A high-pressure PID constant pressure water supply system for dust removal pump rooms

Abstract

This utility model relates to a high-pressure PID constant-pressure water supply system for dust removal pump rooms, comprising: a fully variable frequency water pump unit, including a medium-pressure variable frequency pump unit and a high-pressure variable frequency pump unit connected in parallel, and a small-power variable frequency pressure-stabilizing pump connected to the high-pressure variable frequency pump unit; an intelligent multi-stage pressure-stabilizing fire protection subsystem, including an energy storage tank connected in parallel to the high-pressure water supply main pipe via flanges, a low-pressure switch installed on the outlet pipe of the energy storage tank, and a pressure transmitter installed on the high-pressure water supply main pipe; a signal acquisition module, including a pressure sensor and a flow meter installed on the water supply main pipe; and a centralized monitoring and intelligent control platform, including a centralized control console located in the central control room, a host computer monitoring system connected to the centralized control console, and a PLC with a built-in PID control algorithm module. This utility model can ensure stable production water pressure and fire protection pressure that meets standards at all times, while significantly reducing energy consumption and improving the system's intelligence and reliability.

Description

Technical Field

[0001] This utility model relates to the field of water supply system technology, and in particular to a high-pressure PID constant pressure water supply system for a dust removal pump room. Background Technology

[0002] Currently, a certain production water supply system, built in 2006, consists of two systems: a medium-pressure system and a high-pressure system. The medium-pressure system supplies water to on-site tippers, transfer room, stacker-reclaimers (water tanks), building fire protection systems, above-ground and underground fire hydrants, ship loaders, and dock flushing and firefighting systems. The high-pressure system supplies water to the high-pressure spray gun station and firefighting systems in the storage yard. With the increasingly stringent environmental and fire safety requirements, the number of on-site water usage points and the amount of water used are constantly increasing. The existing system suffers from defects such as unstable water supply pressure (especially during peak water usage and firefighting demands), inability to guarantee firefighting pressure, frequent equipment start-ups and shutdowns, high energy consumption, and decentralized and outdated control systems, seriously affecting production safety, efficiency, and compliance. Therefore, to solve these problems, there is an urgent need to research a high-pressure PID constant-pressure water supply system for dust removal pump rooms that can ensure stable production water pressure, consistently meet firefighting pressure standards, significantly reduce energy consumption, and improve the system's intelligence and reliability. Summary of the Invention

[0003] This utility model aims to address the shortcomings of existing technologies by providing a high-pressure PID constant pressure water supply system for dust removal pump rooms.

[0004] To achieve the above objectives, this utility model adopts the following technical solution: a high-pressure PID constant-pressure water supply system for dust removal pump rooms, comprising:

[0005] The fully variable frequency water pump unit includes a medium-pressure variable frequency pump unit and a high-pressure variable frequency pump unit set in parallel, which are connected to the water supply network through the water supply main pipe. It also includes a small-power variable frequency pressure stabilizing pump connected to the high-pressure variable frequency pump unit. The drive motor of each water pump is connected to an independent frequency converter control cabinet.

[0006] The intelligent multi-level pressure-stabilized fire protection subsystem includes an energy storage tank connected in parallel to the high-pressure water supply main pipe via flanges, a low-pressure switch installed on the outlet pipe of the energy storage tank, and a pressure transmitter installed on the high-pressure water supply main pipe.

[0007] The signal acquisition module includes a pressure sensor and a flow meter installed on the water supply main pipe;

[0008] The centralized monitoring and intelligent control platform includes a centralized control console located in the central control room, a host computer monitoring system connected to the centralized control console, and a PLC with a built-in PID control algorithm module connected to the host computer monitoring system, the frequency converter control cabinet, the low-pressure switch, the pressure transmitter, the pressure sensor, and the flow meter, respectively.

