Self-regulating open circuit pump unit

Abstract

A self-regulating fire pump unit that can be controlled to operate under required conditions for supplying a fire protection system such as a sprinkler. The fire pump unit can be operated according to a control curve based on detected pressure and flow. The control curve may include: a) a first set point for a rated total value of system load for pressure and flow, b) a second set point at a minimum fractional percentage of the rated total pressure value at an excess percentage of the rated total flow value, c) a path that maintains the rated total pressure value for all flow values ​​up to the first set point, d) a path between the first set point and the second set point, e) a path starting from the second set point that limits the pressure value for flow values ​​greater than the second set point.

Description

[0001] This application is a divisional application of Chinese invention patent application 201680082381.X, entitled “Self-regulating open circuit pump unit”, filed on November 25, 2016.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of priority to U.S. Provisional Patent Application No. 62 / 350,038, filed on June 14, 2016, entitled “SELF-REGULATING OPEN CIRCUIT PUMP UNIT,” which is hereby incorporated by reference in its entirety into the detailed description of the example embodiments set forth below. Technical Field

[0004] Some example embodiments relate to open loop flow control systems, and some example embodiments relate specifically to domestic water booster pumps or to fire suppression or sprinkler pumps. Background Art

[0005] An open circuit pump system draws fluid from a supply source and pressurizes the pump discharge to achieve many different objectives, including but not limited to: providing a high working pressure fluid supply to a valve, nozzle, or other device so that the fluid can be delivered to a higher altitude or downstream, so that the fluid can pressurize an inflation balloon, or any combination of these and other objectives.

[0006] Fire pumps are used to provide pressurized flow to fire protection systems such as sprinklers. For fire sprinkler systems, the purpose of the fire pump is to pressurize the supply side or city main pressure to meet or exceed the design operating pressure of the sprinkler heads. The challenge for many installations is that the city main pressure may vary significantly throughout the day, week or year, and the number of activated sprinkler heads is not a predictable demand.

[0007] In order to enable many sprinkler systems to accommodate a range of operating conditions with a constant speed pump, additional components are often added to the sprinkler distribution, such as a pressure reducing valve (PRV) or a pressure regulating valve. These additional components introduce more potential points of failure, maintenance requirements, and replacement requirements.

[0008] During the life of a fire pump, it may also be subjected to routine operational testing and annual flow testing. A constant speed pump exposes itself and the sprinkler piping system to severe stresses every time it starts and stops during testing. However, this may be mandatory to ensure the functionality of the system over time.

[0009] Another typically installed feature is a soft starter that is used to reduce the severe stresses caused by a "direct on-line" starter, which is a costly feature often included with larger conventional fire pump systems.

[0010] Additional difficulties with prior systems may be appreciated in view of the detailed description of example embodiments that follows. Summary of the invention

[0011] According to some example embodiments, a self-regulating fire pump unit operable to meet desired conditions is generally provided.

[0012] In an example embodiment, a self-regulating fire pump (such as a fire pump unit or a home booster) is provided, which is used to supply a fire protection system such as a sprinkler. The fire pump can be operated according to a control curve. The control curve may include: a) a first set point for a rated total value of a system load for pressure and flow, b) a second set point at a minimum fractional percentage of the rated total pressure value at an over-percentage of the rated total flow value, c) a path to maintain the rated total pressure value for all flow values ​​up to the first set point, d) a path between the first set point and the second set point, e) a path starting from the second set point to limit the pressure value for flow values ​​greater than the second set point, f) a zero flow shutoff head pressure set point, and g) a path from the zero flow shutoff head pressure set point to a path to maintain the rated total pressure value.

[0013] In another example embodiment, a control system for sourcing a system load is provided, comprising: a variable speed device having an operable element to source the system load; and one or more controllers configured to determine control curve information for variable operation of the operable element of the variable speed device, the control curve information being dependent on at least a first parameter and a second parameter, the first parameter and the second parameter being related. The control curve information may include: a) a first set point for a rated total value of the system load for the first parameter and a rated total value of the system load for the second parameter, and b) a second set point for a minimum fractional percentage of the rated total value of the first parameter at an excess percentage of the rated total value of the second parameter. The one or more controllers are configured to receive one or more inputs related to at least one of the parameters, and to operate the variable speed device based on the received one or more inputs according to the control curve information.

[0014] In another example embodiment, a method for controlling a variable speed device having an operable element to supply a system load is provided. The method includes: determining control curve information for variable operation of the operable element of the variable speed device, the control curve information being dependent on at least a first parameter and a second parameter, the first parameter and the second parameter being related. The control curve information includes: a) a first set point for a rated total value of the system load for the first parameter and a rated total value of the system load for the second parameter, and b) a second set point for a minimum fractional percentage of the rated total value of the first parameter at an excess percentage of the rated total value of the second parameter. The method further includes receiving one or more inputs related to at least one of the parameters, and operating the variable speed device based on the received one or more inputs according to the control curve information.

[0015] In another example embodiment, a control curve is provided wherein the zero flow head pressure is less than a "maximum allowable closing pressure" expressed as a percentage of the rated design condition head pressure.

