Regulations for hydrostatic pressure testing have taken a significant step forward with the release of Water UK’s Water Industry Standard for hydrostatic pressure testing of PE pipes, a move that will ensure the safety and reliability of the process, says Tony Kitchen of AHS Pipeline Innovation.

Water companies and contractors are adjusting to the requirements of the new Water Industry Standard 4-01-03, released in March 2024, which outlines the required standards for the hydrostatic pressure testing of polyethylene (PE) and polyethylene barrier pipes. The standard replaces previous guidelines from Information Guidance Notice 4-01-03.

The transition from an Industry Guidance Notice (IGN) to a Water Industry Standard (WIS) marks a shift towards more stringent and enforceable standards that aim to improve the safety and effectiveness of the pressure testing process.

WIS 4-01-03 specifies detailed procedures for pressure testing below-ground water supply pipelines and sewer rising mains comprised of PE and PE barrier pipes. It includes guidelines for testing entire systems as well as replacement sections and service connections.

The specifications emphasise the importance of considering the viscoelastic properties of PE, which exhibits what is known as creep behaviour – deformation that occurs when subjected to pressure over time.

Understanding the difference
It is important to understand the distinctions between WIS and IGN:

● An Information Guidance Notice serves as a set of recommendations or guidelines that offer advice on best practice but does not mandate specific actions or procedures.
● A Water Industry Standard is a more formal document that sets out mandatory requirements for products, materials or operational procedures. WIS documents are intended to ensure uniformity and compliance across the water industry, leading to more standardised and reliable outcomes.

Improving safety
The new WIS is designed to improve both the accuracy and safety of pressure testing which means there is now a zero-tolerance policy on pre-pressurisation. Key points are:

● The pipe must be at ambient pressure prior to testing
● If a test has failed, the operator must leave the pipe for four times the length of the ramp-up time before reattempting the test
● The operators must wait for two to three hours between filling and pressurising the pipeline. This takes into consideration the effects of thermal conditioning and allows the temperature of the pipe to stabilise once it has been filled.
● The allowable air content has now been reduced from 8 to 4 per cent
● The air content must also be accurately calculated during the ‘ramp-up’ stage as the pipeline is brought to system test pressure (STP). This means that the test can be immediately abandoned if it is over the acceptable limit.

What WIS means for contractors
There is no question that the new standard represents a significant step towards leak-free networks, but the new requirements potentially impose a greater burden on contractors. The stringent rules around correct preparation prior to testing, including pre-pressurisation, thermal conditioning, and calculating air content prior to starting the test, making it crucial to get the test right first time, to prevent wasting time and resources in retesting.

A reduction in the allowable air content means less margin for error, which highlights, from a compliance and cost perspective, the importance of contractors carefully managing their own and subcontracted pipeline pressure testing.

Due to the increasing complexity of hydrostatic pressure testing and varying levels of expertise among technicians and operators, some pressure testing providers may not meet the standards outlined in the WIS and could lack the knowledge or skills to correctly prepare the pipe for testing.

Contractors must ensure that all pressure testing activity is fully compliant with the new WIS specifications. Substandard testing potentially creates dangerous situations, with risk to life and limb, if air is not properly removed from the pipeline.

It is crucial for contractors to select subcontractors with proven compliance to ensure the safety and reliability of their projects if they are to maintain both contractual obligations and a good reputation in the industry.

Proven expertise
AHS Pipeline Innovation is recognised as an industry leader in hydrostatic pressure testing with over 20 years of experience and almost 50,000 tests completed. The proven expertise of AHS allowed the company to play a key role in the development of the new WIS as part of a multidisciplinary panel which included pipe manufacturers, water company representatives and trade organisations.

Careful consideration was given to onsite implementation of the new requirements, and how contractors can be supported in meeting the standard.

Pressure testing services at AHS are already fully compliant with WIS 4-01-03 and incorporate the latest technology and real-time assistance from the company’s in-house analyst teams to give contractors unrivalled support throughout the testing process, ensuring that testing is right first-time.

AHS is equipped to guide and support teams in adopting these new standards so that their pipeline operations meet the necessary requirements. Should water companies and contractors be unsure about how WIS 4-01-03 affects their operations, or require support to ensure compliance, AHS is available to provide the knowledge and tools necessary to navigate this transition smoothly and effectively.

WIS 4-01-03 not only mandates stricter controls over variables like air content, ambient pressure and temperature, it also effectively identifies and removes any activities undertaken onsite that can affect test performance. Importantly, it reintroduces rules that had been relaxed in previous guidance, restoring rigorous standards that are essential for maintaining the integrity of water systems and creating more defined regulatory expectations.

In addition, pressure tests carried out in accordance with the WIS are measured using sophisticated algorithms that deliver definitive test outcomes, ensuring clarity and reliability.

At a time when the water sector is experiencing reputational challenges, WIS 4-01-03 represents an opportunity for water companies and contractors to get it right from the start. By carefully navigating these changes, and ensuring that every test not only meets but exceeds the latest standards for safety and efficiency, they can mitigate risk to the public and their own teams altogether.

The water sector needs to build infrastructure at scale over the coming decades. Ahead of her keynote address to the Water Industry Forum on 25 September, Sharon Darcy, chair of the Linear Infrastructure Planning Panel, says competing demands with other sectors over allocation of resources means a collaborative approach is vital.

The water industry faces a monumental challenge: delivering the vast infrastructure needed to meet future demands, while navigating a complex landscape of competing projects in energy, transport and communications.

Projects with robust early stakeholder engagement are more likely to result in success, which is why the Linear Infrastructure Planning Panel (LIPP) works across utility sectors, with representatives from community groups, non-governmental organisations and other external stakeholders, to develop a common language and leading practice on infrastructure planning.

At the Water Industry Forum’s annual dinner in Leeds on 25 September, cross-sector research and insights from LIPP will be shared, which show how planning consent for infrastructure projects can be achieved, and how critical initiatives can be developed and delivered in a cost-effective way that builds community support.