[0009] The PLC receives detection signals from pressure sensors, flow meters, pressure transmitters, and low-pressure switches. After processing by the built-in PID control algorithm module, it outputs control commands to the frequency converter control cabinet to adjust the operating status of each water pump.

[0010] In particular, the high-voltage variable frequency pump set adopts a configuration of one large and two small pumps, namely, one high-power variable frequency high-voltage main pump and two low-power variable frequency high-voltage auxiliary pumps.

[0011] In particular, the medium-pressure variable frequency pump set adopts a two-main-two-standby configuration, which includes two variable frequency medium-pressure main pumps and two variable frequency medium-pressure standby pumps.

[0012] Specifically, the PLC control logic is configured to execute the following control modes:

[0013] Low flow / daily pressure maintenance mode:

[0014] When the system pressure exceeds the first set threshold, all water pumps stop operating, and the system pressure is maintained by the energy storage tank.

[0015] When the second set threshold < system pressure ≤ first set threshold, and the system flow demand ≤ preset small flow threshold, the low-power variable frequency pressure stabilizing pump is started for variable frequency pressure stabilizing operation;

[0016] Medium flow / fire alarm mode:

[0017] When the system pressure is less than or equal to the second set threshold or the system flow demand is greater than the preset small flow threshold, a small-power variable frequency high-pressure auxiliary pump is started for variable frequency operation.

[0018] High flow / fire mode: When the system pressure continues to drop or the system flow demand continues to increase, the high-power high-pressure variable frequency main pump is started, and all operating water pumps work together under the control of PLC.

[0019] Specifically, the energy storage tank has a volume of 500L, and the low-pressure switch has a pump start threshold of 4.0 kg / cm². 2 That is, the second set threshold; the pump stop threshold is 8.0 kg / cm². 2 That is, the first set threshold.

[0020] Specifically, the preset low flow rate threshold is 5L / s.

[0021] In particular, the host computer monitoring system integrates real-time pressure-flow curves, inverter operating parameters, energy consumption statistics, and alarm management modules, and supports linkage control with rainwater and sewage systems and ballast water systems.

[0022] The beneficial effects of this utility model are:

[0023] 1. High stability of water supply pressure and high reliability of fire protection: Through full-frequency PID control, pressure stabilization of the energy storage tank, and priority start strategy for small pumps, the phenomenon of sudden pressure drops is completely eliminated. The production water pressure can be stably maintained at the set value ±0.5 kg / cm². 2 Within the specified range, the fire protection system pressure can be consistently maintained above design requirements, meeting stringent fire protection regulations and eliminating major safety risks. Water efficiency for equipment such as stacker cranes and conveyor belt washing systems is significantly improved.

[0024] 2. Equipment Protection and Extended Lifespan: Variable frequency start-up and operation greatly reduce the mechanical and electrical shocks to water pumps and motors. It avoids frequent start-ups and shutdowns of large power frequency pumps (by using smaller pumps and variable frequency control to handle small flow rates and fluctuations), significantly extending equipment lifespan and reducing the failure rate.

[0025] 3. Significant energy saving and consumption reduction: Variable frequency speed control ensures that the pump power matches actual demand, eliminating ineffective energy consumption caused by "overpowered pumps." The pump operates in its high-efficiency range most of the time, and overall energy consumption is expected to be reduced by 25%-35%.

[0026] 4. Enhanced Intelligent and Centralized Management: The centralized control platform enables "one-stop" monitoring and scheduling of multiple systems and pump stations, significantly improving management efficiency and reducing the intensity of manual inspections. The real-time data monitoring, historical record query, and intelligent alarm functions of the upper-computer monitoring system improve fault prediction and handling speed (response time reduced by more than 60%). This provides a solid data and control foundation for advanced intelligent applications such as optimized water resource allocation and rainwater / sewage network connectivity. Attached Figure Description

[0027] Figure 1 This is a system structure block diagram of the present invention;

[0028] The following will describe in detail the embodiments of this utility model with reference to the accompanying drawings. Detailed Implementation

