- Email: [email protected]
Integrated plant monitoring system
p UMP
MAINTENANCE
which identifies in m e t r i c a n d i m p e r i a l m e a s u r e m e n t alignm e n t t o l e r a n c e s for d i f f e r e n t m a c h i n e o p e r a t i n g needs. Excellent values a n d a c c e p t a b l e values are clearly identified.
Contact: Pruftechnik Ltd, Burton Road, Streethay, Lichfield, S t a f f s , W S 1 3 8 L N , UK. Tel: +44 1543 417722; Fax: +44 1543 417723.
Pump monitor can protect equipment and personnel H e a t b u i l d u p can h a p p e n w h e n a centrifugal p u m p is allowed to run dry, this is u s u a l l y d u e to liquid flow to t h e p u m p being i n t e r r u p t e d . In o t h e r c a s e s liquids being p u m p e d , u s u a l l y a n d a u t o m a t i c a l l y a c t i n g as a lubricant, could v a p o u r i s e a n d leave t h e volute case e m p t y a n d t h e seal dry. In such cases, Stork P u m p s r e c o m m e n d s t h e installation of a P u m p Monitor to provide key protection. The i n t r o d u c t i o n of an electronic P u m p Monitor offers dry run p r o t e c t i o n t h a t w o r k s in a s i m i l a r m a n n e r to a n o r m a l c i r c u i t b r e a k e r by m e a s u r i n g t h e c u r r e n t d r a w n by t h e motor. When t h e p o w e r d r o p s off d u e to lack of liquid, t h e m o t o r load decreases causing the p h a s e angle between t h e curr e n t a n d voltage to c h a n g e a n d t h e m o n i t o r to alarm, a u t o m a tically switching off t h e p u m p s . The Monitor systems available from S t o r k also identify overloading a n d in t h e case of a positive displacement gear p u m p , for e x a m p l e , can t u r n the p u m p off w i t h i n 100th of a s e c o n d t h e r e b y a c t i n g as an electronic relief valve or internal p r o t e c t o r for t h e p u m p i n g element. The P u m p M o n i t o r can be fitted to new o r e x i s t i n g installations.
Contact: Peter Staddon, Stork Pumps, Meadow Brook Industrial Centre, Maxwell Way, Crawley, West Sussex RH10 25A, UK. Tel: + 4 4 1293 553495; Fax: +44 1293 524635.
WORLD PUMPS MARCH 1995
[]
Integrated plant monitoring system
In increasingly c o m p e t i t i v e m a r kets, process manufacturing p l a n t s are u n d e r c o n s t a n t pressure to i m p r o v e efficiency, productivity and profitability. Monitoring t h e c o n d i t i o n of t h e p l a n t is a key a s p e c t o f a t t a i n i n g t h e s e objectives. C o n d i t i o n m o n i t o r i n g ena b l e s p o t e n t i a l p r o b l e m s to be identified a n d c o r r e c t i v e a c t i o n t a k e n -- before costly d o w n t i m e occurs, or the product is spoiled. The collection and s t o r a g e of p l a n t d a t a f a c i l i t a t e s d e t a i l e d analyses of p l a n t performance, while t h e a b i l i t y to feed data directly into the maintenance system substantially reduces the need for e q u i p m e n t to b e f r e q u e n t l y checked by staff. Beaver Valley S y s t e m s uses the Plant Information (PI) System to address the prob l e m s of a c c u r a t e l y r e c o r d i n g p l a n t data. Off-the-shelf interfaces to s t a n d a r d s c a n n e r s , PLC, DCS a n d l a b o r a t o r y s y s t e m s -as well as m a n u a l i n p u t -- feed i n f o r m a t i o n from all a r e a s of t h e p l a n t to t h e PI a r c h i v e w h i c h is a c e n t r a l r e p o s i t o r y for all data. U n i q u e c o m p r e s sion a l g o r i t h m s e n a b l e t h e PI System to store t h i s d a t a online, while r e t a i n i n g its o r i g i n a l accuracy, p r o v i d i n g a c o m p l e t e picture of plant operation a c r o s s a given t i m e s p a n - a specific d a y or shift, o r a n e n t i r e year. By c o n t i n u a l l y m o n i t o r i n g o p e r a t i n g c o n d i t i o n s w i t h detailed minute-by-minute reports, t h e o p e r a t o r m a n a g e r is m a d e a w a r e of a n y p r o b l e m s t h a t m a y arise -- i n s t e a d of having to w a i t u n t i l t h e deter i o r a t i o n of p r o d u c t q u a l i t y o r unscheduled shutdowns of e q u i p m e n t reveal t h a t a prob l e m does exist. PI will p r o v i d e a d e t a i l e d d i s p l a y of each m a c h i n e ' s performance, together with precisely timed records of s h u t d o w n s a n d r e s t a r t s , so t h a t its reliability a n d cost-effectiveness can be a c c u r a t e l y evalu-