Balancing needs
Balancing national and local needs in infrastructure planning decisions is notoriously difficult, but it is a challenge that needs to be faced if the water sector is going to deliver on net zero carbon, resilience and other national goals. Founded in 2023, LIPP aims to listen and incorporate the perspectives of key public interest stakeholders, including social and environmental groups, in the development of good practice and ethical approaches to the implementation of new techniques, including algorithms and advanced software tools, in linear infrastructure planning.

LIPP published a white paper in March 2024, ‘Delivering net zero, resilience and nature recovery: How new tools and approaches can transform infrastructure planning’, which has already fed into UK Parliament’s Environmental Audit Committee reporting on sustainable electrification. The report draws on intensive engagement with key stakeholders and looks at the social, environmental and economic metrics used in the spatial planning of infrastructure such as electricity transmission lines and major water pipelines.

It highlights new technologies and the changes needed to procurement processes to ensure successful delivery of infrastructure that is essential in meeting net zero targets and resilience to climate impacts. The paper also explores ways of managing uncertainty when developing metrics in these areas, including the need for robust data and ways of ranking and weighing-up different metrics.

Informed decision-making
England faces a critical land shortage. A growing population needs to be housed, while producing enough food, protecting nature and tackling climate change. Despite the intense competition for land, there is no system in place to manage it effectively.

Attendees at the WIF annual dinner will hear a swathe of insights from other industries, such as energy, which can be drawn on to help the water sector navigate current and future challenges. The energy sector is grappling with challenges in grid development, with public opposition to the expansion of power lines needed to transport renewable energy to population centres.

The water sector can learn from these experiences by integrating technical and spatial planning much earlier in the decision-making process. The recent King’s Speech outlining the new Planning & Infrastructure Bill acknowledges the need for advanced spatial planning that considers multiple infrastructure sectors.

By joining up technical planning with spatial planning, learning from other sectors, and through early strategic stakeholder engagement, I believe the water sector will be well-placed to streamline the infrastructure planning process and delivery into the next asset management plan (AMP) period – 2025-30, and beyond.

Sharon Darcy will address the Water Industry Forum Annual Dinner in Leeds on 25 September 2024. To register, visit https://www.britishwater.co.uk/events/EventDetails.aspx?id=1841149&group=

Chemicals play a big part in wastewater treatment. Adeel Hassan, product manager at Watson-Marlow Fluid Technology Solutions looks at how different process challenges can be overcome, and the contribution of pumping technology.

Around 359 billion cubic meters of wastewater is produced globally each year, including municipal wastewater, and the many industrial processes that produce wastewater, which includes chemical manufacturing, food processing and power generation.

For effluent water to be discharged back into the environment, it must be treated to comply with regulatory requirements and prevent damage to ecosystems and human health. Alternatively, many industrial firms want to reuse their wastewater to minimise their environmental impact, reduce costs and overcome water shortages. Iit must be treated to suit it to the new purpose, such as providing industrial cooling water.

Difficulties with disinfection
Chemical disinfection involves the use of oxidising chemicals, such as sodium hypochlorite. However, oxidising chemicals off-gas, causing gas to be present in the fluid. This gas can block a diaphragm pump by preventing correct operation of the ball valves. Wastewater treatment providers can overcome this by selecting peristaltic pumps, which push any gas present in the fluid through the pump without causing any maintenance issues.

Sustainability is driving the use of higher concentration chemicals to minimise transport costs and emissions, as well as reduce the size of dosing systems. However, high concentration chemicals, such as sulfuric acid used in neutralisation, can be hazardous if not contained after a pump failure. Therefore, it is important that plant managers select a pump that is compatible with high concentration chemicals and prevents chemical exposure to the operator.

High concentration chemicals require a very accurate and repeatable pump to maintain process capability. Peristaltic pumps with low pulsation and no ball valves result in parts per million (ppm) concentrations with very low standard deviations, minimising chemical usage and maximising process quality.

Problems caused by coagulants and flocculants
Regulations around preventing eutrophication are driving the removal of phosphates from wastewater. Ferric chloride, commonly used in this process, reacts aggressively with metal pumps. By selecting a pump with a plastic case, wastewater treatment providers can ensure their equipment is compatible with ferric chloride systems.

Furthermore, in diaphragm pumps, ferric chloride can pose a threat of solid content becoming stuck under the ball valves that are keeping the pump open. If both valves become stuck, then the pump can start to siphon, and the fluid will travel in the opposite direction as it can flow out of the pump. This creates inaccuracy as the fluid is leaking out. By selecting a peristaltic pump that does not require any valves, these challenges can be avoided completely.

Polymers are commonly used for dewatering of sludge and solids removal from water. Solids removal helps to clean the water for reuse, while dewatering sludge minimises bulk, which can reduce costs associated with storage and disposal by up to 75 per cent. Efficient polymer activation is essential in increasing the efficacy of the polymer and minimising usage. The creation and integrity of polymer chains requires a constant stream of polymer into the dissolution stage, which can be achieved by using a low pulsation pump.

If condensation gets into the source tank, then polymers can agglomerate together and block the valves of some pumps, such as diaphragm pumps. This plugs the discharge of the pump and can cause it to breakdown. This can be avoided completely with peristaltic pumps, which require no valves to operate.

As well as the variety of different chemicals in wastewater treatment providing dosing challenges, the wastewater industry must contend with external factors. Urbanisation means more people are living closer together in towns and cities, increasing the amount of municipal wastewater in one area. The resultant wastewater means bigger wastewater treatment works with larger processing systems are needed.

Therefore, wastewater treatment providers require more powerful pumps with high flow rates and low pulsation to increase efficiency and meet demand. While diaphragm pumps meet the capacity requirements, they can only offer low pulsation when operated at low flow rates. Instead, plant managers should opt for a peristaltic pump that offers low pulsation even at high flow rates.

Rising to the challenge
The design of the Qdos H-FLO attempts to answer calls from plant managers for more powerful and adaptable pumping equipment that enables accurate, flexible and high capacity dosing . The pump is capable of flow rates up to 600 litres per hour and can handle pressures up to 7 bar via a range of interchangeable pump heads. The different pumpheads enable the pump to be used in a wide range of wastewater applications and allow plant managers to respond quickly as treatment processing requirements change.

