新闻中心

新闻中心 > 品牌资讯 >

ALLWEILER案例研究:热传导系统中泵的连续监测


更新日期:2020-11-08 22:49:35
关键词: ALLWEILER 导热油泵

状态监测系统提供早期泄漏检测,并允许用户优化他们的传热泵

作者克里斯蒂安·马丁,CIRCOR | Allweiler

许多生产过程依赖于泵来移动导热油,在选择泵时,安全和系统稳定性是用户考虑的最重要的因素,其次是最长的运行时间和低运行成本。


在传热应用方面的苛刻要求

导热油泵必须安全可靠地运行,以确保生产过程中的高稳定。这种泵经常受到高负荷的影响,它们的故障可能会造成严重的后果,特别是当热油泄漏时。因此,传热系统的操作人员对泄漏很敏感。虽然热水通常以蒸汽的形式通过密封件逸出,而且通常不会造成重大损害,但逸出的热传导油会迅速扩散到大范围,造成严重损害的可能性很大。任何来自热油泵的泄漏都代表着一个危险的情况,需要快速、有效的反应。而升高的液体温度使这成为一项具有挑战性的任务。解决方案是监测泄漏率,以检测早期阶段的密封磨损。这样,当泄漏开始时,泵操作员能立即知道。

在传热系统中使用的泵容易受到高温和温差大引起的高负荷的影响。此外,当热载体处于高热负荷时,泵送液中经常发生化学分解反应。特别是,链状碳氢化合物随着时间的推移会分解成“低沸物”和“高沸物”。当低沸物比例过高时,存在泵汽蚀的危险。另一方面,高沸物会加速泵的磨损,并以多种形式出现,从沥青状的稠度到高度碳化的产品。两者都对泵的轴承和轴封构成威胁。合成传热油的使用降低了低沸物和高沸物的出现,但是这些材料的低粘度和润滑性还有其他缺点,例如:机械密封的滑动部件上的摩擦载荷非常高。


应用实例

总部位于德国的Odenwald Faserplattenwerk GmbH (OWA)是一家隔音板制造商,该公司使用热传导泵在大约270℃的温度下移动矿物油。

ALLWEILER案例研究:热传导系统中泵的连续监测

图1所示

CIRCOR公司的Allweiler IN-1000系统可以添加到Allweiler ALLHEAT和NTT泵中,同时兼容其他制造商的配备了标准化的传感器(模拟和数字)的泵。

烘干机最重要的部件是加热寄存器和加热盘管。它们以高度均匀的方式将热量冲击到矿物纤维面板上。要做到这一点,需要泵将热载体(基于石油或合成的热油)均匀可靠地输送到烘干机内。保持稳定的温度是实现高质量、高可靠性、连续工作等功能的工艺所需的必要条件。

作为OWA内部工程的一部分,泵在传热系统中持续运行。

“我们经常认为,为我们的生产线提供热量是一个不言而喻的事实”,OWA技术和工艺工程部的Jan Herrschaft说。“我们的员工在生产过程中通过以太网将控制面板或无线发送到移动设备上。绿灯表示正常的操作。在大多数情况下,一盏黄灯会让人们注意到需要维护的水泵,一旦灯变成红色,立即干预通常是必需的。在某些情况下,必须停止生产。如果检测到严重的泄漏或轴承温度过高,系统就会指示密封磨损或必须更换轴承。大的振荡表明泵是不对准或联轴器损坏。当这些不规则操作条件的出现得到全面监控时,操作者就有机会计划更换或每天集中精力保持生产中稳定的优秀质量。他们面临的特殊挑战是拥有一个极其可靠的系统,并允许预防性维护和足够的数字化水平”。

在过去,OWA依靠的是热油泵收集盘中的检漏器。不幸的是,这种方法只在它们已经被改进时才检测到泄漏,预防性维修的选择也很有限。2017年,OWA部署了他们的第一套来自CIRCOR的Allweiler IN-1000状态监测系统,并在2018年底增加了额外的系统。

ALLWEILER案例研究:热传导系统中泵的连续监测

状态监测系统能够监测机械密封的功能、轴承的温度和泵的振荡。如果其中一个被监视的参数超过了主要或次要阈值,系统将以适当的警告或警报消息作出反应。每个泵的状态可以直接从主单元的显示器上读取,给维护人员机会快速响应。

