This KSB PaT offered 80% efficiency and compared exceptionally well against other turbine suppliers, exceeding expectations in power generation versus asset cost. KSB worked alongside May Gurney to put forward the most cost effective solution whilst ensuring maximum power generation and revenue for the end user, South West Water.

PaTs can also be used with fluctuating water flows by using several different sized units, bringing them into and out of service according to changing demand. This requires only minimal control, so PaTs are starting to create significant interest in the current economic climate, where reducing energy costs are becoming a top priority. The fact that the turbine and the generator are both widely used pieces of equipment, so can be operated and maintained by existing staff without the need for any specialist training, adds to their attraction.

Many types of pumps - end suction, axially split case and multistage ring section, for example - can be used as PaT’s, both in horizontal and vertical configurations, so there is flexibility in adapting this technology to suit specific flows, heads, site conditions and space constraints. Couple this to that fact that PaT’s can be used to generate from as little as 1kW up to hundreds of kilowatts, even megawatts, only serves to underline the usefulness of the technology.

KSB have found there is also scope to use our PaTs in pumped storage schemes, where low cost energy is used outside peak hours to run the units as pumps, lifting flows to a higher level, where it is stored to be used to generate electricity at times of high demand by returning the flow through the same units. This concept is also being considered as a way of dealing with energy generated from renewable sources such as wind power, where the power is not necessarily generated when demand exists.

www.ksb.com

Pumps used as turbines

Monitoring pump efficiency is critical in advanced pump station control, based on either a calculation on flow in and out of the sump, using ‘rate of change of level’ or the installation of an expensive and invasive magflow meter, neither of which typically pinpoints individual pump issues. Now, using Pulsar Process Measurement’s non-contacting ultrasonic level measurement equipment along with their latest non-invasive flow device, Flow Pulse, it is possible to provide pump station control, pump management and efficiency monitoring with minimal

installation costs and zero disruption to operations.

Quantum 3 is the latest addition to Pulsar Process Measurement’s range of non-contacting ultrasonic ‘intelligent pump station controllers’, providing sophisticated pump control routines together with advanced, labour-saving functions that, for example, reset tripped pumps automatically and warn on ‘time to spill’ in critical pumping stations.

Now, the capability of the Pulsar system has been extended by the ability to add Pulsar’s unique Flow Pulse sensors to the system. Flow Pulse is a non-invasive flow monitor that simply clamps onto a pipe, giving a repeatable and reliable measurement of flow. As many as four Flow Pulse units can be associated with each Quantum 3, so each pump plus the total station output can be measured directly, monitoring the performance

of individual pumps while also providing total flow, rising main burst and block alarms and more. Result; cost-effective and easy-fit pump station management.

www.pulsar-pm.com

advanced Pumping Station Control with Pump efficiency monitoring: Pulsar Quantum 3

memberS newS PumPAction

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The Pump Centre held its ANNUAL CONFERENCE & EXHIBITION at the International Centre, Telford on the 23rd May 2013. On the evening prior to the Conference over four hundred invited guests attended the Conference Dinner. The dinner provides the ideal environment for the Pump Centre to entertain and network with its clients. The after dinner entertainment was provided by two excellent comedians, Pete Emmett and Lea Roberts and the very dry humour of Dr Kevin Jones who is a practising consultant chest physician. The charity raffle held at the dinner raised just over £4000 on behalf of the “Make A Wish Foundation”, who grant magical wishes to children and young people fighting life-threatening illnesses.

The Pump Centre is a membership club based predominantly, but not

exclusively, within the Water industry and its ANNUAL CONFERENCE & EXHIBITION is the UK’s leading event for anyone interested in pumps and pumping systems. This year it attracted 750 visitors who were able to create their own agenda by; attending the main conference on the theme of “Sustainable Pumping”, sitting in on a selection of engineering breakout sessions, visiting the New Product Zone or walking round the main exhibition made up of approximately 80 stands from the UK’s leading manufacturers and suppliers. The Pump Centre Conference provides the ideal opportunity for all parties within the Water Industry to get together, find out about the latest technologies, share innovative ideas and network with like minded professionals.Over recent years the Pump Centre has grown and membership is at a record high of 123 member companies, members include all the major

Pump Centre Conference & exhibition

Pump Centre exhibition

Pump Centre dinner

ConferenCe & exhIbItIon revIewPumPAction

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water utility companies, most of the water supply only companies, the Environment Agency plus many other companies with an interest in pumps, pumping systems and the associated equipment.

