Tokyo, Japan - January 17, 2019
Yokogawa Electric Corporation (TOKYO: 6841) announces that it has developed a cavitation*1 detection system and will be releasing it for sale on January 31. By detecting cavitation, quantifying information on this, and displaying this data in real time, this system provides an early indication of conditions that can result in a degradation in pump performance. By detecting problems early on, before damage occurs that can cause an increase in both vibration and noise levels, this solution improves the efficiency of plant maintenance.
Cavitation in fluids can cause damage to pumps. To minimize this damage, it is necessary to detect cavitation at an early stage and take corrective measures such as adjusting the flow rate. One issue, however, is that there has been no way to quantify cavitation. In addition, since cavitation occurs inside equipment, it is impossible to visually check whether this is occurring. Cavitation is usually detected by field personnel who rely on know-how gained on the job to detect changes in vibration and noise levels that are caused by excessive cavitation. However, even highly experienced plant personnel and specialists can miss these early signs, and such problems may go undetected until the inevitable increase in vibration and noise occur.
In its analysis of this problem, Yokogawa focused on the principle that there is a direct relationship between differential pressure and cavitation, and in the end was able to come up with a solution that involves the quantification of cavitation based on pressure data.
- Real-time detection
The system that Yokogawa developed consists of a STARDOM™ FCN-500 network-based control system, a Yokogawa cavitation detection logic program, and a highly accurate (±0.075%) DPharp EJX110A differential pressure transmitter, and relies on the FOUNDATION™ Fieldbus industrial digital communication standard to link these components. At 100 ms intervals*2, the DPharp transmitter measures the pressure inside the target equipment, and this data is transmitted via the fieldbus network to the STARDOM FCN-500 system for processing in real time by the logic program. This system is thus able to detect cavitation issues early on, enabling field personnel to take quick remedial action by, for example, reducing the flow rate to a level that suppresses cavitation without interfering with production line operations.
Note: There is no universal indicator for the extent of cavitation and these are only rough descriptions of the different levels of cavitation.
Valves, pumps, and other types of plant equipment can all experience problems such as cavitation that are caused by anything from the opening/closing of a valve, a change in viscosity level or some other physical property of a liquid, or a change in the external environment. Field personnel have conventionally relied on their own know-how and the use of analytical tools to find out what is causing these problems. Thanks to the development of this new system, field personnel will now have a tool that will help them troubleshoot problems with greater efficiency by identifying and quantifying cavitation in plant equipment.
*1 A physical phenomenon whereby the differential pressure of a liquid in a pump or some other kind of plant equipment causes bubbles to rapidly form and then burst. The shock produced by the bursting of the bubbles damages the equipment.
*2 Outputs pressure data every few seconds to a control system for monitoring and control. The transmitter stores in its internal memory pressure data that is collected at 100 ms intervals.
Major Target Markets
Oil, petrochemicals, chemicals, iron and steel, pulp and paper, water supply and wastewater treatment pharmaceuticals, food, etc.
Maintenance of plant facilities such as pumps that tend to deteriorate due to cavitation
OpreX is the comprehensive brand for Yokogawa's industrial automation (IA) and control business. The OpreX name stands for excellence in the technologies and solutions that Yokogawa cultivates through the co-creation of value with its customers, and encompasses the entire range of Yokogawa's IA products, services, and solutions. This brand comprises the following five categories: OpreX Transformation, OpreX Control, OpreX Measurement, OpreX Execution, and OpreX Lifecycle. The real-time cavitation detection system is an OpreX Asset Management and Integrity family solution in the OpreX Transformation category, which delivers operational excellence throughout an enterprise's activities, from production through to supply chain optimization and risk and business management.
With this brand, Yokogawa will deliver integrated solutions that address specific needs and support its customers in their efforts to transform and grow their businesses.
For more information
Founded in 1915, Yokogawa engages in broad-ranging activities in the areas of measurement, control, and information. The industrial automation business provides vital products, services, and solutions to a diverse range of process industries including oil, chemicals, natural gas, power, iron and steel, and pulp and paper. With the life innovation business the company aims to radically improve productivity across the pharmaceutical and food industry value chains. The test & measurement, aviation, and other businesses continue to provide essential instruments and equipment with industry-leading precision and reliability. Yokogawa co-innovates with its customers through a global network of 113 companies spanning 61 countries, generating US$3.8 billion in sales in FY2017. For more information, please visit www.yokogawa.com.
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By detecting cavitation, quantifying information on this, and displaying this data in real time, this system provides an early indication of conditions that can result in a degradation in pump performance.