[0016] In another example embodiment, a method for selecting a variable speed device from a plurality of variable speed devices is provided, the variable speed device having a variably controllable motor to supply a system load, wherein control curve information of the variable speed device depends on at least a first parameter and a second parameter, the first parameter and the second parameter being related. The method includes: determining a first set point for a rated total value of the system load for the first parameter and a rated total value of the system load for the second parameter; determining a second set point for a minimum fractional percentage of the rated total value of the first parameter at an excess percentage of the rated total value of the second parameter; and selecting a variable speed device having a variably controllable motor having a power capacity that satisfies the power necessary to achieve the first set point and the second set point to a minimum extent. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Various embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0018] Figure 1 illustrates an example diagram of a self-regulating fire pump and sprinkler system according to an example embodiment;

[0019] Figure 2 Explains the use of Figure 1 Example electrical arrangement diagram of the fire pump starter arrangement for a self-regulating fire pump;

[0020] Figure 3 illustrates design criteria for shutoff head, rated flow and head, and overflow head along with example conventional fixed speed pump curves for maximum power curves selected for a non-overloaded drive;

[0021] Figure 4 illustrates an example pump curve for a self-regulating fire pump along with a maximum power curve for shutoff head, rated flow and head, and overflow head according to an example embodiment;

[0022] Figure 5 illustrates an example detailed block diagram of a self-regulating fire pump according to an example embodiment;

[0023] Figure 6 a flow chart illustrating an example method for operating a self-regulating fire pump according to an example embodiment; and

[0024] Figure 7 A flow chart illustrating an example method for selecting a self-regulating fire pump from a plurality of fire pumps according to an example embodiment.

[0025] The same reference numbers may be used throughout the drawings to identify similar elements and features. DETAILED DESCRIPTION

[0026] Variable speed solutions for fire pump applications can be used as an economical solution that helps save designers, contractors money on the initial installation of the total fire sprinkler system and reduces maintenance challenges in the field over the duration of the system's service life.

[0027] In various example embodiments, an intelligent variable speed pump is a pump that has onboard capability to be aware of its current operating conditions and has onboard logic (intelligence) to adjust its behavior in accordance with a predetermined operating method.

[0028] In example embodiments, the smart pump knows the flow it is providing, it knows the boost pressure it is creating, it knows the speed of the impeller, it knows the amount of power it is drawing, and / or it has performance maps for predefined load conditions it will encounter. In an example embodiment, the smart pump can perform self-diagnostics to provide useful information for predictive maintenance measures that may be too expensive for most owners to consider.

[0029] In an example embodiment, the smart pump may be a self-regulating fire pump unit for supplying a fire protection system such as a sprinkler. The fire pump unit may be operated according to a control curve. The control curve may include: a) a first set point for a rated total value of a system load for pressure and flow, b) a second set point for a minimum fractional percentage of a rated total pressure value at an excess percentage of the rated total flow value, c) a path for maintaining the rated total pressure value for all flow values ​​up to the first set point, d) a path between the first set point and the second set point, e) a path starting from the second set point for limiting the pressure value for flow values ​​greater than the second set point, f) a zero flow shut-off head pressure set point, and g) a path from the zero flow shut-off head pressure set point to a path for maintaining the rated total pressure value.

[0030] In another example embodiment is a control system for sourcing a system load, comprising: a variable speed device having an operable element to source the system load; one or more controllers configured to determine control curve information for variable operation of the operable element of the variable speed device, the control curve information being dependent on at least a first parameter and a second parameter, the first parameter and the second parameter being related, the control curve information comprising: a) a first set point for a rated total value of the system load for the first parameter and a rated total value of the system load for the second parameter, and b) a second set point for a minimum fractional percentage of the rated total value of the first parameter at an excess percentage of the rated total value of the second parameter. The one or more controllers are configured to receive one or more inputs related to at least one of the parameters, and to operate the variable speed device based on the received one or more inputs according to the control curve information.

[0031] Another example embodiment is a method for controlling a variable speed device having an operable element to supply a system load. The method includes: determining control curve information for variable operation of the operable element of the variable speed device, the control curve information being dependent on at least a first parameter and a second parameter, the first parameter and the second parameter being related. The control curve information includes: a) a first set point for a rated total value of the system load for the first parameter and a rated total value of the system load for the second parameter, and b) a second set point for a minimum fractional percentage of the rated total value of the first parameter at an excess percentage of the rated total value of the second parameter. The method further includes receiving one or more inputs related to at least one of the parameters, and operating the variable speed device based on the received one or more inputs according to the control curve information.

[0032] Another example embodiment is a method for selecting a variable speed device from a plurality of variable speed devices, the variable speed device having a variably controllable motor to supply a system load, wherein control curve information of the variable speed device depends on at least a first parameter and a second parameter, the first parameter and the second parameter being related. The method includes: determining a first set point for a rated total value of the system load for the first parameter and a rated total value of the system load for the second parameter; determining a second set point for a minimum fractional percentage of the rated total value of the first parameter at an excess percentage of the rated total value of the second parameter; and selecting a variable speed device having a variably controllable motor having a power capacity that satisfies the power necessary to achieve the first set point and the second set point to a minimum extent.

[0033] Another example embodiment is a non-transitory computer readable medium including instructions that, when executed by one or more controllers, cause the one or more controllers to control a variable speed device having an operable element to source a system load, including instructions for performing the described method.

[0034] Most pumps have a rated flow and head pressure range for which they are designed to operate. These design conditions of suction pressure, discharge pressure, speed, flow and mechanical input power define the operating efficiency of the pump. For any constant speed pump application, the actual operating conditions may temporarily or permanently drift away from the design conditions of the original application, causing the pump to draw more power from the driver (usually an electric motor) than the power that was intended for the application. In order to prevent motor / driver failure or false tripping of the overcurrent protection relay, in traditional situations, the size of the pump driver (motor) is set to accommodate the maximum power that the pump may require due to changes in the suction pressure and discharge pressure of the fluid density. The term "non-overload motor selection" is a common phrase describing this practice in the pump industry.