信号也可以通过以太网传输到控制面板或无线发送到移动设备。绿灯表示正常运行。在大多数情况下,一盏黄灯会让人们注意到需要维护水泵。一旦灯变成红色,通常需要立即进行干预。在某些情况下,必须停止生产。

如果检测到严重的泄漏或轴承温度过高,系统就会指示密封磨损或必须更换轴承。大的震动表明泵偏离了对中或联轴器损坏。当出现这种不正常的操作条件时进行监控。

Herrschaft说:“对我们而言,无干扰运行是使用IN-1000监控系统的最重要方面,也是最大优势。此外,我们可以及早发现即将出现的磨损并制定对策。”

该系统采用模块化结构,使其能够适应被监控系统的需要。该系统的主/外(卫星)组合可以处理各种监测要求,从简单的单一状态监测到复杂的多泵情况。主模块配备了web服务器,该服务器允许通过web浏览器或远程访问主模块,通过以太网连接的现有进程监控系统的应用程序专用接口。在OWA,该系统被集成到一个更大的控制系统中,因此泵的状况可以被直接检索。


通过持续监控节约成本

状态监测系统允许用户从安装时就优化他们的泵。因此,一项投资很快就能收回成本。例如,当使用IN-1000对现有装置进行监测时,发现多达75%的泵没有正确对齐,这将导致高振荡,并最终导致损坏和过早失效,而这些都是可以避免的。

此外,集成数据记录可以精确地、每天测定泵的性能,为用户提供优化泵的其他方法,如速度控制或水力优化。

连续监测也有长期优势。由于状态监测系统可以检测到密封磨损的临界水平,因此减少了预防性维护的需要。这使得操作人员能够充分利用高质量泵的长期使用寿命。因此,在热传导系统中,泵的典型维护成本降低了,同时为操作人员提供了一种安心,让他们知道一切都在控制之中。


Case study: Continuous monitoring of pumps in heat-transfer systems

Condition monitoring systems provide early leak detection and allow users to optimize their heat-transfer pumps.

By Christian Martin, CIRCOR | Allweiler


many production processes depend on pumps for the movement of heat-transfer oils. When selecting a pump, operator safety and system stability are top considerations,followed by maximum uptime and low operating costs.

Demanding requirements in heat-transfer applications

Heat-transfer pumps must operate safely and reliably to ensure a high level of quality in production processes. Such pumps are frequently subject to high loads, and their failure can have serious consequences,especially if hot oil can escape.Therefore, operators of heat-transfer systems are sensitive to leaks. While hot water normally escapes through the seal in the form of steam - and usually does not cause major damage - any escaping heat-transfer oil rapidly disperses across a wide area and has a high potential for serious damage. Any leaks from thermal oil pumps represent a precarious situation that requires a rapid, effective response. And elevated liquid temperature makes this a challenging task. The solution is to monitor the rate of leakage to detect the early stages of seal wear. That way,pump operators immediately know when a leak starts.

Pumps used in heat-transfer systems are subject to high loads induced by elevated temperatures and large temperature differentials. What's more, chemical decomposition reactions often occur in the pumped liquid whenever the heat carrier is under high thermal loads. In particular,the chain-like hydrocarbons decompose over time into "low boilers" and "high boilers." When the proportion of low boilers becomes too high, there is a risk of pump cavitation. High boilers, on the other hand, accelerate pump wear and occur in numerous forms, from a bituminous-like consistency to highly carbonized products.Both represent a threat to the bearing and shaft seal of the pump. The use of synthetic heat-transfer oil reduces the appearance of low and high boilers, but the low viscosity and lubricity of these materials have other drawbacks. The tribological loads working on the sliding components of mechanical seals are extremely high.


Application example

German-based Odenwald Faserplattenwerk GmbH (OWA), a manufacturer of acoustic panels, uses heat-transfer pumps to move mineral oil at temperatures of approximately 270°C.


Figure 1. 

The Allweiler IN-1000 system from CIRCOR can be added to Allweiler ALLHEAT and NTT pumps, as well as compatible pumps from other manufacturers if they are equipped with standardized sensors (analog and digital).

The most important elements of any dryer are the heating register and the heating coils.They impinge heat onto the mineral fiber panels in a highly uniform manner. Doing so requires pumps that move the heat carrier (petroleum-based or synthetic thermal oil) to the dryer both uniformly and reliably.Maintaining the temperatures required of the process is essential for achieving high product quality as well as ensuring reliable,continuous functionality.

