KSB生命周期管理

Energysavingsinexistingplants现有工厂的节能Dr.SönkeBrodersenHangzhou,October202015th

Theroleofsystemefficiency系统效率的作用InvestmentEnvironment环境7%投资~30%Installation安装9%Pump泵Energy14%能量~32%Energy能量32%Operation操作9%Downtime停工期9%ReliabilityMaintenance&Repair维护/维修可靠性~38%20%EnergysavingsinexistingplantsIBildquelle:http://www.n-droid.de/wp-content/uploads/2015/01/Internet-der-Dinge.png2SönkeBrodersenIHangzhouOct.2015

Example:Lifecyclecostsofindustrialpumps例如:生命周期成本的工业泵FactorcforenergycostsinLCCequation能源成本的因素cELCC方程SystemEfficiencyServices系统效能服务EnergyCostsE0Q(t)H(t)dtPPtzjg1Cnt0eipnhhMPj11能量费用100Theflowrate-timediagramoftherepresentativeyearinthelifecyclehasanapplicableinfluenceonthedesignofapumpsystem!nz===lifecycleinyears寿命年限numberofpumps泵的台数spec.Energyprice典型能源价格discoutingfactor折扣系数densityofmediumt0;t1=beginningandterminationoftheoperationcycleintheyearEo年内操作循环开始与中止时间一个寿命周期的典型年度的流量-时间i-p=Q(t)=currentflowrateofpumpp图对泵的系统设计有着参考性的影响=泵的当前流量tobepumped吸入介质密度gravitationalacceleration重力加速度H(t)=currentdevelopedheadofpg=singlepump当前单级泵扬程hP=efficiencyofpump泵效率hM=efficiencyofmotor电机效率EnergysavingsinexistingplantsI3SönkeBrodersenIHangzhouOct.2015

Histogramofoperatinghours操作时间柱状图TypicalexampleforchemicalPlant化工厂的典型例子Researchproject‚Re-Main‘研究方案，Re-Main‘05/21/-06/10/200965pumpsmeasured参与测试的泵有65台Source:FraunhoferIML,KSBAG:„ForschungsprojektReMain”,2008EnergysavingsinexistingplantsI4SönkeBrodersenIHangzhouOct.2015

Head扬程[%]abrasionofimpellerInfluenceofoperatingpointonLCCCavitationDurability耐久性[%]叶轮磨损气蚀ImpellerrecirculationLCC中操作点的影响ideal:-10%..+5%ofoptimum叶轮回流100xh92xh理想：最佳工况的-10%至+5%reducedopertinglifebearingandgasketOverheatingpartloadvortex操作寿命短的轴承和垫圈过热reducedoperatinglifebearingandgasketgood:-20%..+10%ofoptimum部分负荷漩涡53xh较好：最佳工况的-20%至+10%Cavitation气蚀操作寿命短的轴承和垫圈10xhEfficiencyCharacteristicCurvenormal:-30%..+15%ofoptimum效率性能曲线正常:最佳工况的-30%至+15%PumpCurve泵曲线ReliabilityCurve可靠性能曲线100Flowrate流量[%]Source:JudyHodgson(DuPont),„PredictingMaintenanceCostsAccurately”,Pumps&Systems,April2004EnergysavingsinexistingplantsI5SönkeBrodersenIHangzhouOct.2015

-adequatepumpcontrol适当的泵管理-demandrelatedoperation需要相关操作-reductionofflowresistance流动阻力的减小Identificationofsavingpotentials节能潜力鉴定upto60%M-dimensioningofpiping管道尺寸的标注System主系统upto10%-trimmingofimpeller叶轮的调整3~3~M3~-reviewofsafetymargins再次检查安全极限Module子系统-optimizationofsinglecomponents单个零件的优化(e.g.highefficiencydrivesIE2,IE3(NEMAPremium)orIE4(SuperPremium))3~3~M3~Components零部件(例如，驱动IE2,IE3,IE4)approx.3,5%大约3.5%EnergysavingsinexistingplantsI6SönkeBrodersenIHangzhouOct.2015

Governmentalproductrelateddirectivesandregulations政府产品有关指令和法规SystemAnalysisSystemAnalysis系统分析系统分析AdditionallyEnergy-andMaintenanceCosts能源与维修费用PumpFailures泵的不足另外地CorrectiveMaintenance改善性维修PreventiveMaintenance预防性维修SiteAcceptanceTest现场验收试验Measurementduringdesignstage设计阶段测量FailureAnalysisEnergyAudit不足分析能源审计EnergysavingsinexistingplantsISource:F.Schäfer,KSB,20137SönkeBrodersenIHangzhouOct.2015

Typicalsystemanalysis典型的系统分析temperature温度(T)rotationalspeed转速(min-1)tanklevel水箱液位(%)Vibrationmeasurement振动测量:vibrationvelocity振动速率(veff)frequencyanalysis频率分析(FFT)Source:F.Schäfer,KSB,2013EnergysavingsinexistingplantsI8SönkeBrodersenIHangzhouOct.2015

