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AbstractA novel pressure control system based on a applications. During the operation of the centrifugal pump
centrifugal pump Simulink model is proposed aiming to reduce system, the value of pressure can change considerably due to
energy consumption during pump operation. The system time-varying demands on the delivery side. The safety of the
developed provides the possibility of power reduction during pumping systems and pipelines in a water distribution system
pressure maintenance with the help of mixed pressure control greatly depends on the possibility to control the level of
strategy. To evaluate the system, a series of tests have been pressure within the acceptable limits [7]. Therefore, it is
conducted that proved that the designed system is more necessary to vary the operation point of the centrifugal pump to
beneficial from power consumption point of view than traditional control the output pressure despite the disturbances caused by
pressure control methods. The system can be useful for pressure
the operation process. At the same time, the growing interest in
control optimization of centrifugal pumps.
energy savings and greenhouse gas reduction requires
Keywordspumps, pressure control, centrifugal pump, Matlab, development of novel control strategies for pressure
variable speed drive, power measurement, modelling, simulation maintenance. Every conventional pumping system incorporates
variable speed pumps, consisting of centrifugal pumps,
variable frequency converters, and induction motors. In order
I. INTRODUCTION to reduce energy consumption, special attention should be
Centrifugal pumps are widely used in different industrial payed to the input power of the system in general [8].
applications. They are essential parts in applications that
require transferring fluids at a variable flow rate and variable There are several solutions how to control output pressure
pressure [1], [2]. Usually, centrifugal pumps are among the of the centrifugal pump system. In [9], the author proposes the
main consumers of electricity within the distribution networks pressure control in the calculated working point based on the
driven by induction motors, which operate at either fixed or electro-hydraulic model. Other authors discuss the possibility
variable speed [3], [4]. Energy consumption of a centrifugal to apply the fuzzy control to cater system nonlinearities at the
pump system greatly depends on an electric drive. For instance, same time providing robust regulation under the large
at a constant speed operation, it is necessary to use throttle disturbances [10], and exanimating the operation of water
valves to control either the flow or pressure. The use of distribution systems to provide the ways of increasing the
variable speed drives (VSDs) gives the possibility to control efficiency of the system [11]. These approaches do not concern
both the flow and pressure, and potentially reduces power about the possibilities to reduce power losses caused by VSDs.
losses [5]. Frequency converters that are parts of VSDs allow They also do not focus on centrifugal pump input power
implementing soft start and shutdown of the pumps. Unlike estimation during the pressure regulation. To regulate pressure,
throttling method, the advantage of VSDs is that they do not mainly the speed control is taken into account in these papers.
influence efficiency of the system much. Another important This paper describes the developed pressure control method
aspect is that lifecycle costs of such systems also depend on based on the DriveSize/Simulink model of the centrifugal
energy consumption [6]. pump system. The model consists of two parts. The first one
Nevertheless, even in the case of using VSDs, the pumping represents the VSD and the second one a centrifugal pump
systems generally consume much more energy than the itself. The data from the model is used to calculate the energy
optimum level. Significant energy savings can be obtained by consumption of the whole system. With the help of proposed
applying both methods throttling and speed control at the algorithm, which is based on the data from a model, it is
same time. Due to the fact, that the energy costs are increasing, possible to choose the operational point of the centrifugal
the possibility to reduce energy consumption of pump drives is pump system optimal from an energy point of view. To achieve
becoming more important. the optimal working point both throttling and speed pressure
control methods are applied simultaneously. It can help to
Pressure is one of the main process variables in pumping improve potential of energy saving in the pumping system.
application. It is rather important to maintain the desired level
of pressure to meet the requirements of various industrial The paper is organized as follows. In the following
Section II, the conventional pressure control methods are
~~ M
Throttled
Power converter Pressure system
sensor
Unthrottled
Centrifugal system
Valve
pump
z1 Q
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The advantage of this control method is that this approach Fig. 4 illustrates the topology of the designed model for
can lead to the considerable energy saving and at the same input power estimation. The model consists of several
time can prolong the operational period of a centrifugal pump. subsystems. The elements indicated as boxes contain various
parts of the centrifugal pump system:
Despite the fact that variable speed pumps are capable to
maintain the relatively high efficiency by scaling the DS DriveSize,
performance curve, they are attached to the same system POM parameters of motor,
curve. This operation mode cannot be much beneficial from
the energy point of view. The objective of the research work is POFC parameters of frequency converter,
to check the possibility of the pressure maintenance PCM pressure control module,
optimization with the help of a combination of both methods.
BPC brake power calculator,
III. MIXED PRESSURE CONTROL SYSTEM LC power losses calculator,
To study the input power of a single-stage centrifugal IPC input power calculator.
pump, it is necessary to know the power on the shaft and power
losses of the VSD. Equation (2) gives the brake power of a
centrifugal pump [15]:
nT , DS
Ppum T (2)
30
POM
where
Ppum brake power on the pump shaft, W
rotational speed of the pump, rad/s POFC
n rotational speed of the pump, rpm
T pump torque, Nm
The full input power of a centrifugal pump system is
given by the equation (3):
Pin = Ppum + Ploss . (3)
Simulink Model
To estimate the input power, the simulation of a
centrifugal pump system is proposed. The model is based on PCM
both the pump and the VSD models. To develop the
appropriate model of a pumping system, two different
simulation environments are used. The pump model contains
various sensors, pipeline, throttle valve, single-stage centrifugal
BPC
pump, and fluid reservoir. All of these parts were modelled in
the Simulink environment. The model of a VSD contains the
characteristics of the induction motor and the frequency
LC
converter. It was developed with the help of ABB DriveSize
simulation environment [16]. Parameters of the VSD are
shown in Table I [17].
