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Silo tanks, pipelines, factory building of Ahlstrom-Munksjö (outside view)
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Engineered pump control systems at the leading decor paper producer

An integrated variable speed system with a single controller as successfully used by KSB in numerous projects frequently reaches its limitations in complex plant processes. This is where an intelligent pump control system comes in, which keeps an eye on all relevant details and responds automatically and flexibly at the critical moment. KSB's engineered pump control systems are also employed by one of the world's leading decor paper producers, silently ensuring a reliable supply of fresh water.
An integrated variable speed system with a single controller as successfully used by KSB in numerous projects frequently reaches its limitations in complex plant processes. This is where an intelligent pump control system comes in, which keeps an eye on all relevant details and responds automatically and flexibly at the critical moment. KSB's engineered pump control systems are also employed by one of the world's leading decor paper producers, silently ensuring a reliable supply of fresh water.

The project:

Multiple pump control system for fresh water tanks

To make the paper production processes at the site in Aalen more effective as well as sustainable, decor paper producer Ahlstrom-Munksjö decided to replace the high-level fresh water tanks with silo tanks. To this end, a multi-pump system was procured that could generate the required service water pressure and reliably maintain it even when demand considerably fluctuated.

The client:

Ahlstrom-Munksjö

Ahlstrom-Munksjö is a leading supplier of sustainable and innovative fibre-based materials based in Helsinki. The Finnish-Swedish company employs some 8000 people worldwide. The company's product range includes filter media, release paper, food packaging, baking and cooking solutions, beverage filter media and packaging solutions, decor paper, backing paper, electro-technical insulation paper, glass fibre materials, medical fibre materials and a variety of specialty paper for industry and private use.
Etanorm pumps, piping and valves with control system

Three main-load pumps and one low-load pump from the Etanorm series

The challenge:

A comprehensive automation solution

What was required was a comprehensive automation solution that is supplied as a perfectly matched package and ready for use immediately following installation.
Ahlstrom-Munksjö also wanted Siemens components to be used, which needed to harmonise with the various KSB products as well as be compatible with the existing process control system.
An intelligent monitoring solution should likewise monitor the activity of all pumps and report potential irregularities before a failure actually occurs.

The solution:

KSB SupremeServ

For KSB SupremeServ, assembling complex multi-pump control systems from components of different manufacturers to realise an impressive overall solution is part of getting the job done. The engineers also specialise in configuring heterogeneous systems ex works so that they can be put together at the customer's site and commissioned in just a few work steps.
KSB SupremeServ therefore did not have any problems combining the Siemens modules requested by Ahlstrom-Munksjö with the company's own products. Three powerful Etanorm pumps are now used to control the service water pressure up to a maximum consumption of 600 m³/h. For lower consumption, a small Etanorm pump is integrated. The pumps operate without interruptions or pressure surges, ensuring energy efficiency and low wear. The inlet pressure of the pump system is impacted by the fill level and filling operation of the silo tanks.
Etanorm pump with mounted KSB Guard sensor unit and transmission and battery unit

KSB Guard mounted on an Etanorm pump 

The strengths of the multi-pump control system lie in the continuously variable and demand-driven speed control of several pumps via a frequency inverter. The control system can be universally used for centrifugal pumps of all types and makes and comprises the SIMATIC S7 controller, which has been programmed ready for use, with interactive display (SIMATIC HMI) as well as all required power elements such as fuses and contactors in a ready-wired control cabinet. The system control unit is specially tailored to the application and ensures data exchange with the customer's SIMATIC PCS 7 process control system.
Many functions are prepared and can be easily activated or blocked via parameters entered on the operator panel – without a programming device – as well as offer protection against incorrect operation and dangerous operating conditions. Automatic control of the entire pump characteristic curves is a standard feature. The selective fault management of the pumps also factors in inlet-side faults regarding the fill level and filling of the silo tanks. Measured data such as the flow rate, pressure and temperature for water management as well as the operating times can be accessed at any time. Error messages that are easy to understand are displayed for maintenance purposes.
KSB Guard Gateway next to the SIMATIC HMI interactive display

