KSB生命周期管理

Energysavingsinexistingplants現(xiàn)有工廠的節(jié)能Dr.S?nkeBrodersenHangzhou,October202015th

Theroleofsystemefficiency系統(tǒng)效率的作用InvestmentEnvironment環(huán)境7%投資~30%Installation安裝9%Pump泵Energy14%能量~32%Energy能量32%Operation操作9%Downtime停工期9%ReliabilityMaintenance&Repair維護/維修可靠性~38%20%EnergysavingsinexistingplantsIBildquelle:http://www.n-droid.de/wp-content/uploads/2015/01/Internet-der-Dinge.png2S?nkeBrodersenIHangzhouOct.2015

Example:Lifecyclecostsofindustrialpumps例如:生命周期成本的工業(yè)泵FactorcforenergycostsinLCCequation能源成本的因素cELCC方程SystemEfficiencyServices系統(tǒng)效能服務EnergyCostsE0Q(t)H(t)dtPPtzjg1Cnt0eipnhhMPj11能量費用100Theflowrate-timediagramoftherepresentativeyearinthelifecyclehasanapplicableinfluenceonthedesignofapumpsystem!nz===lifecycleinyears壽命年限numberofpumps泵的臺數(shù)spec.Energyprice典型能源價格discoutingfactor折扣系數(shù)densityofmediumt0;t1=beginningandterminationoftheoperationcycleintheyearEo年內(nèi)操作循環(huán)開始與中止時間一個壽命周期的典型年度的流量-時間i-p=Q(t)=currentflowrateofpumpp圖對泵的系統(tǒng)設計有著參考性的影響=泵的當前流量tobepumped吸入介質(zhì)密度gravitationalacceleration重力加速度H(t)=currentdevelopedheadofpg=singlepump當前單級泵揚程hP=efficiencyofpump泵效率hM=efficiencyofmotor電機效率EnergysavingsinexistingplantsI3S?nkeBrodersenIHangzhouOct.2015

Histogramofoperatinghours操作時間柱狀圖TypicalexampleforchemicalPlant化工廠的典型例子Researchproject?Re-Main‘研究方案，Re-Main‘05/21/-06/10/200965pumpsmeasured參與測試的泵有65臺Source:FraunhoferIML,KSBAG:?ForschungsprojektReMain”,2008EnergysavingsinexistingplantsI4S?nkeBrodersenIHangzhouOct.2015

Head揚程[%]abrasionofimpellerInfluenceofoperatingpointonLCCCavitationDurability耐久性[%]葉輪磨損氣蝕ImpellerrecirculationLCC中操作點的影響ideal:-10%..+5%ofoptimum葉輪回流100xh92xh理想：最佳工況的-10%至+5%reducedopertinglifebearingandgasketOverheatingpartloadvortex操作壽命短的軸承和墊圈過熱reducedoperatinglifebearingandgasketgood:-20%..+10%ofoptimum部分負荷漩渦53xh較好：最佳工況的-20%至+10%Cavitation氣蝕操作壽命短的軸承和墊圈10xhEfficiencyCharacteristicCurvenormal:-30%..+15%ofoptimum效率性能曲線正常:最佳工況的-30%至+15%PumpCurve泵曲線ReliabilityCurve可靠性能曲線100Flowrate流量[%]Source:JudyHodgson(DuPont),?PredictingMaintenanceCostsAccurately”,Pumps&Systems,April2004EnergysavingsinexistingplantsI5S?nkeBrodersenIHangzhouOct.2015

-adequatepumpcontrol適當?shù)谋霉芾?demandrelatedoperation需要相關(guān)操作-reductionofflowresistance流動阻力的減小Identificationofsavingpotentials節(jié)能潛力鑒定upto60%M-dimensioningofpiping管道尺寸的標注System主系統(tǒng)upto10%-trimmingofimpeller葉輪的調(diào)整3~3~M3~-reviewofsafetymargins再次檢查安全極限Module子系統(tǒng)-optimizationofsinglecomponents單個零件的優(yōu)化(e.g.highefficiencydrivesIE2,IE3(NEMAPremium)orIE4(SuperPremium))3~3~M3~Components零部件(例如，驅(qū)動IE2,IE3,IE4)approx.3,5%大約3.5%EnergysavingsinexistingplantsI6S?nkeBrodersenIHangzhouOct.2015