The Centre offers its members a range of important services including:• Technical support• Collaborative projects• Conference and events• Training• Networking and marketing activities

The Pump Centre is operated by a small team within ESR Technology Ltd consisting of:John Howarth (Pump Centre Manager)Jim Eaves (Business Development)Karen Bridgeman (Events & Training Co-ordinator)Roger Marlow (Principal Technical Consultant)

for more details about membership or exhibiting at next year’s conference, contact Jim eaves on 07968 707753 or email [email protected]

Panoramic view of Pump Centre exhibition

Pump Centre conference

John Howarth giving the welcome address at the Pump Centre dinner

ConferenCe & exhIbItIon revIew PumPAction

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www.eaton.eu

New PowerXL™ variable frequency drives with outputs of up to 250 kW.

The new DC1 and DA1 series.With its PowerXL™ DA1 and DC1 series, Eaton has taken variable frequency drives to a whole new level. From engineering and configuring parameters to installation and commissioning, these variable frequency drives redefine efficiency and raise the bar in terms of reliability and heavy-duty use.

· Convenient basic parameter configuration and an info card for quick commissioning

· Use a communication stick to clone parameters

from one device to another without having to use a computer

· Strong performance: No derating at 50 °C, 200% torque at 0 rpm.

To order a catalogue, please contact: [email protected]

Eaton PowerXL 190x252 SWDT RZ UK.indd 1 25/06/2013 14:39


ProMinent is setting a new benchmark with the redesign of their product range of motor-driven metering pumps, the new Sigma Control. Safety, efficiency and environmental protection are not only an option; it is a standard feature of this pump.

The entire range of Sigma motor-driven diaphragm metering pumps, control type S1Cb/S2Cb/S3Cb, has been thoroughly redesigned with additional intelligent features, which provide a high level of operator interaction, safety, efficiency and accuracy.

removable operating/control unit for operator interaction

The removable operating/control unit provides additional ‘ease of use’, for practical applications. Being an interchangeable component, the operating/control unit can be used on multiple pump duties for quick and easy application set ups, thus removing the requirement to purchase multiple pumps all with individual expensive control capabilities.

energy saving of 15% and more

For the first time, the New Sigma can record any motion and speed profile in combination with the power demand required to meet the duty. This takes place via intelligent software that controls the motor electronically. It identifies the power demand and controls the power feed according to the specific requirements of the application.

In total there is an energy saving of over 15 % at full load compared to conventional pump controls; at half or 2/3 loading, the saving is even higher and can be as much as 30 %, a key in today’s utility saving climate.

metering profiles for optimum metering results

To achieve an optimum metering result, metering profiles can be used to match the pump metering behavior to the characteristics of the chemicals or application. With the new product range, the speeds of the drives can be varied. This permits intelligent movement control, which saves energy and optimises every application or duty. As an example, the pump can be profiled to operate with a slow suction and rapid discharge stroke function; this profile would suit applications where viscous chemistry is being injected or the system is operating with restricted suction conditions. However, the pump can also be set to have a rapid Suction Stroke and a Slow Discharge; this set up could suit

such applications as batch injection processes, where the pump is required to be in a state of readiness or even for chemicals that are subject to gassing issues.

Internal overload switch for reliable pump protection

The new product range has a power demand control function, which switches the pump off upon exceeding of a defined tolerance range. This ensures the maximum protection of your investment: the switch triggers at an overload of 30 % thus obviating the need for additional pump protection equipment such as relief valves or manometers, while supporting burst protection equipment for the whole system.

low chemical consumption, environmental protection and process safety

With their multilayer safety diaphragm with integrated diaphragm rupture signalling, the motor metering pumps of the New Sigma series increases the process-safety and protects the environment. At the same time the application-adapted metering profiles meets the demands of chemical injection process. This decreases the impact on the environment and the costly overdosing of chemicals within the process or worse, the loss of production down time.

