Pump Maintenance Prediction via Power Ratio Analysis
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Solution Overview
Problem
There is a need for a better method to predict and manage maintenance needs of pumps, particularly large diameter slurry pumps, to balance efficiency and wear, minimizing costs associated with power consumption and maintenance downtime.
Innovation Solution
A system using a signal processor to compare historical data on hydraulic and electric power consumption, adjusting maintenance intervals based on wear rates, and implementing algorithms to dynamically adjust pump clearances and replace worn parts, thereby optimizing maintenance schedules and reducing total cost of ownership.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If pump internal clearances are reduced to increase efficiency, then power usage is reduced, but wear increases due to higher shear rates and wall friction
Solution Approach 1:
The patent implements dynamic adjustment of pump clearances based on real-time monitoring of pump performance parameters. The system continuously monitors head, flow rate, and power consumption to detect clearance changes and automatically adjusts clearance dimensions to optimize the balance between efficiency and wear, rather than using fixed clearance settings
Solution Approach 2:
The patent employs a feedback control system that monitors pump performance parameters (head, flow rate, power consumption) and uses this information to detect clearance changes and adjust maintenance schedules. The system provides continuous feedback on pump efficiency and wear indicators, enabling proactive maintenance decisions that prevent excessive wear while maintaining optimal efficiency
2Duration of action of stationary object
If maintenance is performed frequently to reduce wear and extend pump life, then pump lifespan is extended, but productivity decreases due to more downtime
Solution Approach 1:
The patent implements preliminary monitoring and detection of clearance changes and wear indicators before actual wear becomes critical. By continuously tracking pump performance parameters and detecting early signs of clearance enlargement or component wear, the system allows maintenance to be performed just in time, extending pump life without requiring frequent scheduled maintenance shutdowns
Solution Approach 2:
The patent dynamically adjusts maintenance intervals based on actual pump condition and wear rate rather than using fixed time-based schedules. The system monitors wear indicators in real-time and adapts maintenance timing to match actual component degradation, maximizing pump utilization while preventing failures
3Reliability
If pump clearances are increased to reduce wear, then wear decreases, but efficiency drops and power usage increases
Solution Approach 1:
The patent dynamically adjusts clearance dimensions based on real-time monitoring of pump performance. The system continuously optimizes clearance settings to maintain the optimal balance between wear reduction and efficiency, adapting clearance dimensions to operating conditions rather than using fixed conservative clearance values
Solution Approach 2:
The patent changes physical parameters (clearance dimensions) based on monitored performance data and operating conditions. The system adjusts clearance parameters dynamically to optimize the trade-off between wear and efficiency, using parameter changes to respond to varying load conditions and component wear states
Data Source
Figure 1(a)
Figure 1(b)~2(b)
Figure 3~4(f)
AI summary
Signal processor modules configured to compare signaling containing information about historical data related to the performance of a pump, and provide corresponding signaling containing information about predicted maintenance needs of the pump on a real time basis based at least partly on the signaling compared containing information about the historical data related to the performance of the pump. The signal processor modules may be configured to compare over time the hydraulic power generated by the pump and electric power consumed by a motor driving the pump including tracking a ratio of hydraulic to electric power. The signal processor modules may be configured to predict maintenance needs based on an algorithm that takes into account a trade-off between the cost of power consumed by a motor driving the pump and the cost associated with the pump maintenance in order to minimize the total cost of operating the pump.