Wastewater Pump Station Flow Engine Using Accurate Level Generator
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Solution Overview
Problem
Volumetric flow meters in wastewater pump stations suffer from inaccuracies due to level measurement errors caused by wave fluctuations, leading to average flow rate calculations that are not real-time, and inefficient pump management results in uneven wear and energy inefficiency across pumps.
Innovation Solution
Implementing an Accurate Level Generator and Real Time Inflow Calculator using multiple readings and averaging algorithms to improve level accuracy, and a pump selector system that chooses pumps based on efficiency to balance operation and reduce simultaneous operation of multiple pumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If volumetric flow meters use predetermined levels to calculate flow rate, then the installation is simple and inexpensive, but the accuracy is highly variable due to wave fluctuations on the water surface
Solution Approach 1:
The patent applies preliminary action by implementing an accurate level generator that processes raw level measurements before they are used in flow calculations. The system performs preliminary averaging of multiple level readings and applies corrections for wave fluctuations, pump startup effects, and overflow conditions before the levels are used to calculate volumetric flow. This pre-processing ensures that the level data fed into the existing volumetric flow calculation is already corrected, maintaining installation simplicity while dramatically improving accuracy.
2Duration of action of stationary object
If the distance between predetermined levels is maximized to minimize pump wear, then pump startup stress is reduced, but the flow rate calculation accuracy decreases
Solution Approach 1:
The patent applies feedback by continuously monitoring multiple level readings and using this feedback to dynamically adjust the calculated flow rate. The accurate level generator compares successive level measurements, detects wave patterns, and applies corrections based on the observed behavior. This feedback mechanism allows the system to maintain accurate flow calculations regardless of the distance between predetermined levels, decoupling the pump wear benefit from the accuracy penalty.
3Productivity
If multiple pumps operate simultaneously to handle high flow rates, then the pumping capacity is sufficient, but the energy consumption and wear increase
Solution Approach 1:
The patent applies dynamics by enabling real-time flow rate calculation that dynamically adjusts pump operation decisions. The accurate level generator provides continuous, corrected flow measurements that allow the control system to optimize pump scheduling in real-time based on actual demand. This dynamic approach allows the system to operate fewer pumps at higher efficiency when possible, or coordinate pump operations to minimize simultaneous startup events, thereby reducing energy consumption and wear while maintaining sufficient pumping capacity.
Data Source
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AI summary
Method and system for determining the real-time flow into a wastewater pump station using analog level sensing technologies. An Accurate Level Generator mechanism supplies an accurate mean value out of multiple readings for each level used to calculate the volume between levels. Two consecutive levels are used to calculate the volume between them using an Accurate Flow Calculator and the time it took to get from one level to the other. A Real Time Inflow Calculator adds results regarding the pumps in operation and overflow events, which are ways for the water to exit the pumping station. At a water level approaching where the pumps start or stop, or when abnormal events occur, a Predictive Abnormal Event Adjuster replaces the highly probable abnormal Real Time Inflow Result by a more stable and possible value, which is the last one calculated plus its variation over time.