The present invention relates to a method and system of detecting cavitation of a pump, and more particularly to a method and system, with which the cavitation of a pump controlled with a frequency converter can be detected without additional measurements.
A known problem relating to pumps is their tendency for cavitation. Cavitation refers to a situation, in which suction pressure into the pump drops below a value in which the liquid to be pumped starts to boil, i.e. below vapour pressure of the liquid. This phenomenon generates vapour bubbles which collapse abruptly once the bubbles enter the higher pressure area in the pump. The abrupt change from gas phase back to liquid phase causes sudden pressure changes which cause audible noise and may damage the mechanical parts of the pump.
The detection of cavitation or the possibility of cavitation is an important aspect relating to pumping processes. If the cavitation or risk of cavitation can be detected, the mechanical wearing of the pumps is greatly reduced and the pump may be operated safely in a larger operating area.
Pumps, such as centrifugal pumps, are often controlled using a variable speed drive having a frequency converter which provides controlled voltage to a motor. The shaft of the motor is connected to the pump thereby providing mechanical power for the pumping action.
Known publications for detecting cavitation include U.S. Pat. No. 6,757,665, in which it is suggested to observe the frequency spectrum of stator current of the motor rotating the pump using a separate current transducer. This method is based on measured values to which some known features appear when the pump is near cavitation or is cavitating. The method does not take into consideration the operating point or the pumping process itself.
Another approach for detecting cavitation is a model-based solution. In this approach a system model is formed for the system starting from electrical or mechanical parameters of the motor and pump. The inputs for the model are, for example, motor currents, voltages and frequency. As proposed in U.S. Pat. No. 6,918,307, the pump model estimates the produced volumetric flow rate and head it can deliver. If the volumetric flow rate and the pressure difference (head) are measured simultaneously, error variables can be determined for both quantities. Based on the error variables, the abnormalities in the pump behaviour can be determined and possible malfunctions can be diagnosed. This method suffers from the additional measurements, which are required for producing the error variables. The measurements require additional transducers, which cause further expenses due to costs for installation, maintenance and cabling. The transducers are also a potential risk as to reliability of the whole system, since the transducers are mechanical components which are subjected to possibly harsh conditions. A failure of one transducer makes the detection of cavitation impossible. Further the transducers are difficult to change, which causes possibly long downtimes in the pumping process.
U.S. Pat. No. 6,663,349 discloses a method for detecting cavitation or likelihood of the pump cavitation. In this method the net positive suction head required (NPSHR) and the net positive suction head available (NPSHA) are determined from values obtained from sensors. The net positive suction head required and the net positive suction head available are compared and the likelihood of cavitation is determined on the basis of the comparison. A problem relating to this method is also the requirement for additional measurement sensors or transducers.
An object of the present invention is to provide a method and a system for implementing the method so as to solve the above problems. The objects of the invention are achieved by a method and a system which are characterized by what is stated in the independent claims. The preferred embodiments of the invention are disclosed in the dependent claims.
The invention is based on the idea of forming one or more indicators relating to likelihood of pump cavitation or reverse flow in a pump based on estimated values obtained directly from a frequency converter which drives the pump. In particular these indicators are formed from estimated torque produced by the motor and from estimated rotational speed of the motor. The detection of cavitation also requires some parameters relating to the pump process and to the pump used.
An advantage of the method and apparatus of the invention is that cavitation, near cavitation or reverse flow situations can be detected reliably without any additional measurements. The present invention thus eliminates the need of sensors measuring the process variables.
According to the preferred embodiments of the invention, the detection of cavitation or the likelihood of cavitation is performed using multiple indicators simultaneously, which indicators are all based on the estimated values from the frequency converter. The use of more than one indicator makes the detection even more reliable basically without any extra costs.
The invention also relates to a frequency converter that is adapted to carry out the method of the invention.
In the following the invention will be described in greater detail by means of preferred embodiments with reference to the accompanying drawings, in which
a and 3b are graphs relating to determination of an operation point of a pump,
The frequency converter is further connected to an automation system via interface 5. The automation system may be a higher-level controller controlling the process to which the pump is connected. Thus the automation interface gives the instructions for the operation of the pump which the frequency converter tries to implement. In
According to the present invention the frequency converter, which controls the pump, provides torque estimate Test and rotational speed estimate nest of the motor. Since the motor is mechanically connected to the pump, estimates describe also the pump operation. As mentioned, these values are readily available in the control system of the frequency converter.
