Process Fluid Flow Control via Pump Speed and Valve Coordination
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Solution Overview
Problem
Existing process fluid flow control systems in process industry plants face challenges in achieving energy-efficient and wear-reducing control, particularly due to high construction and energy expenditure when replacing control valves with speed-controlled pumps.
Innovation Solution
A method and arrangement that coordinates the pump speed and control valve position to optimize control valve-specific parameters such as valve authority and energy efficiency, while maintaining the target flow rate, by evaluating actual parameters like pressure difference and cavitation intensity, to reduce energy consumption and wear on control valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a control valve is used to adjust the flow cross-section, then the fluid flow can be varied according to control requirements, but the pressure differential across the actuator increases and flow loss increases
Solution Approach 1:
The patent combines the control valve with a pump system to form an integrated flow control arrangement. The control valve is positioned upstream of the pump, and the pump provides suction that assists in opening the control valve, reducing the pressure differential across the valve actuator and minimizing flow loss while maintaining control capability.
Solution Approach 2:
The pump acts as an intermediary element between the control valve and the downstream system. By positioning the pump upstream and using its suction effect, the system mediates the pressure distribution to reduce the energy loss associated with traditional downstream valve control.
2Productivity
If the flow cross-section of the control valve is narrowed, then the fluid flow is reduced, but the pressure differential across the actuator increases
Solution Approach 1:
The control valve and pump are merged into a coordinated system where the pump's suction effect assists valve opening. This combination allows the valve to reduce flow rate while the pump compensates for the pressure differential, preventing excessive pressure buildup across the actuator.
Solution Approach 2:
The system uses feedback from the pump's operation to influence the control valve's pressure conditions. The pump's suction creates a pressure environment that automatically assists valve opening, providing a form of pressure feedback that prevents excessive differential pressure buildup.
3Adaptability or versatility
If a speed-controlled pump is used to replace control valves, then process consumer-specific control is achieved, but design, control and energy expenditure increase extremely
Solution Approach 1:
The control valve within the integrated arrangement serves multiple functions: it provides flow control capability while also benefiting from the pump's suction effect to reduce its own pressure differential. This multi-functionality allows the system to achieve adaptability without requiring completely speed-controlled pumps for each consumer, thus reducing overall complexity.
Solution Approach 2:
The control valve utilizes the pump's suction effect to assist its own operation, particularly in opening the valve. This self-service mechanism reduces the need for additional control infrastructure and simplifies the overall control system while maintaining adaptability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for energy-efficient and low-wear process fluid flow control by optimizing the valve position and pump speed, preventing excessive differential pressure and maintaining precise control of the flow rate, thus reducing operational costs and extending the lifespan of control system components.
Implementation Method 1
a pump is provided. For cost and control reasons, this pump typically provides a constant fluid pressure to generate the flow
Implementation Method 2
A disadvantage of controlling the process fluid flow using a control valve is that the control valve acts as a variable flow resistance
Implementation Method 3
the control device is actuated by a pneumatic actuator controlled by a positioner with a current-to-pressure converter
Data Source
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AI summary
In a method for controlling a process fluid flow generated by a pump in a process industry plant, such as a chemical or petrochemical plant, a pasteurization plant, a brewery, a food production plant, a pharmaceutical plant, etc.In a system where a target flow rate of the process fluid is set at a control valve by positioning the control valve to a corresponding valve position, and the actual valve position is sensed, it is provided that an actual parameter relating to the process fluid flow at the control valve is determined, and both the actual parameter and the actual valve position are evaluated against a predetermined optimization parameter, such as valve authority, optimized control activity of the control valve, optimized energy efficiency, or minimum control valve throttling effect. In the event of a deviation from the actuator-specific optimization parameter, a drive parameter, such as a speed, of the pump and the valve position are coordinated in such a way as to approximate the optimization parameter, in particular to achieve the optimization parameter, without substantially changing the flow rate controlled with respect to the target flow rate.