EP3740682B1 - Méthode d'autodiagnose de l'état mécanique ou hydraulique d'une pompe centrifuge - Google Patents
Méthode d'autodiagnose de l'état mécanique ou hydraulique d'une pompe centrifuge Download PDFInfo
- Publication number
- EP3740682B1 EP3740682B1 EP19700893.1A EP19700893A EP3740682B1 EP 3740682 B1 EP3740682 B1 EP 3740682B1 EP 19700893 A EP19700893 A EP 19700893A EP 3740682 B1 EP3740682 B1 EP 3740682B1
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- EP
- European Patent Office
- Prior art keywords
- pump
- mechanical
- power
- speed
- operating point
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Links
- 238000000034 method Methods 0.000 title claims description 46
- 238000012937 correction Methods 0.000 claims description 32
- 238000005457 optimization Methods 0.000 claims description 7
- 238000004092 self-diagnosis Methods 0.000 claims description 4
- 230000006978 adaptation Effects 0.000 claims description 2
- 230000009897 systematic effect Effects 0.000 claims description 2
- 238000010586 diagram Methods 0.000 description 12
- 230000002308 calcification Effects 0.000 description 7
- 230000008859 change Effects 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000012544 monitoring process Methods 0.000 description 4
- 230000008569 process Effects 0.000 description 3
- 238000001514 detection method Methods 0.000 description 2
- 238000011156 evaluation Methods 0.000 description 2
- 230000007257 malfunction Effects 0.000 description 2
- 238000013178 mathematical model Methods 0.000 description 2
- 230000003321 amplification Effects 0.000 description 1
- 230000003750 conditioning effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000003199 nucleic acid amplification method Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
- F04D15/0088—Testing machines
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2260/00—Function
- F05D2260/80—Diagnostics
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2270/00—Control
- F05D2270/30—Control parameters, e.g. input parameters
- F05D2270/335—Output power or torque
Definitions
- the invention relates to a method for self-diagnosis of the hydraulic and/or mechanical condition of a centrifugal pump, in particular a circulating pump.
- the quality of the estimation result of the operating point module depends, among other things, on the reference values or parameters stored in the pump memory, which are determined on an identical reference pump and in the pump controller be deposited. Since reference values for selected specimens are usually only generated on a random basis in series production, these can be too imprecise for certain pump specimens due to manufacturing tolerances. In such a case, subsequent optimization of these reference values during initial commissioning and subsequent operation is desirable. Furthermore, signs of wear can also lead to erroneous results.
- the WO 2008/138520 A1 discloses a method for fault monitoring in which a current engine operating point is evaluated in relation to a limited operating range of the engine and a fault is detected when the operating range is left, the limited operating range being formed by engine operating points.
- the U.S. 2010/0300220 A1 shows another method for monitoring a centrifugal pump.
- the object of the present invention is therefore to expand the pump control with a type of self-diagnosis function that can detect errors in the operating point estimate and, as a result, can identify signs of wear at an early stage or carry out subsequent parameter optimization.
- a method for diagnosing the mechanical and/or hydraulic condition of a centrifugal pump is therefore proposed.
- the method according to the invention is designed primarily for circulating pumps, but the core aspect of the invention can be applied to centrifugal pumps in an open hydraulic circuit without restrictions.
- a circulating pump is always spoken of below, with the statements made also applying to centrifugal pumps in an open circuit.
- the method is intended for a centrifugal pump, in particular a circulating pump, which provides pump control with an implemented motor model for determining the mechanical pump output and the driven pump speed.
- the pump controller includes an operating point module for estimating the operating point of the pump based on the pump speed and the mechanical pump power.
- the operating point module is usually implemented in the pump control software.
- the engine model determines the mechanical pump power for a defined pump speed in order to diagnose the mechanical and/or hydraulic pump state and to compare this with an estimated mechanical pump power, which is determined by an inversely executed operating point estimate of the operating point module on the basis of the defined pump speed .
