On Demand INtelligence delivers savings for high-pressure pumps

High-pressure, high-flow pumps require considerable energy input in order to deliver the demands of each application, be that in the mining or the steel industry. Increasing energy prices continue to apply additional pressure to these industries and so the manufacturers of these systems are developing more efficient control systems such as ODIN (On Demand INtelligence), which has been designed and implemented by RMI Pressure Systems.

Traditionally, pumping stations have been supplied with either fixed-speed pumps or with one variable speed drive fitted to the lead pump. However, the modulating demand for pressure and flow means that additional pumps are regularly starting and stopping which leads to higher energy consumption.

The first step in addressing the variable demand is to ensure that all pumps are equipped with variable speed drives and then all the pumps can be run at the most efficient level required to achieve the desired pressure and flow. This approach ensures that demand is met while also providing a smooth change in pressure and reducing the stress and wear on the pump components.

However, variable speed drives can only react to the available information, which could be just a simple pressure sensor. The next step is to develop a series of sensors which feed into a central controller that is capable of anticipating demand and therefore deliver pressure and flow as it is required with maximum efficiency.

RMI has produced a robust and reliable control logic system, known as ODIN (On Demand INtelligence) that is capable of rapid response and close control of system pressure. This sophisticated control technology enables the drive motors to run at their optimum speed and provide maximum output with minimal energy.

ODIN is available in three modes, Local, Remote and Prime, which can be arranged to provide the level of control appropriate to each application. In Local mode, the controller uses information provided by the pumping station itself to control the pressure and speed of the motor. This may be appropriate for descaling operations in steel mills and smaller underground mining applications.

Remote mode uses additional pressure signals from equipment located away from the pumping station, such as the roof supports of a mine. This extra information allows the pumping station to be more responsive and efficient in providing hydraulic flow.

ODIN Prime is designed predominately for a longwall mining application and can interrogate the individual components of the system to allow changes in demand to be fulfilled in the most efficient manner. The control system regulates the speed of all the pumps in the system and matches the pressure and flow characteristics required by the shearer and the roof supports.

Pressure signals

Taking account of pressure signals at the valve banks and digital information, fed-back from the shearer electronics regarding both cutting speeds and linear travel, ODIN Prime calculates the anticipated roof support movements and the subsequent increased demand for hydraulic fluid from the pump station. Calculating the changes in demand before they occur allows the pumps to modulate in speed and thus change the flow and pressure, which enables the roof supports to operate in a more responsive manner which can increase the productivity of the mine.

In the steel industry, RMI has been working closely with a number of clients to understand the varying demands for flow and pressure in a descaling application. It is crucial to obtain as much information as possible to allow the maximum reduction in energy usage from the pump station. Traditionally in a rolling mill the mill stand pumps have been selected to cater for the design flow rate required for the maximum coil, billet, bloom or slab size. However, during operation the mill will produce various sizes and differing material specifications, all of which has a direct correlation to the actual pressure and flow required.

Taking this information on flow, along with the time taken per product, RMI calculates the flow and pressure requirements for all the variants and specifies the most efficient pump selection, size and quantity. On each pass of the material, the pumps will ramp up to the optimum speed for the duty required, ensuring that both flow and pressure are optimised in order to minimise energy losses.

ODIN stores all the key operating parameters allowing for interrogation of the history traces, which enables the user to adjust the parameters and fine-tune the system for even better control. Linking these three major components together has enabled RMI to not only reduce the pump running cost, typically by around 55 per cent, but also enable the steel industry and mine operators to increase production.

For more information about the ODIN control system, please go to www.rmipsl.com.

RMI Pressure Systems Ltd

Armstrong Fluid Technology
Wolverton Street
M11 2ET

+44 (0)161 223 2223



More products
2 days ago
Wave of new product development investment is coming, and Igus ready to support
Survey results from a big PwC / Make UK survey shows that new product introduction is the biggest area for planned investment among manufacturers. This reflects robust Igus enquiries, says managing director Matthew Aldridge, and Igus is primed to support this new product bonanza.
3 days ago
Industrial automation leaders are endorsing TSN
With a rapidly growing demand for the technology, the number of industrial automation vendors offering TSN-compatible devices continues to grow, reports CLPA.
3 days ago
Mouser Electronics wins gold in 2023 TDK European Distribution Awards
Mouser Electronics has won gold in the e-Catalogue Distributor category as part of the TDK European Distribution Award 2023.
3 days ago
International online event from Eplan addresses best practice
What challenges are machine builders and switchgear system manufacturers facing in today’s global markets? How can the right course be set for efficient engineering at an early stage in the game? This year’s Eplan L!ve 2023 event on 21 June 2023 is providing distilled answers.
1 week ago
Cranfield University team up with the RBTX UK team
In this video you can see how Cranfield University and the Igus RBTX team came together, with a snapshot into the recent event that took place.
1 week ago
Lenze opens door to digitalisation at ITMA
Lenze is using ITMA as a platform to showcase how textile machine providers can exploit the opportunities of digitalisation and be ready for future challenges with today’s solutions.
1 week ago
New Norgren website offers extended self-serve functionality
Norgren has launched its enhanced global website, offering customers improved functionality that includes the ability to select, order and track products on a ‘self-serve’ basis.
1 week ago
Spelsberg UK announces nationwide roadshow and open day
Spelsberg UK is excited to announce its “Spelsberg on the Road” roadshow. A state-of-the-art tour bus, equipped with a working showroom, will visit numerous locations across the country beginning late May.
1 week ago
Single controller for robot and machine axes optimises productivity
Installing a robotic pick-and-place and integrated conveyor solution has increased productivity for a pharmaceutical manufacturer while maintaining regulatory compliance. Combining a vision system optimised for accuracy that assures end-to-end traceability, a single controller from Trio manages both the robot and conveyor axes, increasing reliability for the end user.
1 week ago
Schaeffler rewards suppliers for outstanding performance
Schaeffler presented 19 of its suppliers with the Schaeffler Supplier Award at the Supplier Day in Herzogenaurach, Germany, in honour of their exceptional performance.

Login / Sign up