INTERNATIONAL PUMP USER CONFERENCE

BIO
Andrew has worked in the electricity industry for the past 21 years in a wide range of fields including power system planning, information technology, business planning and demand-side management. Andrew is a Senior General Manager, currently responsible for Eskom's integrated demand management programme which involves collaboration with business and society to reduce the demand for electricity through energy efficiency, whilst growing South Africa's economy.

ABSTRACT
"Despite a large capital expansion programme underway, the South African electricity supply situation will remain under pressure for several years. The electricity supply challenges do however offer a great opportunity for energy efficiency programme implementation. The presentation will provide an overview of the current electricity supply situation and the measures in place to deal with it over the short to medium term. Eskom's demand-side management programme will be covered to a fair degree of detail."

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BIO
Gunnar Hovstadius has more than 30 years of experience in Engineering and Technology management, mostly within ITT Fluid Technology Corporation where he served as Director of Technology. He has served on the steering committee of the U.S. Motor Challenge/Best Practices Program and is deeply involved with governments, NGOs and trade organizations. Selected by U.S. DOE as a leading "international expert," he continues to promote energy efficiency issues both nationally and internationally.

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The presentation will describe the pump part of the Unido Industrial Energy Efficiency Project. This project aims at capacity building in South Africa regarding pump system optimization. It includes awareness seminars and training of end-users, vendors as well as experts.

The different types of training will be briefly described with emphasis on the expert training. The experts will be trained both in classrooms and in the field on how to assess and optimize pump systems. The assessments will be conducted according to the ASME EA-2-2009 assessment standard, which is presently being worked on to make it an ISO standard supporting the new ISO 50 001 standard for Energy Management Systems.

The ASME EA-2 pump system assessment standard will be reviewed in detail.

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BIO
Awie Bosman is a Technical Specialist with ABB South Africa. Awie has a Masters degree in electrical and electronic engineering from the North West University. He is an experienced energy consultant, and has been responsible for the successful completion of energy efficiency studies in several industrial operations. He has five years' experience in industrial energy efficiency, including feasibility studies, simulations, research and development. In addition, he has three years' experience in process automation and optimisation, which included design, development, commissioning and management.

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With the case for energy efficiency becoming more significant and topical in South Africa, there is a need to evaluate the different approaches that have been adopted in industry to address the energy efficiency challenge.

The paper proposes a structured and holistic approach to energy management. It illustrates how changes made to a pumping system can affect the rest of the process, as well as how energy savings initiatives on the rest of the process can create more savings opportunities on the pumping system. There are two broad groupings in the prevailing approaches to energy management: the "ad-hoc improvement projects" approach, and the "extensive energy management strategy" approach.

The ad-hoc projects approach is where attempts at improving energy performance are done by executing stand-alone, unrelated projects. This method is typically the default approach adopted in operations where the focus is on production and not (energy) efficiency; and although some gains can be made initially, savings are typically not sustained. The extensive energy management strategy approach typically involves exhaustive planning, with detailed and documented procedures and protocols required before any implementation can be started. While this approach usually allows for a structured and holistic evaluation of energy use, a potential pitfall is getting trapped in "analysis paralysis". This is where it is endeavoured to having the strategy 100% complete and comprehensive, but actual savings are slow in coming, if at all.

For most companies, the adopted approach lies on the continuum between the two extreme approaches described above. Real and sustainable improvements in energy performance can only be delivered when the right balance between strategy-making and project implementation is attained, as per the unique requirements of a specific industrial operation. This paper describes an energy improvement program, ABB's Industrial Energy Efficiency program, which is designed to strike a good balance between strategy formation and implementation.

Case studies are presented to show how this program helped industrial customers realise sustainable energy saving opportunities covering a wide range of plant systems and processes.

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BIO
Greg Adcock, a graduate of Wits University, has experience as a process and mechanical engineer in several industries. His focus on the practical aspects of pumping system performance assessing and monitoring over the last decade has given him insight into the potential for optimisation in plants built over thirty years ago.