Processdata过程数据:Pressure压力(ps,pd)powerconsumption功率(P)motorcurrent电机电流(I)flowrate流量(Q)Theconventionalwaytodetectenergysavingpotentialsinexistingplants现有工厂节能潜力检测的常规方法Takereadings取读数Motorcharacteristics电机特性…EnergysavingsinexistingplantsI9SönkeBrodersenIHangzhouOct.2015

Flowrate流量Vibrations振动Pumpcharacteristics泵特性Bymeansof按方式Installedmonitoringsystems(online,offline)安装监控系统(在线,离线)Temporarilyinstalledinstrumentation(online,offline)临时安装仪表(在线,离线)SmartsoftwaresolutionsaspartofIoT智能软件解决方案作为物联网的一部分Howdoesitwork?它是怎样运作的?EnergysavingsinexistingplantsIBildquelle:http://www.n-droid.de/wp-content/uploads/2015/01/Internet-der-Dinge.png10SönkeBrodersenIHangzhouOct.2015

Theunconventionalwaytodetectenergysavingpotentialsinexistingplants非传统的方法来检测现有工厂的节能潜力Ashortlookback:MilestonesofIndustrialDevelopment一个简短的回顾：工业发展的里程碑Revolution工业革命Revolution工业革命Revolution工业革命?Endof18thcenturyBeginning20thcenturyEarly70ies20thcenturyTodayEnergysavingsinexistingplantsI11SönkeBrodersenIHangzhouOct.2015

Mechanizing机械化Electrification电气化Automation自动化IndustrialIndustrialIndustrial231Ashortlookforward:MilestonesofIndustrialDevelopment一个简短的展望：工业发展的里程碑23?Endof18thcenturyBeginning20thcenturyEarly70ies20thcenturyTodayEnergysavingsinexistingplantsI12SönkeBrodersenIHangzhouOct.2015

Mechanizing机械化IndustrialRevolution工业革命Electrification电气化Automation自动化Digitalization数字化IndustrielleIndustrialRevolution工业革命IndustrialRevolution工业革命1IndustrialRevolution工业革命4.Socio-economicMegatrendsRequirementsforIndustrialProcesses,andothers工业过程的要求，和其他environmentallyfriendly环境友好型effective效率efficient高效adaptiv自适应flexibel柔性i.e.ressourceefficient资源高效EnergysavingsinexistingplantsI13SönkeBrodersenIHangzhouOct.2015

MostimportantchallengesforindustrySmartFactory工业智能工厂面临的重要挑战Increasingproductivityandindividualisingofproductsbymeansof:提高生产力和个体化的产品通过Ressourceefficiencyandoptimizedmaterialusage资源效率和优化材料的使用Availabilityandoperatingreliability可用性和运行可靠性Flexibilityviashort-termreconfigurability灵活性通过短期的可重构性ReductionofTime-To-Market减少进入市场的时间EnergysavingsinexistingplantsIBildquelle:http://www.n-droid.de/wp-content/uploads/2015/01/Internet-der-Dinge.png14SönkeBrodersenIHangzhouOct.2015

Thenewapproach:新方法：Listentoyourpump!听你的泵！EnergysavingsinexistingplantsI15SönkeBrodersenIHangzhouOct.2015

Thenewapproach:新方法：EnergysavingsinexistingplantsI16SönkeBrodersenIHangzhouOct.2015

Andusewhat´sathand手上有什么用什么“KSBSonolyzer”enablesuserstoappraisetheefficiencyorinefficiencyofpumpsandotherrotatingequipmentbysimplylistening可以让用户通过简单的听力效率或泵等转动设备的效率评价ForaquickenergyefficiencyCheck用于快速节能检查It´sthefirstappthathearswhetherenergycanbesaved它的第一个应用程序,听到是否可以节省能源Howdoesitwork?KSBSonolyzerelectricalmechanicalhydraulicalP1P2P3P4QLoadcoeffcient:Q负荷系数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(PBEPBEPEnergysavingsinexistingplantsISönkeBrodersenIHangzhouOct.201517

Systemmodel系统模型Acousticmeasurementofcurrentspeednx当前速度的NX声学测量Klossequation:克洛斯方程MechanicalpowerP机械功率CalculationofMotorTorqueandPowerOutput电机转矩和功率输出的计算BreakdowntorqueTB打破扭矩TBKSBSonolyzerMotormodel电机模型TrTnnnSpeedr0EnergysavingsinexistingplantsI18SönkeBrodersenIHangzhouOct.2015

