Cutting energy costs with smart pumps and sustainable solutions

<p>At weekends the space hosts millions of visitors and tourists annually. A major challenge to solve the issues without disrupting continuity.</p>
<h2>The Problem:</h2>
<ul>
<li>Due to excessive fats, oils and grease, two pump stations in the underground delivery yard were steadily failing.</li>
<li>Anglo Pumps sister company, Metcor Environmental, investigated and identified the problems</li>
<li>Engineers including CCTV technicians and a breathing apparatus team, with confined space and safety training, attended.</li>
<li>Drilling into the side of the tank chambers, core samples of the concrete were taken and analysed to assess and test their integrity, and for weaknesses.</li>
<li>Pipes inside the valve chambers were clogged with FOG, restricting flow by 80%</li>
</ul>
<h2>The Solutions:</h2>
<ul>
<li>4,000-gallon tanker brought on site in delivery yard</li>
<li>Coned off pathways for deliveries to continue so tanker and works teams could operate safely</li>
<li>Each pump pit renovated in turn</li>
<li>Pump pits stripped, chambers removed, specialised coating applied to concrete walls</li>
<li>Anglo Pumps installed new Sulzer pumps in stations, with inverters to maximise efficiency and sustainability</li>
</ul>
<p>&nbsp;</p>
<blockquote><p>&#8220;This was a challenging project requiring 24/7 attendance in difficult conditions. A range of our engineers from both Anglo Pumps and our sister company, Metcor Environmental, combined their expertise to deliver an exceptional result.&#8221;</p></blockquote>
<h5>TIM SAMPSON, Operations Director, Metcor Environmental</h5>


Pumps and Pump Stations Installation at Major Office, Retail and Hospitality site

End to End

<p>Anglo Pumps are able to assess and evaluate methods for a reduction of carbon emissions and increased energy efficiency in plant rooms and at pumping stations.</p>
<p>There are various approaches used to control the flow rate of a pump, but they all come with their own inefficiencies. However, there are tried and tested solutions for efficiently managing the performance of pumps in the form of inverters or variable frequency drives (VFDs).</p>
<p>Pumps with inverters are more energy efficient because they provide variable flow rate control that delivers energy efficiencies during operation, and are intrinsically more efficient because of the affinity laws, where running a pump motor at lower rates reduces energy consumption by a significant percentage. A 25% decrease in pump motor speed can reduce energy consumption by as much as 60%.</p>
<h2>The problem:</h2>
<ul>
<li>A customer running a 7.5KwH pump that cost £4,600, consumed over 65,000 KwH annually. The energy bill was over £19,000 per annum.</li>
</ul>
<h2>The solution:</h2>
<ul>
<li>Anglo Pumps installed a 7.5KwH inverter at a cost of £7,500.</li>
<li>Coupled with appropriate sensors and transducers, the inverter-controlled pump motors provided pumping power according to the demand requirements of the system, rather than at either peak operating output or at a suboptimal and lower efficiency output.</li>
</ul>
<h2>The benefits:</h2>
<ul>
<li>The inverter reduced energy consumption by 30%, cutting the yearly energy bill to under £14,000.</li>
<li>The return on the investment was realised within 16 months, and over the 15-year life span of the system, expected to save the customer over £80,000.</li>
<li>Running the pump motor with soft starting and stopping, less strain was placed on the motor and the wider system, protecting seals, joints and pipelines.</li>
<li>The mechanical elements of the motor will run smoothly without additional friction and wear.</li>
</ul>
<h2>Heat Exchanger:</h2>
<ul>
<li>Two-week project including the design and installation of two hot water calorifiers and replace with new plate heat exchangers</li>
<li>Exchanger units able to cater for abnormal/intermittent peak demands.</li>
</ul>
<h2>Benefits:</h2>
<ul>
<li>Upgrade of existing equipment to new, more energy efficient units, but still able to accommodate peak demands.</li>
</ul>


