Method and apparatus of detecting disturbances in a centrifugal pump
First Claim
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1. A motor controller for a motor-driven pump, the controller having at least one voltage sensor and at least one current sensor and configured to:
- receive a voltage and a current signal of the pump in operation from the at least one voltage sensor and the at least one current sensor;
determine a power signal from the voltage signal and the current signal;
generate a real-time spectrum analysis of the power signal;
determine undesirable torque conditions in the pump from the spectrum analysis; and
automatically disable the pump if the undesirable torque condition exceeds a threshold.
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Abstract
The present invention is directed to a centrifugal pump wherein voltage and current data are detected from voltage and current sensors in the motor controller of a pump motor. A power signal is then generated from the voltage and current data and spectrally analyzed to determine the presence of unwanted harmonics which are indicative of mechanical disturbances in the pump. As such, anomalies resulting from mechanical interference may be detected and a warning flag provided without additional transducers and other instruments on the motor or pump.
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Citations
18 Claims
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1. A motor controller for a motor-driven pump, the controller having at least one voltage sensor and at least one current sensor and configured to:
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receive a voltage and a current signal of the pump in operation from the at least one voltage sensor and the at least one current sensor;
determine a power signal from the voltage signal and the current signal;
generate a real-time spectrum analysis of the power signal;
determine undesirable torque conditions in the pump from the spectrum analysis; and
automatically disable the pump if the undesirable torque condition exceeds a threshold. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A computer readable storage medium having stored thereon a computer program to detect the signal mechanical anomalies in a motor-driven centrifugal pump and representing a set of instructions that when executed by a processor causes the processor to:
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determine an instantaneous pump motor power signal from voltage and current data collected by one or more voltage and current sensors in a motor starter of the motor-driven centrifugal pump;
signal process the instantaneous pump motor power signal;
compare the processed instantaneous pump motor power signal to a pump motor power signal modeled during healthy operation of the pump motor;
if the processed instantaneous pump motor signal exceeds a threshold, provide an external notifications signaling mechanical anomalies in the pump; and
differentiate noise from mechanical anomalies. - View Dependent Claims (8, 9, 10, 11, 12)
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13. A method of detecting mechanical anomalies in an operating centrifugal pump motor, the method comprising the steps of:
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capturing an operational model of a centrifugal pump motor assembly known to be operating normally;
generating a baseline power signal from the modeling;
acquiring instantaneous voltage and current signals of the pump motor assembly from voltage and current sensors in the motor assembly;
determining a real-time power signal from the instantaneous voltage and current signals;
determining undesirable harmonics in the real-time power signal based on a comparison with the baseline power signal; and
delineating between a transient condition in the pump and an undesirable mechanical condition based on several cycles of undesirable harmonics in the real-time power signal. - View Dependent Claims (14, 15, 16)
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17. An apparatus for detecting undesirable torsional/mechanical conditions in a pump, the apparatus comprising:
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at least one voltage sensor and at least one current sensor;
a processor configured to receive data from the at least one voltage sensor and the at least one current sensor, the processor having;
means for determining a power signal from the voltage and current data;
means for generating a spectrum analysis of the power signal;
means for comparing the spectrum analysis to a spectrum analysis of a modeled power signal;
means for determining undesirable harmonics indicative of mechanical disturbances in the pump from the comparison; and
means for interrupting pump operation in response to an indication of a mechanical disturbance. - View Dependent Claims (18)
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Specification