The combination of variable speed drives, sensors and inherent control features provide a better basis for the pump to adapt to operating conditions. The result is cost savings and increased efficiency. The combination of these two factors makes it easier for chemical plant operators to accept this technology. However, considering design issues is not enough. Attractive system solutions may be more persuasive.
- HJBITTERMANN
In the chemical industry there seems to be a mystical relationship between the number of employees and the number of pumps used. BASF is not the only company moving in the direction of "one man, one pump." In short, the rapid growth of the pump is an obvious manifestation of its importance in chemical plants. However, Dr. Udo Stezer is quite clear about the "working conditions" of pumps in chemical plants. You must evaluate the change in media properties and suction conditions. It is usually necessary to consider the special hazards posed by the media. All of this means that the pump must meet stringent quality and safety requirements. "Although the intent of all the stakeholders is good, standardizing the pump can be very difficult due to the required changes," explains Stezer. However, if the pump is efficient and has a minimum life-cycle cost (LCC), the pump should fit well into the entire system. There are many ways to get a lower LCC:
Increase effectiveness (electrical, mechanical and hydraulic) and use new drives and control schemes (especially to reduce local load losses) in order to make better use of energy.
Increase service life (MTBF) by introducing mechanical improvements (such as shaft seals), durable materials and using early warning and status diagnosis strategies.
Adopt innovative maintenance strategy to increase input-output ratio.
Reduce investment and costs by streamlining and standardizing vendors, products, models and types. This last point at BASF is a big deal, Stezer said explicitly. This is good news for large industrial players, but it is hard for a small manufacturer to do so.
Useful information, not just data
Moving mechanical parts are always subject to wear and tear, no matter how good and durable the individual parts are. So, how can we better deal with wear and tear caused by an unpredictable failure?
Traditional sensors pick up a measurement and send out something that all operators are unwilling to see, in other words, the wrong message. Ideally, early error detection intervenes before this phase, sending a fault signal before the pump fails to work or damage occurs. Gerhard Berge of KSB talked about this topic at the recent Dechema Pumping Conference in Frankfurt, Germany. Operators have raised questions they are worried about, which are caused by sensors, which send large amounts of unanalyzed data. Mr. Berge can answer these questions. KSB's PumpExert system has been designed as an intelligent diagnostic system that alerts operators in a timely manner that damage may occur. KSB also promised to give "a clear idea of ​​what the status displays and what should be done." PumpExpert features a modular structure. The operator can decide which one to use and which one to use, and which he can install at any time to upgrade and extend the product. These modules turn the pump into an intelligent system that can help minimize life-cycle costs. The precise conditions and details regarding the pump in service increase the reliability of the process and the efficiency of the system, but also reduce the possibility of maintenance and operating costs.
Vacuum pump mechanical and electronic solutions
Sterling SIHI has introduced a new technology for vacuum drying pumps. Vacuum is used for basic thermal operations in the chemical industry, such as concentration, distillation and drying, all at low temperatures in order to avoid damaging the product. Suitable pumps must be capable of safely delivering flammable gases without any permanent damage caused by corrosive media. Mechatronic vacuum systems operate at no-load, gearless screw pumps (each with its own electronically connected drive). This type of pump is developed for use in the field of conveying explosive media. The special heat dissipation features and electronic synchronization of the shaft eliminate potential sources of ignition during normal operation or under conditions that may cause errors. The vacuum system is a Type 2 instrument and can operate without a flame trap. Electronic synchronization is used to monitor the shaft's torque during operation. If the shaft is lifted beyond the permissible limits, the pump will decelerate automatically or stop in extreme conditions.
The application of electronic equipment must not increase the risk of failure
Although the application of electronic components (speed adjustment components, early misrecognition, etc.) can make the operating environment more harmonious, experts cautioned that this must not come at the cost of additional risk. Events in the automotive industry have shown that too much use of electronic components can easily lead to new problems. Failure of mechanical components is generally due to wear and tear (the degree of wear can be measured or predicted empirically), while the failure rate of electronic components can usually only be described in statistical terms.
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