Multi-pump Control System with Power Optimization
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Solution Overview
Problem
Existing multi-pump control systems for water supply networks face challenges in identifying the most energy-efficient subset of pumps due to unknown or changing pump characteristics, especially when pre-knowledge from manufacturers is lacking, and lack of flow measurement data, leading to inefficient energy consumption.
Innovation Solution
A control system comprising a control module, processing module, communication interface, and storage module that runs zero flow configuration cycles to determine approximated pump characteristics and power consumption by ramping up or down pumps, using algorithms like cumulative sum to identify signal changes, and adjusts pump speeds to maintain constant head and flow, allowing for smooth operation and energy optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If pre-knowledge of pump characteristics from manufacturer is used, then control decisions can be made, but the information becomes outdated due to manufacturing tolerances, wear and fouling
Solution Approach 1:
The system performs preliminary characterization cycles during commissioning to establish initial pump curves, and then periodically updates these characteristics during operation. This preliminary action captures the actual pump behavior at different operating points, replacing outdated manufacturer data with real-world measurements that account for manufacturing variations and initial wear.
Solution Approach 2:
The system continuously monitors pump performance by measuring power consumption, flow rates, and head pressures. This feedback is used to detect deviations from expected pump characteristics and trigger re-characterization cycles. The feedback loop ensures that control decisions are always based on current, accurate pump data rather than outdated manufacturer specifications.
2Measurement precision
If flow sensors are installed to measure current flow, then accurate flow data is available, but installation and maintenance costs increase
Solution Approach 1:
The invention extracts flow information from alternative measurements rather than directly measuring flow. By using power consumption data from motor sensors, pressure differential measurements from existing pipeline pressure sensors, and pump performance curves, the system calculates flow rates without requiring flow sensors. This extraction approach eliminates the need for complex flow measurement hardware while maintaining sufficient accuracy for control decisions.
Solution Approach 2:
The system uses power consumption and pressure measurements as intermediary variables to infer flow rates. Instead of directly measuring flow with complex sensors, the system measures easily obtainable parameters (power, pressure) and uses pump characteristic models to translate these into flow information. This intermediary approach simplifies the measurement system while providing the necessary flow data for optimization.
3Loss of energy
If multiple configuration cycles are run to identify pump characteristics, then accurate energy-efficient subset is found, but time consumption increases
Solution Approach 1:
The system performs a limited number of configuration cycles (typically 2-5) during commissioning to capture the essential pump characteristics, rather than exhaustively testing all possible pump subsets and operating conditions. This partial action provides sufficient accuracy for control optimization without consuming excessive time. The system accepts that not every edge case is characterized, but the captured data is sufficient for practical energy optimization.
Solution Approach 2:
Comprehensive pump characterization is performed once during the commissioning phase before normal operation begins. This preliminary action establishes accurate pump performance curves that can be reused for many control decisions without requiring repeated measurement cycles. The time investment is made once upfront rather than continuously, minimizing ongoing time losses while maintaining optimization accuracy.
4Productivity
If pumps are operated at partial load to match required flow, then flow demand is met, but power consumption increases compared to full-load operation
Solution Approach 1:
The system dynamically adjusts the number of operating pumps based on real-time flow and head requirements, rather than running a fixed number of pumps at constant speed. By continuously evaluating the optimal pump subset configuration and adjusting operations accordingly, the system keeps pumps operating near their efficient full-load points while meeting varying demand, avoiding the energy penalties of prolonged partial-load operation.
Solution Approach 2:
The system changes operational parameters (number of active pumps, operating speeds) to maintain pumps in their high-efficiency operating ranges. When demand varies, the system adjusts the configuration of the pump fleet rather than allowing individual pumps to operate inefficiently at partial load. This parameter adjustment ensures that operating pumps run near their design points, minimizing energy consumption while meeting flow requirements.
Data Source
AI summary
A multi-pump control system includes a control module, a processing module, a communication interface, and a storage module. The control module is configured to run a zero flow configuration cycle by either ramping up the speed of at least one pump in addition to a subset j of i pumps of a multi-pump system until the communication interface receives a signal change indicative of the at least one pump starting to contribute to the total flow, wherein the processing module is configured to determine an approximated pump characteristic or power consumption or ramping down the speed of at least one pump of a subset j of i pumps of a multi-pump system until the communication interface receives a signal change indicative of the at least one pump stopping to contribute to the total flow, wherein the processing module is configured to determine an approximated pump characteristic and/or power consumption.