[0029] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0030] like Figure 1 As shown, a high-pressure PID constant-pressure water supply system for a dust removal pump room includes:

[0031] The fully variable frequency water pump unit includes a medium-pressure variable frequency pump set and a high-pressure variable frequency pump set arranged in parallel, connected to the water supply network via a main water supply pipe. It also includes a small-power variable frequency pressure-stabilizing pump connected to the high-pressure variable frequency pump set. Each pump's drive motor is connected to an independent variable frequency control cabinet. The high-pressure variable frequency pump set adopts a "one large, two small" configuration, consisting of one high-power variable frequency high-pressure main pump and two small-power variable frequency high-pressure auxiliary pumps. The medium-pressure variable frequency pump set adopts a "two main, two standby" configuration, consisting of two variable frequency medium-pressure main pumps and two variable frequency medium-pressure standby pumps. Specifically, the high-pressure system preferably uses a variable frequency combination configuration of one high-power main pump and two small-power auxiliary pumps, while the medium-pressure system uses a "two main, two standby" variable frequency pump set. By matching large and small pumps and adjusting the frequency, frequent start-stop of the large pump is avoided, optimizing energy consumption. Each frequency converter control cabinet receives instructions from the PLC and dynamically adjusts the water pump speed based on the real-time pipeline pressure signal (acquired through a pressure sensor) using a PID closed-loop control algorithm to achieve precise water supply with constant pressure or variable flow and pressure.

[0032] The intelligent multi-stage pressure-stabilized fire suppression subsystem includes an energy storage tank connected in parallel to the high-pressure water supply main pipe via flanges, a low-pressure switch installed on the outlet pipe of the energy storage tank, and a pressure transmitter installed on the high-pressure water supply main pipe; the energy storage tank has a volume of 500L, and the pump start threshold of the low-pressure switch is 4.0kg / cm³. 2 That is, the second set threshold; the pump stop threshold is 8.0 kg / cm². 2 This refers to the first set threshold. Specifically, energy storage tanks (pressure tanks) are added at key nodes of the main water supply pipeline (especially the main fire protection system pipeline). When the system is not using water or operating at a very low flow rate, the system's base pressure is mainly maintained by the expansion of compressed gas inside the pressure tank.

[0033] The signal acquisition module includes a pressure sensor and a flow meter installed on the main water supply pipe; the preset minimum flow threshold is 5L / s. Specifically, high-precision pressure transmitters are added at key pipeline nodes to provide reliable feedback signals for PID control, and electromagnetic flow meters can be used for accurate flow monitoring and >5L / s judgment logic.

[0034] The centralized monitoring and intelligent control platform includes a centralized control console set in the central control room, a host computer monitoring system connected to the centralized control console, and a PLC with an internal PID control algorithm module connected to the host computer monitoring system, frequency converter control cabinet, low-pressure pressure switch, pressure transmitter, pressure sensor, and flow meter respectively. Among them, the PLC receives the detection signals of the pressure sensor, flow meter, pressure transmitter, and low-pressure pressure switch, and after operation by the internal PID control algorithm module, outputs control instructions to the frequency converter control cabinet to adjust the operating states of each water pump. The host computer monitoring system integrates real-time pressure-flow curves, frequency converter operating parameters, energy consumption statistics, and alarm management modules, and supports linkage control with the rain and sewage system and the ballast water system. Specifically, the console integrates the monitoring signals and control authorities of multiple decentralized systems such as the rain and sewage system, ballast water system, on-site medium and high-pressure water supply system, and dust removal pump house, and realizes unified centralized monitoring, data display, and remote operation.