[0035] First reference Figure 1, which illustrates in diagrammatic form a fire sprinkler system 100 having one or more intelligent variable speed devices, such as one or more control pumps 102 (one is shown), according to an example embodiment. In an example embodiment, the fire sprinkler system 100 is an open circuit sprinkler system for supplying a building 104 (as shown) for sprinklers or other suitable fire protection devices on some or all floors of the building 104. The control pump 102 may be a self-regulating fire pump unit including a corresponding pump device 106 and a driver control device 108 for controlling the operation of the pump device 106. In some example embodiments, another example of a control pump 102 is a domestic water booster, which can be used to boost water supply pressure in residential, commercial, and light industrial applications where low or insufficient water pressure exists, and which can be used to boost the pressure of a city water supply, underground or surface water supply.

[0036] like Figure 1 , the sprinkler system 100 may include one or more loads 110 that may be controlled by fire dampers 112 (such as sprinkler valves, fire hose valves, standpipe valves, water mist valves, and / or mains valves). The valves 112 and loads 110 may be connected in parallel (e.g., on each floor of the building 104) in some example embodiments, and / or may be connected in series in some example embodiments. The system loads 110 may be based on changing usage requirements such as activation of a specific valve 112 on a floor where a fire or a required water pressure supply exists. In an example embodiment, each valve 112 may have a binary control (open or closed) to provide the maximum required water flow to handle the fire, and in some other open circuit scenarios, the valves 112 may be variably controlled to manage the flow rate to the corresponding loads. Since the overall system load 110 requires more flow, the control device 108 responds to the change by increasing the pump motor speed of the pump device 106 to maintain or reach the required pressure set point. If the overall system load 110 requires less flow, the control device 108 responds to the change by reducing the pump motor speed of the pump device 106 to maintain or reach the pressure set point. In some example embodiments, the pressure set point may be set according to a control curve described in more detail herein.

[0037] Still reference Figure 1, the control pump 102 is fed by a water source 120. The water source 120 may be a variable pressure water source such as from a city or municipal line. An example secondary water source 120 is a surface or underground water tank. The control pump 102 pressurizes the water source 120 received on the suction side in order to adequately supply the load 110 of the building 104. The circulating medium in this example is an open circuit or open loop because it is not intended that the circulating medium is returned directly to the control pump 102, but rather is used to extinguish the fire. It is important to note that some conventional fixed speed fire pumps may do nothing or make system assumptions in order to adjust for changes in the supply side pressure.

[0038] Still reference Figure 1 In an example embodiment, the output attribute 114 of the control pump 102 is controlled to achieve a pressure set point measured at the control pump 102 for a given flow or load requirement of the building 104. Figure 1 As shown, a pressure sensor 118 (e.g., a pressure transducer (PT)) is used to detect pressure information located locally or proximal to the control pump 102. In an exemplary embodiment, the pressure sensor 118 is integrated into the control pump 102, for example as part of an integrated factory-built unit. Similarly, a local flow sensor 130 ( Figure 5 ) is also located locally or proximal to the control pump 102 to detect flow information by the control pump 102. In an example embodiment, the control pump 102 may further detect equipment properties, such as the speed of the impeller (motor speed), and the amount of power that the control pump 102 is currently using.

[0039] The output property 114 is located locally to the control pump 102 and may be typically controlled to achieve a fixed pressure set point to adequately source the building 104, including the most extreme load locations (or ends of lines) at the height of the building 104. For example, the rated total pressure value and the rated total flow value of the system loads 110 of the building 104 may be determined by the system designer and may represent, for example, a portion or all of the valves 112 that are opened to adequately source all of the loads 110. The pressure set point at the output property 114 located proximal to the pump 102 may be set to achieve a constant pressure that will satisfy the rated total value of the building 104 at all flow scenarios up to the rated total value. Accordingly, in some example embodiments, a remote pressure sensor is not necessary.

[0040] Still reference Figure 1, the pump device 106 can take various forms of a pump with variable speed control. In some example embodiments, the pump device 106 includes at least a sealed housing that accommodates the pump device 106, and the pump device at least defines an input element (suction side) for receiving the circulating medium and an output element (discharge side) for outputting the circulating medium. In an example embodiment, the pump device 106 is a centrifugal pump. The pump device 106 includes one or more operable elements, including a variable motor that can be variably controlled to rotate at different speeds according to the control device 108. The pump device 106 also includes an impeller that is operably coupled to the motor and rotates based on the speed of the motor to circulate the circulating medium. Depending on the type of the pump device 106, the pump device 106 may further include additional suitable operable elements or features.

[0041] The control device 108 may be used to control the motor speed of the pump device 106, for example, via a variable speed drive (VSD) 524 ( Figure 5 ), which is sometimes referred to as a variable frequency drive (VFD). VSD 524 can be used to vary the speed of the motor. For example, in an example embodiment, VSD 524 converts 60 Hz (50 Hz outside the United States) input AC power to DC power and then recreates AC power at its load terminals to operate the motor at an appropriate frequency, as directed by an internal control loop, that is proportional to the frequency supplied to it. By adjusting the motor speed as flow changes, the discharge pressure of pump 102 can be maintained constant for a sensed flow rate according to a control curve that is described in more detail herein.