Safety as standard

The motor-driven pump is also equipped with a multi-layer safety diaphragm and intelligent diaphragm rupture signaling device. The structural design of the new safety diaphragm ensures that feed chemicals remain in the dosing head, even in the event of diaphragm rupture, and leakage into the environment is completely avoided.

In addition, an optical display of this condition is fitted as a standard. In the event of a fault indication, the user can react promptly, carrying out remedial action. Even greater convenience is offered by the diaphragm failure indicator on the control version of the New Sigma pump. In this case, a diaphragm failure is indicated by the illumination of a red LED as well as an error message shown on the LCD screen. Depending on the setting, the pump can either stop or continue to meter with a simultaneous alarm message.

operation comfort, safety and efficiency

With their multi-layer safety diaphragm, integrated diaphragm rupture signalling and integrated overload protection, the motor metering

pumps of the New Sigma series, increases the process-safety and protects the application environment. At the same time the application-adapted metering profiles meet the demand of chemicals while offering considerable energy savings,

www.prominent.co.uk

Mechanical Optical Indication of diaphragm servicablity; Electronic re-transmit option available upon request

the Standard; for more efficient and better

metering results

normal modethe suction stroke and pressure stroke are of equal lengths

optimised pressure strokethe pressure stroke is extended and the suction stroke undertaken as quickly as possible

optimised suction strokethe suction stroke is carried out as slowly as possible, the pressure stroke preferably short, which allows for accurate and uncomplicated metering of viscous and gaseous media

talkIng teChnICal PumPAction

17


The most common cause of pump shaft failure is due to fatigue cracking.

“Fatigue is a process of slow crack growth occurring under the action of fluctuating tensile stresses. Few, if any load bearing structures carry truly constant loads, this is particularly true for rotating shafts.”

Fatigue is a serious danger because it occurs in normal service, without excessive overloads, under normal operating conditions and without warning. Although the final failure occurs rapidly the fatigue crack itself can take a significant number (many millions) of stress cycles to initiate and propagate to a critical size.

Shaft Stresses

A variety of loads are carried by a pump shaft including the weight of the rotating assembly, drive misalignment forces and hydraulic loads due to pressure build-up in the pump casing.

The magnitude and direction of the hydraulic forces mentioned above depend on the flowrate of the pump. Figure 1 is a simplistic representation of how the size and direction of the radial force acting on the impeller varies as the pump increases from 0 to 125% of the best efficiency flowrate.

Size of arrow represents magnitude of force

The resultant effect of the radial force is to deflect the pump shaft causing one side of the rotating shaft to be in tension and the other to be in compression. As the shaft completes a single revolution, a point on the surface will cycle from tension to compression or vice-versa depending on its starting point.

In a pump operating at 3000 rpm the shaft will experience over 4 million stress cycles in a day’s continuous operation.

Pump days of Continuous operationSpeed 1 day 10 days 100 days 1000 days

3000 rpm 4.3 mil 43 mil 430 mil 4.3 bil



Table 1: Accumaltion of Stress Cycles in a Rotating Shaft

Crack formation & growth

Fatigue is a quite devious mechanism of failure because the fluctuating stress that the shaft experiences is often well below the tensile strength of the material. Fatigue failures start from microscopic cracks that initiate under the fluctuating stress and then propagate slowly until they reach a critical size.

The first stage of a fatigue failure is the “initiation” of the crack. Initiation occurs at a sub-microscopic level due to imperfections in the crystalline structure of metal undergoing minute, but irreversible changes due to the repeated stress fluctuations. As the imperfections move and combine they form microscopic cracks.

The second stage of fatigue failure is crack “propagation”. The crack front is extremely sharp and acts as a stress concentrator to drive the crack deeper into the metal. Each time the crack is subjected to tensile stress the crack opens and advances and when subjected to compressive stress the crack closes and stops. This method of propagation causes the fracture surface created to have a characteristic “striated” or “beachmarked” surface. The striations run perpendicular to the direction of crack growth.