a t e d over any given period. In a d d i t i o n , PI f a c i l i t a t e s o p t i m a l m a c h i n e o p e r a t i o n , for e x a m p l e , by t r a c k i n g inventory so t h a t m a c h i n e r y can c o n t i n u e to o p e r a t e even w h e n s u p p l i e s are r u n n i n g low. One customer, who h a b i t u a l l y s h u t down machinery to prevent damage w h e n less t h a n 50 t o n s of r a w i n g r e d i e n t s were h e l d in stock, f o u n d t h a t , with PI, a saving of a t l e a s t two days p r o d u c t i o n t i m e could be effected in t h e first year. A n d t h e m a c h i n e s were able to run safely with a reserve of j u s t 9 tons! I n f o r m a t i o n r e l a t i n g to p l a n t c o n d i t i o n collected by t h e PI S y s t e m c a n a l s o b e fed to a n o t h e r p r o d u c t in t h e Beaver Valley p o r t f o l i o -- t h e MAXIMO m a i n t e n a n c e m a n a g e m e n t system. As a result, t h e requirem e n t for the m a n u a l i n p u t of this type of d a t a is r e d u c e d a n d w o r k o r d e r s can be t r i g g e r e d directly. The PI System will r e c o r d t h e n u m b e r of h o u r s e q u i p m e n t such as p u m p s or c o m p r e s s o r s have been running, or the frequency with which t h e y have s t o p p e d a n d started. This inform a t i o n is s e n t by t h e PI System so t h a t life factors, i n c r e m e n t a l life fractions a n d c u m u l a t i v e life fractions can be a s s e s s e d a n d reported. This system can also be u s e d to d e t e r m i n e w h e n t h o s e comp o n e n t s t h a t a r e s u b j e c t to t h e r m a l stresses are a p p r o a c h ing t h e e n d of t h e i r o p e r a t i n g lives. I n f o r m a t i o n s t o r e d in the PI System also h e l p s to determine which plant operating p r o c e d u r e s will c o n t r i b u t e to achieving t h e o p t i m u m lifespan of t h e s e c o m p o n e n t s . Because t h e PI archive prov i d e s a c o m p l e t e h i s t o r y of p r o d u c t i o n for t h e plant, it is also u s e d for a wide range of m o n i t o r i n g a p p l i c a t i o n s , as well as c o n d i t i o n monitoring. Many c o m p a n i e s find it i n v a l u a b l e for reporting their compliance with increasingly s t r i n g e n t s t a t u t o r y environmental requirements a n d o p e r a t i n g conditions.
Contact: Beaver Valley Systems, 2-4 Park Street, Cirencester, Gloucestershire GL7 2BN, UK.
MAINTENANCE
which identifies in m e t r i c a n d i m p e r i a l m e a s u r e m e n t alignm e n t t o l e r a n c e s for d i f f e r e n t m a c h i n e o p e r a t i n g needs. Excellent values a n d a c c e p t a b l e values are clearly identified.
Contact: Pruftechnik Ltd, Burton Road, Streethay, Lichfield, S t a f f s , W S 1 3 8 L N , UK. Tel: +44 1543 417722; Fax: +44 1543 417723.
Pump monitor can protect equipment and personnel H e a t b u i l d u p can h a p p e n w h e n a centrifugal p u m p is allowed to run dry, this is u s u a l l y d u e to liquid flow to t h e p u m p being i n t e r r u p t e d . In o t h e r c a s e s liquids being p u m p e d , u s u a l l y a n d a u t o m a t i c a l l y a c t i n g as a lubricant, could v a p o u r i s e a n d leave t h e volute case e m p t y a n d t h e seal dry. In such cases, Stork P u m p s r e c o m m e n d s t h e installation of a P u m p Monitor to provide key protection. The i n t r o d u c t i o n of an electronic P u m p Monitor offers dry run p r o t e c t i o n t h a t w o r k s in a s i m i l a r m a n n e r to a n o r m a l c i r c u i t b r e a k e r by m e a s u r i n g t h e c u r r e n t d r a w n by t h e motor. When t h e p o w e r d r o p s off d u e to lack of liquid, t h e m o t o r load decreases causing the p h a s e angle between t h e curr e n t a n d voltage to c h a n g e a n d t h e m o n i t o r to alarm, a u t o m a tically switching off t h e p u m p s . The Monitor systems available from S t o r k also identify overloading a n d in t h e case of a positive displacement gear p u m p , for e x a m p l e , can t u r n the p u m p off w i t h i n 100th of a s e c o n d t h e r e b y a c t i n g as an electronic relief valve or internal p r o t e c t o r for t h e p u m p i n g element. The P u m p M o n i t o r can be fitted to new o r e x i s t i n g installations.
Contact: Peter Staddon, Stork Pumps, Meadow Brook Industrial Centre, Maxwell Way, Crawley, West Sussex RH10 25A, UK. Tel: + 4 4 1293 553495; Fax: +44 1293 524635.