[0042] Reference now Figure 2 , which illustrates an example electrical system diagram of a sprinkler system 100 according to an example embodiment. In the example shown, power line signals are represented by thicker lines, while control signals are represented by thinner lines. Pressure sensor 118 provides pressure information to control device 108 and other devices that control pump 102.

[0043] like Figure 2 As shown, an electric direct-on-line (DOL) fire pump controller 122 may be used in an example embodiment, such as the GPA+GPU model available from TornaTech (TM). The electric DOL fire pump controller 122 may be used to control the VSD 524 ( Figure 5) provides high voltage power. In various example embodiments, the electric DOL fire pump controller 122 provides full service full voltage and has an automatic power transfer switch connected to at least one power source. In an example embodiment, the electric DOL fire pump controller 122 can be microprocessor-based. Some conventional DOL electric fire pump controllers 122 may also include a starter, although it can be appreciated that a bypass or direct-on-line (DOL) starter is not required in at least some example embodiments, but may be used for redundancy and / or to meet process requirements, such as safety standards, regulations, regulatory agencies, standards, or compliance requirements. For example, NFPA 20 requires automatic bypass for VFDs in variable speed electric controllers, and return to full speed through governor control on PLD diesel engines. Similarly, the pressure sensor 118 can provide pressure information to the electric DOL fire pump controller 122.

[0044] The electric DOL fire pump controller 122 may transfer full power to provide full voltage from more than one high power generator, such as grid distribution power 124 and diesel generator 126, to the controlled pump 102. This backup generator configuration may also be used in order to meet compliance requirements.

[0045] In an example embodiment, if Figure 2 As shown, the control pump 102 can be a fire pump unit provided as an integrated unit, where the components including the pressure sensor 118 are all in one unit or at least together in the same room location. For example, this can facilitate installation, maintenance, replacement, testing, etc. more conveniently.

[0046] Reference now Figure 3 , which illustrates an example operating diagram 300 of a conventional fixed speed pump necessary to supply a typical fire protection system of a building 104. In general, the operation of such a fixed speed pump is necessary to meet the operating conditions or total rated value of the building 104. A typical performance curve 302 and a corresponding power curve 304 of a fixed speed pump are shown on the operating diagram 300. When there is an overpressure at the fixed speed pump, this may require the use of a pressure reducing valve (PRV) or a pressure regulating valve or other mechanism to relieve the overpressure. In addition, fixed speed pumps typically require a direct online (DOL) bypass starter so that the initial activation of the fixed speed pump can be successfully performed. As shown in the power curve 304, the fixed speed pump requires a relatively large non-overload power capacity in order to achieve operation and meet the safety factor requirements at the overflow, which increases the total cost. For example, a fixed speed pump may require a power capacity of 200HP. Similarly, a fixed fire pump can be operated using assumptions regardless of the variable suction side pressure from the water supply source.

[0047] Figure 4An example operational graph 400 of a variable speed controlled pump 102 is illustrated in accordance with an example embodiment. Graph 400 shows an example control curve 402 (shown in dashed lines) and a corresponding power curve 416 for controlling the pump 102 in accordance with an example embodiment.

[0048] Graph 400 includes axes containing related parameters. For example, mean square flow is approximately proportional to head, and flow is approximately proportional to speed. In the illustrated example, abscissa (or x-axis) 404 illustrates flow in U.S. gallons per minute (GPM), and ordinate (or y-axis) 406 illustrates head (H) in pounds per square inch (alternatively in feet) (psi). Another y-axis 408 illustrates power in horsepower (HP). Control curve 402 is a superimposed representation of the intelligent controlled operation of variable speed controlled pump 102 relative to those parameters on graph 400. In an example embodiment, each parameter is measured locally at the control pump 102.

[0049] The relationship between the parameters can be approximated by specific affinity laws, which can be affected by volume, pressure, and power or brake horsepower (BHP). For example, for a change in propeller diameter, at constant speed: D1 / D2 = Q1 / Q2; H1 / H2 = D1 2 / D2 2 ; BHP1 / BHP2=D1 3 / D2 3 For example, for a change in speed, with a constant propeller diameter: S1 / S2 = Q1 / Q2; H1 / H2 = S1 2 / S2 2 ; BHP1 / BHP2=S1 3 / S2 3 . Where: D = propeller diameter (Ins / mm); H = pump head (Ft / m); Q = pump capacity (gpm / lps); S = speed (rpm / rps); BHP = brake horsepower (shaft power - hp / kW). These variables can work together to interact in such a way that the operating point / path of one output variable can determine or limit the operating point of other output variables.

[0050] In an example embodiment, the control curve 402 is defined and programmed for controlling the pump 102, which is configured as an intelligent variable speed device. Figure 5) detected parameter, the operation of the pump device 106 may be maintained on the control curve 402 (e.g., at a higher or lower flow point) based on instructions from the control device 108. References herein to a "smart" device include a control pump 102 that is capable of self-adjusting the operation of the pump device 106 along the control curve 402, depending on a particular desired or detected load. In some example embodiments, at least some aspects of the control curve 402 may be stored in the memory 508 ( Figure 5 In some example embodiments, at least some aspects of the control curve 402 may be calculated or determined by the control device 108 in real time or prior to operation.

[0051] The first set point 410 of the control curve 402 is defined as the nominal total of the loads 110 for head and flow. The nominal total is represented as 100% head capacity and 100% flow capacity. The first set point 410 may be set by the system designer and may represent, for example, a scenario when a portion or all of the valves 112 are open to source all of the loads 110 (flow).

