Cloud computing, big data analytics, augmented reality, and the industrial internet
of things have been embraced by leading pumps and valves supplier KSB.

Thanks to a variety of ‘smart’ products and services – like the PumpMeter, KSB Guard, SES, Sonolyzer and motion amplification – pumping systems are becoming more efficient and more reliable. KSB clients can obtain up-to-date, relevant information regarding the status, operation and history of a pump at any given time.

KSB Guard

“KSB has experience in developing solutions for Industry 4.0 and offers a wide range of smart products and services designed to improve the productivity of its pumps. One such product is KSB Guard, which offers pump monitoring in real time, optimising maintenance, reducing downtime and significantly increasing pump system efficiency,” says DeWet Holtzhausen, draughtsman, KSB.

KSB Guard continuously records the vibration and temperature data of a pump and transfers it to the cloud. Analysis of this and other pump data is then available via the KSB web portal and KSB Guard app. This provides a reliable database for further optimisation measures on a system and rapidly detects faults.

Vibration and temperature data can be presented via a graph over a specified period of time (month, year or day). Furthermore, KSB Guard uses a complex algorithm patented by KSB to calculate the optimal load conditions of any pump and will indicate if a pump is running at a partial load, optimal load or is overloaded.

The system consists of hardware components that are linked to a KSB cloud app, where the status and operating data of pumps can be remotely monitored. Notifications are sent (via email or cell phone) when irregularities are detected.

“Access to detailed information on the efficiency and overall condition of a pump enables our customers to optimise their maintenance strategy. Faults can then be remedied before failure occurs and substantial damage is caused. Better maintenance strategies facilitate the procurement of spare parts and other maintenance services in good time. By predicting and reducing downtime, operating costs are reduced,” explains Holtzhausen.

Users can receive scheduled maintenance reminders and all maintenance work can be recorded and stored along with related documentation such as maintenance manuals and data sheets.

The KSB Guard system comprises:

• Sensor – a three-axis vibration sensor and a temperature sensor that records data directly at the pump.

• Transmission unit and battery – supplies power to the sensor unit and transfers measured data to the gateway.

• Gateway – connects wirelessly with the transmission unit. One gateway can connect with up to 40 transmission units within a 50 m free field and 30 m in plant environment radius. It uses a KSB sim card to communicate through local cell phone towers.

• KSB Guard web portal and app – data and additional information on the pump can be evaluated conveniently and easily in the app or accessed via a computer.

“This product is easy to install. The kit is supplied with magnets (inside the sensors), cable ties and adhesive pads. The transmission and battery unit are mounted near the sensor. The gateway should be installed near the pump and the plug to the mains is connected. Once mobile reception has been established, a few basic data entries are made for each pump on a mobile device or desktop, and it is ready to be used,” adds Holtzhausen.

All data is protected according to ISO 27001. If there is a power cut, the battery-operated transmission unit can store data and send it to the gateway once there is power again.

Other monitoring equipment

Jaco de Pooter, operations manager, KSB SupremeServ, reveals that while the vibrations and temperature on the bearings of a pump are good parameters to monitor, it is important to look at the entire performance of a pump, taking into consideration all operating parameters such as suction and discharge head, as well as flow. “In order to estimate the operational life of the pump and its maintenance needs, one must consider all the parameters of the pump, as well as the system in which it operates.”

The KSB Sonolyzer is a noise analysis app for asynchronous motors. “In essence, it’s an app that can determine by way of analysing the noise frequency emitted from the motor’s performance. This then can be used to determine possible faults, which, when rectified, could enhance or lead to improved energy efficiency. In just a few seconds, the KSB Sonolyzer can measure the noise frequency of an asynchronous motor in order to find out if there is energy saving potential.

The app uses an estimation algorithm developed by KSB and is the first of its kind on the market. This is a very simple tool and can be used on not only KSB pumps but also on rotating equipment produced by many other manufacturers,” De Pooter adds.

System Efficiency Service (SES)

KSB also provides its SES service, which increases the economic efficiency of a pumping system through comprehensive system analysis.

A data logger takes measurements on site and records process variables and vibration levels to determine the pumps’ operating behaviour. Power analysers, in conjunction with pressure transmitters and a flow meter, are used in order to obtain all the relevant data to compare against the pump performance curve.

“Once all of the data has been collected, KSB analyses all the captured information, compares it to the pumps’ design conditions and, after a series of calculations, we advise our customer on corrective measures for potential savings in energy costs. We identify potential savings (energy-efficiency analysis) as well as any causes of damage (damage analysis),” says Charl van Loggerenberg, technician: SES, KSB.

He adds that the SES identifies where a pump may be operating on the curve. “A pump operating to the left of a curve would indicate an increased head with a reduction in flow, that can cause bearing and mechanical seal issues and high vibrations. If a pump is operating to the right of a curve, there will be increased power consumption as well as the aforementioned anomalies.”

The SES provides a detailed overview of the current energy efficiency of the pumps and systems. On this basis, KSB makes recommendations for increasing energy efficiency. This significantly lowers a pump’s life-cycle costs, reduces breakdowns, and achieves the energy objectives set out in ISO 50001.

Careful examination of the pump’s load profile is required both under current operating conditions and with a view of future demands. The aim is to identify pump system issues, opportunities for improvement, and savings potential – both today and tomorrow – in a comprehensive, systemic approach.

A pump is a complex component in a larger system. Improvements in energy efficiency come from lots of small details, but the focus always has to be on the analysis of the overall system. That is just as true for existing plants as for new designs.

Regardless of the field of application or specific industry sector, type of installation or manufacturer (energy, iron and steel, API, water or wastewater), the system efficiency service can be conducted on all pumps from ratings of 30 kW. This includes explosive zones.

KSB Guard. Umfassende Kontrolle über Ihre Pumpen – sicher, schnell und einfach (German) – YouTube

Other technologies of the future

KSB also provides a new service concept based on augmented reality and has recently purchased new technology called motion amplification.

With augmented reality, device users or technicians are guided during their service work by an expert per video and audio by using data glasses. The experts, looking into their screen at their usual service workplace, can assess the situation through the eyes of the person present at the site.

This helps instruct technicians who are not specialised in pumps, for example, to carry out common maintenance measures, step by step. Further, the data glasses can be used to transmit exploded views or screenshots that can then be viewed in the corresponding field.

“Motion amplification uses proprietary video and image processing to detect subtle motion and make it visible to the naked eye. This assists our teams in visualising complex vibration problems that may be invisible to the naked eye. It can save time and costs in vibration analysis, routine condition monitoring programmes, troubleshooting and root cause analysis,” explains De Pooter.

“Customers are hesitant to adopt a new technology or system that is unfamiliar to them. But digitalisation can make significant improvements to operational efficiency. However, De Pooter does encourage customers to embrace a systematic approach. “There is seldom an overnight solution when tackling pump performance issues.”

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