[0035] The PLC control logic is configured to execute the following control modes:

[0036] Small flow / daily pressure maintenance mode: [[ID=q]]

[0037] When the system pressure > the first set threshold, all water pumps stop running, and the energy storage tank maintains the system pressure;

[0038] When the second set threshold < system pressure ≤ the first set threshold, and the system flow demand ≤ the preset small flow threshold, start a small-power variable-frequency voltage stabilizing pump for variable-frequency voltage stabilizing operation;

[0039] Medium flow / fire warning mode:

[0040] When the system pressure ≤ the second set threshold or the system flow demand > the preset small flow threshold, start a small-power variable-frequency high-pressure auxiliary pump for variable-frequency operation;

[0041] Large flow / fire mode: When the system pressure continues to drop or the system flow demand continues to increase, start a high-power high-voltage variable-frequency main pump, and all operating water pumps work together under the control of the PLC.

[0042] Current Status of the Existing System: The original high-pressure system was only used for high-pressure water spraying and the yard fire-fighting system. Normally, a single pressure-stabilizing pump supplied and maintained pressure at 4-8 kg / m³. When high-pressure spraying was needed, two high-pressure pumps were activated to supply pressure, generally maintaining it at 11 kg / m³. However, after the modification of equipment such as the washing box and stacker water supply systems, the pressure-stabilizing pump could no longer meet the on-site water supply requirements. The daily pressure was mostly maintained at around 1 kg / m³. The high-pressure pumps were started with soft starts, which could not achieve frequent starts and continuous high-pressure water supply. Therefore, in addition to slow stacker water supply (40 minutes per cycle) and low pressure in the washing box, the fire-fighting pressure could not be met, posing significant risks to equipment operation, production, and safety. The medium-pressure system is equipped with four pumps, one in operation and three on standby. Each pump has a flow rate of 200 tons / hour, and the variable frequency constant pressure water supply is set at 7.2 kg / m³. For many years, a single pump has been running continuously 24 hours a day to meet the on-site water supply pressure and maintain it stably above 6.9 kg / m³. Later, in conjunction with environmental protection and cleaner production, the number of on-site renovation projects increased significantly, leading to an increase in water usage points and a higher frequency of water intake for each tank. Water volume increased from an average of 1500 tons per day to 2500 tons per day in 2023 and 3000 tons per day in 2024, with water pressure maintained above 6.5 kg / m³. Only when there is large-scale simultaneous water use on-site, such as at tippers, dock washing, or when three tanks are filled simultaneously, will the pressure drop instantly to 1.7 kg / m³, making it impossible for a single pump to maintain pressure. The existing control room, installed in 2006, has an outdated host computer and console with limited functionality. With the gradual implementation of improved management, networked rainwater and sewage systems, optimized water resource allocation, and intelligent remote water data transmission, along with the numerous and widely distributed sewage systems, ballast water systems, medium- and high-pressure water supply points, and dust removal pump stations, the existing control room can no longer meet future usage requirements and overall allocation needs.

[0043] Therefore, in this embodiment, hardware modifications are made. The soft starter cabinets of the original two high-pressure pumps are removed, and two high-voltage frequency converter control cabinets (such as ABB ACS880 series or equivalent products) matching the motor power are installed. The original single pressure-stabilizing pump is replaced with a small-power variable frequency pressure-stabilizing pump (power is calculated and determined based on daily pressure maintenance and low flow requirements), and a corresponding frequency converter control cabinet is provided. A 500L capacity energy storage tank (pressure tank) is installed in parallel near the pump outlet of the high-pressure fire protection system main pipe. A low-pressure switch (set value: 4.0 kg / cm² for pump start) is installed on the main pipeline after the energy storage tank outlet. 2 Pump stoppage 8.0 kg / cm 2 A high-precision pressure transmitter (4-20mA output to PLC) and a flow meter are installed at a suitable location on the high-pressure water supply main pipe. The existing old high-pressure control cabinet is completely replaced with a new integrated cabinet, which houses the aforementioned frequency converter, a new PLC module, low-voltage switchgear and terminal blocks, and optimizes the layout and heat dissipation.