The Qdos H-FLO has a pressure sensor that detects leaks and blockages. The pump stops before the system becomes damaged and alerts the operator with diagnostic feedback. In addition, all of the chemicals are safety contained within the pumphead, preventing operator exposure. If there is a problem, the pumphead can just be changed.

The twin-tube technology provides extremely low pulsation, with an offset rotor design protecting pipework integrity and providing consistent chemical supply compared with diaphragm pumps delivering similar flow rates. Unlike diaphragm pumps, the Qdos H-FLO has no valves, eliminating the issue of valves becoming stuck or blocked. In addition, the pump has a high accuracy of ±1%, which prevents chemical waste and saves costs.

Wastewater treatment providers face a variety of operating challenges, including handling a wide range of chemicals, meeting high demand, and becoming more sustainable. However, with the correct pumping technology, wastewater plant managers can ensure their operations run efficiently, accurately and safely.

Notes
[1] https://essd.copernicus.org/articles/13/237/2021/
[2] https://www.wwdmag.com/sludge-and-biosolids/article/10933951/sludge-energy-from-sludge

This article contains paid for content produced in collaboration with T-T Flow.

Government-backed funding saw a Stockport site become the first in the UK to be retrofitted with an innovative new technology that boosts biogas production by up to 20%. Valves play a critical role in its deployment.

The Stockport Sludge Treatment Centre in Greater Manchester processes over 600 m3 of sludge from local wastewater treatment facilities every day. Anaerobic digestion (AD) transforms the sludge into biogas that is used to produce electricity to power more than 1200 homes p.a.

As part of the retrofit, T-T Flow were asked to provide a complete valve package, including knife-gate valves, swing-check valves and fast-acting relief valves.

The supplied relief valves are set to play a crucial role in on-site safety. Given the pressure produced by the system’s AD processes, the need is all the greater to lessen the likelihood of surge events like water hammer occurring. Flow inefficiencies, damage to infrastructure and explosions are all potential consequences of not effectively managing system pressure. The self-acting relief valves mitigate the risk. Calibrated to maintain the desired pressure, they operate by opening when this pressure is exceeded and discharge excess fluid to avoid an over-pressure event.

T-T Flow have specified relief valves that respond quickly and reliably to pressure fluctuations, featuring fast-acting annealed springs and a smooth, lightweight internal profile that minimises operational resistance. To guarantee long-term operational reliability within the corrosive environment of the sludge treatment facility, the chosen valves are comprised of a high-strength/low-weight ductile iron body, a precision machined stainless steel seat, and A2-70 stainless steel fasteners.

ttpumps.com/products/valves

WWTW pumps: Design is fundamental to controlling costs
Table 1 is a summary of the wide variety of potential wastewater treatment plant pump applications.
Picking the right design for the specific application is critical for ensuring the pump (and the overall system) is going to operate properly. This will in turn be the major influence on the overall cost of ownership (COO).

Much of the cost is determined by the initial system design and pump technology selected. A common rule of thumb suggests that about 80 percent of overall equipment life costs (maintenance, operation, and energy consumption) has to do with the initial design of the overall plant and process equipment, and the pumps used. In other words, whatever is designed comes with a set amount of fixed costs. So, selecting the right equipment (in terms of size, technology and features) will have a major effect on costs; selecting the wrong equipment will result in higher costs and more downtime. Another 10 percent goes to environmental costs (disposal), installation, and downtime. This leaves approximately 10% for the initial purchase of the pump.

There are several progressing cavity (PC) pump configurations that can be used for these applications. Each has advantages and disadvantages, and some are more appropriate than others for a particular application. PC pumps can run a long time without service, but when needed, the service required can depend on the design and options selected for the pump. Joints, access windows, type of seal, stator design, rotor materials and coatings, bearings, and ancillary equipment around the pump impact service. Ultimately the pump needs to be designed for minimal and easy servicing.

When one examines the total cost of ownership, including the initial cost of purchase, the electricity used, parts, and maintenance, what looks like a lower cost option may actually end up being the higher cost option. Reduction of service frequency, reduction of required pump parts, and easier, faster serviceability are critical attributes for pump selection. Focusing on these particular areas and spending a little bit more money upfront, will pay dividends.

Pump design considerations
Most operators will work in collaboration with an engineering firm to select and size the right equipment. Keeping in mind that the correct design is important for reducing costs, operators should consider the following factors when selecting a PC pump. Each one has its own positive and negative impact.

• Speed: The faster you run the pump, the faster it will wear and the more frequently service will be needed. In other words, greater speed = exponential wear. However, a fast pump usually means a smaller footprint and lower upfront cost (but you pay on the back end with more repairs). Slower is usually better for most applications.

• Drive configuration (with bearing frame or direct drive): The key issue is how much space is available for the pump. PC pumps are long in nature. Adding a bearing frame adds more length, but provides a robust drive shaft supported by independent bearings to handle the thrust load of the pump. This is the force (axial load) pushing the opposite direction from flow across the centerline of the pump. This is essentially what the pump undergoes as it pumps against the system backpressure. Whereas the direct drive is shorter and is sufficient for many applications.
Typically bearing frames are used when the need for high pressures exceeds direct drive capabilities, when the desire for easier servicing is required, or when a belt configuration for space restraints is preferred. Piggyback/overhead or L-shaped bases can shorten the installation footprint. Vertical mounting of the pump can also accommodate limited space.

• Viscosity: The thickness of fluid limits the pump speed, suction, discharge piping ID, and pipe length from the pump by significantly influencing the design and the pressure losses of the system. This affects the suction side or the NPSHa (Net Positive Suction Head available) for the pump. Pumps have a specific amount of head pressure required to operate correctly. Otherwise, the result is cavitation and potential failures.

• Pump rotor and stator geometry: For the most part, two geometries dominate the various applications. For simplicity’s sake, we will call them low flow/high pressure and low pressure/high flow. Both have their own inherent ratings for NPSHr (Net Positive Suction Head required) based on the pump’s internal design. There are other geometries that can provide higher flow at higher pressures and another for higher flow at lower pressures. Typically, you trade off flow for pressure and vice versa.

