Water & Wastewater Treatment

6 WWT PUMP AND VALVE SUPPLEMENT 2018 In Focus attention based on performance data – is considered by many to be best practice. Anglian Water is a leading example of a utility that has concentrated on monitoring the performance of its pumps through its Energy Efficiency Manage- ment System, which identifies where a piece of equipment is performing inefficiently and can help to focus operator attention. Manufacturers are well positioned to help with performance monitoring and optimal maintenance. For example, Grundfos offers iSolutions, a service to optimise the efficiency of the entire pumping system, and service agreements where regular reports are given on pump performance and visiting maintenance engineers ensure pumps continue to run at the optimal place on the energy curve. Maintenance-in-place design Given that even the best-performing pumps will occasionally need to be repaired and eventually replaced, it makes sense to design pumping installations so there is ease of access for personnel carrying out this work. Preferably, the pumps should not have to be physically removed from their location, which is what maintenance-in- place design is all about. "When there is conclusive proof that, for example, one design of pump may require just one hour of maintenance, compared with say, four hours' work on a more cumbersome design, there are massive savings to made – savings that you'd think would put a very big tick in any water company's asset delivery box," says David Brown, UK managing director at pump manufacturer Börger. "Maintenance-in-place doesn't require special tools, and can mean the difference between just one person carrying out the work, or two. Likewise, with a bigger, more difficult pump to fix, it could mean having to send out just one van, rather than two. These savings are so substantial that they should not be ignored," adds Brown. Technical training It might seem obvious, but the best way to ensure that potential problems are spotted early and do not develop into a costly maintenance headache is for operators to be fully trained in the workings of the pumping systems deployed; while maintenance work itself can be outsourced, there is no substitute for a knowledgeable and skilled operator. Many pump suppliers offer operation and maintenance training: Sulzer, for example, offers courses that can be delivered at its manufacturing facilities or on the customer's site. "Training from Sulzer specialists delivers more than the skills to disman- tle, repair and rebuild a pump," says the company. "With a foundation in the prin- ciples of pump operation and related systems, trained staff can quickly and accurately identify poor installations and take appropriate corrective action to avoid premature failures." Failure analysis When running a large number of assets of a similar type, it is important to analyse the specific cause of individual failures so that operators can identify any weak points that might need closer monitoring across the asset base. For example, 98 per cent of mechanical seals on pumps fail before their optimum design life, and seal failure is the leading cause of pump and mixer downtime, according to Flowserve SIHI. The manufacturer has developed a simple web-based tool – the Flowserve Seal Failure Analysis App – which enables users to identify visually and diagnose the root cause of seal failure. "This new way of supporting our customers, on a 24/7/365 basis, provides engineers with more than 100 years of acquired knowledge at their fingertips," explains Shaun Hampson, Flowserve SIHI's general manager. "When a seal fails, it is o¢en a critical breakdown situation and companies don't have the time to wait for an engineering expert to visit the site to provide a diagnosis. The app is incredibly easy to use and can lead to extended mechanical seal life." At every stage of the pump life cycle, maintenance and smart operation can ensure that the equipment provides value to the operator and as well as continuing to perform as desired – with no nasty surprises.

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