[0044] Control system upgrade: Add or upgrade a centralized control console in the central control room and install a host computer monitoring system (including a high-performance industrial computer and a large display) connected to it. The host computer monitoring system integrates and displays the status of all equipment in the high-pressure pump room (pump start / stop, inverter status, frequency, current, pressure, flow, energy storage tank pressure, etc.), real-time curves, alarm information, and energy consumption statistics.

[0045] A PLC with a built-in PID control algorithm module (Siemens S7-1200 series can be selected) implements the following core logic:

[0046] Daily pressure holding / low flow mode: Pressure > 8.0 kg / cm³ 2 All pumps stopped. Pressure dropped to 8.0 kg / cm². 2 Below but >4.0kg / cm 2 When the flow rate is ≤5L / s (or the estimated flow rate is small), prioritize starting the low-power variable frequency pressure stabilizing pump, and maintain the pressure at 7.5-8.0kg / cm² during variable frequency operation. 2 .

[0047] Medium flow / fire alarm mode: When the pressure drops to 4.0 kg / cm² 2 If the low-pressure switch activates or the flow rate exceeds 5 L / s (e.g., a fire hydrant activates or a stacker starts water supply), the PLC immediately starts a small-power variable frequency high-pressure auxiliary pump (in variable frequency operation), either alone or in conjunction with the existing pressure-stabilizing pump (if running), to raise and maintain the pressure at 9.0-10.0 kg / cm². 2 .

[0048] High Flow / Firefighting Mode: If the pressure continues to drop (or the flow rate continues to increase, such as when multiple spray guns start), the PLC starts the high-power variable frequency high-pressure main pump (variable frequency operation). All operating water pumps work together under the PID control of the frequency converter to maintain the pressure at 10.5-11.0 kg / cm³. 2 The design fire-fighting pressure is set. After the pressure is restored, pumps are shut down one by one according to the "first-in, first-out" strategy or a preset strategy.

[0049] Configure pump rotation logic and automatic fault switching logic.

[0050] After the modification, the daily pressure of the high-pressure system stabilized at 7.5-8.0 kg / cm². 2 The water filling time for the stacker has been reduced to less than 15 minutes, and the pressure in the washing box is sufficient. During fire testing, the pressure responds quickly and remains stable at 10.5 kg / cm². 2 That's all. The equipment starts and stops smoothly, and energy consumption is significantly reduced. All data can be monitored in real time at the central control console.

[0051] This invention offers high stability in water supply pressure and high reliability in fire protection: through full-frequency PID control, pressure stabilization via an energy storage tank, and a priority start strategy for small pumps, it completely eliminates sudden pressure drops. The production water pressure can be stably maintained at the set value ±0.5 kg / cm². 2 Within the specified range, the fire protection system pressure can be consistently maintained above design requirements, meeting stringent fire protection regulations and eliminating major safety risks. Water efficiency for equipment such as stacker cranes and conveyor belt washing systems is significantly improved.

[0052] Equipment protection and lifespan extension: Variable frequency start-up and operation greatly reduce the mechanical and electrical shocks to pumps and motors. It avoids frequent start-ups and shutdowns of large industrial frequency pumps (by using smaller pumps and variable frequency control to handle low flow rates and fluctuations), significantly extending equipment lifespan and reducing failure rates.

[0053] Significant energy savings and consumption reduction: Variable frequency speed control ensures that the pump power matches actual demand, eliminating inefficient energy consumption caused by over-powered pumps. The pump operates in its high-efficiency range most of the time, and overall energy consumption is expected to be reduced by 25%-35%.

[0054] Enhanced intelligent and centralized management: The centralized control platform enables "one-stop" monitoring and scheduling of multiple systems and pump stations, significantly improving management efficiency and reducing the intensity of manual inspections. The real-time data monitoring, historical record query, and intelligent alarm functions of the upper-level computer monitoring system improve fault prediction and handling speed (response time reduced by more than 60%). This provides a solid data and control foundation for advanced intelligent applications such as optimized water resource allocation and rainwater / sewage network connectivity.