• Number of stages: The maximum discharge pressure and ultimately the pump rating per stage is determined by the number of stages. Typically, each stage is rated for 90 psi (6 bar). Therefore, 2 stages would be rated for 180 psi (12 bar) and so on. Adding more stages for a given rated pressure divides the pressure affecting each stage. More stages equals lower pressure per stage and allows for longer life. With most applications in WWTPs, there is abrasion. Abrasion comes from grit and other inorganics (as well as some organics), that cause wear over time on the pumping elements. This wear is to be expected; it is normal to de-rate the pressure per stage due to the amount of anticipated wear. For example, pumping polymer is very lubricating, has no abrasion factor, and can be rated for the maximum capability of the pump. As another example, 1-2% sludge may only be derated by 20% per stage (90 psi x 80% = ~70 psi) making the rated discharge pressure 70 psi or less. Finally, if you were to pump cake (20% or higher), each stage would need to be derated to 50% or more.

• Stator design: The design of the stator can help facilitate faster and easier replacement. Each stator inherently uses compressive forces in the design that compresses around the outside of the rotor; which in turn creates the sealing line of the pumping elements. These compressive forces are what make the pump work. However, they also make it harder and more time consuming to replace the stator with a new one. A new stator requires a great amount of force to install. NETZSCH offers a time-saving stator replacement option. The iFD-Stator® design allows for the compressive forces to be released/removed during installation (and removal). Unbolting the compressive shell releases the axial and radial compression of the stator on the rotor. This allows for the new stator tube to slide on with relative ease and then be clamped down without the need for extra turning forces. See Figure 2.

Money-saving stator adjustments can also compensate for wear, using compression to re-establish the stator sealing line, increasing operational life and bringing the stator back to factory performance. The process can extend stator life by up to six times. This is a boon to operators, who would otherwise have to take the pump out of service, shut down the entire process, and lose all the revenue from that train. While standard stator replacement may take as much as 6 hours, with the NETZSCH xLC® (stator adjustment device) attached to a pump, it takes less than 2 minutes (while pumping or not) for the stator to be easily adjusted or tightened to renew the performance back to factory standards. See Figures 3 and 4.

• Materials of construction compatibility: Are important to ensure long life, abrasion resistance, temperature, and resistance to upset conditions. For example……

• Polymers, neat vs blended: Neat polymer requires a specific construction to ensure the rubber does not swell (swelling causes excessive compression and premature failure). This typically requires FKM/FPM elastomers with 316SS construction. Whereas made-down polymer can use Buna and carbon steel.

• Ethylene propylene diene terpolymer (EPDM) avoidance: EPDM is not compatible with oils. This should not be used for typical municipal sludge.

• Corrosion: This is normally seen as a chemical attack. It can be an acidic or a base. It eats away at the material or can cause swelling or detrition of the materials, resulting in premature failure.

• Hardness: This attribute helps to promote long life. Typically the harder the materials for rotors, the longer they will last. However the same cannot be said for stators. Sometimes having a softer stator (<60 Shore A durometer), can extend life when pumping very abrasive particles.

• Temperature: It can cause the elastomers to expand resulting in excessive compression or, on the opposite side, shrinkage due to the cold. This will reduce compression of the stator on the rotor resulting in more slip, lower flow or inability to pump against the back pressure of the system. With freezing temperatures, if the fluid is frozen, cast iron castings could crack.

• Adding rotor coatings for increased hardness: Tungsten carbide coatings will make the rotor last 3 to 4 times longer. Re-chroming to add a new layer to the worn rotor is another option and while it is significantly less costly than the rotor coating, it is not recommended. Re-chroming may add a new layer, but the plating is not equally deposited and does not renew to factory tolerances. It also creates high points or low points to the rotor diameter; it does not restore the original diameter. This reduces stator life and may affect pump performance.

• Percent solids: This determines how fast the pump can run and impacts pump configuration. It ultimately dictates the viscosity of the fluid being pumped. Water-like sludges (2% or less), present few limitations on a pump design. However, as the percentage increases, so do the design constraints, such as: mechanical seal, max rpm, motor size, wear resistance, geometry configuration, suction pressure, piping layout, and ancillary equipment.

• Fluid media size (particle and ball sizes): Every pump has a maximum particle size it can handle. When it comes to PC pumps, there are two considerations: particle size and max “ball size”. The particle size relates to the amount of particles and average size of particles in the fluid. The max ball size is the largest soft size particle the pump can handle which is typically 80% of the rotor diameter.

• Type of shaft seal and seal water/flushing options: This is always a highly debated topic. With many options, multiple seal manufacturers, and a wide range of applications, each fluid being pumped has certain requirements, each with pros and cons. Depending on the application the design may require packing, single component seal, cartridge seal, double seal, or some new style of seal. It is best to consult with seal and pump manufacturers for the best solution for your process.

There are a variety of shaft seals for different applications and care must be taken to get the right one for the application. Depending on the seal there may be a complex seal plan that must deliver water or fluid to the seal to ensure it operates properly. Otherwise, operators run the risk of the added expense associated with maintenance to pull the pump apart to get access to the seal – the last piece in the pump. Here are some examples that may not fit every application: wastewater to thin sludges (<6 percent) with or without quench or flush could use single slurry seals with a knife edge, encapsulated component, or a standard single mechanical seal, either a cartridge or component. Thick sludges (6 to 10 percent) with quench and/or flush can use single slurry seals, single inverted slurry seal, double mechanical seals, or packing. Cake calls for packing, double seals (>10 percent) with quench and/or flush, double mechanical, or packing. Neat polymer or made-down/mixed emulsion polymer should use single slurry seals, standard single mechanical seals, or packing, while made-down/mixed/emulsion polymer should opt for single slurry seals or standard single mechanical seals.

• Correct joint type for application along with the right joint options: The joint to be used depends on the pump size, loading, and operation. For smaller pumps, pin joints are adequate. Pin joint longevity can be increased, however, with a double-sealed joint option or the covered-seal joint option which protects against abrasion and sharp objects but, for larger pumps, additional joint options are available.

Pumps that will operate with many stops and starts may function more effectively with a gear joint. Double sealed, oil filled gear joints are preferable to those using grease; oil refills and replenishes itself, whereas grease, once pushed out, does not replenish. This makes for a more robust, long life joint, that will tolerate frequent stops and starts (>3-4 starts/hour).

