FEATURE
CONTINUOUS MONITORING KEEPS THE WATER FLOWING
An automatic condition monitoring system is helping prevent unplanned downtime of pumps at water treatment plant
T
he Perlenbach Water Supply Association supplies fresh drinking
water every day to around 50,000 residents across seven municipalities in the Eifel region of Germany. This equates to around 2.4 million cubic metres of water per year, which needs to be filtered and treated using complex methods. Increased noise and vibration levels on
the centrifugal pumps is often the result of bearing defects, which can result in pump failure. To prevent this, Perlenbach has changed from regular patrol pump monitoring to a continuous online system to allow it to detect of any signs of wear or damage to the bearings before the pumps fail. Schaeffler and its local partner KSA recommended the FAG SmartQB system. As part of a pilot project, two centrifugal pumps were fitted with two SmartQB sensors for measuring vibration and temperature and connected via one FAG SmartQB. In the event of any bearing defects, the FAG SmartLamp installed next to the FAG SmartQB illuminates red and the system generates an alarm message. With only two additional clicks on the touchscreen display, the maintenance technician can view more detailed information about the fault and is provided with specific recommended actions.
The information provided by FAG SmartQB and its automatic fault assessment feature gives an early warning of the onset of any bearing damage. Maintenance personnel are now able to react quickly and in a targeted manner. The pilot project was so successful, that
it led Perlenbach to consider fitting sensors to additional pumps and integrating the FAG SmartQB system into its internal maintenance alarm management system. The FAG SmartQB early warning system
comprises of a FAG SmartQB sensor unit, a cube-shaped housing with touchscreen display, and a cable for power and data transmission (Power-over-Ethernet). The
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The two centrifugal water pumps are fitted with SmartQB sensors for measuring vibration and temperature and connected via one FAG SmartQB
system was developed for detecting faults in electric motors, pumps, fans and other rotating plant and equipment supported by rolling bearings. It is supplied with ready-to-use, preset measurement configurations. Five causes of faults can be identified and displayed using the system – bearing damage, imbalance, friction/cavitation (for centrifugal pumps), temperature increases, and general changes in vibration patterns that cannot be clearly attributed to one of the aforementioned causes and so may require additional analyses. The automatic fault assessment feature provides text messages on its display, giving users clear instructions for action. Installation and initial operation of the
system are simple and it can be installed and operated by any in-house maintenance technician or electrician without the need for a expert in vibration technology. When starting FAG SmartQB for the first time, the customer selects one of the 16 languages provided and, if required, replaces the preset standard contact details of Schaeffler’s technical support with their own details. After selecting the component on which the FAG SmartQB sensor is mounted (i.e. a motor, pump or fan) the user then specifies whether the machine operates at constant or variable speed, and enters the individual name of the drive system/ assembly. FAG SmartQB then automatically selects the best measurement configuration. The system is immediately ready for the automatic learning mode. This self-learning mode
enables the device to automatically adjust alarm thresholds. After set up and commissioning, FAG SmartQB operates autonomously. The relevant machine parameters are measured and saved continuously in the system, creating a substantial database of historical data over time. A total of six sensors can be connected to one FAG SmartQB and allocated to multiple machines, individual machine components or sub-assemblies as required. Sensors can be added using the display – in a similar way to initial system installation. After initial operation, FAG SmartQB displays relevant information such as operating hours counter, fault frequency, maximum values, average values, trend curves, and the alarm status of each individual FAG SmartQB sensor. If an alarm due to a change in vibration signal occurs, which cannot be attributed to one of the five main causes, the system makes a recommendation to maintenance staff via the display, to send the measurement data to Schaeffler’s technical support centre, where a more in-depth analysis can be undertaken. The system is said to be suitable for use
in a range of industry sectors including cement, paper, steel and water, as well as other process manufacturing and mechanical engineering industries and it is currently being trialled in projects in these sectors.
Schaeffler
www.schaeffler.co.uk T: 0121 313 5870
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