The final stage of fatigue failure occurs when the remaining cross-section of the shaft becomes too weak to carry the operational loads. Under these conditions a single application of the load is sufficient to cause a rapid final fracture.

Characteristic fracture Surfaces

Fatigue cracking generates characteristically different fractures surfaces depending on:

1. How the cyclic stress is generated2. The magnitude of the stress3. The number of initiation sites4. The degree of stress concentration5. The properties of the material

The typical fracture surfaces exhibited on shafts by rotating bending fatigue are shown in the schematic diagrams below (Figure 3A to 3D). The red dots represent initiation sites and the grey area represents the region of final rapid failure.

talkIng teChnICal

Pump Shaft failuresJ Howarth, Pump Centre Manager

The Pump Centre is operated by ESR Technology

Figure 1 – Variation of Radial Loads with flowrate

Figure 2 – Stress cycle due to single rotation of shaft

tension

Compression

Stress

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500

750

105 106 107 108

250

Figure 3A

High Nominal Stress

Single Initiation Site

Mild Stress Concentration

Figure 3B

Low Nominal Stress

Single Initiation Site

Severe Stress Concentration

Figure 3C

High Nominal Stress

Multiple Initiation Sites

Mild Stress Concentration

Figure 3D

Low Nominal Stress

Multiple Initiation Sites

Severe Stress Concentration

In reality the patterns exhibited on the majority of fracture surfaces are generally damaged due to the final failure or disassembly of the failed machine. Often the striations/beachmarks are not easily visible and therefore they are very difficult to understand. More often than not the fracture surfaces need to be viewed under magnification and determining the failure mode requires expert interpretation.

fatigue life

The number of stress cycles to cause failure can be represented in the

form of an SN Curve, an example of which is shown below.

Typically the greater the stress amplitude per cycle the lower the number of stress cycles to cause failure. Most steels exhibit a fatigue limit, a stress amplitude below which fatigue failure will not occur. However, most shaft fatigue failures occur in regions where there is a “stress concentration”.

The most common areas of crack initiation in shafts are at the design stress concentrations which occur at:

• Keyways• Changes in cross-sectional area• Circlip grooves• Threaded regions

To minimise the stress concentration during manufacture it is important to follow good design practice. Changes in section need to be properly radiused, keyways need to be sized correctly and have radiused corners, the same is true for threads and grooves.

The effect of stress concentration is to significantly raise the local stress amplitude thus accelerating the initiation and propagation of cracking. Other fatigue accelerators include:

a) Corrosion can affect fatigue in two ways; firstly corrosion pits can act as initiation sites for fatigue and also corrosion can accelerate the propagation phase by a chemical reaction taking place between the active constituents in the atmosphere/fluid and the clean metal which is exposed at the tip of a fatigue crack.

b) Surface condition has a profound effect on fatigue strength and life. Possible physical and geometric defects at the surface of the metal include roughness, porosity and foreign inclusions such as slag or oxide particles.

c) Microstructure can greatly affect fatigue performance. The main factors are grain size, alloying elements and second phase particles. Generally speaking, microstructural changes that increase the yield stress will improve the fatigue strength of the metal.

Summary

Most pump shaft failures occur due to rotating bending fatigue. This type of failure usually results in complete fracture of the shaft. The fracture surface tends to occur in locations where the fatigue process is accelerated by factors that can significantly increase the stress concentration. These factors include surface damage, corrosion, poor design and poor quality material. The likelihood of fatigue is also increased by operating the pump away from it best efficiency point, because the amplitude of bending stress will be increased.

references

1. Understanding How Components Fail – Donald Wulpi ASM 19852. Pump Shaft Failures – F Berndt, A van Bennekom 19993. Mechanics of Engineering Materials – PP Benham & RJ Crawford 1987

fatigue limit

Photograph of the fracture surfaces of a pump shaft that has failed by fatigue

Stress amplitude (mPa)

Cycles to failure


19

Chemical Dosing Anaerobic digestion & Food waste

Bespoke turnkey package systems

CONSULTATION

PumpSolutions

INSTALLATION & COMMISSIONING

PROJECT MANAGEMENT

DESIGNSERVICING

+44 (0) 1924 221 001

[email protected]

www.verder.co.uk

Verder Pumping Solutions

Verder provides pumping solutions to

many of the leading utility companies,

waste management organisations,

manufacturing and chemical process-

ing plants.

