Our technology. Your success.Pumps n Valves n Service

Die Analyse des Systems

Transparenz schaffen Lastverhalten ermitteln

Die Auslegung

Anlagenstruktur definieren Komponenten auswählen

Die Inbetriebnahme

Fachgerechte Installation Professionelle Inbetriebnahme

Der hocheffiziente Betrieb

Intelligente Pumpentechnologie

Kontinuierliches Monitoring

Die Analyse des Systems

Transparenz schaffen Lastverhalten ermitteln

Die Auslegung

Anlagenstruktur definieren Komponenten auswählen

Die Inbetriebnahme

Fachgerechte Installation Professionelle Inbetriebnahme

Der hocheffiziente Betrieb

Intelligente Pumpentechnologie

Kontinuierliches Monitoring

Your system rendered fully transparent with SES System Efficiency Service

System analysis Creating transparency

Determining the load profile

Selection Commissioning Highly efficient operation

The analysis is the first step to systematically optimising your system with FluidFuture®

Systematically identifying optimisation potential with SES and FluidFuture®

Operating a hydraulic system reliably and efficiently requires knowledge and understanding of how the system is actually behaving. To this end we perform extensive measurements of all relevant process variables. Our expertise and long-standing experience allow us to precisely analyse the recorded load profile and provide recommendations for action regarding energy efficiency and improved system availability.

Efficient and reliable system operation thanks to FluidFuture®

An analysis of potential optimisations provides the basis for

improving your system’s energy efficiency and availability

sustainably. With FluidFuture® we look at the entire life cycle

of your hydraulic system and then apply a four-step procedure

to perfectly match the system’s individual components to one

another. Combining our expert knowledge with smart products

and services enables us to exploit all potential savings, lowering

your operating costs significantly. As well as increasing the

economic efficiency and availability of your system, the energy

objectives in accordance with ISO 50001 are also achieved.

For more information visit www.ksb.com/fluidfuture

0302 Introduction

Increasing system profitability through comprehensive system analysis

Process variables:

■n Pressure (EN ISO 9906)

■n Effective power

■n Rotational frequency

■n Fluid and bearing temperature

■n Flow rate

■n Analog signals (customer) 0/4-20 mA

Pump Operation Check for single-pump applications

The efficiency of single pumps is analysed using Pump Operation Check.

This includes measuring the pressures over a representative period of time and esta-

blishing a qualitative load profile based on the data compiled. The measurement is

performed with KSB’s PumpMeter without interrupting the operating process. In

addition to the load profile, our experts not only give specific recommendations for

action based on the efficiency analysis but also provide a profitability analysis. For

more information visit www.ksb.com/poc

Identification of potential with KSB Sonolyzer®

Whether or not detailed measurements of a pump are worthwhile depends on what

potential savings are possible. The free KSB Sonolyzer® app analyses the motor sound

of fixed-speed asynchronous motors to identify whether the operating point is inside

or outside of the part load range. Performed during a site survey, this quickly and

reliably reveals savings potential and prevents unnecessary measurements.

Discover your savings potential: www.ksb.com/sonolyzer-en

Whatever the application – energy, industry, water or waste water – comprehensive system

analyses include the recording of the pumps’ actual load profile using a data logger.

Experienced project engineers evaluate the measurement data and compare it with the

pumps’ design conditions. This allows them to identify potential savings (energy efficiency

analysis) as well as any causes of damage (damage analysis).

Regardless of the installation type (dry/wet) and manufacturer, a system analysis can be

performed for all pumps from ratings of 30 kW.

Etanorm with PumpMeter

50001ISOOverview of system analysis

■n Energy efficiency analysis in

accordance with ISO 50001

■n Identification of causes of damage

by means of vibration analyses

■n Report and presentation of

findings including action plan

and profitability analysis

■n Verification of implemented

measures via a free-of-charge

second measurement

Vibration levels to DIN ISO 10816

■n Vibration velocity

■n Frequency spectra

■n Natural frequency analyses

■n Diagnosis of rolling element

bearing noises

First methods for evaluating potential savings

0504 System Analysis

Energy efficiency analysis: a waterworks achieves energy savings of 25 %

Our system analysis revealed significant potential savings for the

clean water pumps used in a waterworks. Three variable speed

pumps installed in parallel transported clean water to an elevated

tank. The every-day demand was covered by a single clean pump

running at reduced speed in continuous operation. With approx.

60 m3/h, it delivered an almost constant flow rate, thus keeping

the elevated tank fill level constant. This meant that the clean water

pumps were continuously operated in the part-load range, reducing

overall efficiency and increasing specific energy consumption.

