AUTOMATION & CONTROL
POSSIBILITIES AND BENEFITS OF SMART MONITORING
KSB recently introduced remote acceptance testing for the live testing of pumps and hydraulics via the internet
Cloud computing, big data analytics, augmented reality, and the industrial internet of things have been embraced by leading pumps and valves supplier KSB.
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hanks 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-todate, 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.
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MAY /JUN 2022
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.