[0052] For example, a building 104 having 150 feet in height from the discharge of the control pump 102 to the topmost fire damper 112 can benefit from variable speed by eliminating the possibility of PRVs that would be used in a conventional system. For example, for a building height of 150 feet, the pressure set point at the discharge of the pump 102 can be set to 175 psi, drop 65 psi due to the height, and have 110 psi at the topmost valve 112. This leaves 10 psi for friction losses, which is typically achievable with straight runs of 4-inch and 6-inch risers.

[0053] In an example embodiment, a second set point 412 of the control curve 402 may be determined or calculated based on the first set point 410. The second set point 412 of the control curve 402 represents a minimum fractional percentage of the rated total head value at an excess percentage of the rated total flow value. In the example embodiment shown, the second set point 412 may have a minimum requirement of 65% pressure head at a flow rate of 150% relative to the rated capacity of the building 104. In an example embodiment, the second set point 412 represents a safety factor so that the minimum pressure is maintained at an unforeseen scenario where additional flow is required. For example, in an example embodiment, the second set point 412 represents a regulatory or standard requirement or compliance, such as set by the National Fire Protection Association (NFPA) or other regulatory agency as is familiar in the art. For example, the NFPA requires a minimum pressure of 65% pressure head at a flow rate of 150% relative to the rated capacity of the building 104. The NFPA does not have any specific requirements for flows greater than 150%.

[0054] The third set point 414 of the control curve 402 is a zero pressure point for flow values ​​greater than the second set point 412. For example, there may not be a specific pressure requirement here, and the pressure can be controlled to drop to zero pressure as quickly as possible. For example, this can reduce the required power capacity rating of the pump 102.

[0055] The first path 420 of the control curve 402 extends from zero flow to the first set point 410. The first path 420 is for 0% to 100% of the rated flow (capacity). The first path 420 maintains the pressure set point for all flow values ​​from 0% to 100% of the rated flow. The pressure value is maintained at 100% for all of these flow values ​​up to the first set point 410. As can be seen, the 100% pressure set point is controllable so that excessive pressure is not created. Accordingly, in some example embodiments, for example, a pressure reducing valve (PRV) is not necessary for operation.

[0056] The second path 422 of the control curve 402 is between the first set point 410 and the second set point 412. The second path 422 is shown as a straight path. Other types of paths or curves may be used in other example embodiments.

[0057] The third path 424 of the control curve 402 is from the second set point 412 to the third set point 414. The third path 424 starting from the second set point 412 limits the pressure value for flow values ​​greater than the second set point 412. The third path 424 may have a steeper slope or curve to zero pressure, for example, when compared with a constant speed device. As can be appreciated, the power capacity of the control pump 102 may be selected to minimally satisfy the third path 424 using the second set point 412 as a guide. Therefore, the additional power capacity of the control pump 102 is not necessary for flow values ​​greater than the second set point 412 or the third path 424. For example, the control pump 102 may require a power capacity of 120HP.

[0058] Another constraint 426 is a zero flow head constraint such as during closing of all valves 112. For example, the maximum allowed closing pressure may be 140% pressure at 0% flow, such as based on process requirements or safety or regulatory compliance requirements. In an example embodiment, the control pump 102 is controlled to have a pressure set point for 0% flow (closed) that may be anywhere from a rated total pressure value to the maximum allowed closing pressure, such as 100% to 140% in an example embodiment. Figure 4 As shown, the fourth set point 428 is a zero flow shut-off head pressure set point, which can be expressed as an excess percentage of the rated pressure, such as, for example, 130%. In an example embodiment, there is a fourth path 430 on the control curve 402 from the fourth set point 428 to the first path 420.

[0059] In an example embodiment, during the start-up of the control pump 102 to supply power to the load 110, the VSD 524 ( Figure 5 ) may not run at full speed but may gradually increase to a desired set point due to the variably controllable motor speed. This type of softer start cycle does not result in typical fire motor inrush current demands, such as may be experienced by a direct-on-line (DOL) starter. In addition, some components in the system 100 are less likely to experience failures during testing or when called upon. This soft start is not specifically shown on the diagram 400.

[0060] In the event that the external pressure sensor fails (or provides poor readings), the embedded intelligence of the control pump 102 can ensure that the maximum head (boost) pressure is provided for the control pump 102 rating for flow demand, wherein the overflow flow rating is not exceeded, thereby removing the non-overload motor sizing requirement as was necessary in traditional situations.

[0061] During the rating test, the control pump 102 may be controlled to operate within the required "fire pump" constraints specified by some regulatory agencies (such as FM) as are familiar in the art. For example, certain parameters and boundaries of pressure and flow may need to be tested during the rating test.

[0062] For the control curve 402, in some other example embodiments (if applicable), other example paths besides straight lines between the set points 410, 412, 414 may include arcs, polynomials, exponentials, or quadratic formulas to provide customized or more gradual operation when desired. In some other example embodiments, additional set points may also be provided on the control curve 402.

[0063] Figure 5 An example detailed block diagram of a control pump 102 is illustrated in accordance with an example embodiment. The control pump 102 and its associated control device 108 ( Figure 1 ) may include one or more controllers 506, such as processors or microprocessors, which control the overall operation of the control pump 102. The controller 506 may also include circuitry, such as high power circuitry for high power transfer functions from the generators 124, 126. The controller 506 interacts with other device components such as a memory 508, system software 512 stored in the memory 508 for executing applications, an input subsystem 522, an output subsystem 520, and a communication subsystem 516. A power supply 518 provides power to the control device 108. The power supply 518 may include circuitry, alone or in combination with the controller 506, for transferring power directly from the generators 124, 126 to directly power the VSD 524 for variable control.

