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PuK - Process Technology & Components 2023

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Pumps and Systems

Pumps and Systems Diaphragm metering pumps Condition monitoring and prediction for diaphragm metering pumps Detect and avoid failures at an early stage Moritz Pastow Pump and plant availability are key factors for success in manufacturing companies. Production standstills mean sales losses. Due to more complex production systems and increasingly rigorous requirements for specific operator know-how, support from digital monitoring and analysis systems is necessary now in order to remain competitive in the future. 1. Diaphragm metering pump trends in the process industry Pumps are often primary units in the process industry. Diaphragm metering pumps are particularly used in critical processes. The trouble-free and efficient operation of the installed pumps is crucial for a safe and profitable plant. The major driver of innovation in the process industry is digitalization – and it doesn’t stop at pumps. It is true that a diaphragm metering pump is initially a mechanical product and, with proper maintenance, it is also quite durable and troublefree. Nevertheless, continuous operational monitoring is necessary in order to detect process deviations and damage in time. In addition, the requirements for energy efficiency and safety are becoming more stringent. As a result, various trends are visible in numerous companies: Smart Factory The process industry is in the middle of a digital transformation. Factories are becoming increasingly networked and data exchange both within and between process chains is increasing. Since pumps are often operation-criti cal units but few have a digital moni toring system, there is neither data nor characteristic values for many processes. Many operators use their pump based on experience and follow cyclical or reactive maintenance strategies. System complexity The complexity of production systems is continuously increasing. This is related to the requirements for quality and process reliability, as well as to the general digitalization of many production facilities. Know-how The changes in the labor market also impact the day-to-day operations in the process industry. More and more experienced employees are retiring, turnover is rising and specific process and plant knowledge is declining. For this reason, many operators are increasingly turning to digital monitoring and support systems. Safety and environmental requirements The requirements for operational safety are increasing, and characteristic values that reflect the ecological footprint of production are taking on greater importance. The comprehensive environmental report has long been more than a marketing gimmick for companies. For investors, authorities and employees, it is an essential factor for evaluation, auditing or personal identification. Energy management The transformation in the energy sector directly affects the process industry. Pumps in the process industry often run 24/7 and are thus major consumers of energy. Optimizing their efficiency can have a significant impact on the energy efficiency of the entire plant. But here, too, evaluation requires characteristic values. 2. Pump monitoring requirements Based on the trends in the process industry, various focal points can be derived for monitoring systems for diaphragm metering pumps. Condition monitoring and predication First of all, the operating states of the pump must be monitored and deviations from target values must be detected in good time. In the process, various parts of the pump must be monitored in a specific context: – Drive unit – Hydraulic system – Pump head – Valves System monitoring Within the plant, the pump can be used as a sensor for the complete system. With diagnostics collected in the pump, it is possible to derive statements about the system status: – Piping suction side – Piping pressure side – Pulsation – Flow rate – Fluid state Energy management and efficiency By measuring incoming energy and hydraulic power, it is not only possible to determine efficiency and CO 2 balance, but also to diagnose material-related signs of wear. – Efficiency – CO 2 balance – Load collectives 3. Digital monitoring and operational support LEWA Smart Monitoring is a monitoring system consisting of sensors, a programmable logic controller (PLC), an industrial PC (IPC) and 22 PROCESS TECHNOLOGY & COMPONENTS 2023

Pumps and Systems Diaphragm metering pumps Fig. 1: Structure of LEWA Smart Monitoring data analysis for new and existing pumps. The system determines characteristic values and key performance indicators. There is no process control intervention or direct contact between the sensor system and the conveyed fluid. With parameter-based condition monitoring, operators detect and monitor their pumps proactively. They can also optimize the overall output and robustness of their pump and piping systems. This increases the efficiency of their entire production plant. Characteristic value determination is based on recording measured variables such as structure-borne noise, hydraulic pressure and trigger. To get results, 2,000 signals per pump head are processed per second. These signals are recorded by the connected PLC. The characteristic values and diagnoses are output and transmitted via various interfaces. The IPC has a web-based interface for making settings and visualizing the determined characteristic values and diagnoses. An OPC UA server is provided for transmission to a control center. In addition, characteristic values and diagnoses can be transmitted to the LEWA cloud and the customer portal via an Internet connection. Overview of diagnosis Fig. 2: Diagnoses with LEWA Smart Monitoring Hydraulic system: Diagnoses that are possible based on the analysis of the hydraulic operation of the pump Drive unit: Diagnoses that enable statements to be made about the action and condition of the pump unit Valves: Statements on the condition of valves on the suction and discharge sides of the pump Pump head: Diagnoses regarding the pump head and the diaphragm System: Diagnoses regarding the connected system, which consists of piping, pulsation dampers and MSR technology Table 1: Pump design 5. Use case: Data-based failure prevention and root cause analysis As described above, the various requirements for a monitoring solution for diaphragm metering pumps can be summarized in the categories of condition monitoring and prediction, system monitoring and energy management & economy. In the following, various use cases are described based on the practical use of a Smart Monitoring System in a metering system. The characteristic values used to describe the use 4. Smart Monitoring System performance The following diagram shows the possible diagnoses and characteristic values in the cross-section of a diaphragm metering pump. A distinction is made between five main areas for diagnostics. Bar force [N] 2000 Stroke adjustment type Electric Stroke frequency max [min -1 ] 163 Metering flow at pmax [l/h] 367 Max. perm. working pressure [bar] 19.5 Motor power [kW] 0.55 PROCESS TECHNOLOGY & COMPONENTS 2023 23

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