Pump Staging Control Using Peak-Efficiency Speed Thresholds
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Solution Overview
Problem
Existing strategies fail to determine dynamic conditions affecting centrifugal pump operations when system components are static, particularly during changes in load, leading to inefficiencies in fluid distribution systems.
Innovation Solution
A system that monitors dynamic changes in fluid distribution systems, using parameters like fluid flow, differential pressure, and pump speed to determine the optimal pump staging by comparing operating conditions with peak-efficiency curves, and implementing adjustments within 'dead bands' to ensure smooth operation and maintain peak efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing pump staging strategies are used, then pump operation continues without interruption, but system efficiency deteriorates when load changes occur
Solution Approach 1:
The patent implements dynamic pump staging control that continuously monitors system conditions (flow rate, pressure, power consumption) and adjusts the number of operating pumps in real-time based on actual load requirements. This dynamic adjustment allows the system to maintain optimal efficiency across varying loads while ensuring continuous operation through automated pump activation and deactivation based on predetermined efficiency thresholds
Solution Approach 2:
The system incorporates feedback mechanisms by monitoring key operational parameters (flow rate, differential pressure, power consumption) and using this information to determine when to stage pumps on or off. The control system compares actual system conditions against target efficiency criteria and adjusts pump staging accordingly, creating a closed-loop control system that maintains efficiency while ensuring continuous operation
2Productivity
If the number of operating pumps is increased, then fluid flow capacity increases, but energy consumption increases
Solution Approach 1:
The patent changes the operational parameters by establishing dynamic thresholds for pump staging decisions based on multiple parameters including flow rate, differential pressure, and power consumption. The system adjusts the number of operating pumps based on combinations of these parameters rather than relying on a single threshold, allowing optimal balance between flow capacity and energy consumption under varying system conditions
Solution Approach 2:
The system dynamically adjusts pump staging based on real-time monitoring of flow capacity requirements versus energy consumption. When system demand increases, pumps are staged on to increase flow capacity; when demand decreases, pumps are staged off to reduce energy consumption. This dynamic response ensures the system maintains adequate flow capacity while minimizing energy usage at all times
3Loss of energy
If pump staging adjustments are made frequently, then system efficiency is optimized, but system stability deteriorates
Solution Approach 1:
The patent implements cushioning against excessive pump staging adjustments by incorporating hysteresis bands and minimum time intervals between staging decisions. The system requires that efficiency thresholds be exceeded by a predetermined margin before triggering a pump staging change, and enforces minimum time delays between consecutive staging decisions. This prevents frequent, minor adjustments that would destabilize the system while still capturing significant efficiency improvements
Data Source
AI summary
At least one computer-readable medium on which are stored instructions that, when executed by at least one processing device, enable the processing device to perform a method. The method includes determining a peak-efficiency range of a set of one or more pumps. The peak-efficiency range has an upper limit and a lower limit. The upper limit has an associated stage-down pump speed and the lower limit has an associated stage-up pump speed. The pump speed of the set of one or more pumps is determined. If the pump speed of the set of one or more pumps exceeds the stage-down pump speed, an operating pump of the set of one or more pumps is deactivated. If the pump speed of the set of one or more pumps falls below the stage-up pump speed, an operating pump is added to the set of one or more pumps.