GEA Nu-Con Generation 3 Rotor Detection System (RDS)

GEA Nu-Con’s Generation 3 Rotor Detection System (RDS) technology is designed to detect contamination during production while monitoring the condition of the critical components within the rotary valve, warning operators before replacement is required.

Contamination is often caused by either the rotor making contact with the body of the valve, resulting in metal entering the product, or by an increase in substances such as moisture or fats. By measuring the electrical resistance in the valve against a known value, the system is able to detect changes that indicate a fault.

The system is also able to continually monitor the condition of the valve’s seals using flow metering. As the seals wear, the flow increases; by analysing the data, the degree of wear can be ascertained without the need for a physical inspection. This allows engineers to strategically plan maintenance and minimise downtime.

Pressure on the seals is also monitored to make sure the correct pressure is maintained. If a reduction in pressure is detected, a controller automatically adjusts the pressure to maximise efficiency and prolong the life of the seals.

The RDS incorporates a number of systems to log the running time of the valve and give advance warning of when critical components, such as bearings and drive chains, need to be checked or replaced. In applications using valves with ATEX certification, tip clearance is alerted as a maintenance warning to ensure the correct tolerances are maintained and that the valve will protect the rest of the plant in the event of an explosion.

Data showing the running resistance, speed, operating pressure and any contact or circuit faults in the rotary valve is continually logged by the system. In the event of an anomaly, the data can be remotely accessed by GEA Nu-Con to assist engineers in diagnosing the problem.