US20260153101A1
METHOD FOR CONTROLLING AND/OR MONITORING AN OPERATION OF A PUMP SYSTEM
Publication
Application
Classifications
IPC Classifications
CPC Classifications
Applicants
SIEMENS AKTIENGESELLSCHAFT
Inventors
Dirk Scheibner, Jürgen Schimmer, Jürgen Zettner, Ulf Bormann
Abstract
A computer-implemented method for controlling and/or monitoring an operation of a pump system. The pump system includes a pump and a motor that is connected to drive the pump. The method including the steps of: determining a plurality of cavitation indicators, wherein each cavitation indicator indicates cavitation or a likelihood of cavitation of the pump for different operating ranges, wherein each operating range is given by a combination of values of a first and a second motor characteristic.
Figures
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001]The present patent document is a § 371 nationalization of PCT Application Serial Number PCT/EP 2023/079801, filed Oct. 25, 2023, designating the United States which is hereby incorporated in its entirety by reference. This patent document also claims the benefit of EP 22204352.3 filed on Oct. 28, 2022, which is hereby incorporated in its entirety by reference.
FIELD
[0002]Embodiments relate to the field of pump systems and the control and/or monitoring of the same.
BACKGROUND
[0003]When operating pumps, the undesirable phenomenon of cavitation occurs when the suction pressure is too low and this leads to boiling bubbles in the pumped medium. At the very least, unplanned work operations will be needed to maintain the pump system, e.g., replace the impeller and/or housing of the pump.
[0004]From European patent application no. EP 21200024.4 it is known to measure the magnetic stray flux of an electric machine and to feed this magnetic stray flux into a simulation model of the electric machine. The simulation model determines operating parameters of the electric machine and analyses these operating parameters to identify faults in the electric machine.
[0005]From European patent application EP 2 196 678 A1 a method and a system in accordance with a pump controlled with a frequency converter has become known. Therein, one or more features indicating cavitation or likelihood of cavitation of the pump are determined in order to detect cavitation or likelihood of the cavitation of the pump from one or more of the formed features.
[0006]From US patent application US 2016/010639 A1 a sensor less technique for pump differential pressure and flow monitoring has become known.
[0007]From European patent application EP 1 198 871 A1 a malfunction detection of a machine driven with a variable rotational speed by an electric motor, whereby the motor is switched off when a malfunction occurs has become known. To this end, the machine and/or a unit actuated by the machine runs through all possible operating states in which the operating values of the motor recorded during the learning function are, in their association with the machine and/or the unit driven by the motor, stored, brought forward and used for monitoring malfunctions.
BRIEF SUMMARY AND DESCRIPTION
[0008]The scope of the embodiments is defined solely by the appended claims and is not affected to any degree by the statements within this summary. The present embodiments may obviate one or more of the drawbacks or limitations in the related art.
[0009]Cavitation may lead to erosion of the impeller and/or housing and thus to the destruction of the pump. Prolonged operation of the pump during cavitation must be avoided at all costs.
[0010]It is thus desired to prevent interruptions (and therefore expensive downtimes) in a plant and provide optimal motor load. It is also desired to prevent faults in the system and recognize impending failures before they happen.
[0011]Embodiments provide a more accurate assessment of the operating status, possible changes and the distance of the operating point to an unwanted operation with cavitation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012]
[0013]
[0014]
[0015]
[0016]
[0017]
[0018]
DETAILED DESCRIPTION
[0019]In
[0020]As depicted in
[0021]A plurality of characteristics of the pump system may be measured using one or more sensors. Hence, a plurality of sensor signals may be measured. For example, the electrical active power of the motor 3, the flow rate of the pumped medium, the input pressure (suction pressure) of the pump 2, the outlet pressure (delivery pressure) of the pump, and/or a binary signal indicating whether the motor is running may be determined. Additionally for cavitation monitoring the temperature of the pumped medium may need to be determined. In addition, in case of speed-controlled pumps, the pump speed may be determined. In case a converter 6 supplies the (shaft) power of the motor 3 the mechanical power may be determined. Further characteristics of the motor 3 may include nominal speed, nominal power, nominal efficiency. Characteristics of the pump 2 may include a minimum flow, a nominal flow, a delivery characteristic (H/Q characteristic), a power curve (P/Q curve), and/or an efficiency curve. Further characteristics may be determined, e.g., in case of a fluid other than water, a fluid specific vapor value may be determined.
[0022]A fault in the operation of a pump 2 may pose serious threats. Different monitoring and/or control functions may be relevant for the pump system dependent on the appropriate reaction and/or urgency. Diagnoses such as an acute blockage, dry running, and/or cavitation may be reported immediately to the plant operator as an alert, e.g., an alarm, since such operating conditions may quickly damage the pump. An automatic emergency stop of the pump and/or closing of a valve may then be initiated. For example, operating states such cavitation may lead to damage to the pump after some time, but as a rule one still has to react relatively quickly. In this case, the diagnostic information may be reported to the plant operator and/or the maintenance engineer.