- the conventional motor model of the pump control is used here, which determines and outputs the mechanical pump performance during ongoing pump operation on the basis of the actual speed driven.
- the operating point module provided is used for estimating the operating point, i.e. for estimating the current flow rate or head, in order to determine a mechanical pump output estimated by the operating point module based on a defined speed.
- the accuracy of the operating point module for estimating the operating point can be evaluated by comparing it with the output mechanical pump power of the engine model, which corresponds to the real pump power.
- the estimated mechanical pump power should correspond to the mechanical pump power determined by the engine model. If there are deviations here instead, the pump control can therefore conclude that there is a fault within the centrifugal pump or circulating pump.
- a delivery quantity and/or delivery height to be expected for the defined pump speed is supplied to the operating point module to determine the estimated mechanical power.
- the delivery quantity and/or delivery height to be expected is preferably determined using the laws of affinity.
- affinity the statement of the law of affinity is used here, according to which the flow rate is proportional to an increase in speed.
- the delivery head increases quadratically with the change in speed.
- a difference between the power values is preferably determined by means of the comparison. If there are no errors, the difference is zero or almost zero. In the event of deviations, the pump can instead conclude that there is an error.
- the method is executed repeatedly for a series of deviating, defined speed values in the event of a malfunction.
- the corresponding comparison results or the difference values obtained between the power values can then be evaluated in order, for example, to be able to specify the type of error more precisely using mathematical relationships between the individual difference values and the associated speed values.
- the mechanical power loss depends quadratically on the speed. If such a mathematical relationship between the difference values and speed values is recognized, a mechanical wear component can be detected as the main cause of the error behavior.
- Other mathematical relationships can indicate, for example, hydraulic errors, including, for example, calcification of the can of the pump drive.
- the operating point module used to estimate the operating point is usually also based on the affinity laws. For the applicability of these laws, however, it is absolutely necessary to calculate the proportion of the mechanical pump performance that characterizes the mechanical power loss in advance, since this proportion is not subject to the named laws.
- a corresponding power correction value is used, which is added to the supplied mechanical pump power before the operating point estimation, in particular subtracted from it.
- the correctness and accuracy of this correction value is of great importance for the quality of the operating point estimation, i.e. how precisely the correction value reflects the actual mechanical power loss within the pump. The more precisely this parameter is determined, the more precise the operating point estimate will ultimately be.
- this parameter can also be used subsequently to be able to further specify the type of error after an error has occurred.
- the power correction value is systematically varied during the repeated execution of the method for different defined speed values.
- an attempt is made to find a new, uniform correction value which results in a differential amount equal to or close to zero for all defined speeds. If this is the case and it can be assumed that the power correction value used when the pump was started up for the first time was not incorrect, the necessary change in the power correction value that has now been determined can represent an indication of the mechanical wear within the pump.
- An adjustment of the performance correction value in particular an increase in value, is a clear indication of increasing wear within the pump. The increase in value is also a measure of the progress of mechanical wear.
- the method is carried out during the initial commissioning of the centrifugal pump or circulating pump or alternatively at a later point in time during ongoing pump operation.
- the method according to the invention can be used to optimize any parameters for estimating the operating point, for example the power correction value mentioned above.
- an iterative optimization method can be used to optimize the operating point estimate by correcting the power correction value.
- a time-variant extended Kalman filter can also be used for permanent adaptation of the power correction value according to quadratic optimization.
- the method can instead be used to conclude that there is a mechanical or hydraulic fault in the pump and this can be indicated to the user visually and/or acoustically. It is particularly preferred if a warning is displayed to the user shortly before a possible pump defect or pump failure. It is also conceivable that the pump would constantly inform the user of its status and warn him about a failure.
- the present invention also relates to a centrifugal pump, in particular a circulating pump, with a variable-speed pump drive and a pump controller for carrying out the method according to the invention.