Further in the present method, one or more features, which indicate cavitation or likelihood of the cavitation of the pump and/or reverse flow of the pump, are formed from the provided estimates. The features, which are obtainable from the estimated values, are explained in detail below.
When one or more of the indicating features have been formed, cavitation or likelihood of the cavitation of the pump controlled with the frequency converter is detected. Reverse flow may also be detected with or without detection of the cavitation. The detection is carried out in
According to an embodiment of the invention, a feature indicating cavitation or likelihood of cavitation and/or reverse flow is formed by comparing an RMS value of alternating component (AC) of the torque estimate with the normal RMS value of alternating component of the torque estimate.
The AC component of the estimated torque can be calculated as follows. Simultaneously, also the DC component is calculated, and its use in the method is explained in detail further below. The DC component can be removed from the sample data of x (x being general representation of any variable, such as torque) by, for example with a high pass filter having a very low cut-off frequency. Alternatively, an average can be calculated from the sample data [x0 . . . xn-1], which corresponds to the value of DC component at the time of sampling
Then for the AC component of variable x
x
ac
=[x
0 . . . xn-1]−xdc,est.
The effective value or RMS value of the AC component can be calculated with the general formula for the RMS value (Root Mean Square)
Once the RMS value of the AC component is calculated, it is compared with normal value of RMS value of the AC component Tac, N. The normal or typical value of RMS of the AC component may be detected and stored before the use of the invention or it can be detected and stored during the use of the method in circumstances in which the pump is certainly operating in normal operation point.
The comparison between the normal RMS value and the calculated RMS value is carried out in block 24 in
To avoid cavitation the pressure ratio should be at least above one since NPSHR represents a situation, in which the head produced by the pump has dropped by 3%. As seen from
The ratio Tac, RMS/Tac, N grows when the pump is near cavitation due to the fact that, when cavitation starts or reverse flow occurs, the operation of the pump becomes discontinuous. This is seen in the shaft of the pump as growth of torque ripple (AC component). In other words, the power required by the pump oscillates. Consequently, the RMS value of the low frequency AC component increases, when compared to the normal situation. Thus the cavitation or reverse flow can be determined on the basis of Feature1 presented in
According to another embodiment of the invention, an indicating feature is formed by comparing the RMS value of alternating component of the rotational speed estimate with the normal value of alternating component of the rotational speed estimate. The rotational speed estimate can be used in similar manner to estimate the cavitation or reverse flow as the torque estimate. With reference to
As can be seen from
The mathematical calculations for estimated torque and estimated speed are similar for obtaining the features indicating abnormal pump operation, and therefore the calculations are omitted for estimated speed.
The normal operating point in which both normal value for alternating component of torque and rotational speed are determined, can be, for example a situation, in which the pressure ratio is over 1.5. In operation points where the pressure ratio is above 1.5, the AC component is considerably smaller than in near cavitation situations or reverse flow situations. The normal value has to be determined since the RMS levels depend largely on application, thus each pump and each installation has its own characteristics and the measured RMS values do not have any absolute limits for comparison.
According to an embodiment of the invention, an indicating feature is formed by calculating estimated volumetric flow in the pump from the direct components of the torque estimate and rotational speed estimate using a pump model. After the estimated volumetric flow is calculated, it is compared with minimum allowable volumetric flow. The result of this comparison is used as an indicating feature for detecting the likelihood of cavitation or reverse flow of the pumped media. Especially, this comparison is used in determining the likelihood of reverse flow.
In
After the DC values of the estimates are calculated, the DC values Tdc,est and ndc,est are fed to a block 30 containing a pump model, which calculates from the inputted estimates the estimated volumetric flow Qest. The pump model incorporates a database or similar to which data relating to the pump can be stored. The stored data includes Q-P graph of the pump or selected data points from the graph. An example of a Q-P graph is shown in
The estimated power Pdc,est delivered to the pump is calculated from the estimated DC levels of the rotational speed and torque with
Since the Q-P graph is usually known for only one rotational speed, it must be transformed using affinity laws to correspond with the current rotational speed
where index nom refers to nominal speed at which the graphs are given. Alternatively affinity laws may be applied to the power consumed by the pump Pdc,est so that number of mathematical calculations is reduced.