KSB Guard Gateway next to SIMATIC HMI

KSB Guard plays a key role in the preventive maintenance strategy required by Ahlstrom-Munksjö. The small sensor module, which can be attached to any pump (including those from other manufacturers) in a few simple steps, immediately reports deviations from normal operation so that corrective measures can be implemented in good time.
Registered users can access all pump status data (e.g. temperature, vibrations and load condition) around the clock via a web portal and are immediately notified by e-mail if any deviations occur. In this way, major damage and downtime can be reliably avoided. This results in considerable benefits for the plant operator for a comparatively low investment, including greater transparency, less downtime, better maintenance work planning thanks to specific status data and reduced operating costs.
As is the case with other complex projects, KSB supplied everything from a single source. One contact person ensured that planning, procurement and configuration of the pumps and pump control system were handled entirely in the background and the software was tested at the factory.
Ahlstrom-Munksjö quickly learned that using KSB Guard in particular was extremely effective. As of October 2021, no fewer than 20 KSB Guard units are being used in other plants run by the decor paper producer. And that number will continue to rise.
KSB Guard, pumps, piping and valves

KSB Guard Gateway next to SIMATIC HMI

Data | Facts | Figures

Plant: Water supply for paper and corrugated board production
Customer: Ahlstrom-Munksjö
Application: Production of fiber-based products
Project year: 2021
Products:
1 x engineered pump control system for pumps operated on frequency inverters
3 x Etanorm ETN 150-125-315 30 kW low-pressure centrifugal pump
1 x Etanorm ETN 065-050-200 11 kW low-pressure centrifugal pump
4 x PumpMeter pressure transmitter with on-site display as accessory
4 x KSB Guard Kit
1 x KSB Guard Gateway
3 x swing check valve: SERIE 2000 DN 200 PN16
1 x swing check valve: SERIE 2000 DN 100 PN16
2 x BOA-CVE H automated control valve in straight-way pattern
2 x B6150011 SAR 10.2 AUMA NORM actuator

Used products

Etanorm/Etanorm MyFlow/Etanorm Pro

Etanorm/Etanorm MyFlow/Etanorm Pro
Documentos

Bomba de voluta monoetapa en ejecución back pull-out, con potencias y dimensiones principales conforme a EN 733, con sistema de accionamiento PumpDrive 2 compatible con IEC, con SuPremE o PumpDrive 3, de la clase de eficiencia IE4 IE5, conforme a IEC TS 60034-2-3:2016 y con variador de frecuencia integrado en el motor. La bomba está equipada con anillos de desgaste intercambiables, impulsor radial cerrado con álabes curvados, cierres mecánicos simples o dobles según EN 12756, eje con casquillo protector intercambiable en la zona del cierre de eje. El diseño «back pull-out» permite un desmontaje del acoplamiento, de los soportes de cojinetes y del impulsor sin tener que separar la carcasa de la bomba de las tuberías. Los puntos de montaje son conformes a IEC 60072; las dimensiones de la superficie envolvente son conformes a DIN V 42673 (07-2011). Disponibles en versión ATEX. Muy adelantada a las exigencias de eficiencia de la directiva ErP.

Detalles

PumpMeter

PumpMeter
Documentos

Dispositivo de monitorización del servicio de una bomba. Es un sensor de presión inteligente para bombas con indicación local de valores de medición y datos de servicio. Registra el perfil de carga de la bomba para indicar cualquier potencial de optimización de la eficiencia energética y la disponibilidad de la bomba. El dispositivo consiste en dos sensores de presión y un panel de visualización. PumpMeter viene totalmente equipado de fábrica y está configurado conforme a la bomba correspondiente. Se conecta mediante un conector M12 y está listo para funcionar de manera inmediata.

Detalles

KSB Guard

KSB Guard
Documentos

Servicio de vigilancia inteligente e integral para bombas y otras máquinas rotativas: disponible las 24 horas del día, los 7 días de la semana, e independiente del fabricante. Con KSB, se beneficiará de un mantenimiento predictivo y una transparencia total de los datos, así como de mayor disponibilidad, más fiabilidad operativa y un funcionamiento eficiente (de las bombas de velocidad fija). Los datos importantes del funcionamiento, como las vibraciones, la temperatura, las horas de servicio y el estado de carga (de las bombas de velocidad fija) se pueden consultar en cualquier momento y en cualquier lugar con KSB Guard. Si se produce alguna desviación del funcionamiento normal, se envía una notificación inmediatamente a través del portal web o la aplicación KSB Guard. Además, los expertos del centro de vigilancia de KSB le ayudarán a analizar la causa.

Detalles

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