• Joint angularity: This is the distance between the joints. Increased joint distance provides a longer joint life. Three forces impact joints: axial (X), shear/bending (Y), and rotational (torque). Higher angularity (Y-axis forces) means less joint life. While you do not want too long a pump, one with a longer joint distance will last longer.

• Suction lift requirements, up to 30 feet (ftwc – feet water column): It is common to have suction life requirements for WWTP applications. PC pumps work great for suction lift. However, there are some tricks for ensuring the pump is set up correctly to perform as intended. Having the wrong setup can cause the pump to not work properly or to fail. Consult with your pump manufacturer on their recommendations for suction lift.

• Pump orientation (horizontal, vertical, wall mount, upside down, etc.): The pump orientation can make all the difference for operational longevity, space saving or for simplifying the piping layout. PC pumps can be positioned in many ways. With PC pumps being inherently long due to the design, it is possible and becoming more prevalent to install them vertically as older plants make upgrades with limited room in the existing buildings. This saves space and preserves the benefits and capability of using a PC pump.

Pump serviceability
Pump servicing in place: Most pump manufacturers offer a full service-in-place (FSIP®) option without needing any additional footprint in the often space-constrained process line. In this case the rotor, stator, and mechanical seal can be removed without the need to remove suction or discharge piping, drive, or electrical components. Some can even upgrade existing installed pumps; however, flow and pressure reductions may apply. This can be a time-saving alternative to standard servicing, which may require removing piping to get the space needed to service the pumps, as well as unbolting numerous components to take the stator off, and even calling in an electrician to remove electrical components to access the pump for servicing. See Figure 6.

Piping systems and accessories
The system design should consider these piping system factors:
• Suction side liquid trap for priming
• Large pipe inner dimensions (IDs) to reduce friction losses
• Long Radius Elbows
• Reduce suction and discharge pipe lengths as much as possible
• A discharge check valve
• Expansion joints
• Avoid pipe stress on pump
• Some form of pressure relief, for example a pressure relief valve (PRV), pressure switch, or burst disc

Pump protection
Pump design should include consideration of stator dry run protection, choice of motor thermostats, flowmeter, variable frequency drive (VFD) or over-current. The pump should be designed to avoid cavitation and should include pressure gauges for suction and discharge and isolation from process fluid.

Optimizing pump design for cost-efficiency and longevity
The design of progressing cavity pumps plays a crucial role in controlling maintenance costs and extending product life in wastewater treatment plant applications. By carefully considering key design elements such as speed, drive configuration, sealing options, joint types, and piping systems, operators can make informed decisions that contribute to cost reductions and minimize downtime. Also, selecting the right equipment and implementing money-saving strategies post-installation can further enhance the efficiency and longevity of pump systems. Ultimately, a well-thought-out design benefits the immediate operation and ensures long-term cost-effectiveness and reliability.

By Al Gunnarson, VP of Sales and Marketing, Warren Controls.

The advent of online sizing and selection tools has transformed the process of selecting valves, providing a more efficient and accurate way to determine the best valve for each application. These tools consider varying flow requirements, pressure differentials, and fluid compatibility across different applications within a facility.

Choosing an unsuitable process control valve can result in serious control issues, and lead to premature failure and costly downtime. The consequences include not only increased maintenance costs but also the potential for safety hazards and reduced system reliability.

An unsuitable valve can fail to regulate flow properly, causing pressure surges or water hammer effects that can damage the piping system, leading to further leaks or catastrophic failures. These events not only increase the risk to personnel safety but also amplify the financial burden on the organization due to emergency shutdowns, increased maintenance requirements, and the need for replacement parts.

Choosing valves without using online tools
Before the advent of these online tools, choosing the right valve for a specific application relied heavily on complex differential equations and extensive engineering know-how based on the ISA (International Society of Automation) standards. This method, while precise, was incredibly arduous and error-prone, typically requiring upwards of 45 minutes for each process control valve to determine the correct specifications. Few were skilled or patient enough in the required math to achieve the necessary accurate results. Even when this is accomplished, selecting the correct complete P/N from a manufacturer, and gathering all this into a comprehensive report to present to a customer is another huge drain on time.

Given the complexity and time constraints faced by engineers and specifiers who don’t use online tools, there is too often a tendency to bypass these detailed calculations in favor of educated guesses or approximations.

In a typical scenario where a facility requires 30 process valves, all ostensibly needing to be 4 inches, a specifier might opt to select 30 of the same 4-inch valves rather than doing the arduous calculations to select different valves optimized for each particular application.

This one-size-fits-all approach often results in some valves being oversized or undersized for their specific tasks, resulting in higher initial costs for unnecessary capabilities or future costs due to premature wear, maintenance issues, and even system failures and safety and environmental hazards.

Importance of proper valve selection
Preventing cavitation damage is crucial. Certain valve types are prone to cavitation when exposed to higher flowing differential pressures, while others are not. Cavitation involves the formation and subsequent collapse of vapor bubbles within a liquid, inflicting severe damage to the valve. Such conditions can lead to valve failure in just a few weeks.

The consequences of cavitation go beyond damage to the valve itself; it can also cause leaks that pose safety and environmental hazards, alongside the direct and indirect costs associated with valve failure and replacement.

Vibration is a critical factor to consider, as aerodynamic noise can reach up to 120 decibels. High aerodynamic noise levels tend to occur in conjunction with higher flow rates and higher flowing differential pressures which often necessitate the use of sound insulation blankets or other sound-deadening techniques like silencers. Moreover, excessive vibration can damage the valve, leading to premature wear and failure. In some cases, one or more valves in series, sharing the pressure drops can be more cost-effective than a single valve with expensive, aerodynamic noise tuning trim.
Selecting the appropriate trim material for valves is crucial, especially in applications involving higher flowing differential pressures. Often, there is a lack of awareness regarding the impact of differential pressure on trim material selection. The reality is that the higher the flowing differential pressure, the more durable the trim material needs to be. This ensures that the valve trim can withstand the conditions and remain functional over an extended period.

Temperature is also crucial in valve selection, especially for processes above 450°F (about 232ºC). Materials like engineered plastics or elastomers, which don’t withstand these temperatures, limit choices. Selecting valves that can handle high temperatures without degrading is essential for maintaining process integrity and safety.

