Check Valve Leak Detection Using Pump Motion Monitoring
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Solution Overview
Problem
Verifying leaks caused by solids in check valves of liquid pumping systems is difficult due to impurities accumulating and preventing proper valve closure, leading to potential damage and operational issues.
Innovation Solution
A method and system that utilize motion information from sensors to identify and indicate leak situations in liquid transfer systems, using a frequency converter to monitor the pump's direction and speed, and trigger alarms or control the pump to prevent further damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If check valves are used to prevent liquid flow in one direction, then liquid backflow is prevented, but solids accumulate on the valve mechanism causing leaks
Solution Approach 1:
The patent replaces mechanical leak detection methods with a motion sensing system that uses sensors to detect pump movement and a control unit to analyze motion patterns. This substitution allows for reliable leak detection without mechanical contact that could be affected by solid accumulation in the check valve.
Solution Approach 2:
The patent introduces motion information as an intermediary parameter to detect leaks. Instead of directly monitoring the check valve condition, the system uses pump motion data as a mediator to indirectly detect leak situations, avoiding the problem of solid accumulation affecting the detection mechanism.
2Measurement precision
If motion monitoring is continuously performed, then leak detection accuracy is improved, but energy consumption increases
Solution Approach 1:
The patent implements periodic motion monitoring by configuring the control unit to perform leak verification at specific intervals or under specific conditions (e.g., after pumping operations). This periodic approach maintains adequate leak detection accuracy while significantly reducing energy consumption compared to continuous monitoring.
Solution Approach 2:
The system performs motion monitoring selectively based on operational conditions rather than continuously. The control unit determines when leak verification is necessary based on pump operation status, providing sufficient detection capability only when needed, thus optimizing energy usage.
3Strength
If pump operation is restricted to prevent reverse rotation, then pump damage is reduced, but system flexibility decreases
Solution Approach 1:
The patent uses feedback control where the control unit continuously monitors pump motion and provides feedback signals. When reverse rotation is detected or predicted based on motion patterns, the system responds by controlling the frequency converter to prevent damage, while allowing normal operational flexibility through intelligent decision-making based on real-time motion data.
Solution Approach 2:
The system dynamically adjusts pump operation based on real-time motion information. Rather than imposing static restrictions, the control unit adapts the pump's operational parameters dynamically, allowing reverse rotation only when safe and preventing it when dangerous, thus maintaining both durability and flexibility.
Data Source
AI summary
Exemplary embodiments relate to a method for verifying a leak situation in a liquid transfer system a system and a control unit for implementing the method. The liquid is transferred with a frequency-converter-controlled pump from a lower pressure to a higher pressure and where liquid is prevented from being transferred from a higher pressure to a lower pressure with one or more check valves positioned in a pipe system. The method includes generating, for the frequency converter, motion information on the motion of the pump between the motion operations, and indicating a leak situation of the check valve if the direction of operation of the pump is, in the motion information, opposite to the direction of operation during the use of the pump.