How to Monitor Pump Performance with a Panel PC, HMI & Ethernet I/O

Defining the Problem:

Pumps are integral to a wide variety of both industries and processes. When you monitor pump performance, you can lower operating costs, improve process throughput, and reduce downtime and schedule maintenance. An automation system is needed with local displaying of real-time parameters, analytical calculations, data storage, trending, set warning and shutdown alarms, issue event driven messages, as well as network communications. Additionally, with vibration monitoring and proactive maintenance, machine condition monitoring can be implemented.

System Requirements:

• An industrial panel PC with either Windows or Linux OS and a suitable HMI for distributed control and process automation.
• Ethernet I/O to interface the pump sensors with the HMI.

Converting pump analog signals to Ethernet facilitates an easy connection to the PC, simplifies wiring, and minimizes electrical noise in harsh environments.

Featured Products:

• XT1211-000: Ethernet I/O Module, 8-Channel Differential Analog Current Input
• TT339-0700: Transmitter, Frequency/Pulse/PWM Input, 12-32V DC Loop/Local Power

Implementing the Solution to Monitor Pump Performance with a Panel PC, HMI & Ethernet I/O:

1. To optimize the pump performance, add the following sensors to monitor:

• Electrical power: current transformer (CT) with 4-20mA output
• Flowrate: flowmeter with 4-20mA output
• Suction pressure at the inlet side: pressure transmitter with 4-20mA output
• Discharge pressure at the output side: pressure transmitter with 4-20mA output
• Pump specific speed: Hall Effect speed sensor with frequency output to signal conditioner TT339-0700, converting to 4-20mA as a result.

2. An Ethernet connection from the XT1211-000 to the Panel PC for Modbus TCP/IP communications. The HMI will then Poll the XT and read back the pump parameters to display and perform calculations.

3. Add a device driver to the PC OS:

• For a PC running Windows: add either a Modbus TCP/IP ActiveX Control or .NET Control
• For a PC running Linux: add an Ethernet Modbus C Library utility to build Modbus TCP/IP commands

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