METHOD FOR CORRECTING PUMP MODEL
20220196008 · 2022-06-23
Inventors
Cpc classification
F04B2205/07
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B49/106
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B2203/0208
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B2205/09
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B49/065
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
A method for correcting pump model includes: obtaining a pump model for a pump, the pump model including a Q-P curve and a Q-H curve at each of a plurality of frequencies; at each frequency, determining a power error based on a zero-flow-rate power or an actual operating point of the pump under one of the frequencies; and determining a corrected pump model based on the pump model and the power error. The determination of the corrected pump model includes: at each frequency, determining a corrected Q-P curve to be the Q-P curve shifted by the power error; determining a Q-H-P surface based on the corrected Q-P curves and the Q-H curves at all the frequencies; at each frequency, determining a head error based on the surface and the power error; and at each frequency, determining a corrected Q-H curve to be the Q-H curve shifted by the head error.
Claims
1. A method for correcting pump model, comprising: obtaining a pump model for a pump, the pump model comprising a Q-P curve and a Q-H curve at each of a plurality of frequencies for the pump; at each of the plurality of frequencies, determining a power error based on a zero-flow-rate power or an actual operating point of the pump at a first frequency of the plurality of frequencies; and determining a corrected pump model based on the pump model and the power error, comprising: at each of the plurality of frequencies, determining a corrected Q-P curve to be the Q-P curve shifted by the power error; determining a Q-H-P surface based on the corrected Q-P curves and the Q-H curves at the plurality of frequencies; at each of the plurality of frequencies, determining a head error based on the Q-H-P surface and the power error; and at each of the plurality of frequencies, determining a corrected Q-H curve to be the Q-H curve shifted by the head error.
2. The method of claim 1, further comprising: at each of the plurality of frequencies, determining an estimated operating point based on the corrected Q-H curve; determining a fitted demand curve based on the estimated operating points at the plurality of frequencies; determining a residual sum of squares between the estimated operating points at the plurality of frequencies and the fitted demand curve; and if the residual sum of squares is less than or equal to an error threshold, then the corrected pump model is set.
3. The method of claim 2, further comprising: if the residual sum of squares is greater than the error threshold, then: at each of the plurality of frequencies, updating the power error based on the estimated operating point and the fitted demand curve; at each of the plurality of frequencies, updating the Q-P curve of the pump model to the corrected Q-P curve and updating the Q-H curve of the pump model to the corrected Q-H curve; and after updating the power error and the pump model, performing the step of determining the corrected pump model based on the pump model and the power error.
4. The method of claim 3, wherein the step of updating the power error based on the estimated operating point and the fitted demand curve comprises: determining a head residual between the fitted demand curve and the estimated operating point; determining a flow rate correction amount based on the head residual and a differential of a function corresponding to the fitted demand curve; and updating the power error to be a product of the flow rate correction amount and a slope of the corrected Q-P curve.
5. The method of claim 1, wherein the step of determining the power error comprises: determining a first estimated flow rate of the pump based on the Q-P curve at the first frequency; determining a flow rate error ratio to be a difference of the zero-flow-rate power and a P-intercept of the Q-P curve at the first frequency, divided by a slope of the Q-P curve at the first frequency, and further divided by the first estimated flow rate; determining a second estimated flow rate of the pump based on the Q-P curve at a second frequency of the plurality of frequencies; and determining the power error at the second frequency to be a product of the flow rate error ratio, the second estimated flow rate and a slope of the Q-P curve at the second frequency.
6. The method of claim 1, wherein the step of determining the head error comprises: at each of the plurality of frequencies, iteratively calculating the head error based on the Q-H-P surface and the power error.
7. The method of claim 6, wherein the step of iteratively calculating the head error based on the Q-H-P surface and the power error comprises: determining a second head error based on a derivative of the Q-H-P surface and the power error; determining a second estimated operating point based on a second Q-H curve, wherein the second Q-H curve is the Q-H curve shifted by the second head error; determining a power difference to be a difference of an estimated power at the second estimated operating point and an input power of the pump at corresponding frequency; and determining the head error to be the second head error if the power difference is within an allowable range, or else updating the second head error based on the power difference and returning to the step of determining the second estimated operating point.
8. The method of claim 7, further comprising: determining a second Q-H-P surface based on the second Q-H curve; and determining the estimated power based on the second Q-H-P surface and the second estimated operating point.
9. The method of claim 1, wherein the step of determining the Q-H-P surface comprises: determining the Q-H-P surface based on the corrected Q-P curves and the Q-H curves at the plurality of frequencies by means of surface fitting; wherein the Q-H-P surface is expressed as P=f(Q,H), in which f has highest degree of 3 in flow rate Q and has highest degree of 2 in head H.
