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PUMPS, VALVES & ACTUATORS GUIDANCE ON OPTIMISING PUMP PERFORMANCE
BGEN offers some pump optimisation tips to help water companies reduce energy consumption and leakages
GEN, a specialist, multi-discipline engineering solutions business, has issued guidance to help water companies to optimise pump performance to reduce energy consumption and leakages. The advice comes at a time when energy prices are at a record high and UK consumers have been faced with hosepipe bans due to the challenges of another warm summer.
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“Rising energy costs and warmer summers as a result of climate change are significant challenges facing the water industry,” said Andy O’Rourke, senior engineer at BGEN. “While there is no silver bullet to addressing these issues, water companies can make energy savings and reduce leakages by following the below guidance.”
Tip #1 – It’s a marathon, not a sprint
Pumps are fundamental to the water industry. They regulate the pressure in pumping mains to ensure water reaches its final destination, while also removing and enabling treatment of wastewater. The key to optimising pumps is to implement consistent flow rates to meet
demand and avoid excessive peaks and troughs which often results in more energy being consumed.
Tip #2 – Don’t follow the status quo
While providing a supply of clean water is the number one priority of a water company, in today’s day and age the focus needs to be on working smarter. Implementing a dynamic control solution to meet customer demand with minimal excessive pressure is one example. Needlessly pumping water or generating excessive pressure equals more energy and could be hiding a leak.
Tip #3 – Make informed decisions based on real-time data
Embracing a real-time operating philosophy to include pressure / flow / tariff profiles is key to optimising performance. This will determine the most cost-effective way to produce water on a minute-by-minute basis.
NON-METALLIC AODD PUMP ADDED TO RANGE
The range of Finish Thompson FTI Air-Operated Double Diaphragm pumps (AODD) has recently been expanded with the addition of a new ¼” non-metallic model, available in polypropylene, PVDF and also conductive polypropylene for use in ATEX areas.
Available in the UK from MICHAEL SMITH ENGINEERS, the FT025 model delivers a maximum flow rate of 22l/min (5.8 gpm) at a maximum air supply pressure of 120 psi (8.3 bar). The FT025 extends the minimum flow capabilities of these rugged and reliable pumps and brings the important benefits of using AODD pumps to a wider range of pumping applications. For example, as with all FTI AODD pumps, they are simple to install, easy to operate, require less maintenance resulting in lower running costs and are self-priming so can be dry-run. Furthermore, they are suited to handling abrasive, viscous and shear-sensitive liquids and even ‘dirty’ liquids with particles up to 1.8 mm (0.06”) for the FT025 model. Typical applications will include handling acids, bases, plating solutions, wastewater, paints, inks, solvents, ceramic slip and glaze, lubricants and oils. This would include industries such as mining, painting, finishing, ceramics, electroplating and anodising, pulp and paper, wastewater and marine, chemical manufacturing and distribution.
In common with the other FTI Air models, the FT025 includes a lube-free air valve design which represents simple, rugged and reliable design. This means fewer components compared to other air valves, resulting in reduced servicing time and the associated maintenance costs and downtime. The air valve components include a low friction slide valve on a ceramic plate to allow for long- life and superior sealing, and a moulded Buna gasket which ensures total sealing and eliminates flat gasket tearing. FTI Air’s modular construction results in simplified maintenance with individually replaceable, lower cost wearing parts which do not require special tools for fitting.
www.michael-smith-engineers.co.uk
Tip #4 –Consider a digital twin
A digital twin is a real-time virtual simulation of a physical process or system. Using a digital twin when assessing operational changes to improve performance, enables operators to see the impact of any updates in ‘real terms’ before they go live. This methodology also enhances the design and commissioning phase and minimises disruption.
Tip #5– Automate
Like other industries, automation can play a significant role in helping water companies to optimise operations through efficiency and cost improvements. In addition, it can free up precious resources to be diverted to proactive work to strengthen resilience.
Tip #6 – Monitor and optimise
Technology is now available to truly support water companies in enhancing their operations. In addition to traditional process alarms, effective monitoring will use real- time data to flag efficiency and cost concerns.
“The above guidance provides a steer on how water companies can look to optimise their pump operations,” concluded Andy O’Rourke. “For companies with more complex needs we have a team of specialists on hand to provide bespoke support.”
BGEN
b-gen.co.uk
OCTOBER 2022 | PROCESS & CONTROL 19
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