ABSTRACT
A practical look at the outcome of pump performance assessments at coal washing plants.

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Andrew has worked in the mining industry for 30 years where he spent most of his time in the refrigeration and pumping sections. He is currently responsible for multi-stage pump, refrigeration plant, water treatment condition monitoring and performance testing. His current position is Pump & Refrigeration Manager at Anglo Gold Ashanti.

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"It is a fact that the efficiency of a new motor is in the vicinity of 95%. For a long time we have realized that as there are copper losses and an increased air gap during refurbishment and the efficiency of motors deteriorate but there was no practical way to measure the motor efficiency on site. With the increase in the price of electricity and our constant striving towards greater accuracy we again investigated means of measuring power at the coupling. The technology was found at ESTEQ Engineering. This presentation will show and discuss motor efficiency testing insitu."

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BIO
Willem matriculated in 1979 from Edenvale Hoerskool. He obtained a Masters Diploma in Technology T5 (Mechanical Engineering) from Vaal Triangle Technikon and a Graduate Diploma in Engineering (GDE) and MSc (Mechanical Engineering) at Wits University.

Willem joined Eskom in 1982 as a Pupil Technician. In 1989 he became a Technologist-in Training and in 1993 he became a Senior Consultant and later a Chief Consultant (Boiler feed pumps and pumps in general).

In 1987 he had the opportunity to gain design and research experience at Sulzer Pumps head office in Switzerland.

He joined Sulzer South Africa in January 2000 as a Senior Design Engineer in the pump department. His main responsibilities were to apply his knowledge and experience to pump design, investigations, tests, and research and development activities.

Willem resigned from Sulzer in October 2005 and started his own pump consulting business, "OPTIMUM PUMPING SOLUTIONS CC".

He is presently contracted by Eskom as a Pump Consultant to help with pump specifications for the New Eskom Power Stations.

He has also written six International and twelve National papers on various aspects of pumps.

He has also conducted numerous pump failure investigations on various types of pumps.

He also presents a two day ECSA Accredited pump course to industry and lectures mechanical subjects for the Government Certificate of Competency candidates at Eskom College.

ABSTRACT
The paper discusses and highlights the most important pump related challenges and experiences the critical pumps at Eskom have been faced with during the past 20 years.

The challenges include the following:

• The effect the Pump System resistance has on the operating point of the pump which includes NPSH related and cavitation problems.
• The effect of the boiler feedwater quality has on the mechanical seal face life and changes made to seal face materials to be compatible with the specific boiler feed water quality.
• The pros and cons of gear type mechanical couplings compared to flexible membrane couplings.
• Experiences and lessons learnt through retrofitting a BFP designed in 1960 with utilising modern tools and new technology.
• Two times line frequency vibrations experienced on our wet-wound BWCP's installed on assisted recirculation boilers.
• What to expect when critical pumps are refurbished by a Non OEM using reverse Engineering and Non OEM parts.
• Using different coating applications on pump components.
• The pros and cons of having a long term contract/partnering agreement with a partner or a pump supplier.

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BIO
Keith Gass, Director of Verder Pumps SA Pty Ltd., has over 20 years of engineering experience in the mining industry and has been active in sales and marketing throughout his career.

Keith started his career with De Beers Mining on the West Coast and on qualifying as an engineer, has worked for mining supply companies throughout his career with his last position being Marketing Manager for Komatsu SA Pty Ltd.

Keith is well conversant with the mining processes from earthmoving to final production of minerals and Coal in Southern Africa.

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Is the water crisis in South Africa as bad as they say it is?
Scarcity of quality drinking water and water safety is becoming a forceful topic of discussion in South Africa, Africa and the rest of the world.

A combination of polluted water sources and poor management of dams, sewerage works and treatment plants and the uncontrolled industrial (mining) activities over the past 120 years, have led to a situation where water supply in South Africa is under serious threat.

Studies show that acid mine water is rising at a staggering rate of 15m per day. The water situation is in fact threatening our survival.