10. The method of claim 1, wherein the step of determining the power error comprises: determining a first estimated flow rate of the pump based on the Q-P curve at the first frequency; determining a flow rate error ratio to be a difference of a flow rate at the actual operating point and the first estimated flow rate, divided by the first estimated flow rate; determining a second estimated flow rate of the pump based on the Q-P curve at a second frequency of the plurality of frequencies; and determining the power error at the second frequency to be a product of the flow rate error ratio, the second estimated flow rate and a slope of the Q-P curve at the second frequency.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] To make the objectives, features, advantages, and embodiments of the present disclosure, including those mentioned above and others, more comprehensible, descriptions of the accompanying drawings are provided as follows.
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DETAILED DESCRIPTION
[0016] For the completeness of the description of the present disclosure, reference is made to the accompanying drawings and the various embodiments described below. Various features in the drawings are not drawn to scale and are provided for illustration purposes only. To provide full understanding of the present disclosure, various practical details will be explained in the following descriptions. However, a person with an ordinary skill in relevant art should realize that the present disclosure can be implemented without one or more of the practical details. Therefore, the present disclosure is not to be limited by these details.
[0017] Reference is made to
[0018] As shown in
[0019] In the illustrate embodiment, the pump is configured to operate at 60 Hz, 55 Hz, 50 Hz or 45 Hz. The Q-P curves QP1-QP4 are Q-P curves for the pump at 60 Hz, 55 Hz, 50 Hz or 45 Hz respectively. The Q-H curves QH1-QH4 are Q-H curves for the pump at 60 Hz, 55 Hz, 50 Hz or 45 Hz respectively. In some embodiments, the Q-P curves QP1-QP4 are substantially straight lines. In other words, each of the Q-P curves QP1-QP4 may be expressed as P=A1*Q+A0, in which the coefficient A1 is the slope of the line and the coefficient A0 is the power at zero flow rate.
[0020] In the illustrated embodiment, the unit of flow rate Q is m.sup.3/h (cubic meter per hour), the unit of power P is kW (kilowatt), and the unit of head H is m (meter). In some embodiments, the pump is a centrifugal pump driven by a frequency converter.
[0021] As shown in
[0022] For a sensorless pump system, step S104 includes: at each of the plurality of frequencies, determining the power error ΔP based on a zero-flow-rate power of the pump at one of the frequencies. In some embodiments, step S104 includes: (1) determining a first estimated flow rate of the pump based on the Q-P curve at a first frequency at which the zero-flow-rate power is obtained; (2) determining a flow rate error ratio to be a difference of the zero-flow-rate power and a P-intercept of the Q-P curve at the first frequency, divided by a slope of the Q-P curve at the first frequency, and further divided by the first estimated flow rate; (3) determining a second estimated flow rate of the pump based on the Q-P curve at a second frequency; and (4) determining the power error at the second frequency to be a product of the flow rate error ratio, the second estimated flow rate and a slope of the Q-P curve at the second frequency.
[0023] As shown in
[0024] For a sensor-equipped pump system, step S104 includes: at each of the plurality of frequencies, determining the power error ΔP based on an actual operating point of the pump at one of the frequencies. In some embodiments, the actual operating point of the pump is obtained by: at a first frequency, using a pressure sensor to measure the head at the actual operating point; and determining the flow rate at the actual operating point based on the Q-H curve at the first frequency and the measured head. In some embodiments, step S104 includes: (1) determining a first estimated flow rate of the pump based on the Q-P curve at the first frequency corresponding to the actual operating point; (2) determining a flow rate error ratio to be a difference of a flow rate at the actual operating point and the first estimated flow rate, divided by the first estimated flow rate; (3) determining a second estimated flow rate of the pump based on the Q-P curve at a second frequency; and (4) determining the power error at the second frequency to be a product of the flow rate error ratio, the second estimated flow rate and a slope of the Q-P curve at the second frequency.
