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System for optimising pump station control — Part II

Article  in  World Pumps · July 2004

DOI: 10.1016/S0262-1762(04)00261-5

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Leszek Szychta
University of Science and Technology in Bydgoszcz
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 feature pump controls

System for optimising pump

station control — Part II
In the second of his two-part article on attaining optimum control of a pump assembly
(World Pumps February 2004), Leszek Szychta, Eng.D determines a control system and
method for pump components. This is based on the criterion for the optimum value of the
pump efficiency.

Power circuit and
the algorithm of
optimum control
We can derive only one rotational
speed hopt that corresponds to hopt ,
where optimum efficiency hopt
occurs (Figure. 2), from set of iso-
efficiency curves. Water pumping
processes display a variable head of
water h, corresponding to different
values of optimum efficiency hopt. A
change in the head of water h
requires adjustment of the value of
the pump rotational speed n in order
to maintain the working point
characterised by the optimum pump
efficiency hopt at the optimum speed
nopt. The principle of adjusting the
pump rotational speed n is defined as
the criterion for control, according to
the pump optimum efficiency hopt.
Control of a pump assembly,
including the criterion of optimum
pump efficiency hopt , requires the
fitting of frequency converters on
each pump motor. A structure of a
four-pump set exhibiting the
optimum control system is shown in
Figure 1.
During the varying distribution in a
water supply network, running a
pump that is set at constant head of
water H=Huk, and optimum pump
rotational speed nopt is not feasible.
It is essential to implement a control
system where one pump works as the
lead pump and all the others as
auxiliary pumps. The lead pump
operates at variable rotational speeds
and initiates the work cycle of any
given pump.
The range of variations in rotational
speeds Dn of the lead pump, results
from an appropriate algorithm for
controlling the pump head of water
H. According to pump’s set of iso-
efficiency curves, the key to the
method for controlling the pump
head of water H is to obtain a family
of dependencies of pump’s relative
efficiency hpw as a function of
rotational speed n* .(Figure2). Next,
is to assume that any maximum range
of divergences Dh of momentary
values of the lead pump efficiencies h
from the optimum pump efficiency
hopt is characteristic for a selected
pump’s head of water. The assumed
variations in the lead pump efficiency
Dh produces a range Dn of
recommended values of the lead
pump’s rotational speed. A PLC
controller adjusts the rated value of
frequency of the voltage powering the
motor in order that the pump
rotational speed n fits within the Dn
range of values.
Figure 3 shows a sample design of a
four-pump set implementing the
optimum control system. The freely
programmable controller PLC in the
pump analyses the water supply
system’ parameters, determines the
pump’s head of water h, and then the
optimum value of rotational speed
nopt. In relation to the optimum
rotational speed nopt the next move

Figure.1. Descending portion of pump efficiency hpw together Figure 2. Relative pump efficiency hpw as a function of
with the approximating trend line ht for 10A25A pump and at rotational speed n*
h=0.8