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valve and ideal angular velocity source, both are from the Starting from 0 rpm, it should reach at least the minimum
Simulink libraries. value of 500 rpm, and the valve should be open at least for
60. If the condition is not true, the program starts recursion
The subsystem BPC shown in Fig. 5 is designed to and increases the speed value and valve angle until they reach
calculate the power on the pump shaft. the minimum levels.
a b c d e f
g h i
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Initialization
that, with the growth of the hydraulic power of a centrifugal
pump, the input power is also increasing respectively.
p, bar
Program run
1.7
Calculating the
appropriate valve angle Pressure
and pump speed reference pref
1.5
ref reference angle
nref reference speed
nact
nref 2 4 6 8
+ n
PID Q, m3/h
n
Centrifugal Fig. 8. The power distribution during the mixed pressure control (green area
ACQ810
pump corresponds to the optimal working point zone).
Fig. 7. The mixed pressure control algorithm for a centrifugal pump. Obtained data show the high accuracy of the model and
possibility to save energy during the pressure control by
IV. EXPERIMENTAL VERIFICATION applying the mixed pressure control strategy. Fig. 9 shows data
for the one-hour period.
To validate the proposed pressure control method, the
simulation and experimental study have been conducted. Data Energy of pumping for pressure 1.8 bar
from both the Simulink model and the experimental test bench
described in [20] were examined. 2
Energy [kWh]
1.5
Fig. 8 illustrates the distribution of the input power
1
according to outlet pressure and position of the current working
point. Output pressure was examined in the range from 1.5 bar 0.5
to 2.0 bar. Areas coloured in green are the areas with the 0
optimal energy consumption for a given value of pressure. To 0 10 20 30 40 50 60 70
select the area, a criterion of the minimal acceptable flow was Time [minutes]
taken into account. Areas with red colour are close to the
region where the pump usually operates. When the working pump operating in red zone
point is located in a red area, the highest energy consumption pump operating in green zone
takes place. On the contrary, when the working point is located
on the left side, in the grey area, the energy consumption is Fig. 9. Energy consumption during one-hour period for a centrifugal pump at
lowest but the flow is not enough to meet the minimal 1.8 bar pressure.
requirements. The examination of the obtained results shows
368
To calculate the cost of consumed electricity, it is possible [4] D. J. Anton, Thirsty Cities: Urban Environments and Water Supply in
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Control 1991, International Conference on Control, Edinburgh, 1991,
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According to recent data for a 24-hour rate price in October [7] R. Ahmadullah and K. Dongshik, "Construction of hydraulically
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In comparison with conventional methods, the proposed frequency water pump in building air conditioning system," Consumer
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V. CONCLUSION Mechanisms and Machines (Dynamics), 2014, Omsk, 2014, pp. 1-5.
[10] M. I. Jahmeerbacus, "Flow rate regulation of a variable speed driven
A new pressure control system based on a combination of pumping system using fuzzy logic," Electric Power and Energy
throttling and speed control is proposed in the paper. The Conversion Systems (EPECS), 2015 4th International Conference on,
developed pressure control algorithm is based on a Sharjah, 2015, pp. 1-6.
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The proposed pressure control method was validated with the Practice, John Wiley & Sons, 2015, 388 p.
help of a real test bench based on the EBARA CDX120/12 [13] E. Finnemore and J. B. Franzini, Fluid Mechanics with Engineering
Applications, NY: McGraw Hill, Inc., 2002, 500 p.
centrifugal pump.
[14] M. Al-Khalifah and G. McMillan, Control valve versus variable-speed
Conducted examinations show that the model has high drive for flow control, International Society of Automation, 2013,
accuracy at various operation points corresponding to different http://isa.org/
values of pressure. [15] L. Gevorkov, V. Vodovozov, T. Lehtla and Z. Raud, "Hardware-in-the-
The novelty of developed mixed pressure control is based loop simulator of a flow control system for centrifugal pumps," 2016
10th International Conference on Compatibility, Power Electronics and
on the possibility to combine advantages of both conventional Power Engineering (CPE-POWERENG), Bydgoszcz, 2016, pp. 472-
pressure control methods: throttling and speed control. The 477.
assessment of data obtained during the conducted tests proves [16] DriveSize, [Online]. Available at: http://ds.nodus.info/starter.aspx
that the new approach can lead to energy savings. [17] I. Bakman, High-Efficiency Predictive Control of Centrifugal Multi-
Pump Stations with Variable-Speed Drives, PhD thesis, Tallinn, TTU,
2016, 149 p. Available at: http://digi.lib.ttu.ee/i/?5352.
ACKNOWLEDGMENT
[18] CODESYS in Embedded Automation Complete IEC 61131-3 IDE for
This research was supported by the Estonian Centre of industrial embedded applications, Available at:
Excellence in Zero Energy and Resource Efficient Smart http://www.codesys.com/.
Buildings and Districts, ZEBE, grant 2014-2020.4.01.15-0016 [19] Centrifugal Pumps CDX, Available at: http://ebara-pumps-
funded by the European Regional Development Fund. online.com/CDX.pdf.
[20] L. Gevorkov, I. Bakman, and V. Vodovozov, Hardware-in-the-loop
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