[0023]For example, in case the conveyed liquid is flammable, an explosive atmosphere may be built up inside the pump by the gas/vapor phase together with oxygen (e.g. from air ingress). If cavitation occurs the material of propellers, valve discs or impellers is literally eaten away. In the case of machines at risk of cavitation, particularly hard and strong materials must therefore be used. Cavitation often results in a corrosive attack. Protective layers are removed and the roughened, porous surface offers optimal conditions for corrosion. Criteria for the occurrence of cavitation are mainly the cavitation number and the required net suction lift. The dimensionless cavitation number σ is a measure of when in a fluid cavitation occurs.
[0024]To avoid cavitation, the cavitation number o should be chosen as large as possible. The following measures reduce the cavitation tendency: avoid low pressures, avoid temperatures close to the boiling point of fluids, use thin blade profiles, choose a small angle of attack for the blades, avoid abrupt deflections of the flow, round off the leading edge.
[0025]Another criterion is the NPSH value (Net Positive Suction heads). The NPSH value corresponds to the (pressure) energy of a liquid column under the existing operating conditions on connection flange. The value is always positive. A distinction is made between two NPSH values: NPSHA (Net Positive Suction Head Available): This is the present pressure of the plant at operating conditions as a head difference. NPSHR (Net Positive Suction Head Required): This is the pressure required to operate the pump as a height difference.
[0026]In
[0027]In
[0028]As depicted in
[0029]Thereby, a more accurate assessment of the operating status, possible changes and/or the distance of the operating point to an unwanted operation with cavitation may be determined.
[0030]The cavitation indicator may be determined based on pump vibrations and/or magnetic flux. Hence, this may require a detection of pump vibrations and/or magnetic flux, e.g., in addition to the speed and/or load of the driving motor. The vibrations and/or magnetic flux (values) may be obtained, for example, via a sensor, such as the SIMOTICS Connect 400, attached to the pump and/or motor, using vibration and magnetic field sensors. Furthermore, the temperature of the conveyed medium may be measured or estimated by temperature measurement of the fluid or in the vicinity thereof. Characteristic values for the cavitation activity may then be determined from the vibration and/or magnetic flux signal.
[0031]Cavitation is the emergence and subsequent abrupt disappearance of vapor bubbles in the flow of a liquid. During the operation of pumps, such vapor bubbles may arise as a result of (locally) excessive flow speeds: the higher the speed, the lower the pressure in the liquid. If the pressure falls below the vapor pressure of the liquid, vapor bubbles form. If the pressure increases again in the direction of flow, the bubbles collapse: the gas in the bubble suddenly condenses. This implosion of the bubble results in so-called “jet impacts”. Enormous pressure and temperature peaks occur, that are usually many times higher than the load limits of the material of the pump blade or pump wall. The surface of the blade or wall is permanently damaged and eventually destroyed. In addition, even a small amount of cavitation reduces the efficiency (head) of the pump. Full cavitation may even lead to a complete collapse of production.
[0032]The cavitation indicator(s) may be determined based on vibration signals. Alternatively, other signals such as motor current, stray magnetic field of the motor and/or acoustic signals of a microphone may also be used to determine the cavitation indicators.
[0033]As depicted in
[0034]The data including speed values, load values, and/or vibration and/or magnetic flux values is recorded during a start-up of the pump system or over a, e.g., longer, period of time with varying load and speed. Different acceleration trajectories may also be used in order to capture a, e.g., large, area of the operating ranges. The vibration may be in a range of 0.1 Hz- 20 kHz. The acoustic sound may be in a range of 0.1 Hz-100000 kHz. Furthermore, as described herein a pump or pump system may thus be operated in one or more operating ranges. For example, the pump system may include one or more transitional phases, such as one or more acceleration phases and/or one or more deceleration phases of the pump and/or motor, e.g., during the ramp-up and/or ramp-down of the motor/pump. Thus, a transitional phase may include one or more operating ranges (given by values of the first and second motor characteristics). During such a transitional phase, the pump system, for example the pump and/or the motor, may transition from one operating point or range to another operating point or range. Now, for example one or more measurements may be made during the transitional phase in order to obtain values of the first and/or second motor characteristic. Thus, during a transitional phase, values of the first and second motor characteristic may be obtained. Based on the values of the first and second motor characteristic a cavitation indicator may be determined. That is, for example, for one or more pairs of values of the first and second motor characteristic a cavitation indicator may be determined. The one or more cavitation indicators determined during the one or more transitional phases (or based on the values of the first and second motor characteristic during the one or more transitional phases) may be used to create and/or populate a database with entries relating to the one or more cavitation indicators associated with the respective operating ranges. Thus, even though the one or more values of the first and/or second motor characteristic have been determined during a transitional phase, these one or more (values of the) first and/or second motor characteristics may be used for determining the one or more cavitation indicators, e.g. for the one or more operating ranges or points, for example included in or covered by the transitional phase. A transitional phase may arise due to changing operating conditions of the pump system. For example, based on a valve position, the load may be increased and/or based on a changed volumetric flow, the speed may be changed. Thus, for example a transitional phase may occur or may be initiated, e.g., the valve position may be changed based on a control valve setpoint and/or the volumetric flow may be changed based on a speed setpoint. Similarly, the control valve setpoint and/or the motor speed setpoint may be changed in order to avoid any regions, i.e., one or more operating ranges with a respective cavitation indicator exceeding a predetermined cavitation threshold, e.g., when changing from a first operating point or range to a second operating point or range of the pump system, for example of the pump and/or motor.