Governmentalproductrelateddirectivesandregulations政府產(chǎn)品有關(guān)指令和法規(guī)SystemAnalysisSystemAnalysis系統(tǒng)分析系統(tǒng)分析AdditionallyEnergy-andMaintenanceCosts能源與維修費用PumpFailures泵的不足另外地CorrectiveMaintenance改善性維修PreventiveMaintenance預防性維修SiteAcceptanceTest現(xiàn)場驗收試驗Measurementduringdesignstage設計階段測量FailureAnalysisEnergyAudit不足分析能源審計EnergysavingsinexistingplantsISource:F.Sch?fer,KSB,20137S?nkeBrodersenIHangzhouOct.2015

Typicalsystemanalysis典型的系統(tǒng)分析temperature溫度(T)rotationalspeed轉(zhuǎn)速(min-1)tanklevel水箱液位(%)Vibrationmeasurement振動測量:vibrationvelocity振動速率(veff)frequencyanalysis頻率分析(FFT)Source:F.Sch?fer,KSB,2013EnergysavingsinexistingplantsI8S?nkeBrodersenIHangzhouOct.2015

Processdata過程數(shù)據(jù):Pressure壓力(ps,pd)powerconsumption功率(P)motorcurrent電機電流(I)flowrate流量(Q)Theconventionalwaytodetectenergysavingpotentialsinexistingplants現(xiàn)有工廠節(jié)能潛力檢測的常規(guī)方法Takereadings取讀數(shù)Motorcharacteristics電機特性…EnergysavingsinexistingplantsI9S?nkeBrodersenIHangzhouOct.2015

Flowrate流量Vibrations振動Pumpcharacteristics泵特性Bymeansof按方式Installedmonitoringsystems(online,offline)安裝監(jiān)控系統(tǒng)(在線,離線)Temporarilyinstalledinstrumentation(online,offline)臨時安裝儀表(在線,離線)SmartsoftwaresolutionsaspartofIoT智能軟件解決方案作為物聯(lián)網(wǎng)的一部分Howdoesitwork?它是怎樣運作的?EnergysavingsinexistingplantsIBildquelle:http://www.n-droid.de/wp-content/uploads/2015/01/Internet-der-Dinge.png10S?nkeBrodersenIHangzhouOct.2015

Theunconventionalwaytodetectenergysavingpotentialsinexistingplants非傳統(tǒng)的方法來檢測現(xiàn)有工廠的節(jié)能潛力Ashortlookback:MilestonesofIndustrialDevelopment一個簡短的回顧：工業(yè)發(fā)展的里程碑Revolution工業(yè)革命Revolution工業(yè)革命Revolution工業(yè)革命?Endof18thcenturyBeginning20thcenturyEarly70ies20thcenturyTodayEnergysavingsinexistingplantsI11S?nkeBrodersenIHangzhouOct.2015

Mechanizing機械化Electrification電氣化Automation自動化IndustrialIndustrialIndustrial231Ashortlookforward:MilestonesofIndustrialDevelopment一個簡短的展望：工業(yè)發(fā)展的里程碑23?Endof18thcenturyBeginning20thcenturyEarly70ies20thcenturyTodayEnergysavingsinexistingplantsI12S?nkeBrodersenIHangzhouOct.2015

Mechanizing機械化IndustrialRevolution工業(yè)革命Electrification電氣化Automation自動化Digitalization數(shù)字化IndustrielleIndustrialRevolution工業(yè)革命IndustrialRevolution工業(yè)革命1IndustrialRevolution工業(yè)革命4.Socio-economicMegatrendsRequirementsforIndustrialProcesses,andothers工業(yè)過程的要求，和其他environmentallyfriendly環(huán)境友好型effective效率efficient高效adaptiv自適應flexibel柔性i.e.ressourceefficient資源高效EnergysavingsinexistingplantsI13S?nkeBrodersenIHangzhouOct.2015

