The Kalle-Albert Industrial Park premises at night

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 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.

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 MyFlow/Etanorm Pro

Documentos

Bomba com corpo de voluta de estágio único em construção de processo, com potências e medidas gerais de acordo com a norma EN 733, com sistema de accionamento compatível com IEC PumpDrive 2 com SuPremE ou PumpDrive 3 da classe de eficiência IE4/IE5 de acordo com a norma IEC TS 60034-2-3:2016 e inversor de frequência integrado no motor. A bomba é composta por anéis de desgaste do corpo substituíveis, impulsor radial fechado com lâminas espacialmente curvadas, empanques mecânicos duplos e individuais de acordo com a norma EN 12756, veio na área da vedação do veio com uma camisa de protecção do veio substituível. A construção processual permite que o acoplamento, a caixa de rolamentos e o impulsor sejam desmontados sem a necessidade de separar o corpo da bomba das tubagens. Pontos de fixação em conformidade com a norma IEC 60072, substâncias de revestimento em conformidade com a norma DIN V 42673 (07-2011). Versão com protecção antideflagrante disponível. Muito além dos requisitos de eficiência das directivas ErP.

Detalhes

KSB Guard

Documentos

Serviço de monitorização mais inteligente e abrangente para bombas e outras máquinas rotativas: disponível 24 horas por dia, 7 dias por semana, e independentemente do fabricante. Juntamente com a KSB, poderá obter manutenção preditiva e beneficiar de uma transparência abrangente, maior disponibilidade, maior segurança operacional e um funcionamento eficiente (de bombas não reguladas). Dados operacionais importantes como oscilações, temperatura, horas de funcionamento e estado de carga (de bombas não reguladas) estão disponíveis a qualquer momento e em qualquer lugar com o KSB Guard. Se ocorrer também um desvio do funcionamento normal, é enviada uma notificação de imediato através do portal web KSB Guard/da aplicação. Além disso, os especialistas do centro de monitorização da KSB fornecem suporte na análise de causas.

Detalhes