Booster Pump Control System

Embodiments of the present disclosure are related to booster pumps; more particularly, embodiments disclosed herein related to booster pumps with no flow shutdown controls and dynamic set point adjustment controls for discharge pressure.

A booster pump is used to increase pressure in a water system in order to achieve sufficient water flow and pressure at its endpoints. That is, the booster pump in a boosting pump system is designed to increase low pressure in a water system in order to achieve sufficient water pressure and flow to its customers. Booster pump-based systems usually include one or more pumps that increase the pressure to a certain point independent of flow and inlet pressure. Thus, the booster pump takes water from the source, pressurizes it, and then sends its endpoints so that it arrives with the desired pressure.

Generally, booster pumps are available as ordinary pumps or Variable Speed pumps. The ordinary pumps operate at a constant rate and cannot increase flow rate or adjust their speed. Variable Speed pumps, on the other hand, can adjust speed based on the desired pressure requirements.

Apparatuses and methods for performing booster pump control are disclosed. In some embodiments, a method for controlling a booster pump system includes detecting a no-flow event has occurred based on a booster pump response with respect to a controlled increase in discharge pressure above a discharge pressure set point; and shutting down the booster pump system in response to occurrence of the no-flow event.

In some other embodiments, a booster pump system includes: a pressure sensor, one or more booster pumps, and a control system coupled to the pressure sensor and the one or more booster pumps to: detect a no-flow event has occurred based on a booster pump response with respect to a controlled increase in discharge pressure above a discharge pressure set point; and shut down the booster pump system upon occurrence of the no-flow event.

In yet some other embodiments, a method for controlling a booster pump system includes: monitoring, using a pressure sensor, discharge pressure of the booster pump system; determining the quantity of pumps operating in the booster pump system; adjusting a discharge pressure set point based on preset pressure adjustments that are calculated based on the pressure booster packaged characteristics; and modulating operating pumps to maintain the discharge pressure at the adjusted discharge pressure set point.

Other aspects and advantages of the embodiments will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments.

In the following description, numerous details are set forth to provide a more thorough explanation of embodiments of the present disclosure. It will be apparent, however, to one skilled in the art, that the teachings disclosed herein may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form, rather than in detail, in order to avoid obscuring the present disclosure.

Methods and apparatuses are disclosed herein for controlling booster pumps using no flow shutdown controls and dynamic set point adjustment controls for discharge pressure. In some embodiments, the booster pumps part of a pressure booster. In some embodiments, the booster pumps are part of a booster pump system for supplying water for commercial and/or residential buildings.

shows some embodiments of a booster pump system for pumping water (or other liquid). Referring to, a pumpconnected to one or more water tanks. Water tankscan include a remote hydro-pneumatic tank that is installed in a high point in a cold water piping system. In some embodiments, pumpis a pump for use in residential or commercial water distribution systems that are connected to a municipal water system. If pumpis for use in a distribution system that is connected to a municipal water system, pumpmay not be connected to a water tank.

In some embodiments, pumpcan be used as one of multiple pumps in a pressure-boosting system such as, for example, pumpsA-C. The number of pumps is not limited to four and can be two, three, or more than four. In some embodiments, a pressure booster system includes two or more pumps that are controlled in a lead-lag arrangement.

In some embodiments, pumpoperates in a pressure booster system designed to boost potable water pressure where available pressure is inadequate. Pumpcan be used for other types of water including, but not limited to, grey water, rain water, and irrigation. In some other embodiments, pumpcan be used in liquid distribution systems other than a water distribution system, such as a system for distributing other fluids (e.g., a hydraulic fluid, etc.).

In some embodiments, a pump control systemis coupled to and configured to control operation of pumps, such as pump. Pumpcan include or can be connected to a motorin any conventional manner. Any other pumps (e.g.,A-C) can also be coupled to a motor (e.g., motorA-C). Pump control systemcan be used to control the operation of motor. In some embodiments, motoris an AC induction motor, a brush-less DC motor, or a switch-reluctance motor. Various outputs and/or control parameters of pump control systemcan be modified for each particular type of motor.

In some embodiments, systemincludes a booster pumpin fluid communication with a pipe coupled to an input line (pipe), such as suction inlet, and is operative for boosting water pressure at a water input and outputting the water under a boosted pressure at an output line (pipe), such as discharge output.

Pump control systemcan include one or more pressure sensors. In some embodiments, a pressure sensorcan be positioned between the pumpand the water tank. In some embodiments, pressure sensorcan be positioned to sense the pressure in an output line such as discharge outputbetween the pumpand the water tank. In some embodiments, pump control systemincludes a single pressure sensor. However, in some embodiments, additional pressure sensors, such as pressure sensorcan be placed in any suitable position in a residential or commercial water distribution system, for example, on an input line such as suction inletto monitor the water pressure from a municipal water system.

