Cavitation Detection in Positive Displacement Pumps
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Solution Overview
Problem
Traditional methods for detecting cavitation in positive displacement pumps are inadequate, as they rely on manual inspection and are not effective for continuous monitoring, leading to potential damage and increased maintenance costs, especially in remote or unattended installations with unpredictable fluid characteristics.
Innovation Solution
A system with pressure sensors mounted on the pump to measure suction, interstage, and discharge pressures, which calculates a cavitation severity ratio and adjusts the pump's operating speed based on predefined severity levels to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual visual inspection techniques are used to monitor pump condition, then experienced operators can detect failure modes before failure occurs, but monitoring is only performed periodically and cannot detect adverse conditions that arise between inspections
Solution Approach 1:
The patent replaces manual visual inspection with an automated electronic monitoring system that uses pressure sensors and a controller to continuously monitor pump operation and detect cavitation conditions, eliminating the time gap between manual inspections
Solution Approach 2:
The monitoring system provides continuous real-time monitoring of pump conditions through pressure sensors and controller, ensuring that adverse conditions are detected immediately when they occur rather than only during periodic manual inspections
2Reliability
If automated condition monitoring systems are implemented to provide constant monitoring, then downtime and maintenance costs are reduced, but system complexity increases
Solution Approach 1:
The monitoring system is divided into distinct functional modules: pressure sensors mounted at specific locations on the pump, signal processing circuitry, and a controller that executes monitoring algorithms, making the system easier to implement and maintain
Solution Approach 2:
The controller acts as an intermediary that receives pressure signals from sensors, processes them through algorithms, and generates control outputs, simplifying the overall system architecture by centralizing the intelligence required for cavitation detection
3Ease of operation
If pump operation continues without monitoring and control of cavitation, then the pump is simple to operate, but cavitation-related damage occurs leading to increased maintenance costs
Solution Approach 1:
The monitoring system automatically detects cavitation conditions and generates control signals to adjust pump operation without requiring operator intervention, allowing the system to protect itself from cavitation damage while maintaining ease of operation
Solution Approach 2:
The controller continuously receives feedback from pressure sensors about pump condition and automatically adjusts operation based on cavitation detection algorithms, creating a closed-loop system that prevents damage while requiring minimal operator input
Data Source
AI summary
A system and method are disclosed for monitoring and controlling a positive displacement pump using readings obtained from a plurality of pressure sensors. The pressure sensors may be mounted at the suction, discharge and interstage regions of the pump. Signals from the pressure sensors are compared to obtain a ratio that is used to predict whether a cavitation condition exists within the pump. The ratio can be compared to user provided limits to change an operating characteristic of the pump to reduce predicted cavitation. The pump may be stopped, or pump speed changed, when the ratio is less than a predetermined value. In some embodiments, historical information regarding the ratio may be used to obtain standard deviation information which may then be used to predict whether gas bubbles are passing through the pump. Other embodiments are described and claimed.