WORLD PUMPS MARCH 1995
[]
Integrated plant monitoring system
In increasingly c o m p e t i t i v e m a r kets, process manufacturing p l a n t s are u n d e r c o n s t a n t pressure to i m p r o v e efficiency, productivity and profitability. Monitoring t h e c o n d i t i o n of t h e p l a n t is a key a s p e c t o f a t t a i n i n g t h e s e objectives. C o n d i t i o n m o n i t o r i n g ena b l e s p o t e n t i a l p r o b l e m s to be identified a n d c o r r e c t i v e a c t i o n t a k e n -- before costly d o w n t i m e occurs, or the product is spoiled. The collection and s t o r a g e of p l a n t d a t a f a c i l i t a t e s d e t a i l e d analyses of p l a n t performance, while t h e a b i l i t y to feed data directly into the maintenance system substantially reduces the need for e q u i p m e n t to b e f r e q u e n t l y checked by staff. Beaver Valley S y s t e m s uses the Plant Information (PI) System to address the prob l e m s of a c c u r a t e l y r e c o r d i n g p l a n t data. Off-the-shelf interfaces to s t a n d a r d s c a n n e r s , PLC, DCS a n d l a b o r a t o r y s y s t e m s -as well as m a n u a l i n p u t -- feed i n f o r m a t i o n from all a r e a s of t h e p l a n t to t h e PI a r c h i v e w h i c h is a c e n t r a l r e p o s i t o r y for all data. U n i q u e c o m p r e s sion a l g o r i t h m s e n a b l e t h e PI System to store t h i s d a t a online, while r e t a i n i n g its o r i g i n a l accuracy, p r o v i d i n g a c o m p l e t e picture of plant operation a c r o s s a given t i m e s p a n - a specific d a y or shift, o r a n e n t i r e year. By c o n t i n u a l l y m o n i t o r i n g o p e r a t i n g c o n d i t i o n s w i t h detailed minute-by-minute reports, t h e o p e r a t o r m a n a g e r is m a d e a w a r e of a n y p r o b l e m s t h a t m a y arise -- i n s t e a d of having to w a i t u n t i l t h e deter i o r a t i o n of p r o d u c t q u a l i t y o r unscheduled shutdowns of e q u i p m e n t reveal t h a t a prob l e m does exist. PI will p r o v i d e a d e t a i l e d d i s p l a y of each m a c h i n e ' s performance, together with precisely timed records of s h u t d o w n s a n d r e s t a r t s , so t h a t its reliability a n d cost-effectiveness can be a c c u r a t e l y evalu-
a t e d over any given period. In a d d i t i o n , PI f a c i l i t a t e s o p t i m a l m a c h i n e o p e r a t i o n , for e x a m p l e , by t r a c k i n g inventory so t h a t m a c h i n e r y can c o n t i n u e to o p e r a t e even w h e n s u p p l i e s are r u n n i n g low. One customer, who h a b i t u a l l y s h u t down machinery to prevent damage w h e n less t h a n 50 t o n s of r a w i n g r e d i e n t s were h e l d in stock, f o u n d t h a t , with PI, a saving of a t l e a s t two days p r o d u c t i o n t i m e could be effected in t h e first year. A n d t h e m a c h i n e s were able to run safely with a reserve of j u s t 9 tons! I n f o r m a t i o n r e l a t i n g to p l a n t c o n d i t i o n collected by t h e PI S y s t e m c a n a l s o b e fed to a n o t h e r p r o d u c t in t h e Beaver Valley p o r t f o l i o -- t h e MAXIMO m a i n t e n a n c e m a n a g e m e n t system. As a result, t h e requirem e n t for the m a n u a l i n p u t of this type of d a t a is r e d u c e d a n d w o r k o r d e r s can be t r i g g e r e d directly. The PI System will r e c o r d t h e n u m b e r of h o u r s e q u i p m e n t such as p u m p s or c o m p r e s s o r s have been running, or the frequency with which t h e y have s t o p p e d a n d started. This inform a t i o n is s e n t by t h e PI System so t h a t life factors, i n c r e m e n t a l life fractions a n d c u m u l a t i v e life fractions can be a s s e s s e d a n d reported. This system can also be u s e d to d e t e r m i n e w h e n t h o s e comp o n e n t s t h a t a r e s u b j e c t to t h e r m a l stresses are a p p r o a c h ing t h e e n d of t h e i r o p e r a t i n g lives. I n f o r m a t i o n s t o r e d in the PI System also h e l p s to determine which plant operating p r o c e d u r e s will c o n t r i b u t e to achieving t h e o p t i m u m lifespan of t h e s e c o m p o n e n t s . Because t h e PI archive prov i d e s a c o m p l e t e h i s t o r y of p r o d u c t i o n for t h e plant, it is also u s e d for a wide range of m o n i t o r i n g a p p l i c a t i o n s , as well as c o n d i t i o n monitoring. Many c o m p a n i e s find it i n v a l u a b l e for reporting their compliance with increasingly s t r i n g e n t s t a t u t o r y environmental requirements a n d o p e r a t i n g conditions.
Contact: Beaver Valley Systems, 2-4 Park Street, Cirencester, Gloucestershire GL7 2BN, UK.