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
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
The Challenge:
Extreme conditions for the pumps to handle while simultaneously ensuring minimal monitoring and maintenance
- 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.
The Solution:
KSB Guard identifies failure risks at an early stage, enabling maintenance to be precisely planned
“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
Single-stage close-coupled volute casing pump, with ratings to EN 733, with replaceable shaft sleeve and casing wear rings, with motor-mounted variable speed system. With KSB SuPremE, a magnetless synchronous reluctance motor (exception: motor sizes 0.55 kW / 0.75 kW with 1500 rpm are designed with permanent magnets) of efficiency class IE4/IE5 to IEC TS 60034-30-2:2016, for operation on a KSB PumpDrive 2 or KSB PumpDrive 2 Eco variable speed system without rotor position sensors. Motor mounting points in accordance with EN 50347, envelope dimensions in accordance with DIN V 42673 (07-2011). ATEX-compliant version available.
HGM/HGM-S
Horizontal radially split product-lubricated multistage ring-section pump with radial impellers, axial and radial single-entry inlet.
MegaCPK
Horizontal radially split volute casing pump in back pull-out design, with radial impeller, single-entry, single-stage, to DIN EN ISO 5199, dimensions to DIN EN ISO 2858, complemented by nominal diameters DN25 and ≥DN200, in large range of material and seal variants; also available as a variant with "wet" shaft and conical seal chamber. ATEX-compliant version available.
Movitec
Multistage vertical high-pressure centrifugal pump in ring-section design with suction and discharge nozzles of identical nominal diameters arranged opposite to each other (in-line design), close-coupled. With KSB SuPremE, a magnetless synchronous reluctance motor (exception: motor sizes 0.55 kW / 0.75 kW with 1500 rpm are designed with permanent magnets) of efficiency class IE4/IE5 to IEC TS 60034-30-2:2016, for operation on a KSB PumpDrive 2 or KSB PumpDrive 2 Eco variable speed system without rotor position sensors. Motor mounting points in accordance with EN 50347, envelope dimensions in accordance with DIN V 42673 (07-2011). ATEX-compliant version available.
Multitec
Multistage horizontal or vertical centrifugal pump in ring-section design, long-coupled or close-coupled, with axial or radial suction nozzle, cast radial impellers and motor-mounted variable speed system. ATEX-compliant version available.
RDLO
Single-stage axially split volute casing pump for horizontal or vertical installation, with double-entry radial impeller, mating flanges to DIN, EN or ASME.
KSB Guard
The smart and comprehensive monitoring service for pumps and other rotating machinery, available 24/7 and also for non-KSB pumps. Benefit from predictive maintenance with KSB: comprehensive transparency, increased availability, enhanced operating reliability and efficient operation (of fixed-speed pumps). Important operating data such as vibrations, temperature, operating hours and load condition (of fixed-speed pumps) can be accessed via KSB Guard, anytime and from anywhere. In addition, deviations from normal operation trigger immediate notifications via the KSB Guard web portal and/or app. The experts at the KSB Monitoring Centre also provide support in analysing causes.
PumpDrive 2/PumpDrive 2 Eco
Modular self-cooling frequency inverter that enables continuously variable speed control of asynchronous and synchronous reluctance motors by means of analog standard signals, a field bus or the control panel. As PumpDrive is self-cooling, it can be mounted on a motor, on the wall or in a control cabinet. Up to six pumps can be controlled without needing an additional controller.
PumpMeter
Device for monitoring the operation of one pump. It is an intelligent pressure transmitter for pumps, with on-site display of measured values and operating data. It records the load profile of the pump in order to indicate any potential for optimising energy efficiency and availability. The device comprises two pressure sensors and a display unit. PumpMeter is supplied completely assembled and parameterised for the pump it is used with. It is ready for operation as soon as the M12 plug connector is plugged in.