[0055] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0056] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this utility model, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0057] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0058] The present invention has been described above with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any improvements made using the inventive concept and technical solution of the present invention, or direct application to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A dust removal pump house high pressure PID constant pressure water supply system, characterized in that, include: The fully variable frequency water pump unit includes a medium-pressure variable frequency pump unit and a high-pressure variable frequency pump unit set in parallel, which are connected to the water supply network through the water supply main pipe. It also includes a small-power variable frequency pressure stabilizing pump connected to the high-pressure variable frequency pump unit. The drive motor of each water pump is connected to an independent frequency converter control cabinet. The intelligent multi-level pressure-stabilized fire protection subsystem includes an energy storage tank connected in parallel to the high-pressure water supply main pipe via flanges, a low-pressure switch installed on the outlet pipe of the energy storage tank, and a pressure transmitter installed on the high-pressure water supply main pipe. The signal acquisition module includes a pressure sensor and a flow meter installed on the water supply main pipe; The centralized monitoring and intelligent control platform includes a centralized control console located in the central control room, a host computer monitoring system connected to the centralized control console, and a PLC with a built-in PID control algorithm module connected to the host computer monitoring system, the frequency converter control cabinet, the low-pressure switch, the pressure transmitter, the pressure sensor, and the flow meter, respectively. The PLC receives detection signals from pressure sensors, flow meters, pressure transmitters, and low-pressure switches. After processing by the built-in PID control algorithm module, it outputs control commands to the frequency converter control cabinet to adjust the operating status of each water pump.

2. The dust removal pump house high pressure PID constant pressure water supply system according to claim 1, characterized in that, The high-pressure variable frequency pump set adopts a configuration of one large and two small pumps, namely, one high-power variable frequency high-pressure main pump and two low-power variable frequency high-pressure auxiliary pumps.

3. The high-pressure PID constant pressure water supply system for a dust removal pump room according to claim 1, characterized in that, The medium-pressure variable frequency pump set adopts a two-main-two-standby configuration, which includes two variable frequency medium-pressure main pumps and two variable frequency medium-pressure standby pumps.

4. The dust removal pump house high pressure PID constant pressure water supply system according to claim 2, characterized in that, The PLC control logic is configured to execute the following control modes: Low flow / daily pressure maintenance mode: When the system pressure exceeds the first set threshold, all water pumps stop operating, and the system pressure is maintained by the energy storage tank. When the second set threshold < system pressure ≤ first set threshold, and the system flow demand ≤ preset small flow threshold, the low-power variable frequency pressure stabilizing pump is started for variable frequency pressure stabilizing operation; Medium flow / fire alarm mode: When the system pressure is less than or equal to the second set threshold or the system flow demand is greater than the preset small flow threshold, a small-power variable frequency high-pressure auxiliary pump is started for variable frequency operation. High flow / fire mode: When the system pressure continues to drop or the system flow demand continues to increase, the high-power high-pressure variable frequency main pump is started, and all operating water pumps work together under the control of PLC.

5. The dust removal pump house high pressure PID constant pressure water supply system according to claim 4, characterized in that, The energy storage tank has a volume of 500 L, and the low-pressure switch has a pump start threshold of 4.0 kg / cm 2 , i.e. the second set threshold; and a pump stop threshold of 8.0 kg / cm 2 , i.e. the first set threshold.

6. The dust removal pump house high pressure PID constant pressure water supply system according to claim 4, characterized in that, The preset low flow rate threshold is 5L / s.

7. The dust removal pump house high pressure PID constant pressure water supply system according to claim 1, characterized in that, The host computer monitoring system integrates real-time pressure-flow curves, inverter operating parameters, energy consumption statistics, and alarm management modules, and supports linkage control with rainwater and sewage systems and ballast water systems.

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