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Remote monitoring of variable speed drives (VSDs) helps prevent failures by detecting issues early, whilst real-time data enables proactive, not reactive, maintenance, reducing downtime in water industry operations.The water industry in particular can be seen to benefit from DART's Hydrogen Sulfide (H2S) sensor which gives advanced warning of the build up this toxic,corrosive, flammable, colorless chalcogen-hydride gas. H2S is caused by the breakdown of organic materials (sulphur compounds) in wastewater. Not only does H2S impact worker safety, it inhibits biological treatment of water and causes premature asset breakdown. Here we look at VSDs specifically in the water industry - and the benefits to be gained by monitoring them.
How Remote Monitoring Helps Prevent Failures:
Remote monitoring of VSDs in the water industry involves using advanced sensors and data analysis to track equipment health continuously. This approach helps detect potential problems, such as unusual vibrations or electrical faults, before they lead to breakdowns. By adjusting pump speeds to match demand, VSDs reduce wear and tear, which can prevent failures. Remote monitoring also allows for scheduled maintenance based on actual conditions, minimizing unexpected downtime and emergency repairs.
Benefits for the Water Industry of Using VSDs :
In water supply and wastewater treatment, VSDs maintain constant pressure and flow, preventing issues like water hammer or leaks. For example, in wastewater, they can clear blockages by de-ragging pumps, ensuring smooth operation. This optimization not only enhances reliability but also reduces operational costs by avoiding costly repairs and extending equipment lifespan. ABB even has their own water industry drive - the ACQ580.
Practical Impact of Monitoring you ABB Drives:
The ability to monitor remotely means operators can receive alerts for abnormal patterns, such as pressure drops, and address them promptly. This proactive approach helps prevent major failures, ensuring continuous water service and protecting infrastructure, crucial for public health and safety.
Technical Mechanisms of Remote Monitoring:
Remote monitoring of VSDs leverages advanced sensor technologies and data analytics to provide real-time insights into equipment health. VSDs, which control the speed of electric motors driving pumps, have evolved with Industry 4.0 to act as intelligent elements in automation systems, functioning as smart sensors themselves.
Key monitoring capabilities include (and remember 1 DART unit can monitor 25 variables and 16 drives):
Vibration-Level Monitoring: Vibration sensors detect early mechanical faults, such as bearing wear or misalignment, by correlating with drive-internal signals like speed. This is crucial for identifying issues before they escalate.
Electrical Signature Analysis: By analyzing current and voltage signals, VSDs can detect electrical faults, such as stator winding issues or shaft misalignment, enabling early intervention.
Load Monitoring in Pumps: VSDs calculate motor power, energy, speed, and torque to identify overload or underload conditions, such as fouling or a broken impeller, which can lead to failure if unaddressed.
These capabilities are supported by cloud connectivity, allowing data to be analyzed remotely and alerts to be sent to operators.
Preventing Failures Through Proactive Maintenance
One of the primary ways DART remote monitoring prevents failures is by enabling condition-based maintenance, where maintenance is scheduled based on actual equipment condition rather than fixed intervals.This allows maintenance to be planned and undertaken before a failure occurs, reducing costs associated with unplanned downtime, such as waste materials, labor, emergency spare parts, and reputational damage.
For instance, remote monitoring can detect abnormal patterns, such as variations in pressure or water flow, enabling operators to address them before they lead to bursts or leaks.
Energy and Operational Efficiency
VSDs adjust pump speeds to match real-time demand, which not only saves energy but also reduces mechanical stress on equipment. By operating pumps at lower speeds during low-demand periods, wear and tear are minimized, extending equipment lifespan and preventing premature failures. Historical data analysis can also reveal inefficiencies, such as pumps running during low-demand periods, wasting energy and causing excess wear. Retrofitting VSDs to adjust speed dynamically resolves these issues, improving efficiency and reducing failure risks.
Specific Applications in the Water Industry:
The water industry benefits from VSDs in various applications, each contributing to failure prevention:
Water Supply: VSDs maintain constant water pressure, preventing leaks caused by high pressure and optimizing well exploitation to avoid over-pumping, as discussed in Variable speed drives as smart sensors.
Wastewater Treatment: They perform pump de-ragging, clearing blockages to prevent failures due to clogging, and control multiple pumps in cascade systems to ensure balanced operation and avoid overloads.
General Operations: VSDs can bypass certain frequencies to avoid mechanical resonances, which could lead to equipment damage, enhancing system reliability.
These applications are supported by remote monitoring, which ensures operators can respond promptly to any deviations, particularly in remote irrigation settings with robust communication functionality.
Broader Implications and Benefits
The benefits of remote monitoring extend beyond failure prevention to include reduced downtime, optimized maintenance schedules, and lower operational costs. Condition monitoring reduces downtime, eliminates unexpected production stops, and reduces spare part stock by allowing for planned replacements. This is particularly valuable in the water industry, where continuous operation is critical for public health and safety.
Moreover, the integration with Industry 4.0 technologies enhances data accessibility and analysis for better decision-making.
Statistical and Industry Context
Research indicates that more than 20% of all electric motors are driven by VSDs, primarily to reduce energy use, but also for process control and reliability.This widespread adoption underscores the importance of remote monitoring in maximizing the benefits of VSDs, particularly in energy-intensive water applications.
Table: Key Benefits of Remote Monitoring of VSDs in the Water Industry
This table summarizes the multifaceted benefits, reinforcing the role of remote monitoring in failure prevention.
Remote monitoring of VSDs with DART in the water industry is a transformative approach that leverages smart sensor technology, real-time data analysis, and proactive maintenance to prevent failures and breakdowns. By detecting ambient issues early, optimizing operations, and reducing downtime, it ensures reliable water supply and treatment, protecting public health and infrastructure while lowering costs.The integration with Industry 4.0 and the widespread adoption of VSDs highlight its significance, making it an essential strategy for modern water management.