The actuator is as important as the valve
Choosing the correct actuator to pair with a valve is just as critical as selecting the valve itself. An actuator, responsible for the mechanical operation of opening and closing the valve, must be robust enough to operate reliably under the specific conditions of its environment.
If an actuator fails to actuate the valve when required, serious consequences can follow. This may lead to situations where critical flows are not properly regulated or the valve does not shut off properly to the advertised leakage rating of the valve, resulting in overpressure or overtemperature incidents, uncontrolled chemical reactions, or significant leaks.

Leveraging online tools
Online tools like ValveWorks® mitigate these risks by offering a precise, scientifically-based process that considers all relevant factors of the valve’s intended use. By inputting specific process conditions — such as fluid type, temperature, pressure, and flow requirements — users can leverage advanced algorithms to identify a range of suitable options.

This not only saves time and reduces efforts in the specification process but also enhances safety and reliability by ensuring compatibility with the application’s demands. Furthermore, these tools provide in-depth analysis of the trade-offs between different options, equipping users with comprehensive documentation. This documentation facilitates clearer communication and efficient record-keeping and streamlines the procurement process, making it easier to make informed decisions.
Online tools for selecting process control valves are a critical advance. professionals can avoid the twin pitfalls of over-engineering and under-specification, ensuring that their facilities operate smoothly, efficiently, and cost-effectively.

An applied research project in Scotland involving the use of Earth observation science (EOS) in multiple water applications was just one of the many highlights of BlueTech Forum 2024.

The roundtable delivered by Professor Andrew Tyler, Scotland Hydro Nation Chair at the University of Stirling, was one of 16 where delegates could tackle real-world challenges in creative ways. It was part of a rich two-day programme identifying ways water innovation is being put into action globally. 

“With the EOS project, there’s potential for making much smarter decisions around what we do to invest in a great range of water solutions at catchment scale,” said O’Callaghan. “It will make a much stronger economic case if it can be demonstrated with evidence and data how deploying a solution for nutrient removal and reduced eutrophication will work, for example. 

“This can now be monitored from satellites, based on parameters like the temperature or colour of surface waters. It will be possible to be predictive, because if we know what happens in certain circumstances, we can have advanced warning and alert utilities to issues they may have at the water or wastewater treatment plant or CSO [combined sewer overflow].” 

BlueTech Research provides water technology market intelligence to investors, water utilities and municipalities, industrial end-users and technology companies, to accelerate technology commercialisation. This community of innovators is brought together annually at BlueTech Forum, which took place in Edinburgh from 2-4 June 2024.

Eight areas for opportunity in water, identified by BlueTech, and explored by speakers and delegates, included unlocking SDG 6 – the UN sustainable development goal for water and sanitation. According to O’Callaghan, creating new business models that bridge unmet need for water in low-income countries represents a UN$114 billion opportunity, according to the World Bank. 

The theme was picked up in a keynote address from Gary White, chief executive of non-profit Water.org, which he founded with the actor Matt Damon. Through its WaterEquity initiative, the organisation is building connections into the capital markets for micro-financing initiatives addressing the unmet needs of the world’s poorest people. Nearly US$500 million has been raised at a modest return of 1%, through global corporations like Microsoft, Starbucks, Ecolab and Xylem. 

Other areas of opportunity include solutions for emerging contaminants, non-revenue water, water reuse, sludge & biosolids, and flood management. On the latter, O’Callaghan said “managing too much water” was the biggest issue facing UK utilities, where the public is becoming increasingly impatient, and the regulator is putting on pressure. It is also a case where the coping costs are high, he said.  

“You may not see the market, but you see the coping costs. It’s been estimated that the cost of flooding in the United States is US$400 billion. 

“There’s clearly an issue of abundance and scarcity. In terms of water, there’s an abundance of it, there’s no limit to the value we can create.” 

Sponge planet 
A keynote from the pioneer of China’s sponge city movement, landscape architect Professor Kongjian Yu of the University of Peking, revealed how urban landscapes can be transformed to retain water and create stunning urban landscapes at scale. 

“The key to holistic solutions is … green and blue together as a kind of sponge,” he said. “Not just as a city, but as a planet – a sponge planet – solving all kinds of problems – carbon … biodiversity, meanwhile cooling off the planet, and recharging the aquifer, and creating beautiful habitats, even for people.” 

On a smaller scale, delegates experienced new approaches to water management first-hand during tours of Edinburgh’s stunning Royal Botanic Garden led by Scottish Water’s team. The public utility is partnering the Garden in exploring different approaches to managing urban stormwater.  
Rain gardens and specially designed pools, planters and beds are already changing the landscape of this formally designed green space, creating new habitats for wildlife, and keeping water away from walkways during storms. 

Winning innovations 
Wastewater treatment was a key area of focus for most of the companies represented in the innovation showcase, which included technologies for deployment in complex industrial processes like refineries and textiles.   

Winner of the award for Best Go-To-Market Strategy was UK start-up WASE, whose innovative approach to treating organics in wastewater from the food and beverage industry won over the delegates. The company’s electro-methanogenic reactor (EMR) not only produces 30% more biogas than traditional methods, but also boasts a smaller footprint. 

The Most Disruptive Technology award went to Seattle-based Membrion, whose ceramic ion exchange membranes impressed judges with their ability to recover up to 98% of water from the harshest wastewaters. This opens-up new applications for electrodialysis (ED) and ED reversal processes. 

Amplifying stories
The theme of storytelling underpinned the entire programme, which opened with the UK premiere of Our Blue World, the latest documentary film from the Brave Blue World Foundation. Personal water origin stories of professionals taking part in BlueTech Forum were also shared throughout. 

Aimee’ Killeen, president-elect of the US Water Environment Federation, one of the movie’s partners said, “We need to tell our story better as an industry, so part of our strategic plan is that we need to amplify the stories of water – and again that’s on each of us. We’re very good at talking to each other in this sector, but we also bear the responsibility oas water workers to tell our stories to our families and our friends and get that message out there.” 

Companies and organisations wishing host a private screening of Our Blue World can contact Peter Barden at peter.barden@braveblue.world.