Adv_wateractive_optie_b_UK_(uk)-rev02.indd 1 21-06-13 11:38


The popularity of variable speed drives (VSDs) continues to grow, not least in pump and fan applications where they can deliver big improvements in energy efficiency. But VSDs are by no means all created equal, and users who take a little care to specify products that make good use of the latest technologies will gain valuable additional benefits. Here, Eaton’s Stuart Greenwood explains how.

For anyone specifying an AC VSD, there’s an almost bewildering range of products from which to choose and, at first sight, most seem to do exactly the same job. Look a little closer, however, and differences start to become apparent. These differences can have a big effect on how easy the VSD is to work with, how well it performs in practice and, ultimately, whether it delivers good value for money over its working life. But what exactly is it that VSD specifiers should look out for?

For a start, they should be careful that they’re not paying for features they don’t need. This is particularly true of smaller drives with ratings where extra features such as integrated programmable control functions can represent a significant proportion of the price. To address this issue, the leading VSD manufacturers are now offering their latest products in two ranges – a basic keenly priced range, and an advanced range with enhanced functionality.

Typically the basic drives are only available with ratings up to 11 kW or so because, for larger drives, the advanced features have a proportionately smaller influence on price and so can realistically be provided as standard. The advanced range, typically with products up to 250 kW, will nevertheless include small drives with power ratings that overlap with the basic range, to meet the needs of low power but complex applications.

It would be wrong to assume that the basic range is limited or inflexible though. Modern technology allow features that would have once been considered advanced, like built-in communications options, integral PI control, and high starting torque of up to 175%, to be provided in attractively-priced standard drives.

The basic VSDs can, however, be expected to offer only V/f control, which is perfectly satisfactory for most applications, whereas the advanced VSDs will offer additional options such as sensorless vector (SLV) control and closed-loop vector (CLV) control for use in demanding applications.

Another interesting and useful feature that is provided by the best of advanced drives is programmable controller (PLC) functionality. This not only boosts the flexibility of the VSD by allowing interlocks and similar customisation to be easily added, it also means that in some applications – such as machine control – all of the necessary control functions can be provided without the need to use a separate PLC, which can result in substantial cost savings.

Whether the VSD is a basic or an advanced model, specifiers are entitled to expect that it should be easy to set up and use. Easy set up is best achieved by an auto-tune facility complemented by convenient parameterisation. The number of standard parameters should be small, but not so small as to limit functionality – around 15 is usually considered to be optimum. Other things to look for are easy-to-understand function codes and the ability to transfer parameter settings between drives simply and quickly. In addition, the option to set up the VSD using its own keypad and display, as an alternative to setting it up with an external PC, is invaluable.

To ensure easy integration with modern automation and building management systems, the communications options provided by the VSD should be comprehensive. The best products come with popular options such as Modbus RTU and CANopen provided as standard, and can be readily configured with low cost options to support other popular fieldbus and communications protocols such as Profibus, Profinet, DeviceNet, EthernetIP, EtherCat, Modbus TCP and BACnet.

The latest development in VSDs is to offer support not only for these field-based communications protocols, but also for intelligent control

panel wiring systems such as Eaton’s SmartWire-DT technology. This system allows all major components within a control panel to be linked together using standardised plug-in ribbon cables, which means that conventional control wiring within the panel is no longer needed.

Immediately apparent benefits include greatly reduced wiring time, the almost complete elimination of wiring errors and much easier and faster testing. Less apparent but equally valuable benefits are space savings in the control cabinet, and the ease with which modifications can be made, as no complicated rewiring is ever needed. With the intelligent panel wiring, control commands can be sent to the VSDs and comprehensive diagnostic data can be read from them – in fact, access to the full set of drive functions is accessible, and it is even possible to parameterise the drives via the intelligent wiring.

