PuK - Process Technology & Components 2024

Cover story
temperature. This allowed the system
to monitor components and process
conditions in real-time.
The one-year pilot project involved
two pumps conveying primary
sludge from different locations
for further treatment. One NS 70-24
pump transports the primary sludge
from the Essen-Kupferdreh WWTP
over a distance of eight kilometers
to the sludge treatment facility. The
other BN 130-12 progressive cavity
pump transports the sludge from the
Essen-South WWTP over a distance of
six kilometers. The task was to match
both conveying methods to the capacity
of the sludge treatment facility.
Problem detection and
root-cause analysis
In February 2021, SEEPEX installed
its pump monitoring units at the two
sites. The scope of supply included
the pump monitoring hardware, a
customized sensor package, as well
as the communication infrastructure
and Connected Services for collecting,
monitoring and analyzing the
data. “SEEPEX supported Ruhrverband
with monthly reports, presentation
of findings and recommendations
for action based on algorithms
and our expert knowledge,” says the
Product Manager of Digital Solutions
at SEEPEX.
Early in the analysis, SEEPEX experts
were able to uncover previously unknown
problems and determine the
underlying causes. For example, discharge
pressures were high and
sometimes outside the pump’s specifications.
The experts quickly determined
that resonant frequencies
overstressed the mechanical components,
which was causing loosened
screw fittings and a broken tie rod.
Pump monitoring made the condition
of the rotor and stator transparent
as the test phase progressed.
SEEPEX was able to determine the
ideal time for their replacement with
one month’s notice. This way, the customer
was able to plan the maintenance
work ahead of time and avoid
process interruptions. On the other
hand, the water association was able
to fully utilize the wearing parts without
jeopardizing process reliability.
Further adjustments increased the
service life of the rotor and stator by
more than 50 %, which translates into
annual savings of more than € 6,000
per pump.
25 % less power to operate
By determining three key factors influencing
energy consumption, the
team of the pump manufacturer was
able to identify potential energy cost
savings of more than 25 % and ultimately
recommend actions to improve
energy efficiency. Ruhrverband
implemented process control adjustments
in close coordination with
SEEPEX. Overall, Ruhrverband was
impressed with the detailed energy
analysis of its pumps. The monitoring
system provides a clear overview
of energy consumption and specific
energy costs per cubic meter of
pumped sludge. From now on, continuous
pump monitoring will ensure
optimal process conditions and consistently
low energy consumption.
Predictable maintenance cycles
“The main benefit of SEEPEX’s continuous
condition monitoring, analysis
and reporting is the ability to predict
maintenance cycles, which significantly
reduces operating costs,” explains
the Project Manager for Digitali zation
Projects at Ruhrverband. “We were
very grateful for the in-depth analysis
on how to monitor wear and minimize
the energy consumed per cubic
meter of sludge pumped.”
The compact, easy-to-understand
monthly report, which summarizes
key performance indicators (KPIs),
trends and error messages, is invaluable
to Ruhrverband. Through close
cooperation, the monthly report has
been continuously adapted to the
needs of Ruhrverband. Incidentally,
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