At the center of resolving this problem are water & waste water treatment plants. Possibly the most important infrastructural requirement, relying solely on the design and quality of the equipment installed.

This paper will look at peristaltic dosing pumps used as part of the process to rectify the pH balance of acid mine water. We will highlight a successful implementation at a Uranium Waste water treatment plant focusing but not limited to the following topics:

1. Cost of Ownership
2. Plant performance -
   Plant availability
   Reliability
3. Dosing Accuracy

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BIO
Graeme Harding spent 10 years working on large projects in the pulp and paper industry. This provided excellent experience in pump and control system design as well as a diverse range of project experience from paper machines through to fiber lines, lime kilns and gas turbines.

As Magnets Energy Projects Manager he is once again involved in a broad range of projects from pumping system optimization through to compressed air systems, refrigeration plant optimization, heat recovery and heat pump projects.

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In 2006 with power outages still fresh in everyone’s mind load shifting was one alternative to reduce the risk and effect of short term peaks on the grid. Initially this water treatment and bulk water supply plant was investigated with a view to installing one new pump and saving some power. Investigations revealed a far bigger opportunity which resulted in 7 new pumps a new control system, energy savings and load shifting during both peak periods.

One of the issues with load shifting projects is that in some cases they tend to create new peaks which Eskom was concerned with, in this case it was possible to reduce the baseline and shift load out of the peak periods.

Typically in many pumping energy saving solutions variable speed drives are used, in this case no drives were used and the overall energy saving was 25%. This paper details the investigative process, the solutions found and the reasons for not using variable speed drives.

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BIO
Steve is currently responsible for all BPMA's Technical, Training, IT, Standards, legislative and energy related activities.
With regards to training he has been the main driver for introducing a Nationally accredited on-line qualification in Pumping Technology - a Worlds first!!
On standards he is responsible for the UK administration of over 30 pump related standards
On legislation he is responsible for advice to members on 19 existing Directives emanating from Europe.
On energy and with assistance of EUROPUMP he has been actively involved in many of the European Commission programmes such as "Pump SAVE", "Motor Challenge", "ProMot" "DEXA" and most recently the EuP ( Energy Using Products).
He was active in the working group, which produced the international guide on Pump Life Cycle Costing and subsequently took on the task of secretary for producing the international guides for Variable Speed Pumping and Systems Efficiency. More recently he has worked as the secretary to produce guides on;
"Energy efficient pump systems"
"Variable Speed Electro- Submersible Pumps"
"Guide to the selection of Rotodynamic Pumps"
"Systems Efficiency Group" .
He has also given keynote papers on energy related issues in Europe, USA and South Africa.

Prior to joining the BPMA in 1998 he worked in the Pump Industry for 25 years having held appointments with Mather & Platt/ Weir Pumps, Durco/Flowserve and latterly Hayward Tyler.

ABSTRACT
Many of the items identified in the Energy Using Products Directive 2005/32/EC ( new Energy related products Directive ) have identified energy saving methodologies or technologies and are now either implemented or in their transition period. These include water pumps, circulators and AC motors. The EU has now identified new pump products which are currently under review and studies will start in the summer of 2011. The extended product approach and system approach for pumps and pumping systems now appears to have been accepted by the European Commission as valid methods of saving energy across Europe. An up to date review of all the above will be given and how they can offer significant energy savings will be discussed.

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BIO
Stefan M. Abelin has 30 years of experience from the pump industry having worked in positions such as application engineering, Hydro turbine expert, Engineering manager, Marketing manager, Technical Director, Operations Director and Technical manger for Flygt AB, Flygt France S.A., ITT Flygt Corporation and ITT Water & Wastewater. Mr. Abelin has worked and lived in Sweden, France and the US. He is currently residing in Sweden holding the position of Marketing Director Large Pumps & Applications for ITT Water & Wastewater.