MostimportantchallengesforindustrySmartFactory工業(yè)智能工廠面臨的重要挑戰(zhàn)Increasingproductivityandindividualisingofproductsbymeansof:提高生產(chǎn)力和個體化的產(chǎn)品通過Ressourceefficiencyandoptimizedmaterialusage資源效率和優(yōu)化材料的使用Availabilityandoperatingreliability可用性和運行可靠性Flexibilityviashort-termreconfigurability靈活性通過短期的可重構(gòu)性ReductionofTime-To-Market減少進入市場的時間EnergysavingsinexistingplantsIBildquelle:http://www.n-droid.de/wp-content/uploads/2015/01/Internet-der-Dinge.png14S?nkeBrodersenIHangzhouOct.2015

Thenewapproach:新方法：Listentoyourpump!聽你的泵！EnergysavingsinexistingplantsI15S?nkeBrodersenIHangzhouOct.2015

Thenewapproach:新方法：EnergysavingsinexistingplantsI16S?nkeBrodersenIHangzhouOct.2015

Andusewhat′sathand手上有什么用什么“KSBSonolyzer”enablesuserstoappraisetheefficiencyorinefficiencyofpumpsandotherrotatingequipmentbysimplylistening可以讓用戶通過簡單的聽力效率或泵等轉(zhuǎn)動設備的效率評價ForaquickenergyefficiencyCheck用于快速節(jié)能檢查It′sthefirstappthathearswhetherenergycanbesaved它的第一個應用程序,聽到是否可以節(jié)省能源Howdoesitwork?KSBSonolyzerelectricalmechanicalhydraulicalP1P2P3P4QLoadcoeffcient:Q負荷系數(shù)QxBEPηMηPP,nxxP,nrrQ,HddMP:Powern:SpeedQ:FlowH:HeadΗ:EfficiencyQ,Hd:DesignPointdP,nr:RatedPowerandSpeedrP,n,Q:CurrentOperatingPointPumpcharacteristic:泵特性xxx:In-andOutputPowerMotor:In-andOutputPowerPump:BestEfficiencyPointP,P12P,PQP,n)34QBEPf(PBEPBEPEnergysavingsinexistingplantsIS?nkeBrodersenIHangzhouOct.201517

Systemmodel系統(tǒng)模型Acousticmeasurementofcurrentspeednx當前速度的NX聲學測量Klossequation:克洛斯方程MechanicalpowerP機械功率CalculationofMotorTorqueandPowerOutput電機轉(zhuǎn)矩和功率輸出的計算BreakdowntorqueTB打破扭矩TBKSBSonolyzerMotormodel電機模型TrTnnnSpeedr0EnergysavingsinexistingplantsI18S?nkeBrodersenIHangzhouOct.2015

Calculatingthetorquebyutilizingthemotor‘storque-speedcharacteristic利用電機轉(zhuǎn)矩轉(zhuǎn)速特性計算轉(zhuǎn)矩n–currentspeedN0–電流速度n–syncronousspeedN0–同步速度n–ratedspeed(nameplate)NR–額定轉(zhuǎn)速（銘牌）KSBSonolyzerMax.Peak295.5Hz-1Currentspeed=2955min-1567numberofvanesFrequencyinHzKSBSonolyzerI19Dr.S?nkeBrodersenIBeijing2015

Technicalbackground技術(shù)背景FindingtherotationalnoiseFrequency尋找旋轉(zhuǎn)噪聲頻率Example:例如Ratedpower=11kW額定功率為11千瓦Ratedspeed=2940min額定速度=2940min-1Numberofvanes=6葉片數(shù)=6電流速度=2955min-1KSBSonolyzerMax.Peak295.5Hz567numberofvanesFrequencyinHzKSBSonolyzerI20Dr.S?nkeBrodersenIBeijing2015

RotationalnoisebymeansofFFT旋轉(zhuǎn)噪聲的方法Target:Identificationofnumberofvanes目標：葉片數(shù)的識別Unknownnumberofblades未知數(shù)量的葉片3windowsfor5,6und7blades3個Windows型號5、6和7葉片F(xiàn)romnoisetospeed:從噪音到速度Synchronousrotationalspeed:3000/min同步轉(zhuǎn)速：每分鐘3000Maximumat295.5Hz最大在295.5赫茲Impellerwith6vanes6葉片葉輪Currentspeed:29551/min電流速度：29551/分鐘CalculationofMotorTorqueandPowerOutput電機轉(zhuǎn)矩和功率輸出的計算KSBSonolyzerTrTnnnSpeedr0EnergysavingsinexistingplantsI21S?nkeBrodersenIHangzhouOct.2015

