Pump Surge Control via Vibration Rate Monitoring
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Solution Overview
Problem
Conventional multiphase pumps face instability due to fluctuations in phase distribution, leading to premature wear and potential failure, which is exacerbated by the reliance on complex multiphase flowmeters for surge control, resulting in restricted operational ranges and increased safety margins.
Innovation Solution
A method for operating multiphase pumps that utilizes vibration rate of change and amplitude limits, measured by sensors, to trigger control signals and adjust pump operations, thereby avoiding unstable states without relying on precise phase distribution measurements, allowing for a larger operational envelope.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex multiphase flowmeters are used for surge control, then measurement precision is improved, but device complexity increases and operational range is restricted
Solution Approach 1:
The patent extracts the essential surge detection function from complex multiphase flowmeters by using only vibration sensors and basic operating parameter measurements. This separates the critical surge control function from the unnecessary complexity of precise phase distribution measurement, achieving surge detection with minimal instrumentation.
Solution Approach 2:
Instead of directly measuring complex multiphase flow characteristics, the patent uses vibration signals as a simplified copy or indicator of surge conditions. The vibration measurements serve as a proxy for detecting unstable operating states, avoiding the need for direct complex flow measurement.
2Reliability
If large safety margins are applied for surge protection, then reliability is improved, but operational range is reduced
Solution Approach 1:
The patent implements dynamic surge detection by continuously monitoring vibration rate of change and comparing it against threshold values. This dynamic approach allows the system to adapt to varying operating conditions in real-time, enabling reliable surge protection across a broader operational range compared to static safety margin approaches.
Solution Approach 2:
The system uses feedback from vibration sensors and operating parameter measurements to continuously assess surge risk and adjust control actions. This closed-loop feedback mechanism enables reliable surge protection while maintaining flexibility across different operating conditions, avoiding the need for conservative fixed safety margins.
3Measurement precision
If vibration rate of change monitoring is implemented, then surge detection accuracy is improved, but measurement complexity increases
Solution Approach 1:
The vibration sensor serves multiple functions: it monitors vibration amplitude, vibration rate of change, and provides feedback for surge detection and control. This multi-functionality achieves accurate surge detection without requiring separate measurement systems for each parameter, minimizing overall device complexity.
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 reliable surge control and extended operational ranges by using vibration measurements in conjunction with operating parameters, reducing the need for accurate phase distribution data and minimizing safety margins, thus preventing pump instability and failure.
Implementation Method 1
a pump vibration changes with a rate of change and a current rate of change of the pump vibration is determined
Data Source
AI summary
A method for operating a pump, for conveying a fluid from a low-pressure side to a high-pressure side of the pump includes determining a current rate of change of pump vibrations and comparing the current rate of change with a limit for the rate of change or determining a current vibration of the pump and comparing the current vibration with a vibration amplitude limit for the vibration, storing the limit for the rate of change or the vibration amplitude limit in a surge controller, providing a control signal when the current rate of change reaches the limit or when the current vibration reaches the vibration amplitude limit, and changing a control variable of the pump by the control signal, such that the vibration is reduced and an unstable operating state of the pump is avoided.