When the estimated volumetric flow Qest is compared with the minimum allowable volumetric flow Qmin, which is provided by the pump manufacturer and stored in the pump model, it can be easily determined if the pump is operating in its normal operating area. The minimum allowable flow Qmin depends on the rotational speed of the pump. Therefore the minimum allowable volumetric flow should be calculated using affinity laws at the time of comparison to take into account the operating speed. Commonly a reverse flow occur, if the volumetric flow is below 30-70% of the nominal volumetric flow. Reverse flow causes similar sudden pressure changes and discontinuities in the flow as cavitation. Thus the estimated volumetric flow can be used as a feature indicating a possibility of cavitation or reverse flow situation in a pump.
Another feature indicating the likelihood of cavitation or reverse flow situation according to an embodiment of the invention is formed from the comparison of the net positive suction head required (NPSHR) and the net positive suction head available (NPSHA) which are calculated on the basis of estimated torque, estimated rotational speed and system parameters. The ratio between the two is called a pressure ratio.
As seen from
Since the curves are provided only for the nominal rotational speed, affinity laws must again be used to gain the NPSHR for the rotational speed in question
When compared with other affinity transformations, the suction head required by the pump has a minimum value and the value obtained with affinity transformation cannot be lower than the minimum value. If the volumetric flow produced by the pump is so low that it does not appear on the manufacturers Q-NPSHR curve, the situation must be considered to be a situation where the AC levels of the estimates may have increased due to cavitation which is formed of the reverse flow. Correspondingly, if the volumetric flow produced by the pump is so high that it does not appear on the manufacturers Q-NPSHR curve, cavitation may occur increasing the AC levels of the estimates.
For the pressure ratio to be calculated, also the net positive suction head available is to be determined. NPSHA can be estimated with
where Hs is the suction head of the pump, p0 is the pressure of the environment, pv), is the evaporating pressure of the pumped liquid, pf is an estimate of the pressure losses on the suction side, v0 is the flow rate in the top of the container, g is the gravitation constant, Temp is the temperature of the fluid and p is the density of the fluid.
where a constant k represents the flow resistances on the suction side and the variables are given according the worst case situation.
For the calculation of the pressure ratio it is therefore required
Of the listed parameters, the static head Hs is the most important one.
Once the pressure ratio is calculated, it can be used as a feature indicating likelihood of cavitation, cavitation or reverse flow of the pumped liquid. As mentioned above, the pressure ratio should be at least above one. The required pressure ratio, however, depends on the pump used. The required pressure ratio can be determined on the basis of the operation principle of the pump (radial or axial flow) or the variable reflecting the type of the pump called suction specific speed Nss, which is defined as
where N is the rotational speed of the pump [min−1], Q is the volumetric flow [m3/h] in the best efficiency point of the pump characteristics. If the nominal suction speed of the pump is small (usually a radial flow pump), pressure ratio of 1.5 can be used. In connection with suction specific speeds (usually an axial flow pump) the pressure ratio may have values up to four, meaning that the available suction head must be at least four times higher than the required suction head. Once the pump type is known, the estimated pressure ratio gives clear indication on the operation point of the pumping process. This estimated pressure ratio is shown as Feature3 in
In
It is clear for the skilled person that the decision making block may operate in different ways. The output 33 of the decision making block may be led to an upper control system for further operations, including for a change of the operation state and for giving alarms, for example. With reference to
The decision making block 21, the pump model 30 and the parameters stored for the operation are preferably implemented in the frequency converter controlling the pump. Thus the method of the invention is preferably carried completely out in a frequency converter, for example, by means of software. The required calculations and the stored data may also be situated in the upper control system, whereby the frequency converter provides only estimated rotational speed and torque, and possibly the pump head and flow rate to the upper control system.
It will be obvious to a person skilled in the art that, as technology advances, the inventive concept can be implemented in various ways. The invention and its embodiments are not limited to the examples described above but may vary within the scope of the claims.
Number | Date | Country | Kind |
---|---|---|---|
08171028.7 | Dec 2008 | EP | regional |