Pump monitoring solution saves money and energy

ifm’s Moneo system combines the level of operation technology with the level of information technology. Inside Water spoke to Youssef Attallah, the Regional Sales Manager of ifm efector, to find out more about this technology as a pump monitoring solution.

More companies are looking for a high-end pump monitoring solution for their wastewater and water treatment systems. These all-encompassing projects focus on equipment performance, saving money and energy.

Many companies are looking beyond a single product when discussing pump monitoring systems. They are looking for turn-key solutions from companies they would consider partners. This is where ifm efector steps in, with their Moneo DataScience Toolbox.

ifm efector is a manufacturer of industrial sensors and solutions for technical processes. They specialise in using sensors, networking and control systems for a broad range of specialised applications. As an Industrial Internet of Things (IIoT) platform, ifm’s Moneo system combines operation and information technology. The sensor data generated in the production plants can be read and processed easily and used as a basis for sustainable corporate decisions.

Moneo has a modular structure and consists of a basic software package and applications. It can be used for condition monitoring or IO-Link sensor parameter setting, which makes it possible to create a tailor-made software package for every requirement.

Pump monitoring solution and energy efficiency

Youssef Attallah explained that market trends showed increased energy auditing and monitoring demands around the pumping industry. The big impact was that many industries use pumps, but primarily the water and wastewater industries are at the forefront of utilising the technology.

One issue for industries that use pumps is that they want to operate as efficiently as possible. If they are not working as efficiently as possible, they use more energy, or there can be an increased risk of a fault occurring. The point of optimal efficiency is called the best efficiency point (BEP), which represents the best combination of specific flow rate and head/pressure.

Problems associated with high head and low flow rates include high temperatures, low flow cavitation, low life of seals and bearings, and recirculation issues. If the flow rate is too high, it can also reduce the life of bearings and seals while also causing cavitation.

Getting the calculation right is critical. The Queensland government recently audited 180 farms. The audit found that there were potential savings of over three-gigawatt hours by upgrading pumps and irrigation systems. Attallah pointed out that these upgrades would save the farms nearly $1.5 million and over 2400 tonnes of carbon dioxide.

“The Queensland Government created some incentives and programmes to help increase the efficiency of their pumps,” said Attallah.

“Each pump will have a preferred operating range, close to its BEP. The Moneo system is designed to calculate and monitor the BEP of the pump, providing live feedback to the user. It allows the user to make informed decisions to select the right pump combination to achieve BEP. The Moneo system is also cognisant of each pump type, ensuring that it can operate within its preferred range and close to its BEP while remaining under warranty conditions.”

Why use Moneo

Attallah spoke about the importance of Moneo within a pumping operation. A pump monitoring solution can automatically calculate efficiencies to assist in operating pump schedules, maintenance schedules, plan operations, and various other systems. This artificial intelligence (AI) data system ensures maximum efficiency for the operator.

“One customer has a site with six pumps that they wanted to operate as much as possible. Previously, they had to manage their pump operations manually. That meant they had to do a lot of calculations and mathematics daily, with a dedicated programmer to manage the pumps,” said Attallah.

He highlighted that Moneo could work in most pumping situations. Pumps are used in a highly diverse range of industries, not just water and wastewater. They are used in both wet and dry conditions. Moneo can adjust to any situation.

“This system can be used in irrigation pumps, water supply systems, cooling towers, water treatment plants, wastewater treatment plants, process pumps and pumping stations,” said Attallah.

The system is designed to be simple, user-friendly, intelligent, reliable, and individual. It is also intended to provide the exact information that the users need. One system feature, Data Science Toolbox, is intended to enable the automatic and early detection of anomalies in a critical process value. It uses dependent sensor data and process parameters from the sensor range manufactured by ifm.

How Moneo works as a pump monitoring solution

The system’s toolbox is designed to monitor critical process values on an ongoing basis. It uses AI methods to develop a mathematical model for determining target values. As more data is added, the model changes and adapts, so measured behaviour can be evaluated, and any deviations are adjusted accordingly.

“It is simple because the users do not need data science expertise. Moneo is user-friendly, with automated data preparation and quality checks. AI systems are constantly training their models and verifying their accuracy against incoming data. It is a reliable system running in the background to monitor target variables. Our solutions are focused on what the customer wants, not the same solution we give everyone,” said Attallah.

While many existing methods currently operate on SCADA systems, it has been important for Attallah and his colleagues to explain to clients that Moneo is not supposed to replace their existing setup. It can complement their current system and will not use the bandwidth needed for existing data systems. It is intended to provide insights and foresight into their assets.

The customer’s journey

The individual focus is key for ifm efector. It is critical to understand their client and adjust to their needs. Attallah believes that the future of ifm is all around being part of the customer’s journey.

“We are looking to provide complete solutions that complement their existing systems. I do not believe that we are here just to provide sensors. We focus on communicating at every level of an organisation so that they understand what we can do for them,” said Attallah.

“We want to be a one-stop-shop for customers, working at all levels from a consultancy to hardware to software.”