[0064] The communication subsystem 516 is configured to communicate directly or indirectly with other devices. The communication subsystem 516 can be configured for wired and / or wireless communications. The communication subsystem 516 can be configured to communicate via a network such as a local area network (LAN), a wireless (Wi-Fi) network, and / or the Internet. The communication subsystem 516 can send or receive communications with sensors such as the pressure sensor 118 and the flow sensor 130.

[0065] As a smart device, the control device 102 can communicate with a server and / or cloud server 530 or other higher level system, or with a cloud-based analytics system to, for example, enable owners to manage their total building inventory, or separate buildings one by one.

[0066] The input subsystem 522 may receive input variables. The input variables may include, for example, pressure information from the pressure sensor 118 and flow information from the flow sensor 130. Other example inputs may also be used, such as power and speed. The input variables may include, for example, a fire alarm that notifies the control pump 102 that a fire is occurring that needs to be dealt with by the fire damper 112. The output subsystem 520 may control output variables, such as one or more operable elements of the control pump 102, through the VSD 524. For example, the output subsystem 520 may be configured to control at least the speed of the motor of the control pump 102 to achieve the output attributes 114 (for head and flow (H, F)). Figure 1 ), such as controlling the pump 102 to follow the control curve 402 ( Figure 4 Other example output variables, operable elements, and device properties may also be controlled.

[0067] Control curve 402 ( Figure 4 ) may have some or all of the information stored in memory 508, calculated or determined in real time, predetermined prior to operation, and / or received via the communication subsystem 516. Figure 1 ) may be stored in memory 508.

[0068] Reference now Figure 6 , which illustrates a flow chart of an example method 600 for operating a variable speed controlled pump 102 according to an example embodiment. In an example embodiment, the method 600 is performed by the controller 506 ( Figure 5 ) is executed. At event 602, method 600 includes determining a control curve 402 for controlling a variable operation of pump 102. In an example embodiment, a first parameter of control curve 402 may be pressure, and a second parameter of control curve 402 may be flow. In an example embodiment, reference Figure 4 , the control curve 402 information may include: a) a first set point 410 for a rated total value of the system load for a first parameter and a rated total value of the system load for a second parameter; b) a second set point 412 for a minimum fractional percentage of the rated total value of the first parameter at an excess percentage of the rated total value of the second parameter; c) a first path 420 for maintaining the rated total value of the first parameter for all values ​​of the second parameter up to the first set point 410; d) a second path 422 between the first set point 410 and the second set point 412; and e) a third path 424 starting from the second set point 412 to limit the value of the first parameter for a second parameter value greater than the second set point 412.

[0069] At event 604 , method 600 includes receiving one or more inputs related to at least one of the parameters. Typically, this includes pressure information from pressure sensor 118 and flow information from flow sensor 130 .

[0070] At event 606, method 600 includes operating VSD 524 to control pump 102 based on the received one or more inputs according to control curve 402. In an example embodiment, receiving event 604 and operating event 606 are performed in a loop, such as until such time as the fire has been addressed.

[0071] Figure 7 A flow chart illustrating an example method 700 for selecting an appropriate variable speed controlled pump 102 from a plurality of variable speed controlled pumps to source a system load of a building 104 according to an example embodiment. In an example embodiment, the method 700 is performed by one or more controllers. In an example embodiment, the first parameter of the control curve 402 may be pressure and the second parameter of the control curve 402 may be flow.

[0072] At event 702, method 700 includes determining a first set point 410 (100% of the rated total value of the system load for the first parameter and 100% of the rated total value of the system load for the second parameter). Figure 4 In an example embodiment, the value is set by a system designer and retrieved from memory. At event 704, method 700 includes determining a second set point 412 (a minimum fractional percentage of the rated total value of the first parameter) at an excess percentage of the rated total value of the second parameter. Figure 4 ). This may be calculated based on the first set point 410, or retrieved from memory.

[0073] At Event 706 , method 700 includes selecting a variable speed device having a variably controllable electric machine having a power capacity that minimally meets the power necessary to achieve the first set point and the second set point.

[0074] For example, for flow rates greater than the second set point 414, the pressure may be limited down to a zero pressure point on the control curve 402. For example, there may not be a specific pressure requirement here, and the pressure may be controlled to drop to zero pressure as quickly as possible. For example, this may reduce the required power capacity rating of the pump 102.

[0075] For example, a plurality of control pumps 102 may be categorized by power capacity or power rating. For example, the control pump 102 to be selected may be from a group of rated fire pump units or domestic water boosters. The selected control pump 102 is one that meets these criteria without having unnecessary excess power capacity. This may reduce the startup and replacement costs of the system. The driver size of the selected control pump 102 will not be constrained by a very large multiple of the "rated value" requirement as in a fixed speed fire pump, because the embedded intelligence in the example embodiment will manage the flow and head curves to meet the rated pump requirements (for flow and head).

[0076] Once the control pump 102 is selected, the selected control pump 102 can be installed and programmed to operate to circulate the circulating medium to supply the fire protection system of the building 104. The control pump 102 can then be operated, for example, by executing the control pump 102 described in reference to FIG. Figure 6 The described exemplary method 600 operates as described herein. Controlling the operation of the pump 102 will thus not exceed the power capacity rating, while saving costs by not having to provide equipment to supply excess power.

