Digital monitoring tool KSB Guard continuously monitors pumps
Thanks to KSB Guard, it is now possible to avoid malfunctions and efficiently plan maintenance. The tool is in operation at the ROLF SANDVOSS INNOVATION CENTER of SAMSON AG.
Thanks to KSB Guard, it is now possible to avoid malfunctions and efficiently plan maintenance. The tool is in operation at the ROLF SANDVOSS INNOVATION CENTER of SAMSON AG.
The Project:
KSB equips unique development and test centre with monitoring tool and pumps
As well as being the world’s largest development and test centre for valve technology, it is also unique with regard to its form: the ROLF SANDVOSS INNOVATION CENTER (RSIC) operated by SAMSON. After two years of construction work, the RSIC in Frankfurt was officially inaugurated in 2017.
Since then, the 7,000 square metre facility has been used for research, development and testing. The goal of SAMSON’s innovation centre is to develop reliable and innovative products of excellent quality for a wide range of applications – and to do this as quickly as possible.
A high degree of reliability and quality can only be guaranteed when products are tested in advance under the most extreme conditions, which is exactly what SAMSON does at the innovation centre. The basis for this is a state-of-the-art testing system – the centrepiece of the facility. It enables tests to be performed in a wide variety of test scenarios with regard to the fluids used, process conditions and industrial application fields.
An important part of the system is the KSB Guard digital monitoring tool. It continuously monitors the pumps, which were also supplied by KSB. Continuous monitoring enables SAMSON to avoid unscheduled downtimes and efficiently plan pump maintenance, ensuring that the system is operated economically and smoothly.
In addition to striving for excellent quality products, SAMSON and KSB are also united by their successful collaboration on previous projects which fostered a spirit of mutual trust. In addition to opting for KSB products, SAMSON furthermore asked KSB to act as its full-service partner for this unique project.
The KSB pumps located in the cellar need to start smoothly at all times, even under the most extreme loads and with irregular operating times.
The Client:
SAMSON AG is a manufacturer of control valve technology
Headquartered in Frankfurt am Main, SAMSON AG offers system and product solutions for controlling all types of fluids. The company produces valves, self-operated regulators, actuators, valve accessories, signal converters, automation systems, sensors, thermostats and digital solutions. Fields of application include chemical facilities, power stations, the distribution of district heating, food production and building automation. SAMSON was founded by Hermann Sandvoss in 1907 and today employs around 4,400 staff worldwide.
The Challenge:
Extreme conditions for the pumps to handle while simultaneously ensuring minimal monitoring and maintenance
The project entailed a whole series of challenges.
- SAMSON required a large number of different pumps which had to be able to withstand sometimes extreme conditions. As SAMSON measures Kvs values and tests pressure losses on its valves, the pumps had to be able to handle pressures of up to 120 bar and flow rates of up to 10,000 cubic metres per hour.
- Pump operation: the pumps are operated irregularly and with long downtimes. Nevertheless, the pumps must be able to be started up quickly and smoothly at all times.
- The pumps need to operate reliably and be easy to maintain. Removing the pumps and then reinstalling them again not only disrupts operations, it also costs time and money.
- The system is located in the cellar. However, a stable connection must be established between KSB Guard and the mobile phone network to ensure the exchange of data.
KSB Guard and KSB pumps only account for one part of the system. To successfully complete the project, effective collaboration with other companies involved was also required
The Solution:
KSB Guard identifies failure risks at an early stage, enabling maintenance to be precisely planned
The pumps need to operate smoothly despite extreme loads and irregular operating hours. At the same time, monitoring and maintenance needed to be reduced to a minimum. Thanks to the digital monitoring tool KSB Guard, both are possible. Vibration and temperature sensors installed on the pumps continuously monitor the pumps.
KSB Guard then sends the recorded data to the computer or app via the gateway. As the gateway can be positioned flexibly, this enables a stable connection to the mobile phone network to be established – even if KSB Guard is located in the cellar, as was the case with SAMSON.
This provides SAMSON with an overview of all information at all times. Failure risks can be identified at an early stage and maintenance can be precisely planned in advance. Not only does this reduce unscheduled downtimes and disruptions to operations, it also saves on costs.