Cutting Energy Costs with Inverters

Installation

Pump and Pump Station Installations

Pump Refurbishment and Rebuilds

<p>Whilst it is a spectacular location, a combined mains sewer and surface water drainage system runs alongside it, and in heavy rainfalls, the plant room has been flooded several times, up to 3m deep, requiring expensive remedial works and risks to business continuity.</p>
<p><img loading="lazy" decoding="async" class="alignnone wp-image-1343 size-large" src="https://cms-live.anglo-pumps.co.uk/wp-content/uploads/2024/09/meg-pro-924-d1863-1024x683.jpg" alt="" width="1024" height="683" /></p>
<p>Kessel Drainage Solutions, the global pump manufacturer, called in Anglo Pumps sister company, Metcor Environmental, to assess the problem and recommend solutions for overcoming the<br />
challenges. Our engineers first studied plans of the building, then checked and traced all water pipe and drainage systems, tanks, pumps and electrical installations. They created an up-to-date CAD plan, marking the building’s water and waste management systems in detail, which the client keeps for future reference.</p>
<ul>
<li>The Victorian Grade II listed building meant that access to the plant room was heavily restricted by narrow entrances, stair cases and corridors, posing problems for the extraction of old equipment and the installation of new.</li>
<li>The building resides in a tightly controlled City of London noise restriction area, where noisy works could only take place between 6am and 2.30pm on Saturdays.</li>
<li>The client did not want the walls in the plant room to be drilled.</li>
</ul>
<p>The two new pumps each weighed a quarter of a ton, and there was no entry space large enough to winch the new tank into place.</p>
<p>Metcor Environmental and Anglo Pump&#8217;s experience in bringing large plant into confined spaces came in handy: the tank was delivered as a ‘flat pack’, carried down to the plant room and built on-site by the engineers. The pumps were brought to their required site using specialised motorised battery powered stair climbers and transport.</p>
<p><img loading="lazy" decoding="async" class="alignnone wp-image-1384 size-full" src="https://cms-live.anglo-pumps.co.uk/wp-content/uploads/2024/05/kessel-ecolift-backwater1.jpg" alt="" width="357" height="307" /></p>
<blockquote><p>&#8220;With the challenges we faced with this luxuriously renovated, Grade II Victorian building, we had to adapt to the specific site, and engineer smart ways to overcome them. It was a huge job in confined spaces, with little room for more than 2 or 3 engineers at a time. We’re delighted with the feedback from the client, and to have been part of the flood mitigation for this extraordinary building. As a result, there are several more sites we are being asked to review &#8211; a great acknowledgement of my team’s efforts.&#8221;</p></blockquote>
<h5>JASON SHAW, Lead engineer</h5>
<p>&nbsp;</p>
<p><img loading="lazy" decoding="async" class="alignnone wp-image-1216 size-large" src="https://cms-live.anglo-pumps.co.uk/wp-content/uploads/2024/09/meg-pro-924-d0281-1024x683.jpg" alt="" width="1024" height="683" /></p>


Commercial property gains flood protection

<p>They have rebuilt over 1,000 pumps since 2020, currently renovating one a day. The savings average a quarter of the economic and environmental costs of replacing with new, and makes a major contribution to the pump industry’s sustainability, mitigating further mining and manufacturing of resources, avoiding landfill, and making an economic contribution by reducing costs for the end-user.</p>
<p>Water circulation pump in a 4-hectare lake in St James Royal Park, London had stopped working. Oxygen levels fell, endangering wildlife.</p>
<p>The royal park is a Grade 1 listed historical landscape with tens of millions of visitors annually.</p>
<h2>The challenges:</h2>
<ul>
<li>The pump was sited on an island, accessible only by an old wooden bridge</li>
<li>The condition and state of the pump was not known, but to replace it with new would cost over £45,000</li>
</ul>
<h2>The solution:</h2>
<ul>
<li>After extracting the pump. a lightweight pallet truck, travelling at 3mph, could cross the bridge and carry the pump off the island.</li>
<li>After an inspection by engineers at Anglo Pumps, we proposed it would be possible to overhaul it, rebuild it and replace it back on the island. The client accepted the recommendation.</li>
<li>The 37kw ABS submersible pump was rebuilt to good-as-new in Anglo Pump&#8217;s purpose built workshops; repainted to original colours, tested, then re-installed.</li>
</ul>
<h2>The benefits:</h2>
<ul>
<li>The cost of the rebuild was a quarter of the cost of a new replacement</li>
<li>We extended the pump’s life, enabling almost all of the materials to be recycled, contributing to the aims of the management of the Royal Park for its sustainable, long-term plan.</li>
<li>The work was guaranteed for 12 months, but there is every indication that it will last for at least another 15 years.</li>
</ul>
<p>&nbsp;</p>
<p>&nbsp;</p>


Refurbished pump saves tens of thousands of pounds

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Pumps and Pump Stations Installation at Major Office, Retail and Hospitality site

The Problem:

The Solutions:

TIM SAMPSON, Operations Director, Metcor Environmental