[0077] In an example embodiment, the method 700 is performed by one or more controllers of a server device and is accessible via a web portal or web application over a network connection such as the Internet.

[0078] In view of the foregoing, the use of intelligent variable speed pump technology in the example embodiments may be used in life safety systems via fire suppression systems such as fire sprinkler systems.

[0079] In example embodiments, smart fire pumps can regulate themselves to not operate at flow conditions that exceed the design requirements of the installation by the fact that they know what that maximum flow requirement is and know how much flow they are producing.

[0080] In various example embodiments, the variable speed pump may be provided as a "VFD on the wall", which is an economical approach to overall system design. The control pump 102 and pressure sensor 118 may be provided as part of an integrated factory built unit as a single product. Features of the self-regulating variable speed pump unit include: a mechanical pump, an onboard controller, a variable speed drive, and an electric motor.

[0081] An integrated smart pump assembled from an integrated system may be more reliable than loose field components from multiple suppliers because the factory integration approach ensures that extensive testing is performed to ensure optimal compatibility between the various components of the integrated smart pump, as opposed to a field assembly approach.

[0082] Smart self-regulating pump units can provide lower life cycle costs for some or all of the following reasons. First, installation costs are lower. Maintenance costs associated with single or multiple PRVs are eliminated. Drain risers are no longer necessary. Customers can utilize self-flow and boost pressure information from smart pumps in lieu of more time-consuming manual documentation. Individual replacement parts are smaller and less costly.

[0083] In other example embodiments, some other example parameters may be used instead of pressure and flow as operating maps and control curves. Internal detectors or sensors may be used, which is often referred to in the art as "sensorless" control of the pump because external sensors are not required. Internal detectors may be configured to self-detect, for example, equipment properties such as power and speed of the motor on the pump. Other input variables may be detected.

[0084] Various variations can be made in some example embodiments. Some example embodiments can be applied to any variable speed device, and are not limited to variable speed controlled pumps. For example, some additional embodiments can use different parameters or variables, and can use more than two parameters (e.g., three parameters on a three-dimensional graph). For example, speed (rpm) and power (BHP) can also be used as parameters on the control curve described. In addition, temperature (Fahrenheit) relative temperature load (BTU / hr) can be a parameter or variable considered for the control curve, such as a variable temperature control that can be controlled by a variable speed circulating fan. Some example embodiments can be applied to any device that depends on two or more related parameters. Some example embodiments may include variables that depend on parameters or variables such as liquid, temperature, viscosity, suction pressure, location altitude, and the number of pumps in operation.

[0085] In some example embodiments, each illustrated block or module may represent software, hardware, or a combination of hardware and software, as appropriate. In addition, some blocks or modules may be combined in other example embodiments, and more or fewer blocks or modules may be present in other example embodiments. In addition, in other embodiments, some of the blocks or modules may be divided into multiple sub-blocks or sub-modules.

[0086] Although some of the embodiments are described in terms of methods, it will be understood by those of ordinary skill in the art that embodiments of the present disclosure also relate to various devices including components for performing at least some of the various aspects and features of the described methods, which components are hardware components, software, or any combination of the two, or in any other form. Moreover, an article for use with the device (such as a pre-recorded storage device or other similar non-transient computer-readable medium including program instructions recorded thereon) or a computer data signal carrying computer-readable program instructions may direct the device to facilitate the practice of the described methods and systems. It should be understood that such devices, articles, and computer data signals also fall within the scope of the example embodiments of the present disclosure.

[0087] Although some in the above examples are described as occurring in a particular order, it will be appreciated by those skilled in the art that some of the messages or steps or processes may be performed in a different order, as long as the result of the changed order of any given step will not prevent or weaken the occurrence of subsequent steps. In addition, in other embodiments, some of the above messages or steps may be removed or combined, and in other embodiments, some of the above messages or steps may be divided into a plurality of sub-messages or sub-steps. Further, when necessary, some or all of the steps may be repeated. Each element described as a method or step is similarly applicable to a system or subassembly, and vice versa.

[0088] The term "computer-readable medium" as used herein includes any medium that can store instructions, program steps, etc. for use or execution by a computer or other computing device, including but not limited to: magnetic media (such as magnetic disks, disk drives, magnetic drums, magneto-optical disks, magnetic tapes, magnetic core memory, etc.); electronic storage (such as any type of random access memory (RAM), including static RAM, dynamic RAM, synchronous dynamic RAM (SDRAM), read-only memory (ROM), any type of programmable read-only memory, including PROM, EPROM, EEPROM, flash memory, EAROM, so-called "solid state disks", any type of other electronic storage (including charge-coupled devices (CCDs) or bubble memories), any type of portable electronic data carrying cards, including compact flash, secure digital (SD-cards), memory sticks, etc.); and optical media, such as compact disks (CDs), digital versatile disks (DVDs), or Blu-ray disks.

[0089] Some variations of the example embodiments may be made, and these variations may include combinations and sub-combinations of any of the example embodiments of the above example embodiments. The various embodiments presented above are merely examples and are by no means intended to limit the scope of the present disclosure. Various variations of the invention described herein will be apparent to those of ordinary skill in the art who benefit from the present disclosure, and such variations are within the intended scope of the present disclosure. Specifically, features from one or more of the above-described embodiments may be selected to create alternative embodiments including feature sub-combinations not explicitly described above. In addition, features from one or more of the above-described embodiments may be selected and combined to create alternative embodiments including feature combinations not explicitly described above. On the basis of reviewing the present disclosure as a whole, it will be apparent to those skilled in the art that features suitable for such combinations and sub-combinations are apparent. The subject matter described herein is intended to encompass and include all suitable technical changes.