Through his career, Abelin has actively participated in National and International committee work with the Hydraulic Institute, Euro pump and IPSC. In this work Abelin has Chaired and supported development of International standards such as Pump Intake Design, Submersible Pump testing and Pump Acceptance Testing.

Mr. Abelin holds a BS and a Master's degree in Mechanical Engineering from Stockholm's Royal Institute of Technology.

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Pumps intended for clean water service can be designed without considerations of handling solids in the pumped media. For solids handling applications such as wastewater applications and wastewater treatment plant pumping the challenge is to design pumps that do not clog. Municipal wastewater contains a wide range of organic and inorganic solids, and the main challenge for pump operators are the significant concentrations of soft organic fibrous and stringy materials (rags, cloth, plastics etc.) that have a strong tendency to accumulate in the pump. The traditional approach to avoid clogging has been to increase the pump impeller throughlet size or to recess the impeller into the pump volute. These methods increase the clog resistance but they also lower the pump efficiency. Pump performance data is derived from testing in clean water. Field testing in end user applications show that traditional non clog pumps dramatically loose efficiency as debris accumulates on the impeller and in the volute. Efficiency reductions of 20-50% are not uncommon. New self-cleaning pump hydraulics manage to increase both clog resistance and deliver sustained pump efficiency.

Increased environmental awareness and legislative pressure to lower energy usage, coupled with an always present desire to find ways of lowering operational costs has driven the wastewater pump industry to examine true operational efficiencies. Field and laboratory measurements have demonstrated that pump energy usage is much higher than expected due to reduced pump efficiency as a result of the pumped solids. Performance measurements show that flow and pump efficiency drops off over time in most wastewater pumping applications. This has historically not been well known or highlighted. Partial pump clogging has been found to be a root cause problem to lowered efficiencies while complete blockages are rarer. The increased usage of Variable Frequency Drives and the subsequent long duty cycles has further exaggerated the problem with reduced pump efficiencies

This paper describes the research and field testing of pump efficiencies and defines and explains the concept of "Sustained Pump Efficiency", a critical parameter for energy efficient pumping in solids handling application such as wastewater pumping.

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BIO
2011 sees John's 41st year in engineering. Initially he had exposure to plant maintenance (steam, water, pneumatics, ash handling, boilers, turbines and pumping systems) and marine steam plant. A number of years in the selling, commissioning and trouble shooting of pumping systems were followed by nine years in the designing and presenting of training courses which covered the technicalities and marketing of pump sets, pipes, valves, diesel engines and basic electrical systems for pumping plant.

An extended period followed in which John's career was focused on the marketing, selling and trouble shooting of pumping systems and submersible electric motors. Through his exposure to the international arena and the development and marketing of new products, John has gained a unique perspective of the fluid movement and control industry.

A firm believer in the benefits of high-quality training, John has been at the forefront of training initiatives throughout his career. He can now offer your company the knowledge and skills he has gained over the years, presented in an interactive and practical manner. His courses have drawn a multitude of positive comments, many of which allude to his professional presentation style and the practical examples he offers throughout the training session.

ABSTRACT
Pumps intended for clean water service can be designed without considerations of handling solids in the pumped media. For solids handling applications such as wastewater applications and wastewater treatment plant pumping the challenge is to design pumps that do not clog. Municipal wastewater contains a wide range of organic and inorganic solids, and the main challenge for pump operators are the significant concentrations of soft organic fibrous and stringy materials (rags, cloth, plastics etc.) that have a strong tendency to accumulate in the pump. The traditional approach to avoid clogging has been to increase the pump impeller throughlet size or to recess the impeller into the pump volute. These methods increase the clog resistance but they also lower the pump efficiency. Pump performance data is derived from testing in clean water. Field testing in end user applications show that traditional non clog pumps dramatically loose efficiency as debris accumulates on the impeller and in the volute. Efficiency reductions of 20-50% are not uncommon. New self-cleaning pump hydraulics manage to increase both clog resistance and deliver sustained pump efficiency.