[0025] As shown in
[0026] As shown in
[0027] As shown in
[0028] As shown in
[0029] In some embodiments, step S112 includes: determining the Q-H-P surface QHP based on the corrected Q-P curves CQP1-CQP4 and the Q-H curves QH1-QH4 at the plurality of frequencies by means of surface fitting. In some embodiments, the Q-H-P surface QHP may be expressed as P=f(Q,H) (i.e., power P as a function f of flow rate Q and head H), in which f has highest degree of 3 in flow rate Q and has highest degree of 2 in head H. In some embodiments, the Q-H-P surface QHP may be expressed as P=c.sub.00+c.sub.10Q+c.sub.01H+c.sub.20Q.sup.2+c.sub.11QH+c.sub.02H.sup.2+c.sub.30Q.sup.3+c.sub.21Q.sup.2H+c.sub.12QH.sup.2, in which the coefficients c.sub.nm may be determined based on the corrected Q-P curves CQP1-CQP4 and the Q-H curves QH1-QH4.
[0030] As shown in
[0031] As shown in
[0032] After going through the steps described above to determine the corrected Q-P curves CQP1-CQP4 and the corrected Q-H curves CQH1-CQH4, in some embodiments, the method for correcting pump model 100 further includes verifying the accuracy of the corrected pump model (e.g., steps S118-S124).
[0033] As shown in
[0034] As shown in
[0035] As shown in
[0036] As shown in
[0037] On the other hand, if it is determined that the residual sum of squares exceeds the error threshold in step S124 (i.e., the residual sum of squares is greater than the error threshold), then the method for correcting pump model 100 further updates the corrected pump model (e.g., by proceeding to step S126).
[0038] As shown in
[0039] As shown in
[0040] Reference is made to
[0041] As shown in
[0042] As shown in
[0043] Since the second head error determined ΔH in step S202 can only indicate the initial direction of correction for the Q-H curve, it is necessary to iteratively correct the second head error ΔH afterwards (steps S206-S212), such that the second Q-H curve SQH1 can be more close to the actual characteristics of the pump.
[0044] As shown in
[0045] In some embodiments, step S206 includes: determining a second Q-H-P surface based on the second Q-H curve SQH1; and determining the estimated power based on the second Q-H-P surface and the second estimated operating point. In some embodiments, the step of determining the second Q-H-P surface includes: determining the second Q-H-P surface based on the corrected Q-P curves CQP1-CQP4 and the second Q-H curve SQH1 by means of surface fitting. In some embodiments, the step of determining the estimated power includes: inserting the values of the flow rate Q and the head H of the second estimated operating point into the second Q-H-P surface to obtain the estimated power at corresponding frequency.
[0046] As shown in
[0047] In some embodiments, the second head error may be expressed as ΔH.sub.n=γ.sub.nΔH, in which ΔH is the initial second head error (i.e., the second head error determined in step S202), ΔH.sub.n is the updated second head error after executing step S212 n times (i.e., the updated second head error for the n-th iteration), and γ.sub.n is a value between zero and one, with the initial value γ.sub.0 being one. Define “relative power difference” as the difference of the estimated power at the second estimated operating point and the input power of the pump at corresponding frequency, divided by the input power. The step of updating the second head error based on the power difference includes: if the absolute value of the relative power difference of the current iteration is smaller than the absolute value of the relative power difference of the previous iteration and the sign (plus or minus) of the relative power difference does not change, then decrease the value γ; if the absolute value of the relative power difference of the current iteration is larger than the absolute value of the relative power difference of the previous iteration or if the sign of the relative power difference changes, then increase the value γ.
[0048] Step S212 adjusts the amount by which the Q-H curve is to be shifted based on the power difference, such that shifted Q-H curve can be more close to the actual characteristics of the pump. As shown in
[0049] It should be noted that
[0050] Reference is made to the following table, which shows the procedure of iteratively calculating the second head error for the frequency of 50 Hz. Using bisection method, the relative power difference is lowered to 0.02% after five iterations. The second head error after five iterations may be used as the head error, by which the Q-H curve QH3 at 50 Hz can be shifted to obtain the corrected Q-H curve CHQ3 at 50 Hz.
TABLE-US-00001 n γ.sub.n Relative power difference (%) 0 0 2.15 1 0.5 1.24 2 0.25 0.49 3 0.125 0.11 4 0.0625 −0.07 5 0.0938 0.02
[0051] In sum, the method for correcting pump model provided by the present disclosure determines a corrected pump model based on the original pump model and the information of a zero-flow-rate power or an actual operating point at one frequency. Compared to the original pump model, the corrected pump model can be more close to the actual characteristics of the pump. Accordingly, the corrected pump model can be utilized to estimate the state of the pump to provide more accurate results.
[0052] Although the present disclosure has been described by way of the exemplary embodiments above, the present disclosure is not to be limited to those embodiments. Any person skilled in the art can make various changes and modifications without departing from the spirit and the scope of the present disclosure. Therefore, the protective scope of the present disclosure shall be the scope of the claims as attached.