Claims

1. A control system for supplying a source to a system load, comprising: a variable speed device including a pump and having an operable element to supply power to the system load; one or more controllers configured to determine control curve information for variable operation of the operable element of the variable speed device, the control curve information being dependent on at least a first parameter and a second parameter, wherein the first parameter comprises a pressure parameter and the second parameter comprises a flow parameter, the first parameter and the second parameter being related, the control curve information comprising: a) a first set point for a nominal total value of the system load for the first parameter and for a nominal total value of the system load for the second parameter, b) a second set point of a minimum fractional percentage of the rated total value of the first parameter at an excess percentage of the rated total value of the second parameter, wherein the excess percentage is at 150% of the rated total value of the second parameter at the system load, c) a path between said first set point and said second set point, d) a path starting from the second set point which limits the value of the first parameter for values ​​of the second parameter greater than the second set point, e) maintaining a path of a setpoint total value of the first parameter for all values ​​of the second parameter up to the first set point, f) a further set point of a percentage excess of the nominal total value of said first parameter for a switch-off or zero value of said second parameter, and g) a path from said further set point to said path for maintaining a nominal overall value of said first parameter; The one or more controllers are configured to: receiving one or more inputs related to at least one of the parameters, and The variable speed device is operated according to the control profile information based on the one or more inputs received.

2. The control system according to claim 1, characterized in that: For the second set point, the minimum portion percentage and the excess percentage are set by process requirements.

3. The control system according to claim 1, characterized in that: For the second set point, the minimum portion percentage is at 65% of the rated total value of the first parameter of the system load.

4. The control system according to claim 1, characterized in that: Further comprising a pressure sensor integrated with the variable speed device and used to determine the first parameter, and further comprising a flow sensor integrated with the variable speed device and used to determine the second parameter, wherein the control curve information is used to control the variable speed device to operate at the first parameter for the determined second parameter.

5. The control system according to claim 1, characterized in that: The system loads include one or more fire dampers.

6. The control system according to claim 1, characterized in that: The system loads include one or more loads supplied by the variable speed device in an open circuit.

7. The control system according to claim 1, characterized in that: Operating the variable speed device includes transferring direct power from a generator to the operable element.

8. The control system according to claim 1, characterized in that: Further included is a pressure sensor for determining the first parameter, wherein the pressure sensor, the variable speed device, the operable element, and the one or more controllers are factory integrated into a single product.

9. The control system according to claim 1, characterized in that: One or more of a pressure regulating valve, a direct on-line (DOL) bypass actuator, a drain riser, or a remote pressure sensor are not required.

10. A method for controlling a variable speed device including a pump and having an operable element to supply a system load, the method comprising: determining control curve information for variable operation of the operable element of the variable speed device, the control curve information being dependent on at least a first parameter and a second parameter, wherein the first parameter comprises a pressure parameter and the second parameter comprises a flow parameter, the first parameter and the second parameter being related, the control curve information comprising: a) a first set point for a nominal total value of the system load for the first parameter and for a nominal total value of the system load for the second parameter, b) a second set point of a minimum fractional percentage of the rated total value of the first parameter at an excess percentage of the rated total value of the second parameter, wherein the excess percentage is at 150% of the rated total value of the second parameter at the system load, c) a path between said first set point and said second set point, d) a path starting from the second set point which limits the value of the first parameter for values ​​of the second parameter greater than the second set point, e) maintaining a path of a setpoint total value of the first parameter for all values ​​of the second parameter up to the first set point, f) a further set point of a percentage excess of the nominal total value of said first parameter for a switch-off or zero value of said second parameter, and g) a path from said further set point to said path for maintaining a nominal overall value of said first parameter; receiving one or more inputs related to at least one of the parameters; and The variable speed device is operated according to the control profile information based on the one or more inputs received.

11. The method according to claim 10, characterized in that For the second set point, the minimum portion percentage and the excess percentage are set by safety standards, regulations, or regulatory agencies.

12. The method according to claim 10, characterized in that For the second set point, the minimum portion percentage is 65% of the rated total value of the first parameter of the system load.

13. The method according to claim 10, characterized in that wherein a pressure sensor is integrated with the variable speed device and used to determine the first parameter, and wherein a flow sensor is integrated with the variable speed device and used to determine the second parameter, wherein the control curve information is used to control the variable speed device to operate at the first parameter for the determined second parameter.

14. The method according to claim 10, characterized in that The system loads include one or more fire dampers.

15. The method according to claim 10, characterized in that The system loads include one or more loads supplied by the variable speed device in an open circuit.

16. The method according to claim 10, characterized in that The operation of the variable speed device includes transferring direct power from a generator to the operable element.

17. The method according to claim 10, characterized in that A pressure sensor is used to determine the first parameter, wherein the pressure sensor, the variable speed device, the operable element, and the one or more controllers are factory integrated into a single product.

18. The method according to claim 10, characterized in that The power demand of the variable speed machine will be limited to the maximum of the first set point and the second set point, wherein the selection of non-overload actuation of the operable element will only have to accommodate the power demand of the first set point and the second set point.

19. The method according to claim 10, characterized in that The method is executed by one or more controllers.

20. A non-transitory computer readable medium comprising instructions that, when executed by one or more controllers, cause the one or more controllers to control a variable speed device having an operable element to source a system load, the instructions comprising: Instructions for executing the method according to any one of claims 10 to 19.

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