Method for operating a heating installation and controller with differential pressure sensor
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Solution Overview
Problem
Existing heating systems face inefficiencies and high costs due to the use of differential pressure regulators and self-regulating pumps, which either waste energy or fail to accurately balance heat demands across multiple heating circuits, leading to increased power consumption and fuel usage.
Innovation Solution
A method that measures differential pressure between flow and return lines to dynamically adjust pump speed using a controller, allowing for energy-efficient operation by compensating for changes in heat requirements without additional pressure losses, and can be retrofitted to existing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If differential pressure regulators are used in every heating circuit, then hydraulic balancing is achieved, but flow energy is wasted and additional pressure drop occurs increasing power consumption
Solution Approach 1:
The invention extracts the differential pressure measurement function from traditional differential pressure regulators and implements it separately using a differential pressure sensor. This allows the measurement function to be separated from the flow restriction function, eliminating the need for regulators to create pressure drops while maintaining hydraulic balancing capability through electronic control of pump speeds.
Solution Approach 2:
The invention replaces the mechanical differential pressure regulator system with an electronic control system using a differential pressure sensor and controller that adjusts pump speeds. This substitution eliminates the mechanical flow restriction mechanism while achieving the same hydraulic balancing effect through electronic regulation, thereby reducing energy waste.
2Ease of operation
If self-regulating pumps with constant pressure characteristic are used, then pump speed is adjusted for each system characteristic, but the pumps cannot distinguish whether volume flow reduction is caused by their own heating circuit or another heating circuit
Solution Approach 1:
The invention implements a feedback mechanism where the differential pressure sensor continuously monitors the actual differential pressure across each heating circuit and feeds this information back to the controller. The controller compares the actual pressure with the target pressure and adjusts pump speeds accordingly, enabling the system to respond to actual local conditions rather than making assumptions about flow reduction causes.
Solution Approach 2:
The differential pressure sensor acts as an intermediary that provides direct local pressure information to the controller for each heating circuit. This intermediary measurement capability allows the controller to make informed decisions about pump speed adjustments based on actual differential pressure conditions rather than relying on indirect flow measurements or assumptions.
3Measurement precision
If flow sensors or pump characteristic maps are used to detect volume flow changes, then heat requirement changes are identified, but additional pressure losses occur and system complexity increases
Solution Approach 1:
The invention extracts the pressure measurement function from complex flow measurement systems and implements it using a simple differential pressure sensor. By measuring differential pressure directly across the heating circuit, the system obtains flow information without the complexity of flow sensors or pump characteristic maps, while also avoiding additional pressure losses associated with flow measurement devices.
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 enables power and fuel-saving operation of heating pumps by optimizing pump speed based on real-time differential pressure measurements, reducing energy consumption and maintaining efficient heat distribution across heating circuits, even in the event of pump failures.
Implementation Method 1
the differential pressure between the flow line and the return line of the heating circuit is measured
Implementation Method 2
heating medium is fed to or removed from heating circuits at least via a central supply and discharge line
Data Source
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AI summary
In a method for operating a heating system, in which heating medium is fed to or removed from the heating circuits at least via a central feed and discharge line, it is provided that the differential pressure between the flow and return lines of the heating circuit is measured in each heating circuit, so that the measured pressure value is compared with a stored target value and the differential pressure in the heating circuit is adjusted to the target value with a speed change of a pump used in the heating circuit.