Pumps specialist Dutypoint explains the significance of Environmental Product Declarations (EPDs), and introduces its EPD-certified, all-in-one tank and booster set, ScubaTANK®, with details on how it fulfills these requirements.

Although it may seem like environmentalism and sustainability have exploded in recent times, in fact, it’s nothing new. The concept of sustainability was first embraced in 1972 as a vision recognising the interconnectedness of social, economic and environmental issues.

In 1987, The World Commission on Environment and Development published “Our Common Future”, sometimes known as The Brundtland Report, through the Oxford University Press. It stressed the importance that development meets the needs of the present, without compromising the needs of future generations.

The pursuit of sustainability is a balancing act. It requires navigating policy, strategy, programming, and project implementation, while demanding changes to stakeholders’ mindsets, attitudes, and behaviours.

This is something that Dutypoint has achieved. We are committed to developing products that embrace sustainability and enrich everyone’s future and a prime example of this is our market-leading EPD-certified ScubaTANK®.

Before we get to that, let’s have a look at EPDs, LCAs, and our EPD ScubaTANK® in a little more detail.

EPDs explained
Environmental Product declarations, or EPDs, are Type III declarations which are recognised as the standard baseline for environmental product comparison, sharing objective, transparent information about a product’s carbon footprint, water footprint, and energy consumption.

Valid for five years after being awarded, EPDs showcase a manufacturer’s commitment to measuring and reducing the environmental impact of their products and services, helping consumers to make informed decisions about the products they buy.

Upon completion, the assessment is used to calculate an Environmental Product Declaration (EPD) in line with EN 15804 + A2, with both EPD and life cycle assessment (LCA) being verified against strict, independent protocols.

EPDs and LCAs
Although EPDs are built around lifecycle assessment practice and methodology, their scope extends well beyond lifecycle assessment. Why? They must factor in any additional requirements from EN 15804 and other related standards and frameworks.

There are several types of EPDs that cover the different lifecycle product stages. They are defined as follows:

Cradle-to-gate EPD which focuses solely on the manufacturing process and material harvesting and features a minimal amount of lifecycle assessment data.

Cradle-to-grave EPD which covers the entire product lifecycle, specifically covering its maintenance and end-of-life. Anyone wishing to create a product EPD or utilise a manufacturer’s EPD should choose cradle-to-grave EPD.

Cradle-to-grave EPD with options which include the minimum requirements that are present in the cradle-to-gate option with several additional modules from cradle-to-grave EPD variations.

The Differences Between EPDs and LCAs
LCA reports are one of the most common methodologies for quantifying sustainability. They provide a systematic analysis of environmental impact throughout the whole product, material, or process lifecycle. LCA models the environmental implications of industrial production. An accurate, comprehensive LCA provides valuable, sustainable data that decision-makers can use to support sustainability initiatives.

EPDs, or Environmental Product Declarations are typically shorter, simpler, verified environmental documentation used by organisations for in-house and external communications. They do not contain any sensitive company details or product information, like manufacturing processes.

The commercial benefits of EPDs
Within the construction industry, EPDs support carbon emissions reduction by promoting comparative analysis of different materials and products. This allows decision-makers to select the most sustainable option for their projects while optimising product impact and showcasing transparency.

A voluntary EPD is both internationally recognised and demonstrates a business’ commitment to environmental sustainability. Moreover, EPD-certified products benefit businesses in several different ways. These include:

• Market regulation: using or creating EPDs for a product or project
• Regulation and legal requirements: all public procurement bodies in the EU and EEA are required to use EPDs to assess a product’s environmental footprint
• Credits and certification: LCA credits are cost-efficient and easy to compare other credits’ requirements for your building’s certifications, and EPDs are also recognised by market-based systems

Let’s review the features and performance of our EPD-certified ScubaTANK®, including its key improvements, to demonstrate how it can comply with relevant EPAs.

The EPD-certified ScubaTANK®
Our innovative, sustainable, EPD-certified all-in-one tank and booster set, ScubaTANK®, features multi-stage submersible pumps, an inverter-driven smart tank level control system, and a common volt fault-free contact as standard.

The unit also includes isolation and non-return valves, pressure vessel, and a high flow failsafe close monitored inlet ball valve. These, plus many other features, make it ideal for both residential and commercial application.

More notably, the all-in-one tank and booster set that delivers maximum results with minimum hassle and is the first combined tank and booster set on the market to feature an EPD certification, EN 15804 + A2/ ISO 21930.

Key Improvements to the ScubaTANK®
Our EPD-certified ScubaTANK® features several key improvements. These include:

• Increased tank inflow rate so a higher flow can be achieved
• Smart remote monitoring to predict failures before they arise
• Electronically adjustable tank fill levels fitted as standard
• Improved electrical design for less downtime in the event of a failure
• Improved control bracket design for easier access to critical components
• High level alarm included as part of a common fault
• Manufactured to meet Environmental Product Declarations

Sustainability benefits
Our EPD-certified ScubaTANK® is the leading all-in-one tank and booster set. Below are the sustainability benefits you’ll reap when installing the system.

• ScubaTANK® promotes energy efficiency, whilst reducing your carbon footprint. Its variable-speed pumps ensure a low level of energy consumption. Additionally, the unit will power down when not in use and only use the minimal energy to satisfy demand.
• Designed as one complete packaged system for a tank and booster set, our ScubaTANK® is delivered to site as an individual unit that is ready-to-install, without additional packaging to maximise sustainability.
• The improved electrical design results in reduced downtime in the event of system malfunction or failure. This can lead to less overall runoff pollution and habitat degradation.
• All ScubaTANK® parts are manufactured to the highest quality and are WRAS-approved. This promotes system durability and longevity, complying with the highest standards of UK water regulations for maximum water efficiency.
• As a British manufacturer, Dutypoint promotes transparent product traceability across its entire range, including ScubaTANK®, therefore customers can be assured of superior efficiency, longevity, durability, and finesse.

EPDs and our future
Environment Product Declarations (EPDs) will play a pivotal role in the effort to realize a sustainable, eco-friendly future in which it is still possible to leverage high-performance products.