Technicalbackground技術(shù)背景Calculatingthetorquebyutilizingthemotor‘storque-speedcharacteristic利用電機轉(zhuǎn)矩轉(zhuǎn)速特性計算轉(zhuǎn)矩Example:例如Ratedpower=11kW額定功率為11千瓦Ratedspeed=2940min-1額定速度=2940min-1CurrentSpeed=2954min-1電流速度=2954min-1CurrentTorque=26,0Nm電流轉(zhuǎn)矩=26,0nmCalculationofMotorTorqueandPowerOutput電機轉(zhuǎn)矩和功率輸出的計算KSBSonolyzerTsBsTBssBTrTExample:n=2955min-1n=3000min-1n=2940min-10nnrnn0T=35,7NmP=11kWrrrT=26,0NmP=8.0kWEnergysavingsinexistingplantsIS?nkeBrodersenIHangzhouOct.201522

KlossEquation克洛斯方程FromSpeedtoPower從速度到功率Actualrotationalspeed實際轉(zhuǎn)速Determinationofslip滑移測定Determinationoftorque轉(zhuǎn)矩的測定DeterminationofshaftpowerT2PumpCharacteristicsLoadCoefficient泵特性負載系數(shù)nqSource:AuslegungvonKreiselpumpen,KSBAGEnergysavingsinexistingplantsI23S?nkeBrodersenIHangzhouOct.2015

FromPowertoFlowQ/QBEP從功率到流量asfunctionofP/PBEP作為P/pbep功能andspecificspeednq和比轉(zhuǎn)速(fromextensiveinternalmeasurements)（從廣泛的內(nèi)部測量）KSBSonolyzerTechnicalbackground技術(shù)背景PartialloadFlowrate[%]KSBSonolyzerI24Dr.S?nkeBrodersenIBeijing2015

Estimatingtherelativeflowratebasedonastandardizedpowercurve基于標準功率曲線的相對流量估算Example:示例Ratedpower=11kW額定功率=11千瓦Ratedspeed=2940min-1額定速度=2940min-1Speed=2955min速率=2955min-1Actualpower=8.0kW實際功率=8千瓦負荷Partialload部分負荷KSBSonolyzerHead揚程[%]abrasionofimpellerCavitationDurability耐久性[%]葉輪磨損氣蝕Impellerrecirculationideal:-10%..+5%ofoptimum葉輪回流100xh92xh理想：最佳工況的-10%至+5%reducedopertinglifebearingandgasketOverheatingpartloadvortex操作壽命短的軸承和墊圈過熱reducedgood:-20%..+10%ofoptimum部分負荷漩渦53xhoperatinglifebearingandgasket較好：最佳工況的-20%至+10%Cavitation氣蝕操作壽命短的軸承和墊圈10xhEfficiencyCharacteristicCurvenormal:-30%..+15%ofoptimum效率性能曲線正常:最佳工況的-30%至+15%PumpCurve泵曲線ReliabilityCurve可靠性能曲線100Flowrate流量[%]Source:JudyHodgson(DuPont),?PredictingMaintenanceCostsAccurately”,Pumps&Systems,April2004EnergysavingsinexistingplantsI25S?nkeBrodersenIHangzhouOct.2015

Classificationofpumpoperationpoints泵的KSBsonolyzer分類操作點Strongpartialload強偏載Partialload偏載Optimum最佳Overload過載KSBSonolyzerBackBackEnergysavingsinexistingplantsI26S?nkeBrodersenIHangzhouOct.2015

Handling處理Typeseriesselection泵系列的選擇Enterthedataflowrate,head,ratedpowerandratedspeedofthemotoraccordingthetypeplateinformation輸入數(shù)據(jù)流的速率，揚程，額定功率和根據(jù)類型信息額定轉(zhuǎn)速的