A total of seven different KSB pumps are installed in the system with various different performance profiles. The individual pump models are Multitec, HPKL, MegaCPK, Etabloc, RDLO, HGM and Movitec.
The smaller pumps feature the PumpDrive variable speed system, which is especially recommended for use in systems with fluctuating demand – as is the case with the innovation centre. The flexible speed control system enables demand-driven operation. This saves energy and increases the efficiency and availability of the pump.
Detailed planning and structured organisation between SAMSON and KSB were crucial to the success of the project. Further success factors in the course of the project were a partnership-based approach to cooperation with all of the companies involved and the reliable supply and delivery of the products and services by KSB.
“Due to previous projects we were already very familiar with KSB’s products and were therefore confident that we had chosen the right partner to support us with such a complex project. KSB is also a pioneer in Industry 4.0 and digitalisation, as demonstrated for example by KSB Guard.”
- Domagoj Vnucec, Head of ROLF SANDVOSS INNOVATION CENTER, SAMSON AG
Used Products
Etabloc
Bomba monobloc de voluta, monoetapa, con rendimiento según EN 733, casquillo del eje y anillos de desgaste recambiables y sistema de regulación de velocidad integrado sobre el motor. Con KSB SuPremE, un motor síncrono de reluctancia sin imanes (excepto: los tamaños de motor de 0,55 kW / 0,75 kW de 1500 rpm están equipados con imanes permanentes) con clase de eficiencia IE4/IE5 según IEC TS 60034-30-2:2016, para su uso con sistema de regulación de velocidad de los modelos PumpDrive 2 o PumpDrive 2 Eco de KSB sin sensores de posición del rotor. Los puntos de fijación del motor son conformes a EN 50347. Las dimensiones de la superficie envolvente son conformes a DIN V 42673 (07-2011). Disponible en versión ATEX.
HGM/HGM-S
Bomba de cuerpo segmentado multicelular horizontal, partida radialmente, lubricada por el propio fluido, con impulsores radiales y aspiración radial y axial, de aspiración simple.
MegaCPK
Bomba horizontal de voluta partida radialmente en diseño “back pull-out”, con impulsor radial, de aspiración simple, monoetapa, conforme a DIN EN ISO 5199 , las medidas conforme a DIN EN ISO 2858 complementan los diámetros nominales de DN25 y ≥DN200, en gran variedad de materiales y sellados, disponible también con diseño de eje húmedo y cámara de cierre cónica. Disponible en versión ATEX.
Movitec
Bomba centrífuga vertical de alta presión, multicelular, diseño monobloc y cuerpo segmentado, con bridas de aspiración e impulsión de idénticos diámetros nominales en disposición in-line. Con KSB SuPremE, un motor síncrono de reluctancia sin imanes (excepto: los tamaños de motor de 0,55 kW / 0,75 kW de 1500 rpm están equipados con imanes permanentes) con clase de eficiencia IE4/IE5 según IEC TS 60034-30-2:2016, para su uso con sistema de regulación de velocidad de los modelos PumpDrive 2 o PumpDrive 2 Eco de KSB sin sensores de posición del rotor. Los puntos de fijación del motor son conformes a EN 50347. Las dimensiones de la superficie envolvente son conformes a DIN V 42673 (07-2011). Disponible en versión ATEX.
Multitec
Bomba centrífuga horizontal o vertical de cuerpo segmentado, multicelular, versión en bancada o monobloc, de aspiración axial o radial, con impulsores radiales fundidos y sistema de regulación de velocidad montado en el motor. Disponible en versión ATEX.
RDLO
Bomba de voluta partida axialmente, monoetapa, para instalación horizontal o vertical, con impulsor radial de doble aspiración, bridas de conexión según DIN, EN o ASME.
KSB Guard
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.
PumpDrive 2/PumpDrive 2 Eco
Variador de frecuencia autorrefrigerado de diseño modular que permite modificar gradualmente la velocidad de motores asíncronos y motores síncronos de reluctancia mediante señales estándar analógicas, un bus de campo o un panel de control. Debido a la capacidad autorrefrigerante de PumpDrive, puede ser montado directamente en el motor, en pared o dentro de un cuadro eléctrico. Puede controlar hasta 6 bombas en paralelo, sin necesidad de recurrir a un controlador externo.
PumpMeter
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.