Recommendations for action:

n■ Adapting tank management

n■ Employing measured start/stop operation instead of

continuous pump operation

n■ Operating the clean water pump at nominal speed in

a significantly improved efficiency range

Saving costs through SES – 1st option

Energy costs per year before optimisation 213,772 €

Energy costs per year using a variable speed system 105,065 €

Savings p.a. 108,707 €

Investment costs 172,773 €

Payback period 1.59 Jahre

Energy savings 905,896 kWh/a

CO2 savings 512.7 t/a

Energy efficiency analysis: energy savings of 51 % n the cooling water circuit

Six circulating pumps installed in parallel in the cooling water

circuit of a steel mill were being operated at constant speed with

fluctuating system load. The pumps were continuously controlled

via throttling using discharge-side valves. The system analysis

revealed distinctive signs of wear in combination with increased

vibrations. Repairing the pumps was no no longer economical.

Recommendations for action:

n■ Avoiding throttling losses and

n■ Increasing the efficiency by installing new pumps equipped

with a smart pump control system

1st option: Same number and size of new pumps incl. control

system – therefore no need for piping modifications

2nd option: Same number, however smaller new pumps incl.

control system – piping modifications required (additional costs)

3rd option: Reduced number of pumps with identical system load –

additional costs for adapting the piping, but lower investment

costs for new pump sets

Costs saved thanks to SES

Energy costs per year before optimisation 31,013 €

Energy costs per year with modified control strategy 23,163 €

Savings per year 7,850 €

Costs for control modification 1,381 €

Payback period 0.2 Jahre

Energy savings 78,502 kWh/a

CO2 savings 44.4 t/a

Repeated bearing damage and defective magnetic couplings on

a process pump used in a chemical company have resulted in

increased maintenance costs and reduced system availability.

The process data from the customer did not reveal any irregu-

larities in the system’s process. The system’s actual behaviour

Damage analysis: improved process reliability thanks to measurements with high sample rates

Repeated winding damage was noted on the submersible motors

of UPA pumps installed in a reverse osmosis system for seawater

desalination. Following detailed measurements in the power

grid, we were able to identify impermissible voltage peaks. They

became apparent in the carrier frequency of the frequency inver-

ter between the output filter and the submersible motor.

Damage analysis: increased availability of UPA pumps

These voltage peaks caused the damage to the motor windings.

The suggested remedies: optimise the mains filter, improve the

earthing system and retrofit the motors with special windings

better suited to coping with the increased load conditions resulting

from frequency inverter operation.

only became transparent after KSB had performed process data

measurements with high sample rates. We were thus able to

identify the collapse of vapour bubbles and the resultant pressure

surges which ultimately led to the frequent damage of the pumps.

Burnt submersible motor windings Broken bearing bush of process pump

6

7

8

9

10

11

12

13

14

11:00:00 12:00:00 13:00:00 14:00:00 15:00:00 16:00:00

Pres

sure

[b

ar]

Time [h]

Inlet pressure Discharge pressure Inlet pressure, customer’s PCS

Start of automatic mode

-2

-1,5

-1

-0,5

0

0,5

1

1,5

2

-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10

Mai

ns

volt

age

[kV

]

Time [ms]

U1 U2 U3 U12 U23 U31

Impermissible voltage peaks occurring regularly

Limit for max. permissible voltage peaks

0

10

20

30

40

50

60

70

80

90

100

0

20

40

60

80

100

120

140

160

180

0 20 40 60 80 100 120 140 160 180 200

Dis

trib

uti

on

of

flo

w r

ates

[%

]

Hea

d H

[m

]

Flow rate Q [m3/h]

Distribution n = 1.450 1/min n = 1.300 1/min n = 1.250 1/min Design point

BP1 BP2 BP3 system curve

42,8

= Optimised operating range

57,366,9

71,672,9

70,2

62,6

51,1

42,857,3

66,9

71,672,9

70,2

62,6

51,1

42,857,3

66,971,6

72,9

70,2

62,6

51,1

0

10

20

30

40

50

60

70

80

90

100

0,0

5,0

10,0

15,0

20,0

25,0

30,0

35,0

40,0

45,0

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Distribution 4 x n = 1.250 1/min 4 x n = 1.090 1/min 3 x n = 970 1/min system curve

55,274,6

82,585,7

79,4

55,274,6

82,5

85,7

79,4

55,274,6

82,5

85,7

79,4

Hea

d H

[m

]

Flow rate Q [m3/h]= Optimised operating range

Dis

trib

uti

on

of

flo

w r

ates

[%

]

0706 System Analysis in Practice

009

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3/03

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Technology that makes its mark

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