Multi-Pump Control Using Power-Based Pump Characterization
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Solution Overview
Problem
Existing multi-pump control systems require stored pre-knowledge of pump characteristics and often need to measure and monitor pressure differential and flow to determine an energy-efficient number of running pumps, which is time-consuming and inefficient.
Innovation Solution
A control system that uses a processing module to determine approximated pump characteristics based on power consumption and speed signals, without measuring pressure differential or flow, using scaled parameters to optimize the number of running pumps for energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stored pre-knowledge of pump characteristics is used, then determination of energy-efficient pump configuration is possible, but the system cannot adapt to changes in real pump characteristics due to manufacturing tolerances, wear, and fouling
Solution Approach 1:
The system changes the operational parameters by performing multiple configuration cycles where pumps are sequentially cut in and cut out. By measuring power consumption at different configurations, the system dynamically determines actual pump characteristics rather than relying on stored manufacturer data. This allows adaptation to real-world variations including wear and fouling.
Solution Approach 2:
The control system performs self-characterization by autonomously conducting configuration cycles and measuring its own operational parameters. The system determines its own pump characteristics through power consumption measurements during different pump configurations, eliminating dependence on external manufacturer data and enabling continuous adaptation.
2Loss of energy
If several configuration cycles are run to determine optimal pump configuration, then energy-efficient operation is achieved, but significant time is consumed in the process
Solution Approach 1:
The system performs preliminary characterization by conducting configuration cycles to determine pump characteristics and optimal configurations in advance. Once characterized, the system can quickly reference stored configuration data to make rapid pump control decisions during operation, reducing real-time computational requirements and response time.
Solution Approach 2:
The system performs a limited number of configuration cycles (at least two) to gather sufficient data for determining pump characteristics, rather than exhaustive testing. This partial action approach provides adequate accuracy for energy-efficient operation while minimizing time consumption.
3Measurement precision
If pressure differential measurement is used to determine pump configuration, then accurate system state monitoring is possible, but the system becomes more complex and time-consuming
Solution Approach 1:
The system extracts the necessary information for determining optimal pump configuration from power consumption measurements alone, eliminating the need for pressure differential sensors and flow meters. By focusing on the power consumption parameter during configuration cycles, the system achieves pump optimization without complex measurement infrastructure.
4Measurement precision
If flow measurement is used to determine optimal pump configuration, then accurate flow-based optimization is possible, but the system requires additional measurement equipment and time
Solution Approach 1:
The system extracts flow-related optimization information indirectly through power consumption measurements during configuration cycles, eliminating the need for flow meters. The power consumption data provides sufficient information to determine optimal pump configurations without direct flow measurement.
Data Source
AI summary
A multi-pump control system with a control module, a processing module, communication interface, and a storage module. The system is configured to change a number n of running pumps, and receive a signal indicative of a power consumption P and information about a speed ω of one of the n running pumps before and after two different changes of the number n of running pumps. The system is configured to determine, before and after at least two different changes of the number n of running pumps, without a measurement of a differential pressure Δp and of a flow Q, two approximated pump characteristics Pn and Δ{tilde over (p)}n, wherein each of the approximated pump characteristics Pn and Δ{tilde over (p)}n is unambiguously defined by a pair of parameters (θ1, θ2; θ3, θ4). The system is configured to store the pair of parameters (θ1, θ2; θ3, θ4) for each of the determined approximated pump characteristics Pn and Δ{tilde over (p)}n.