Pump control systemcan have one or more flow sensors capable of sensing flow of water through the section of pipe. While water flows within the pipe interior, the pipe may be pressurized such that it is consistently full of water, which is at times still and at other times flowing. In some embodiments, flow sensoris located along the output line such as discharge output. Flow sensorcan be mounted directly to the pipe exterior or positioned in close proximity thereto. Flow sensorcan be configured for determining a state of fluid flow within piping, without physically contacting the water flowing within the pipe. Flow sensormay use any means, mechanism, or technology for detecting flow within the pipe, whether currently available or prospectively developed.

In some embodiments, pump control systemcan receive data, such as operational data, from pumpand can control at least pumpbased on hardware and/or software. Such control can include pump control systemactivating pumpand deactivating pumpas well as controlling pump speeds. Pump control systemreceives fluid flow sensory information (e.g., measurements) from flow sensorand pressure sensory information (e.g., measurements) from pressure sensor(and pressure sensorif included) and uses the information to at least partially control pump. In a control mode, pump control systemcontrols pumpto pump water in at least partial response to sensing at least the in-use state via pressure sensorsandand flow sensor.

In some embodiments, pump control systemcomprises a pressure booster control panel having a controller to allow for the automatic operation of variable speed pumps piped in parallel in a booster pump system. In some embodiments, the control panel operates using sensory information from input sensors (e.g., pressure sensors, flow rate sensors, temperature sensors, etc.) mounted in piping and wired to the control panel. In some embodiments, the controller in control panel is a programmable logic controller (PLC). The PLC can have a user interface (e.g., a touchscreen Human Machine Interface (HMI)), one or more status indication lights, one or more variable frequency drives (VFDs) and Hand-Off-Auto (HOA) selector switches for each system pump.

In some embodiments, the controller monitors all input sensors and controls pump speed. In some embodiments, the controller controls pump operations by performing no flow shutdown and dynamic set point (DSP) operations. In some embodiments, when performing a no flow shutdown operation, the controller detects a no-flow event has occurred and shuts down one or more pumps in response to the occurrence of the no-flow event. In some embodiments, the no-flow event is based on a booster pump response with respect to a controlled increase in discharge pressure above a discharge pressure set point, and shuts down one or more pumps in response to the detection of a no-flow event. In some embodiments, the controller detects the no-flow event has occurred after controlling discharge pressure of a pump of the booster pump system to increase the discharge pressure to a predetermined amount greater than the discharge pressure set point, starting a no-flow timer that has a duration, and determining that the discharge pressure remains above the discharge pressure set point after increasing the discharge pressure after the timer reaches a certain point (e.g., times out, reaches a predetermined count, etc.). If the discharge pressure remains above the discharge pressure set point, the controller shuts down the pumps.

In some embodiments, while in no-flow shut down, the discharge pressure will set to the no flow pressure adjustment setpoint that is above the pressure discharge setpoint, and the lead pump's VFD will ramp up to meet the new setpoint. Once the setpoint has been met, a no flow idle timer in the control panel starts counting. If the discharge pressure remains at or above the setpoint for the duration of the timer, the no-flow shutdown is satisfied, and if the discharge pressure does not maintain the setpoint for the duration of the timer, the controller exits the no flow shutdown and maintains the original discharge pressure setpoint. If, at any time during the no flow shut down, the discharge pressure drops below the start pressure setpoint, the controller exits the no-flow shutdown and the lead pump's VFD will ramp up to maintain setpoint.

With dynamic set-point adjustment (DSA), in some embodiments, the controller automatically resets the system discharge pressure based upon preset pressure adjustments calculated based on pressure booster packaged characteristics. These calculations can take into account system flow and piping friction loss. In some embodiments, the controller performs DSA by monitoring discharge pressure of the booster pump system using a pressure sensor, determining the flow rate of water (liquid) in the booster pump system, adjusting a discharge pressure set point based on preset pressure adjustments calculated based on pressure booster packaged characteristics (e.g., piping friction loss and the flow), and then modulating the operating pumps to maintain the discharge pressure at, or near, the adjusted discharge pressure set point. In some embodiments, during DSA, the controller automatically stages the pumps and adjusts the pump speed based on this discharge pressure control.

illustrates some embodiments of a pressure booster. Referring to, a control panelis coupled to a suction headerand a discharge header. Control panelis also coupled to control pumpsand. Pumpsandare coupled between the suction headerand discharge header. More specifically, input to pumpis coupled to suction headervia an isolation valve. The outlet of pumpis coupled to discharge header via check valveand isolation valve. The input to booster pumpis coupled to suction headervia isolation valve. The outlet of booster pumpis coupled to discharge headervia check valveand isolation valve. Note that whileonly shows two pumpsand, the techniques disclosed herein are not limited to a booster control system only having two pumps. In some other embodiments, the booster control system has three or more pumps. In some embodiments, the booster pumps are part of a lead-lag system with one or more VFDs to regulate pressure by directly controlling the motor speed of each pump. In some embodiments, the controller uses a single PID loop that produces the same output signal that is used to control all the VFD regardless of the number of VFDs running. In some embodiments, the VFD's discrete outputs control each booster pump's motor so that they all go the same speed. The PID includes a number of set points (e.g., a discharge pressure set point, etc.) to control operation of the booster system. In some embodiments, these set points are adjustable.