[0035]
[0036]
[0037]
[0038]
[0039]A cavitation indicator and thus each cavitation indicator of the plurality of cavitation indicators determined indicates cavitation or a likelihood of cavitation of the pump. The occurrence of cavitation may not be determined with absolute certainty since it is dependent on the specific circumstances. Thus, the cavitation indicator may be interpreted as indicating a probability of cavitation.
[0040]Each cavitation indicator of the plurality of cavitation indicators may be determined for different operating ranges. Each operating range is given by a combination of values of a first and a second motor characteristic. For example, for an interval of values a representative value may be used, for example a median or mean value of the interval or range may be used as a basis for determining the cavitation indicator. Alternatively for all values of an interval or range the cavitation indicator may be determined and a mean or median value of the cavitation indicators may be used.
[0041]Each operating range may be given by a combination of values of a first and a second motor characteristic. The operating range may thus include individual values or may be an interval including multiple values. For example, an operating range may include a first value of the first motor characteristic and a first value of a second motor characteristic. Furthermore, an operating range may include multiple values of the first motor characteristic and multiple values of a second motor characteristic. The values of the first and second motor characteristic may be stored in a memory as described above and be associated with one another and/or with the cavitation indicator. This allows for a coarse-grained mapping of the cavitation of the pump system, e.g., within the allowable operating range of the pump (system) and/or the motor. Hence, the cavitation of the pump system may be determined in a granular fashion, i.e., granularly. To that end, the cavitation indicator may be determined, e.g., estimated, for each one of the plurality of operating ranges, e.g., within the allowable operating range of the pump (system) and/or the motor. The cavitation indicator of an operating range may be updated when the pump (system) and/or the motor is (actually) operated in the operating range or in one or more adjacent operating ranges.
[0042]In a step S3, an alert may be initiated in case the cavitation threshold is exceeded by one or more cavitation threshold of the plurality of cavitation threshold. For example, the alert may be displayed, e.g., on a display of the operating device. The alert may be a notification or an alarm and may include information about the one or more cavitation indicators exceeding the cavitation threshold.
[0043]Turning to
[0044]Turning to
[0045]Turning to
[0046]The distance may be determined in terms of the first and/or second motor characteristic, e.g., given in units of the first and/or second motor characteristic, respectively. The one or more other operating ranges may be associated with or may possess a cavitation indicator that exceeds the predetermined cavitation threshold. Hence, the risk of the operating point of the pump system drifting towards a region of cavitation or likelihood thereof may be determined.
[0047]Thus, in a step S6, the control settings of the motor and/or the pump system may be adapted (automatically) based on the distance. The control settings of the motor and/or the pump system may relate to the first and/or second motor characteristic, for example in order to arrive at an operating point with low/no cavitation indicator. The first motor characteristic may correspond to the motor speed and/or the second motor characteristic may correspond to the motor load (torque).
[0048]Turning to
[0049]Turning to
[0050]In a step S9, the cavitation indicators may be re-determined during the operation of the pump system. For example, for repeated acceleration phase(s) and/or deceleration phase(s) and/or after a predetermined period of operating time of the pump system. For example, at first point in time the cavitation indicator may be determined for one or more operating ranges and at later point in time the (and for the same or different operating ranges) the cavitation indicators may be redetermined.
[0051]Turning to
[0052]Turning to
[0053]Now turning to
[0054]It should be understood that the operating ranges, for example are adjacent to each other and, cover (at least part of) the allowable operating range of the pump system and/or motor. That is, the operating ranges may cover the first and/or second motor characteristics present at nominal speed, nominal power, and/or nominal efficiency. The operating ranges may cover the first and/or second motor characteristic at a minimum flow, a maximum flow, a nominal flow, a delivery characteristic (H/Q characteristic), a power curve (P/Q curve), and/or an efficiency curve of the pump.