2 0262 1762/04 © 2004 Elsevier Ltd. All rights reserved WORLD PUMPS June 2004

Figure 3. Control system according to the criterion of optimum pump efficiency value.
is to determine the range of
variations of the pump’s rotational
speed Dn in order to maintain the
assumed divergences of the pump
efficiency Dh.
An auxiliary pump can operate
during periods of increased water
distribution, complementing the
work of lead pump. An auxiliary
pump operates at constant value of
rotational speed nopt, where
maximum value of pump efficiency is
obtained. When water distribution in
water supply networks is reduced and
the minimum water-discharge of a
pumping assembly exceeds demand
for water, control should feature the
so-called ‘sleeping’ pump (Figure4).
In practice, pumps may ‘sleep’ at a
relative water discharge of less than
0.4. Sleeping begins when the head of
water in the head collector reaches
the rated value Hztzad. The pump
assembly re-starts operating when the
head of water Hzt in a water supply
system drops to the minimum value
defined as the waking level Hztbudz .
Application of the optimum control
algorithm.
In automatic systems, the head of
water is replaced by Mpa-rated
pressure. The input parameter for the
block regulating the drive system
WORLD PUMPS June 2004
shown in Figure 3 is the value of
pressure in the head collector of the
pump assembly as measured through a
pressure converter. Using the PLC
controller, the current value of
pressure przecz is compared to set
value pzad producing the regulation
error e. Depending on the error e ,
appropriate pumps are activated
following the optimum control
algorithm. Each pump motor is
powered from the frequency
converter Pcz1¸Pcz4 working as a
SLAVE. The frequency of the output
voltage of the frequency converter is
set by PLC controller, which
functions as the MASTER.
The PLC controller communicates
with frequency converters through an
RS485 series connection using
Figure 4. Pump operating in the ‘sleeping’ mode
feature pump controls
MODBUS communication protocol.
Analogue and digital signals are
transmitted via a common
communications bus. The universal
connection using MODBUS protocol
allows for communication with other
peripheries, such as electromagnetic
flowmeters, power counters,
recorders, etc. Within this solution,
transmission through a series
connection ensures recording the
current frequency of the voltage
feeding the motor, rms current and
output voltage from frequency
converter. Moreover, the series
connection transmits signals to set
the pump’s rotational speed,
START/STOP signals, collects and
stores data concerning emergency
operation of the frequency converter
in the PLC controller’s memory. In
case of a temporary defect in the
frequency converter, the PLC
controller cancels the error
automatically. Its memory stores data
concerning defective work of the
frequency converters.
Regulator structure
in the controlling
system for auxiliary
pumps
Controlling a pump set according to
the leading pump algorithm assumes
two types of pump operation: lead
and auxiliary pumps. The lead pump
works at variable rotational speed.
The range of such variations Dn
depends on the pump efficiency
divergence Dh on the optimum
efficiency hopt (Figure2). The
www.worldpumps.com 3
 feature pump controls
Figure 5. Flow diagram implementing the optimum control algorithm.
Figure 6. The control flow diagram as per the lead pump algorithm.
auxiliary pump(s) is activated at
times when there is an increased
water demand. One or more auxiliary
pumps work at constant rotational
speed values, where they reach
optimum efficiency hopt. The
number of auxiliary pumps depends
on demand for water in the water
supply network. Assuming operation
of two auxiliary pumps, the following
configuration of blocks controls the
operation of the pump set as per the
lead pump algorithm (Figure 6).
Two PI regulators, connected in a
series, control the output head in the
pump set. The regulator PI1 works as
a process regulator that compares set
pressure pzad with the actual value of
pressure przecz as read by the
frequency converter. The output of
regulator PI1 is the setting for the
frequency f* of regulator PI2. The f*
setting is compared to the actual
frequency of voltage feeding the
4 www.worldpumps.com
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motor of lead pump frzecz. PI2
regulator sets the value of frequency
of voltage feeding the motor of pump
fzad. The signal setting the frequency
fzad is subject to delay in the filter F,
and then transmitted to the
frequency converter, setting the
frequency of voltage feeding the
motor.
According to Figure6, the pump P3
becomes the lead pump with
regulated rotational speed. The lead
pump status is determined by the keys
K1¸K4 (Figure 6) positioned W1¸W4.
Motors of the lead pumps P1¸P4 are
supplied with a voltage, the
frequency of which is f1¸f4 and tends
towards the value of set frequency
fzad.
The flow diagram in Figure 6
designates two pumps, P1 and P2, as
auxiliary units. The auxiliary pump
status is determined by the keys
K1¸K4 positioned D1¸D4. Auxiliary
pumps work at constant rotational
speed as determined by the optimum
frequency setting fopt. The optimum
frequency fopt is constantly updated
depending on the water supply system
parameters. The key K4 is positioned
at ‘0’, which means that the pump P4
is switched off.
Conclusion
Controlling the operation of lead
pump allows for maintaining the
constant value of head Hzt, and
approximately the maximum
efficiency of a pump assembly hg.
However, the method of control
under discussion leaves little room for
changing the amount of pumped
water, which is achieved only by
varying the rotational speed of the
lead pump. The range of rotational
speed variations of the lead pump Dn
is narrow due to a limited range of
efficiencies Dh. For a pump assembly
to match water demand in a water
supply system, the assembly has to be
frequently in ‘sleep’ mode.
In the process of pumping water,
variable pump’s head of water H
occurs occasionally. Taking
advantage of control, as per the
optimum efficiency criterion, it is
possible to set the pump’s rotational
speed in such a way that its efficiency
is maximised for a current pump’s
head of water H. This method of
control helps to reduce pump
operating costs. Its start-up and
checking are smooth, which
eliminates water hammers. Pump
operation according to the diagram
shown in Figure 3 allows for
‘sleeping’, ensures uniform pump
operation, eliminates the less-than-
optimum cascading operation system
and current overload during pump
start-up.
CONTACT
Leszek Sychta works in the Unit of
Machines & Electrical Equipment at the
Faculty of Transport, Technical
University, Radom, Poland.
leszek@elam.pl
WORLD PUMPS June 2004