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Flow control

The possibilities of emerging control, monitoring and communications technologies have not been lost on Bran+Luebbe, which recently unveiled its Novaflow (Figure 4) pump concept. The company's UK systems manager Mike Scott says that the controller package replaces the need for a separate control panel and skid system. "All that the customer requires is mounted on the pump: set flow rate, monitor, start and stop. This is because it has a built-in motor speed control and 24 V power supply fed from a single 240 V supply from the customer," explains Scott. Novaflow also adds a remote input/output (I/O) function for customers with existing PLC control systems, which allows automated setting of all the functions, complete with feedback.

In contrast to many other monitoring systems, which detect vibration in bearings to let the system know there is a problem, Novaflow monitors the exact parameter the customer is interested in, namely flow rate. "For example, the customer tells us the recipe they require, we then set the pump to deliver that recipe, then monitor it via the flow meter to make sure it is being achieved. If it is not, we can trim the pump to deliver the correct quantity. Built-in diagnostics can detect if it is not possible to self-correct the error, thereby alerting the operator to check the fault," Scott explains.

According to Bran + Luebbe, customers buying this new unit can forget about linking in other components in order to get the control to work. "All we need is the customer to send us a set point and acknowledge a confirmation back; we take care of everything else. The beauty of the controller is that it can be easily integrated into existing systems with discrete I/O," says Scott. The controller will enable users to select either of the following control options: Discrete - 4-20 mA in (flow rate required) and 4-20 mA out (flow rate actual) - or Comms (Ethernet, Profibus DP, Devicenet, Interbus, Modbus or CANbus).

There are also benefits for original equipment manufacturers (OEMs) who can buy the unit and link it seamlessly into a master control, be it a PLC or SCADA (supervisory control and data acquisition) system, as the control unit will be available with all communication link options. All information concerning the status and operation of the pump attached to the controller will be available to the OEM's master system, with Bran + Luebbe taking care of controlling the flow.

Monitoring the London Underground

Fluid handling and control solutions specialist Flygt is another company that has responded to its customers' requirements. Working closely with Metronet - the company responsible for renewing two-thirds of London's Tube, and which now plays a key role in helping minimize water-related disruptions across much of the 253-mile, 275-station network - almost 170 Flygt fluid monitoring and control (FMC) pump controller units have been sited at strategic points along the network, gathering critical fluid-related data remotely at numerous vent shafts, tunnels, stations and escalator units.

Information is relayed from the Flygt FMC controllers using various methods of communication (including GSM, telephone line, wide area network [WAN] and internet protocol [IP]) to Aquaview workstations (Figure 5) around the Underground. This is then used to determine when individual Flygt pumps need to be employed and at what rate in order to prevent water rising to levels that could lead to sections of the network being shut down for safety reasons.

In the past, technicians had to visit assets according to a rota. This could often be interrupted by alarms and emergency service calls. Using the Flygt Aquaview system to record and report asset performance and runtimes, this activity has been replaced by planned service and maintenance. According to Metronet asset manager Dave Rooks: "Working with Flygt and armed with real-time information about fluid levels at key points throughout the network, we have been able to activate appropriate pumps before water levels rise to a point that necessitates the closure of a section of track".

Fluid levels are monitored and controlled using remote outstations, which then send data to processor units that use WAN and modems to communicate with a central server. The server records the data and displays it live on control-room workstations, where alarms are triggered when key readings fall outside pre-programmed parameters.

Summary

Industry's remorseless demand that processing and fluid-handling facilities become even more efficient, cost effective, environmentally conscious and safe places to work puts ever-greater pressures on pump manufacturers. Having the capabilities to exercise greater control over processing applications, product traceability, data capture and security puts power into the hands of management. Real-time information processing enables personnel to consider the wider objectives of the business as opposed to specific duties, and this is now being realized by the emergence of simple, low-cost wireless systems.

Contact
Bryan Orchard
E-mail: orchard@primex.co.uk

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