Many pumping processes require an uninterruptable flow of fluid to ensure the safe and cost effective production of an end product. A stoppage in flow can often lead to very serious quality and or safety issues, the recent occurrences at the Fukushima nuclear power plant are a case in point. To this is end, many installations make use of one or two duty pumps while one extra unit is held as a standby in case of an operating pump failure.
This arrangement has a number of obvious benefits but like any other system, it has to be operated in accordance with the original design intent. In a surprising number of instances, the original plan is ignored and the standby pump is run continuously, in parallel, with the operational units. This means that that the pipe work system is subjected to the flow of more pumps than it was originally designed for. For a one operating one standby system this means that the pipe work has to accommodate a 100% increase in capacity. Some of the reasons given for running the standby unit in parallel with the operational pumps are:

1. a decrease in performance of the pumps due to wear and tear
2. an increase in demand for fluid due to changes in the production process.

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Mechanical Engineer with good academics and professional standing.

17 Years of technical and engineering management experience in the largest Public Sector oil Company in India - the Indian Oil Corporation ltd and 3years of experience in a state of the art power plant built by ABB Sweden owned by M/S Indian Charge Chromes ltd.

Erection supervision, commissioning, operation, maintenance and trouble shooting experience in captive thermal power plants and Petroleum Refinery.

Technical experience and knowledge of various kinds of mechanical and process equipment and machinery used in petroleum refinery such as different kinds and types of pump sets, valves, pipelines, coolers, heat exchangers, filters, flocculation equipments, ion-exchangers, molecular sieves, sprayers, scrubbers, fans, chemical dozers, aerators, bio-filters, process line instruments, etc.

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With rising energy cost, process plants are increasing their focus on the amount of energy spent on rotating equipment. Improperly sized or poorly performing pumps are costing companies millions of dollars unnecessarily. Unscheduled repair and poor reliability are causing companies to loose production and spend money on maintenance costs. In many typical pumping systems approximately 50% of the total life cycle cost stems from energy cost. The major factors affecting centrifugal pump performance includes efficiency of the pump and system components, overall system design, efficient pump control, appropriate maintenance cycles and process conditions.

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Larry has more than 30 years of experience in the industrial pump arena. He teaches pump improvements courses at major plants and industries all over the world and has written a book Everything You Need To Know About Pumps.

ABSTRACT
Pump companies publish Owners Manuals and performance curves for their products. The manual advises the pump should be operated at best efficiency (called 100% of design).

"Best Efficiency" is the optimum combination of head and flow at the least energy consumption. Energy is wasted as the pump operates away from best efficiency on the performance curve.

A typical end-suction centrifugal process pump might be 80% efficient if operated between 90% and 110% of design flow. However, studies reveal that most process pumps really operate on the extreme ends of the performance curve, wasting more than half the available energy supplied to the pump.

The pump and electric motor are by far the most popular pieces of industrial equipment in the world, compared to fans and compressors. Therefore, operating the pump at design will conserve tons of energy, and contribute to relieving the global energy shortage. So, why don't we operate our pumps at design?

Most pump companies strive for higher efficiency with better volute and impeller designs. The problem is not in design. The problem is in operation.

You see, an automobile might be designed to the highest standards of efficiency. The car must also be operated efficiently too. If the driver (the operator) abuses the car, driving with the clutch partially engaged, or with a foot resting on the brake pedal, the auto is no longer efficient. It will waste fuel and become a high maintenance vehicle.

My experience indicates the pump operators don't maliciously abuse their pumps. The equipment operators don't receive adequate instruction from the engineers. And frequently, the pumps lack adequate instrumentation (gauges, flow-meters), necessary to make intelligent decisions. Normally, the equipment operator is not authorized to install instrumentation on the pump. The process or production engineer must intervene.

If the engineer doesn't provide proper instrumentation to the operators, it means the engineer doesn't know what instrumentation the pump needs. If the engineer doesn't know what instrumentation belongs on a process pump, it means the engineer doesn’t understand how the pump behaves in a dynamic system.

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