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Accolade for an intelligent monitoring tool

In times of increasingly professionalised cyber attacks, the importance of secure network components is growing exponentially. This is one reason why internet-enabled products are thoroughly scrutinised by customers before they are used. KSB’s cloud-based KSB Guard was examined by the rubber and plastics specialist ContiTech, and passed the validation with flying colours. This achievement almost overshadowed the fact that the main contract involved the refurbishment and modernisation of an entire cooling water system.

The company premises of Continental AG in Hanover from the outside

The project: Renewing the cooling water supply system

2017 saw ContiTech invite tenders for the renewal of the cooling water supply system at its Hanover Vahrenwald factory. The company planned to refurbish and modernise the cooling water system in the entire factory, as well as making it energy-efficient. The work included the renewal of pumps, motors, frequency inverters, shut-off and non-return valves; the installation of prefabricated piping; the construction of pump foundations and baseplates; and the removal of the old pump sets.

The customer: ContiTech

Hanover-based ContiTech is one of the world’s largest manufacturers of rubber and plastic products outside the tyre industry and is part of Continental. In 40 countries, the technology company’s 46,000 employees develop and produce functional parts, components and systems for almost all sectors of industry and commerce and combine them with individual services.

Pumps, piping, sensors and frequency inverters of ContiTech AG’s cooling system

Etanorm pumps with PumpDrive and KSB Guard

The challenge: Intelligent, reliable and secure monitoring solution

It was planned to implement an intelligent and above all reliable and secure monitoring solution to continuously monitor the operation of all pumps and to report potential irregularities in good time before a failure actually occurs. A further challenge was the fact that production at the Vahrenwald factory runs almost around the clock, only stopping for few national holidays. The tender specified that work on the pump systems had to be carried out during ongoing operation without any downtime in production.

The solution: Experience and highest safety standards

When submitting its quotation, KSB was able to refer to its many years of experience and a full range of services as a single-source supplier. A further advantage is that KSB operates a global network of service partners. In its subsidiary Dynamik-Pumpen GmbH, KSB has a reliable and experienced service company available locally and able to provide services around the clock if needed at a later stage.

When drawing up its detailed design implementation plans, Dynamik-Pumpen GmbH went beyond the stipulations set out in the tender documents. After receiving the order, KSB’s specialists made an extensive analysis of the old system. This yielded further important details which complemented ContiTech’s well thought-out specifications and enabled KSB’s experts to maximise the reliability, security and energy efficiency of the entire system while staying within the budget.

As to the choice of pumps, KSB decided to opt for the high-performance Etanorm, the world’s best-selling standardised water pump. It is known for its impressive efficiency and extremely robust and durable motors. Etanorm was supplemented with PumpDrive, a frequency inverter that dynamically adapts pumps’ output and speed to actual demand, making them extremely energy-efficient and reliable to operate. In addition, Etanorm features extremely smooth running characteristics which met ContiTech’s requirement to significantly reduce noise levels on site.

Pumps, pipes and valves of ContiTech AG’s cooling system

Etanorm pumps and new piping

In order to meet the requirement of removing old and installing new equipment without interrupting production, KSB supplied large prefabricated piping sections that could be integrated with the pumps, valves and other components already on site to replace the old equipment.

All areas at ContiTech are subject to strict regulations and guidelines. But having to meet demand criteria is nothing new for KSB pumps and valves, and these products are generally well ahead of their time in terms of meeting exacting standards.

The OK for the installation of KSB Guard came immediately. The security measures integrated into the KSB Cloud and all hardware components proved 100% convincing because they guarantee a level of security comparable with online banking by using maximum data encryption and actively blocking potential external attacks.

But what makes KSB Guard so unique? The innovative and easy-to-install monitoring system includes sensors that detect irregularities in KSB pumps and third-party products before a malfunction occurs so that major damage and failures can be reliably avoided. 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. 

The system operator benefits from predictable and less frequent downtimes, better maintenance strategies and significantly reduced operating costs for a relatively modest investment.

Pumps, piping and valves of ContiTech AG’s cooling system

Etanorm pumps with attached KSB Guard

Data I Facts I Figures

System:
Cooling water supply, Vahrenwald factory

End user:
ContiTech AG

Project data: 

  • 6x Etanorm 100-80-315 with 45kW synchronous reluctance motor, PumpDrive and KSB Guard

KSB on üks maailma juhtivamaid tööstuslike ventiilide ja pumpade tootjaid

KSB asutati aastal 1871 Frankenthalis (Saksamaa) ja on olnud juba üle 100 aasta üks juhtivaid pumpade ja tööstuslike ventiilide tootja. Maailmas enam kui 15 500 töötajaga oma müügi-, tootmis- ja hoolduskeskustes arendab valmistab KSB eritellimusel ja standardpumpasid erinevate valdkondade jaoks.

Ettevõttel on pikaajaline kogemus pumpade tootmisel ning selle tooteportfell hõlmab tooteid ehitusvaldkonnale, tööstustele, elektrijaamadele, katlamajadele, veevarustusele ja reoveele. Tänu uuenduslikule teadus- ja arendustööle suudab KSB täita oma klientide kõige erinevamaid nõudmisi. Tunnustatud pumbatootjana on KSB-l olemas kauaaegne kogemus ja tehniline oskusteave.

Pumbatootja KSB – parem lahendus teie süsteemile
KSB tööstuspumbad ja -ventiilid sobivad paljudele erinevatele rakendustele ning on väga energiasäästlikud. Meie tooted avaldavad muljet nii oma tipptasemel tehnoloogia ja kui ka paljude aastate jooksul katsetatud süsteemidega. Hea näide sellest on Etanorm veepump. Seda on müüdud enam kui 1,5 miljoni, mis teeb Etanormist  kogu maailmas enimmüüdud standardse veepumba. Vaata ka KSB hooldusteenuseid ja varuosad varuosasid.

Hüdraulika, materjalitehnoloogia ja automatiseerimine on KSB tehnoloogilised tugevad küljed ning just selles peitub ka tema suure võimsusega pumpade edu valem.

Kompetentne teenindus algusest peale
Tänu arvukatele esindustele on KSB klientidele lähedal ja suudab pakkuda tipptasemel teenust. Ulatusliku kogemustepagasiga sertifitseeritud spetsialistid tagavad suurepärase kvaliteedi. KSB hooldusteenuse spetsialistid hoolitsevad teie pumpade, ventiilide ja terviklike süsteemide kasutuselevõtmise, ülevaatuse, hoolduse ja remondi eest kohapeal. Samuti tarnib KSB teile varuosad kiirelt. Nii saate kasutada parimat teenust otse pumbatootjalt.