Methodology for Highly Efficient Pump System Management

Maintaining pump operation in the best efficiency zone (BEZ) is one of the most important tasks of the control system. The main management tasks include detecting work outside the BEZ, preventing actions that may move the work point to undesirable areas, and regulating pumping parameters to keep work within the recommended limits. Thanks to the process control architecture of pump systems that use PLCs and programmable frequency converters, new algorithms can be implemented on these devices. This study provides suggestions for using sensor data, internal frequency converter parameters, or pump performance data from performance graphs for new control algorithms. For this purpose, the methodology of predictive control and performance monitoring were described. Pump operation outside BEZ and related phenomena were considered. The proposed algorithm for high-efficiency pump control in certain speed ranges were elaborated. Simulation of test runs of a pumping system relied on computer simulation tools modeling and software for VSD selection. Experimental tests were also introduced on a laboratory installation that simulates a pumping system.