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Predictive maintenance at the Kalle-Albert Industrial Park

75 different companies are located at the Kalle-Albert Industrial Park employing a total of around 6000 staff. A reliable supply of compressed air used for the mechanical control of large production systems is a technical requirement for numerous production plants. Failure of the compressed air supply would have serious consequences – and this is a good reason to ensure that impending changes in status data and potential faults are detected before they actually occur.

The Kalle-Albert Industrial Park premises at night

The project: Reliable monitoring of the cooling system

In the scope of the Industry 4.0 concept, ISW-Technik, a subsidiary of industrial park operator InfraServ Wiesbaden (ISW), uses innovative technologies to implement smart servicing and maintenance processes based on digital condition monitoring of machines and systems for small and medium-sized companies. Predictive maintenance has also achieved positive results indicative of future success. Late 2019 saw digital technology secure the production of compressed air essential for the industrial park and prevent the failure of an important pump used in this process.

The customer: InfraServ Wiesbaden

InfraServ Wiesbaden (ISW) has been operating the 96-hectare Kalle-Albert industrial park since 1997 and provides various utilities including power. The company employs about 900 people. Its subsidiary ISW-Technik has established itself among small and medium-sized companies based in the Rhine-Main region as an innovative service provider for applications including servicing and maintenance of machines and systems.

Logo of InfraServ, Wiesbaden

The challenge: Ensuring round-the-clock system availability

InfraServ Wiesbaden ensures that the industrial park is supplied with compressed air around the clock, providing about 22 thousand cubic metres of compressed air per hour at a gauge pressure of 5 bar which adds up to about 200 million cubic metres per year. ISW relies on two KSB components to keep the vital compressed air system running reliably and to cool the operating temperature continuously: Etanorm pumps and the reliable KSB Guard monitoring unit.

Having already had positive experience with KSB during previous projects, ISW was curious to see how the newly established system would prove its worth in this case. KSB Guard offers ISW production management and KSB technicians round-the-clock access to all pump status data (e.g. temperature, vibrations and load condition) via a web portal.

KSB Guard sensor unit installed on a pump

KSB Guard installed on a KSB pump

The solution: KSB Guard detects bearing damage at an early stage

A deviation from normal operation was reported on one of the pumps in October 2019. After KSB Guard had detected excessive vibrations and output a relevant warning, InfraServ Wiesbaden was informed automatically. Thanks to KSB Guard, ISW-Technik was able to detect impending bearing damage at an early stage – a normal sign of wear that makes bearing replacement necessary at varying intervals depending on the pump’s load.

ISW-Technik initiated a repair in its own workshop during periods when pump operation is not essential. This helped prevent in time a sudden system failure with unplanned downtimes and far-reaching resultant losses. If one pump had suddenly failed, a second pump would have cut in to maintain the production of compressed air. Nevertheless, the advantages of targeted and predictive maintenance measures are tremendous. 

KSB technology has not only helped to increase the safe and reliable supply of energy at the industrial park, this positive experience has also prompted ISW-Technik to install KSB Guard on other customers’ systems located in the industrial park.

Diagram showing the vibration curve of a KSB pump

Vibration profile recorded by KSB Guard indicating a deviation from normal operation

Figures I Data I Facts

System: Cooling system for compressed air supply in the Kalle-Albert Industrial Park
End user: InfraServ Wiesbaden

Project

  • 2x Etanorm 200-150-400
  • 2x KSB Guard
  • 1x KSB Guard Gateway


 

Products used

Etanorm

Etanorm

Horizontal volute casing pump, single-stage, with ratings and main dimensions to EN 733, long-coupled, back pull-out design, with replaceable shaft sleeves / shaft protecting sleeves and casing wear rings, with motor-mounted variable speed system. With KSB SuPremE, a magnetless synchronous reluctance motor of efficiency class IE4/IE5 to IEC TS 60034-30-2:2016, for operation with the 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.

KSB – 産業用バルブとポンプの世界トップレベルのメーカー

KSB は 1871 年にフランケンタール(ドイツ)で創立され、100 年以上にわたりポンプや産業用バルブのトップメーカーとしての地位を確立しています。世界中に 15,500 名以上の従業員を抱え、独自の販売会社、製造工場、サービス会社を持ち、さまざまな用途に向けてカスタマイズされたポンプを開発、製造しています。

経験豊富な当社のさまざまな製品が、建築物管理、産業技術、水輸送、廃水処理、発電所プロセスといった分野で使用されています。革新的な研究開発により、KSB はお客様のさまざまな要求にお応えすることが可能です。有名なポンプメーカーとして、KSB には長年にわたる経験と技術的なノウハウが備わっています。

ポンプ・バルブのKSB : お客様に最高の製品を
弊社のポンプ・バルブは優れた効率性を持ち幅広い用途に適しております。
ポンプでは標準的な水ポンプであるEtanorm をはじめとする数々のシリーズを設けております。
弊社の製品はその卓越した技術により長年にわたる安定した運転を実現し全世界の産業界に貢献しております。

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