[0055]A further embodiment includes a computer program including program code that when executed performs the method steps of any one of the embodiments described herein. A further embodiment includes a, for example non-transitory, computer readable medium including the computer program.
[0056]It is to be understood that the elements and features recited in the appended claims may be combined in different ways to produce new claims that likewise fall within the scope of the present embodiments. Thus, whereas the dependent claims appended below depend from only a single independent or dependent claim, it is to be understood that these dependent claims may, alternatively, be made to depend in the alternative from any preceding or following claim, whether independent or dependent, and that such new combinations are to be understood as forming a part of the present specification.
[0057]While the present embodiments have been described above by reference to various embodiments, it may be understood that many changes and modifications may be made to the described embodiments. It is therefore intended that the foregoing description be regarded as illustrative rather than limiting, and that it be understood that all equivalents and/or combinations of embodiments are intended to be included in this description.
Claims
1. A method for controlling and/or monitoring an operation of a pump system, wherein the pump system comprises a pump and a motor that is connected to drive the pump, the method comprising:
determining a plurality of cavitation indicators, wherein each cavitation indicator indicates cavitation or a likelihood of cavitation of the pump for different operating ranges, wherein each operating range of the different operating ranges is provided by a combination of values of a first motor characteristic and a second motor characteristic.
2. The method of
determining that the cavitation indicator of one or more operating points of the motor, provided by a combination of values of the first and the second motor characteristic within an operating range, exceeds a predetermined cavitation threshold value; and
initiating an alert.
3. The method of
4. The method of
measuring a vibration generated by the motor and/or a magnetic flux generated by the motor at different operating ranges; and
determining the cavitation indicator for the different operating ranges based on a vibration and/or a magnetic flux measured.
5. The method of
determining a cavitation score on a discrete or a continuous cavitation scale, the cavitation scale indicating a first likelihood of cavitation at one end of the cavitation scale, and a second likelihood of no cavitation on the other end of the cavitation scale.
6. The method of
determining for a first operating point within a first operating range, the first operating point associated with a no/low cavitation indicator, a distance, in terms of the first motor characteristic and/or the second motor characteristic, to one or more other operating ranges at which the cavitation indicator exceeds the predetermined cavitation threshold value.
7. The method of
determining for a first operating point within a first operating range, the first operating point associated with high/intermediate cavitation indicator, a distance, in terms of the first motor characteristic and/or the second motor characteristic, to one or more other operating ranges at which the cavitation indicator does not exceed the predetermined cavitation threshold value.
8. The method of
adapting, based on the distance, the control settings of the motor and/or the pump system relating to the first motor characteristic and/or the second motor characteristic to arrive at an operating point with a low/no cavitation indicator.
9. The method of
10. The method of
adapting a motor speed setpoint of the motor and/or adapting a control valve setpoint of a control valve of the pump system, wherein the control valve controls a motor load.
11. The method of
12. The method of
re-determining the cavitation indicators during the operation of the pump system.
13. The method of
comparing the updated cavitation indicators with previously determined cavitation indicators, and
determining an operating condition of the pump and/or the pump system based on the comparison, e.g., a damage of the pump and/or a deposition in a pipe of a pump inlet and/or a pump outlet.
14. The method of
interpolating and/or extrapolating the cavitation indicator of one or more operating points or operating ranges given by at least a first operating point and a second operating point or an operating range; and
determining whether the interpolated and/or extrapolated cavitation indicator exceeds a cavitation threshold value, wherein the one or more transient operating points or operating ranges are located on a curve provided by the first motor characteristic and the second motor characteristic values, connecting the at least one first operating point and the second operating point or the operating range.
15. The method of
determining that the cavitation indicator of one or more transient operating points or operating ranges between a first operating point and a second operating point or operating range exceeds a predetermined cavitation threshold value, wherein the one or more transient operating points are located on a curve, given by the first and second motor characteristic, connecting the first and second operating point or ranges.
16. The method of
adapting a curve, given by a first and second motor characteristic, and connecting the first and second operating point or ranges, in case a cavitation indicator of the or more transient operating points or ranges exceeds a predetermined cavitation threshold value.
17. The method of
visualizing the plurality of cavitation indicators and the corresponding operating ranges on a display.
18. A pump system comprising:
a pump;
a motor that is connected to drive the pump; and
a control unit configured to determine a plurality of cavitation indicators, wherein each cavitation indicator indicates cavitation or a likelihood of cavitation of the pump for different operating ranges, wherein each operating range of the different operating ranges is given by a combination of values of a first motor characteristic and a second motor characteristic, the control unit further configured to determine whether a cavitation indicator of one or more operating points of the motor exceeds a predetermined cavitation threshold value.