Intelligent panel wiring is also the foundation for lean automation systems – those systems where conventional wiring is supplanted by modern networking technologies, leading to unparalleled flexibility and versatility, reduced lifetime costs and enhanced reliability complemented by fast, easy fault-finding and maintenance.

Of course, in considering the flexibility and performance of a VSD it’s important not to lose sight of basic requirements like robust electrical and mechanical construction and the ability to operate reliably under adverse conditions. Nor do the best of today’s drives disappoint in these areas.

They are built to last with long-life cooling fans, and they are often offered with a choice of IP20 protection for use within control panels or IP55 protection for use as standalone devices with no additional enclosure.

Electrically they are also well protected, and they incorporate outputs that are proof against short circuits, as might occur if a motor cable is inadvertently cut. They can also deliver their full output without derating in ambient temperatures as high as 50ºC. Finally, they provide exceptional future proofing by supporting not only standard induction motors, but also the new high-efficiency IE4 permanent magnet motors that are just coming onto the market.

As we have seen, the latest AC VSDs have much more to offer than their predecessors, yet they’re just as competitively priced. Specifiers would be well advised, therefore, to follow the guidance given in this article to ensure that they really are choosing new generation products. After all, when the best costs no more, what possible reason is there to settle for anything less?

www.eaton.eu

lean and versatile: watchwords for the best In drives


21


The Institution manned an exhibition stand at this year’s Pump Centre Conference and had a great response from delegates keen to discuss membership requirements, routes to chartership and understand how the IMechE can help mechanical engineers working in the Water Industry.

We are also holding a key event on 22nd October in London entitled ‘Water and Energy – a Marriage of Convenience’. The purpose of the day is to look at the range of Energy related challenges faced by the Water Industry and describe how the Industry and Academia are facing up to those challenges. Speakers include representatives from Cranfield University, the Environmental Agency, Water Utilities, Engineering Consultancies and Suppliers.

www.imeche.org

news from the Imeche

The Pump Centre presents its prestigious Young Engineer of the Year Award at its annual Conference, which is held at the International Centre, Telford. The award is aimed at young engineers working anywhere in the supply chain from Pump Users, Consultants, Contractors, Manufacturers and Component & Service Suppliers.

The award is open to those engineers who have made a significant contribution to their company in the area of pumps, systems and the associated equipment. Their contribution could be in any of the following disciplines:

• Design • Specification • Project management • Technical support • Maintenance • Operations

Prize

The winner of the award will receive package of prizes worth about £500:

1. A commemorative certificate / trophy.2. A £100 cash prize.3. A one day Pump Centre training course (worth up to £350).4. A copy of the Pump Centre’s Pumping Station Design Guide. 5. An invite to the Pump Centre Conference Dinner on the evening of 29th May 2014.

apply now - for your nomination form

If you are interested in applying, simply send an email to john.howarth@esr technology.com and you will be forwarded the nomination forms.

Calling all Young engineers

Bedford Pumps Ltd have secured contracts for the value of £2m to supply pumps to three of Yorkshire Water’s pivotal pumping stations situated on the picturesque coastline of Yorkshire.

Yorkshire Water is investing £110m to ensure that Yorkshire’s beaches and bathing waters are among the best in Europe. A new European Bathing Water Directive is due to come into force in 2015 and this investment should ensure an “excellent” standard for water quality with the ability to secure some coveted Blue Flags for Yorkshire’s beaches.

The bustling tourist destination of Scarborough will receive £40m of the funds to increase the storage, transfer and treatment of storm water. This will reduce the chance of untreated water entering the sea during times of heavy rainfall. Two of the three pumping stations to be upgraded by Bedford Pumps are located in the town. Scalby Mills Pumping Station will benefit from four new submersible volute pumpsets of a centrifugal mixed flow design and Toll House Pumping Station will receive three new suspended bowl pumps manufactured and installed by pump specialists Bedford Pumps.