Calculatingthetorquebyutilizingthemotor‘storque-speedcharacteristic利用电机转矩转速特性计算转矩n–currentspeedN0–电流速度n–syncronousspeedN0–同步速度n–ratedspeed(nameplate)NR–额定转速（铭牌）KSBSonolyzerMax.Peak295.5Hz-1Currentspeed=2955min-1567numberofvanesFrequencyinHzKSBSonolyzerI19Dr.SönkeBrodersenIBeijing2015

Technicalbackground技术背景FindingtherotationalnoiseFrequency寻找旋转噪声频率Example:例如Ratedpower=11kW额定功率为11千瓦Ratedspeed=2940min额定速度=2940min-1Numberofvanes=6叶片数=6电流速度=2955min-1KSBSonolyzerMax.Peak295.5Hz567numberofvanesFrequencyinHzKSBSonolyzerI20Dr.SönkeBrodersenIBeijing2015

RotationalnoisebymeansofFFT旋转噪声的方法Target:Identificationofnumberofvanes目标：叶片数的识别Unknownnumberofblades未知数量的叶片3windowsfor5,6und7blades3个Windows型号5、6和7叶片Fromnoisetospeed:从噪音到速度Synchronousrotationalspeed:3000/min同步转速：每分钟3000Maximumat295.5Hz最大在295.5赫兹Impellerwith6vanes6叶片叶轮Currentspeed:29551/min电流速度：29551/分钟CalculationofMotorTorqueandPowerOutput电机转矩和功率输出的计算KSBSonolyzerTrTnnnSpeedr0EnergysavingsinexistingplantsI21SönkeBrodersenIHangzhouOct.2015

Technicalbackground技术背景Calculatingthetorquebyutilizingthemotor‘storque-speedcharacteristic利用电机转矩转速特性计算转矩Example:例如Ratedpower=11kW额定功率为11千瓦Ratedspeed=2940min-1额定速度=2940min-1CurrentSpeed=2954min-1电流速度=2954min-1CurrentTorque=26,0Nm电流转矩=26,0nmCalculationofMotorTorqueandPowerOutput电机转矩和功率输出的计算KSBSonolyzerTsBsTBssBTrTExample:n=2955min-1n=3000min-1n=2940min-10nnrnn0T=35,7NmP=11kWrrrT=26,0NmP=8.0kWEnergysavingsinexistingplantsISönkeBrodersenIHangzhouOct.201522

KlossEquation克洛斯方程FromSpeedtoPower从速度到功率Actualrotationalspeed实际转速Determinationofslip滑移测定Determinationoftorque转矩的测定DeterminationofshaftpowerT2PumpCharacteristicsLoadCoefficient泵特性负载系数nqSource:AuslegungvonKreiselpumpen,KSBAGEnergysavingsinexistingplantsI23SönkeBrodersenIHangzhouOct.2015

FromPowertoFlowQ/QBEP从功率到流量asfunctionofP/PBEP作为P/pbep功能andspecificspeednq和比转速(fromextensiveinternalmeasurements)（从广泛的内部测量）KSBSonolyzerTechnicalbackground技术背景PartialloadFlowrate[%]KSBSonolyzerI24Dr.SönkeBrodersenIBeijing2015

Estimatingtherelativeflowratebasedonastandardizedpowercurve基于标准功率曲线的相对流量估算Example:示例Ratedpower=11kW额定功率=11千瓦Ratedspeed=2940min-1额定速度=2940min-1Speed=2955min速率=2955min-1Actualpower=8.0kW实际功率=8千瓦负荷Partialload部分负荷KSBSonolyzerHead扬程[%]abrasionofimpellerCavitationDurability耐久性[%]叶轮磨损气蚀Impellerrecirculationideal:-10%..+5%ofoptimum叶轮回流100xh92xh理想：最佳工况的-10%至+5%reducedopertinglifebearingandgasketOverheatingpartloadvortex操作寿命短的轴承和垫圈过热reducedgood:-20%..+10%ofoptimum部分负荷漩涡53xhoperatinglifebearingandgasket较好：最佳工况的-20%至+10%Cavitation气蚀操作寿命短的轴承和垫圈10xhEfficiencyCharacteristicCurvenormal:-30%..+15%ofoptimum效率性能曲线正常:最佳工况的-30%至+15%PumpCurve泵曲线ReliabilityCurve可靠性能曲线100Flowrate流量[%]Source:JudyHodgson(DuPont),„PredictingMaintenanceCostsAccurately”,Pumps&Systems,April2004EnergysavingsinexistingplantsI25SönkeBrodersenIHangzhouOct.2015

Classificationofpumpoperationpoints泵的KSBsonolyzer分类操作点Strongpartialload强偏载Partialload偏载Optimum最佳Overload过载KSBSonolyzerBackBackEnergysavingsinexistingplantsI26SönkeBrodersenIHangzhouOct.2015

Handling处理Typeseriesselection泵系列的选择Enterthedataflowrate,head,ratedpowerandratedspeedofthemotoraccordingthetypeplateinformation输入数据流的速率，扬程，额定功率和根据类型信息额定转速的