By providing transparency and comparability while encouraging sustainable choices, EPDs help people make better, eco-friendly decisions about the type of products they use. This is exactly why Dutypoint has developed the market-first EPD-accredited ScubaTANK® all-in-one tank and booster set.

To learn more about EPDs or browse our selection of sustainable products like Dutypoint’s EPD combined tank and cold-water booster ScubaTANK®, get in touch with Dutypoint today.

Electric valve actuation expert AUMA Actuators Limited (AUMA UK) has added Southern Water to its growing list of successful frameworks with major UK water companies.

Southern Water provides essential water services to 2.5 million customers and wastewater services to more than 4.7 million customers across Sussex, Kent, Hampshire and the Isle of Wight. The new framework agreement will see AUMA deploy its new and unique process to service, maintain and replace a range of actuators across the entire Southern Water region, which covers almost 4,450km².

MIchael Upcraft is Southern Water’s Framework Manager. He said: “With a 13,929 kilometre network of pipes and 205 service reservoirs, Southern Water delivers a continuous supply of clean water to our customers. Our 39,808 kilometres of sewers and 3,321 pumping stations collect wastewater from our customers’ homes and businesses and from outside drains.

“AUMA’s capacity to source and supply its comprehensive range of high quality, high performance electric actuators and critical spare parts from within the EU is a major benefit to us. It means we are able to respond quickly, serving people and businesses throughout our supply region.”

As part of the new framework agreement, Southern Water now has access to AUMA’s unique ‘rapid response’ service to replace both AUMA and other manufacturers’ equipment, as well as a ‘replacement in advance’ for critical actuators.

Paul Hopkins is AUMA UK’s Managing Director. He says: “Southern Water constantly monitors its water and wastewater sites and networks, conducting maintenance and developing new infrastructure where necessary. We have built a close and positive relationship with the company, which has resulted in securing our framework with this important water utility.

“The water company plays a critical role that goes beyond providing an essential public service. It aims to help tackle the climate emergency, support the communities it serves and contribute to the growth of the south west’s regional economy. It is great to be part of that journey.”

Southern Water aims to maximise the availability of actuated valve operations throughout its region. The size and operating parameters of each installation varies, with a wide combination of actuators, controls and drive couplings required to be available at short notice. AUMA’s extensive range of high performance actuators is designed using a modular approach to actuator components. Actuators can be quickly combined to provide a bespoke actuator assembly constructed to the exact requirements of applications.

AUMA is creating a unique online Southern Water Knowledge Base, which will be accessible to all registered Southern Water engineers and technicians. This will provide 24/7/365 access to essential information, video tutorials and technical information. In addition, AUMA has introduced a number of innovations – from reducing its environmental impact through the use of sustainable packaging, to improving health and safety by reducing time on site undertaking repairs.

AUMA is also providing full training to Southern Water maintenance staff via its AUMA Certified Engineering (ACE) training. Delivered on-site, on-line or in AUMA’s dedicated training suite at its head office in Clevedon, Somerset, ACE is a structured programme that trains technicians to install, operate, maintain and troubleshoot AUMA actuators, meeting asset management obligations to maintain equipment in line with the manufacturer’s recommendations. Accredited ACE Technicians are provided with ID cards to prove their level of competency.

The firm behind water handling and treatment solutions Selwood and Siltbuster has appointed a new CEO.

Dan Lee is now Workdry International CEO, with a brief to lead market-leading water handling and treatment businesses and oversee expansion into Europe

Dan has 15 years’ experience at the helm of high-performing asset-based industrial services businesses. He will work closely with Arcus Infrastructure Partners, a leading European infrastructure investment firm, which manages funds holding a majority shareholding in Workdry, to “deliver on its strategy to establish the Group as the number one provider of pump and wastewater treatment rental solutions in the UK and Europe”.

His appointment follows Workdry’s recent acquisition of Vanderkamp, which brought a leading Dutch pump rental solutions specialist into the Workdry Group alongside its established Selwood and Siltbuster businesses.

Dan said: “I am excited to be joining Workdry International at a time of huge momentum, inheriting a business that is in great shape and embarking on a new phase of domestic and international growth.

“In my time getting to know the business I’ve already been hugely impressed by the Workdry, Selwood, Siltbuster, and Vanderkamp businesses – and particularly by the professionalism, expertise and commitment of their teams.

“Workdry’s success is built on those exceptional people and their commitment to sustainability, innovation and strong partnership with customers, which will be the foundation stones of future growth.

“I am looking forward to working with a dedicated team of colleagues to help deliver the vision and strategy for the coming years as Workdry continues to grow organically and through acquisition to expand on its leading position in asset rental solutions for water and wastewater handling and treatment in the UK and Europe.”

Dan joins Workdry with a strong track record in capital equipment rental and service businesses. He began his industry career with US-based industrial chemical service provider NCH Group before moving to industrial parts cleaning and washer hire services specialist Safetykleen, where he spent 11 years in senior leadership roles.

Following the sale of Safetykleen to private equity firm Apax Partners in 2017, Dan served as Group Managing Director at workplace services leader phs Group. He subsequently founded chemical surface treatment business Krystal Kleen Heritage UK, which was acquired in 2020, and served as President of EMEA region at Tosca, a global leader in reusable packaging and performance pooling solutions.
He takes the reins from outgoing CEO Richard Brown, who is retiring after almost three decades in various roles at Selwood and Workdry.

Richard said: “Dan has a very strong track record in building a positive and inclusive work environment. He is full of energy, passion and vision, and is ready to lead the business to new heights, focused on delivering growth while supporting our fantastic teams to deliver outstanding service and solutions to our customers. I am in no doubt that the best days for our business lie ahead under his leadership.”

Jordan Cott, Partner at Arcus, said: “Dan has an exceptional track record as a leader in the industrial asset rental and solutions space across the UK and Europe. His core focus on supporting his people and delivering the highest quality solutions for customers, coupled with his vision-led strategic thinking and deep understanding of long-term value creation levers, will make him an ideal leader to champion Workdry through its next chapter of growth.

“We at Arcus look forward to working with Dan and the team to build on Workdry’s enviable track record and growth ambitions by investing in innovation and new markets – a journey that has already begun with the recent acquisition of Vanderkamp and which we are excited to continue in the months and years to come.”