As part of OWA's in-house engineering,the pumps are in continuous operation in the heat-transfer systems.

"We often think of the provision of heat to our production lines as a self-evident fact,"said Jan Herrschaft with the technology and process engineering department at OWA. "Our employees in the production across an Ethernet to a control panel or sent wirelessly to mobile devices. A green light indicates normal operation. In most cases, a yellow light draws attention to the need for pump maintenance. Once the light switches to red, immediate intervention is usually required. In some cases, production must be stopped.If significant leaks or high bearing temperatures are detected, the system indicates that the seal is worn or that the bearing must be replaced. Large oscillations indicate that the pump is out of alignment or the coupling is damaged.When the appearance of such irregular operating conditions is monitored comprehensively, the operator has the opportunity to plan for replacement or area are focused each day on maintaining the premium quality of our ceiling panels. The special challenge they face is to have a system that is extremely reliable and allows for preventive maintenance and a sufficient level of digitization".

In the past, OWA relied on leak detectors in the collection pans of the thermal oil pumps. Unfortunately, this method detected leaks only when they were already advanced. Preventive maintenance options were also limited. In 2017,OWA deployed their first Allweiler IN-1000 condition monitoring system from CIRCOR and added additional systems near the end of 2018.

The condition monitoring system monitors the functionality of the mechanical seal, the temperature of the bearing and oscillations in the pump. If one of the monitored parameters exceeds the primary or secondary thresholds, the system reacts with the appropriate warning or alarm messages. The status of each of the pumps can be read directly from the display on the master unit, giving maintenance personnel the opportunity to respond quickly to disturbances. The signal can also be optionally transmitted across an Ethernet to a control panel or sent wirelessly to mobile devices. A green light indicates normal operation. In most cases, a yellow light draws attention to the need for pump maintenance. Once the light switches to red, immediate intervention is usually required. In some cases, production must be stopped.

If significant leaks or high bearing temperatures are detected, the system indicates that the seal is worn or that the bearing must be replaced. Large scillations indicate that the pump is out of alignment or the coupling is damaged.When the appearance of such irregular operating conditions is monitored comprehensively, the operator has the opportunity to plan for replacement or repair in a timely manner on scheduled maintenance days, thereby avoiding unanticipated production downtime.Early detection of disturbances and wear saves money by minimizing service and repair costs."For us, distur bance free operation is the most important aspect and the greatest advantage of monitoring our systems with IN-1000," said Herrschaft."In addition, we can detect upcoming wear early and plan for countermeasures."

The condition monitoring system is also modularly constructed, which makes it possible to adapt the module to the system being monitored. The master/satellite combination of the system handles a variety of monitoring requirements, from straightforward monitoring of a single condition to complex situations with multiple pumps. The master module is equipped with a web server that enables remote access to the master module through a web browser or the application-specific interface of an existing process monitoring system via Ethernet connection. At OWA, the system is integrated into a larger control system so pump conditions can be retrieved directly, providing implementation into existing IT structures.


Cost savings with continuous monitoring

Condition monitoring systems allow users to optimize their pumps from the time of installation. Therefore, an investment can quickly pay for itself.For example, when existing installations were monitored with IN-1000, it was discovered that up to 75 percent of the pumps were not properly aligned, which would have resulted in high oscillations and ultimately bearing damage and premature failure. These cases can avoid costly damages.

Also, integrated data recording enables precise, daily determination of pump performance, giving users additional ways to optimize their pumps, such as speed control or hydraulic optimization.

There are also long-term advantages of continuous monitoring. Since condition monitoring systems detect critical levels of seal wear, the need for preventive maintenance is reduced. This allows operators to exploit the long service life of high-quality pumps. As a result,typical maintenance costs for pumps in heat-transfer systems are reduced,while providing operators the peace of mind in knowing that everything is under control.



查看更多
ALLWEILER泵各系列的行业应用
ALLWEILER泵各系列的行业应用

May 30, 2020

Allweiler中文叫什么
Allweiler中文叫什么

May 30, 2020

Allweiler GmbH 品牌介绍
Allweiler GmbH 品牌介绍

May 30, 2020

化工泵选型需要注意的地方
化工泵选型需要注意的地方

May 30, 2020

化工泵使用中的注意事项解析
化工泵使用中的注意事项解析

May 30, 2020

立即联系

工业用泵只考虑两种,超高精度用德国Allweiler,其他精度用国产品牌