- a centrifugal pump in particular the circulating pump, is characterized by the same advantages and properties as have already been shown above using the method according to the invention. For this reason, a repeated description is dispensed with.
- the centrifugal pump according to the invention in the form of a circulating pump is equipped with a frequency converter and a speed controller.
- a frequency converter and a speed controller.
- the pump control In order for the pump control to be able to set the speed as required, it needs knowledge of the current operating point (flow rate Q and head H). These values are estimated using an operating point module implemented in software, i.e. the current operating point is estimated based on the mechanical power and the speed. Both data are supplied by a mathematical model of the engine, which runs redundantly with the pump on the processor.
- the operating point is estimated using the affinity laws, taking into account stored characteristic curves and a correction value for the mechanical power losses the pump.
- Diagram a) shows the relationship between the flow rate and the mechanical power P mech delivered by the motor for the nominal speed n N .
- Diagram b) shows the relationship between delivery head and delivery flow at nominal speed n N .
- the mechanical power P mech corresponds to the sum of the hydraulic power P hydr , the hydraulic power loss P hydr,loss and the mechanical power loss P mech,loss .
- figure 2 shows the individual performance curves depending on the flow rate.
- the figure 3 shows the complete process of an operating point estimation by the pump's internal operating point module.
- the input variables are the values provided by the motor control for the speed n ist and the mechanical power P mech .
- the mechanical losses P mech,loss are subtracted from the motor power P mech by the correction value P corr , thereby enabling the application of the affinity laws.
- the power is transformed using the affinity laws to the normalized power P N , which would be present if the speed were to be increased to nominal speed n N .
- the normalized power P N using the stored P/Q characteristic ( Figure 1a ) the normalized flow rate Q norm can be derived, which would occur with normalized power P N and nominal speed n N .
- the present invention describes a method with which deviations between real pump behavior and stored power correction values P korr or the factor ⁇ can be detected in the closed water circuit. This method is based on the fact that the pump changes its speed briefly during operation. The resulting changes in the operating point can be calculated using affinity from the previous operating point as well can be estimated from the mechanical power P mech of the engine. By comparing the two determined operating points, conclusions can be drawn about the quality of the power correction values P corr or the factor ⁇ stored in the pump.
- Step 1 (initial situation) is considered first.
- the pump is still in regular operation; the "Determination of the state of wear" operating mode is not yet switched on.
- the engine gets a target speed n 0 . It is assumed that the target and actual speeds are identical.
- the operating point estimate determines the current head ( H est,0 ) and the flow rate ( Q est,0 ).
- step 2 preparation for speed variation
- the pump uses this to calculate the expected mechanical power P exp .
- the value of the expected power P exp is stored.
- step 3 vary speed
- the pump will actually increase the current speed n 0 by the value k and obtain a current mechanical power ( P mech,1 ) from the motor model. This power value is saved.
- step 4 the evaluation takes place. Two power values P mech , 1 , P exp were determined, belonging to the same operating point. P exp was calculated from another operating point using affinity laws. P mech,1 was determined from the actual associated operating point.
- steps one to four described are carried out several times using different k values.
- the mechanical wear component can be clearly separated by systematically varying the power correction value ⁇ (Eq. 4). If this succeeds in bringing the error P error to zero for all k values, then the deviations are due to mechanical friction. Otherwise, the error P error can be traced back to non-mechanical influences (such as calcification of the can). These non-mechanical influences will follow other mathematical relationships, which can also be determined by varying the amplification factor k . The exact relationship between losses due to calcification of the can and speed must be determined in an experiment.
- the pump is able to record its own status. You can correct the error in your stored data both after commissioning as well as during the service life. The error during the initial start-up is due to manufacturing tolerances. A change over the service life indicates wear and hydraulic wear. The pump could constantly communicate its status to the user and warn him about a failure.