The third pumping station will be a new construction and located on the promenade at South Beach in Bridlington. Belgrave Road Pumping Station is designed to pump excess storm water during heavy rainfall and high tides more than 1km out to sea. Four suspended bowl pumps from Bedford Pumps operating at a duty of 2,500l/s at a head of 8m will move the water through a connecting storm water transfer tunnel and a new coastal pipe to achieve this objective.

Bedford Pumps are delighted to be working once again with civils contractor Morgan Sindall Grontmij (MGJV) to revitalise the Yorkshire coastline. Yorkshire Water’s investment is part of a larger multi-agency project involving the Environment Agency and local councils to improve the quality of beaches and bathing water along Yorkshire’s coast.

www.bedfordpumps.co.uk

bedford Pumps clean up on the Yorkshire Coast

NETZSCH Pumps & Systems Ltd.

[email protected]

Progressing Cavity or Rotary Lobe?

Some might claim these pumps compete with each other but, as the only global manufacturer of both, NETZSCH knows they complement one another. Correct pump type selection, based only upon application requirements, is critical. NETZSCH can offer you genuinely impartial advice as to which pump type is best for you.

Which Pump is Better?

Ben Welton of Gilbert Gilkes and Gordon Ltd receiving the 2013 apprentice award

from Mike Rush (Mechanical & Electrical Engineering Manager, United Utilities and

Pump Centre Chairman)

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newS from the ImeChe


training & awareness day Programme 2013/14

Pump Centre members receive 30% discount off training courses and 20% discount off awareness days.

All courses unless indicated will be held at:

The Rhinewood Country House Hotel, Glazebrook Lane, Glazebrook, Nr Warrington, Cheshire WA3 5BB

Tel: 0161 775 5555

The majority of our training courses can be run “In-House” at a venue selected by the Client. In-house courses become cost effective when clients have 8 or more members of staff to be trained. Please contact the Pump Centre for a quote.

to discuss your training requirements contact:

Jim Eaves: 07968 707753 or email [email protected]

to reserve your places contact:

Karen Bridgeman: 01925 843512 or email [email protected]

Title Date Full Price

Contract Law for Engineers 18 & 19 September 2013 £550 + VAT

Pumps for Beginners & Intermediates 18 & 19 September 2013 £550 + VAT

Pumps for Beginners 18 September 2013 £350 + VAT

Pumps for Intermediates 19 September 2013 £350 + VAT

Compressors & Compression 01 & 02 October 2013 £550+ VAT

Scottish Mini-Conference - Pumps & Pumping (Glasgow) 10 October 2013 £120 + VAT

Waste Water Screening & Preliminary Treatment 30 October 2013 £350 + VAT

Pumping in the Water Industry 11 – 15 November 2013 £995 + VAT

Improving Pump Maintenance 20 November 2013 £350 + VAT

Condition Monitoring Awareness 27 November 2013 £350 + VAT

Water Industry Processes & Equipment 28 January 2014 £350 + VAT

Introduction to Motors & Drives 25 February 2014 £350 + VAT

Positive Displacement Pumps 26 February 2014 £350 + VAT

Why Mechanical Seals Fail 04 March 2014 £350 + VAT

Pumps for Beginners & Intermediates 19 & 20 March 2014 £550 + VAT

Pumps for Beginners 19 March 2014 £350 + VAT

Pumps for Intermediates 20 March 2014 £350 + VAT

Rolling Element Bearings 19 March 2014 £350 + VAT

Optimising Pump Systems 25 & 26 March 2014 £550 + VAT

(Awareness Days are highlighted in red).

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traInIng & awareneSS daY Programme 2013/14


Great news! Neveruse a diaphragmpump again

• Reduce maintenance costs - no valves to gas lock

• Slash chemical costs - accurate and linear flow even when process conditions vary

• Cut installation costs - no dampeners, strainers, de-gassing, back pressure or foot valves needed and a competitively priced pump

Fully sealed for life, one minute,tool-free maintenance

REVOLUTIONARYPERISTALTIC PUMPHEAD

qdospumps.comwmpg.com 01326 370370

50 years of innovation in pump technology

NEWFROM WATSON-MARLOW

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