Customer application 27 May 2020
Seepex capitalizes on MTP with WAGO, streamlining the integration of system modules into process technology.

These eccentric screw pumps are specifically designed for conveying highly viscous media and abrasive products. When nothing else works, then it’s time for Seepex pumps. The company, based in Bottrop, Germany enjoys a reputation as an international leader in process technology. With the MTP – the “Module Type Package” from WAGO – Seepex plans to integrate its future solutions directly into the customer’s control system or the process control level. The pump then becomes an intelligent device in the automation architecture without time-consuming interface work or complex SCADA programming. This saves time and money.

MTP: The abbreviation stands for the “Module Type Package.” The standardized integration interface was originally developed by WAGO and is currently defined in the 2658 Directive adopted jointly by NAMUR, ZVEI and VDMA, with the title, “Automation Engineering of Modular Systems in the Process Industry.” A common working example of MTP can be found in printer drivers from the IT world. Drivers enable the connection of any computer to various printer models – regardless of the manufacturer. Connect, switch on, print: the champions of the MTP are pursuing a similar goal within working groups of the various industrial and trade associations.

Expectations Are Rising

From now on, Seepex plans to use the MTP to integrate its pump solutions into higher-level production processes. This includes the chemical industry, as well as food processing and wastewater treatment. “The MTP makes life easier and automation more affordable,” summarizes Dr. Christian Brehm about the advantages. The background for this statement by the Global Product Manager Digital Solutions: process technology is becoming increasingly complex. Therefore, companies are searching for system modules that do not generate much work for software engineering, save time, and offer a host of additional benefits. “The level of expectations from our clients is high.” An example, Brehm notes the capacity for easy integration, including preferences for condition monitoring and predictive maintenance.

Eccentric screw pumps are subject to wear and tear caused by everyday operation. This primarily affects the stator, in which the eccentric screw turns and is made from an elastomer. During operation, conveying chambers and a sealing line form between the rotor and stator. Friction, and eventually, wear, develops at the contact surface, which becomes noticeable because of an increasing gap and reduced pump output. Indicators for increased wear included a reduction in pump pressure and higher power consumption by the drive motor in volume-controlled applications. Deviation from the ideal path can be easily measured in both cases. The MTP provides a path for using the data directly for status monitoring, without expensive integration into the control system, which guarantees operational safety.

Guaranteed Wear Detection

In the field, this two-step service begins remedying pump wear by first using innovative technology to readjust the stator – Seepex uses a patented, two-part stator for this. In the second step, it seals the leaking gap. Because it is produced from a flexible elastomer, the pump can be recalibrated using a higher clamping pressure. “How quickly and strongly wear occurs depends on the conveyed medium – greasy substances are always better than granular road salt,” notes Brehm. This statement makes it clear that Seepex does not make blanket statements about how long the stator and rotor will ultimately endure. Consequently, they use measured values from actual operation, which enable predictions about the pump's current status within the context of system monitoring.

Collecting such status data and subsequently processing it moves beyond system security into questions about sustainability and efficiently using resources. Instead of replacing worn parts as a precaution, based solely on operating hours and ensuring system availability, the decision should be made with the aid of performance indicators. Dr. Brehm explains that, “Sensors relevant to the process are not sufficient for this. They show an image of the process, yet provide no information about a module’s operating state. We have to clearly distinguish here between the quality of a process and the operation of the process technology.” This aspect underscores the value of the WAGO MTP for system operations because it significantly simplifies the integration of system indicators from completely different manufacturers into the central process control level. Additionally, information relevant for the process is separated from the status data of individual assemblies.

The MTP provides a different way of operating system modules. Seepex demonstrates how this looks in use with their “Smart Dosing Pump.” With the MTP, a user can determine whether to employ continuous dosing or filling. “In both cases, the transmission of a few setpoints is sufficient, since our module automatically regulates the dosing operation,” explains the product manager. Regarding the MTP, automation engineers talk about a service that's accessed by the module. Typical services in process technology include temperature control, agitation, or mixing.

Taken to a logical conclusion, Seepex sees an opportunity to use the MTP to flexibly adjust pump modules to the required operating conditions and the delivery rates. This flexibility is comparable to the sport and eco modes in a car. "I have the choice of optimizing the operation for delivery rates, energy consumption, service-life related to wear, or the gentle treatment of the medium that will be pumped." The settings for the pump that result from this are controlled by the module thanks to its intrinsic intelligence. The user's task then only involves selecting the desired service or operating mode for the module via the control system. And no one has to dig deeply into a module’s PLC or reprogram the SCADA system to do this.

Conclusion

Seepex has a goal of providing its customers in process technology with fully automated pump solutions. Due to the MTP, time-consuming interface adjustments can be brought directly into the process control level. As a result, system modules can soon be considered as service providers within a production system. The MTP takes on the role of the standardized integration interface to close a substantial gap on the way to manufacturer-independent, modular automation. The new integration technology allows users to focus on the essential aspects of their business. And this is possible solely in part to transparent, fast, and easy-to-integrate modules.

Author:
Benjamin Böhm | Global Industry Manager Process | WAGO Kontakttechnik GmbH & Co. KG

Pictures:
Thorsten Sienk | freier Fachjournalist | Bodenwerder
www.sienk.de

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