- the pump knows the error in its stored data and can conditionally distinguish between hydraulic influences and mechanical wear. In this way, it can optimize its own estimate of the operating point by adjusting the stored data. This can be done by iterative parameter tuning. Alternatively, a permanent parameter tuning according to a quadratic optimization can be carried out with a time-variant extended Kalman filter.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Control Of Non-Positive-Displacement Pumps (AREA)
- Control Of Positive-Displacement Pumps (AREA)
Claims (11)
- Procédé d'autodiagnostic de l'état mécanique et/ou hydraulique d'une pompe centrifuge, notamment d'une pompe de recirculation, la commande de pompe comprenant un modèle de moteur mathématique destiné à déterminer la puissance de pompe mécanique et la vitesse de rotation réelle de la pompe et à effectuer un autodiagnostic de la pompe, la puissance de pompe mécanique déterminée au moyen du modèle de moteur pour une vitesse de rotation de pompe définie étant comparée à une puissance de pompe mécanique estimée, caractérisé en ce qu'un module de point de fonctionnement destiné à estimer le point de fonctionnement de la pompe en fonction de la vitesse de rotation de pompe et de la puissance mécanique de la pompe est fourni, la puissance de pompe mécanique estimée étant déterminée par inversion du module de point de fonctionnement pour la vitesse de rotation de pompe définie et une valeur de correction de puissance étant introduite par calcul dans la puissance de pompe mécanique dans le module de point de fonctionnement afin de compenser une perte de puissance mécanique.
- Procédé selon la revendication 1, caractérisé en ce qu'un débit de refoulement et/ou une hauteur de refoulement attendus pour la vitesse de rotation de pompe définie sont fournis au module de point de fonctionnement pour déterminer la puissance mécanique estimée, le débit de refoulement et/ou la hauteur de refoulement attendus étant de préférence déterminés à l'aide des lois d'affinité.
- Procédé selon l'une des revendications précédentes, caractérisé en ce qu'une différence entre les valeurs de puissance est déterminée au moyen de la comparaison et un dysfonctionnement de la pompe est détecté si la différence n'est pas égale à zéro.
- Procédé selon l'une des revendications précédentes, caractérisé en ce que le procédé est mis en œuvre de manière répétée en cas de dysfonctionnement pour différentes valeurs de vitesse de rotation définies et une détermination d'erreur est effectuée par évaluation du résultat de comparaison ou des valeurs de différence.
- Procédé selon la revendication 4, caractérisé en ce que l'on fait varier la valeur de correction de puissance systématiquement lors de la mise en œuvre répétée du procédé.
- Procédé selon la revendication 5, caractérisé en ce que la variation systématique de la valeur de correction de puissance permet de tenter de déterminer une nouvelle valeur de correction de puissance uniforme qui permet une différence égale à zéro ou proche de zéro pour les différentes vitesses définies.
- Procédé selon la revendication 6, caractérisé en ce que la commande de pompe suppose une usure mécanique accrue de la pompe si une nouvelle valeur de correction de puissance uniforme peut être déterminée et suppose sinon un défaut non mécanique, en particulier un défaut hydraulique, à l'intérieur de la pompe.
- Procédé selon l'une des revendications précédentes, caractérisé en ce que le procédé est mis en œuvre lors du démarrage initial de la pompe ou à un instant ultérieur pendant le fonctionnement continu de la pompe.
- Procédé selon la revendication 8, caractérisé en ce que, lorsque le procédé est mis en œuvre lors de la première mise en service, l'estimation du point de fonctionnement peut être optimisée par correction de la valeur de correction de puissance, notamment au moyen d'un procédé d'optimisation itératif et/ou à l'aide d'un filtre de Kalman étendu variable dans le temps destiné à effectuer un ajustement permanent de la valeur de correction de puissance selon une optimisation quadratique.
- Procédé selon l'une des revendications 8 ou 9, caractérisé en ce que, lorsque le procédé est mis en œuvre en cours de fonctionnement, un défaut mécanique et/ou hydraulique de la pompe est détecté et indiqué à visuellement et/ou acoustiquement à l'utilisateur, en particulier, un avertissement étant effectué peu de temps avant la panne de la pompe.
- Pompe centrifuge, en particulier pompe de recirculation, comprenant un entraînement de pompe à vitesse variable et une commande de pompe, qui est conçue pour mettre en œuvre le procédé selon l'une des revendications précédentes.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102018200651.2A DE102018200651A1 (de) | 2018-01-16 | 2018-01-16 | Verfahren zur Eigendiagnose des mechanischen und/oder hydraulischen Zustandes einer Kreiselpumpe |
PCT/EP2019/050883 WO2019141658A1 (fr) | 2018-01-16 | 2019-01-15 | Procédé d'auto-diagnostic de l'état mécanique et/ou hydraulique d'une pompe centrifuge |
Publications (3)
Publication Number | Publication Date |
---|---|
EP3740682A1 EP3740682A1 (fr) | 2020-11-25 |
EP3740682B1 true EP3740682B1 (fr) | 2023-06-28 |
EP3740682C0 EP3740682C0 (fr) | 2023-06-28 |
Family
ID=65036783
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP19700893.1A Active EP3740682B1 (fr) | 2018-01-16 | 2019-01-15 | Méthode d'autodiagnose de l'état mécanique ou hydraulique d'une pompe centrifuge |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP3740682B1 (fr) |
CN (1) | CN111566354B (fr) |
DE (1) | DE102018200651A1 (fr) |
WO (1) | WO2019141658A1 (fr) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102019002826A1 (de) | 2019-04-18 | 2020-10-22 | KSB SE & Co. KGaA | Verfahren zur Schwingungsvermeidung in Pumpen |
EP4019779A1 (fr) * | 2020-12-23 | 2022-06-29 | Grundfos Holding A/S | Système et procédé de surveillance de pompe pour associer un état de fonctionnement actuel d'un système de pompe à un ou plusieurs scénarios de panne |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102007022348A1 (de) * | 2007-05-12 | 2008-11-13 | Ksb Aktiengesellschaft | Einrichtung und Verfahren zur Störungsüberwachung |
EP2039939B2 (fr) * | 2007-09-20 | 2020-11-18 | Grundfos Management A/S | Procédé de surveillance d'un dispositif de transformation d'énergie |
DE102009022107A1 (de) * | 2009-05-20 | 2010-11-25 | Ksb Ag | Verfahren und Vorrichtung zur Betriebspunktbestimmung einer Arbeitsmaschine |
CN104298875B (zh) * | 2014-10-13 | 2017-10-31 | 浙江工业大学之江学院 | 一种基于功率和压差的离心泵流量预测方法 |
CN106772041A (zh) * | 2016-12-23 | 2017-05-31 | 江苏大学镇江流体工程装备技术研究院 | 一种基于Android平台的离心泵电机状态监测装置及监测方法 |
-
2018
- 2018-01-16 DE DE102018200651.2A patent/DE102018200651A1/de active Pending
-
2019
- 2019-01-15 CN CN201980008620.0A patent/CN111566354B/zh active Active
- 2019-01-15 EP EP19700893.1A patent/EP3740682B1/fr active Active
- 2019-01-15 WO PCT/EP2019/050883 patent/WO2019141658A1/fr active Application Filing
Also Published As
Publication number | Publication date |
---|---|
WO2019141658A1 (fr) | 2019-07-25 |
EP3740682C0 (fr) | 2023-06-28 |
CN111566354B (zh) | 2022-06-24 |
CN111566354A (zh) | 2020-08-21 |
RU2020123872A (ru) | 2022-02-17 |
DE102018200651A1 (de) | 2019-07-18 |
EP3740682A1 (fr) | 2020-11-25 |
RU2020123872A3 (fr) | 2022-02-17 |
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