The control panelis also coupled to pressure transducer (sensor)and. Also coupled to pressure sensors (transducers)andare pressure gaugeand pressure gauge, respectively. Pressure sensorsandprovide pressure measurements to control panelat the output of the discharge headerand the input of suction header, respectively. A temperature sensoris also coupled to control paneland measures temperature off the suction header. If the water temperature is above a threshold (e.g., the water gets too hot), then an alarm is triggered and the controller of control panelshuts down pumpsand. In some embodiments, the pressure booster has a suction sensor at an end of suction headerof the pressure booster to measure the suction pressure. The suction pressure can indicate is the water is getting low in general, and the controller can determine whether to stop one or more pumps to prevent the pumps from running without water as running the pumps without adequate fluid pressure (or running them dry) causes damage to the pump via cavitation, drying out components, ceasing rotating components and/or adding excessive heat into the water.

Pressure boosterwill be coupled to the city water supply (inlet)that it provides a building water supplyto a building or other structure that includes a remote hydro-pneumatic tank. In some embodiments, tankis installed at a high point in the cold water piping system. The city water supplyincludes a flex connection pointthat can be coupled to connection pointof suction headerand a flex connection pointof the city water supplythat can be coupled to connection to pointof discharge header. In some embodiments, a check valveand an isolation valveare coupled between the flex connection pointsandof city water supply. An isolation valvecouples the building water supplyto tank.

In some embodiments, under software control, the controller of control paneluses sensor data from pressure sensors on the input at suction headerand the output at discharge headerand provides control signals or other indications to pumpsand/orto increase or decrease the pump speed to maintain a set point. The controller of control panelmakes changes to pumpsand/ordepending on the operation.

In some embodiments, under software control, the controller (e.g., a PLC, etc.) of control paneldetects if there is a no flow event, indicating there is no flow in the system or the flow is below a threshold. If the controller determines that a no-flow event has occurred no flow in the system, it will automatically shut off.

In some embodiments, under software control, the controller of control panelperforms a no flow shutdown operation. In some embodiments, no flow shutdown operation is only enabled when a single pump is operating. In some embodiments, when performing a no flow shutdown operation, the controller detects a no-flow event has occurred based on a booster pump response with respect to a controlled increase in discharge pressure above a discharge pressure set point and shuts down one or more pumps in response to the occurrence of the no-flow event.

For no flow shut down, the controller controls pumpscontrols pumpto increase the pressure to a certain point above a predefined discharge pressure set point. After the pressure is increased to that level above the predefined discharge pressure set point, then the controller stops the pressure increase operation and drops the pump speed down to a speed associated with an adjustable set point. This should cause the discharge pressure to return to predefined discharge pressure set point. After dropping the pump speed back down, if the controller verifies that discharge pressure is maintained at the higher level and does not drop below a set point, then the controller concludes that a no flow event has occurred. On the other hand, if after dropping the pump speed back down, the controller verifies that discharge pressure remains above the discharge pressure set point, then the controller determines that there is not a no-flow event.

As the controller detects the no-flow event has occurred by controlling discharge pressure of a pump of the booster pump system by increasing the discharge pressure to a predetermined amount greater than the discharge pressure set point, the amount of the increase is dependent on the booster system and the water supply system. In some embodiments, the amount of PSI that is added to the discharge pressure is between two and five PSI. The amount has to be more than negligible but should be selected such that it does not over pressurize the system. The amount to add is dependent on the system and based on the flow. For example, a higher building can have a high discharge pressure to begin with in comparison to a shorter building. Thus, with the shorter building, the controller can ramp it up higher since the overall pressure if not that high. Thus, building height can influence the amount selected to increase the discharge pressure. In some embodiments, the accuracy of the sensors can be important as the sensors have to be able to measure a discernible difference in the resulting pressures. In some embodiments, the speed of the water flow can influence the amount of the increase over the discharge pressure set point.

In some embodiments, after ramping up the pressure, the controller starts a no flow timer having a predetermined duration. The duration of the timer is selected to enable the discharge pressure in the system to return to its set point. In some embodiments, the timer is 30 seconds, though other durations can be used. After the timer expires or otherwise reaches a predetermined point, the controller determines whether the discharge pressure remains above the discharge pressure set point (after its controlled increase). If the discharge pressure remains above the discharge pressure set point, the controller determines that a no-flow event has occurred and shuts down the pumps.

In some embodiments, the controller controls water pressure in the system to maintain the pressure at a certain level. In some embodiments, the controller controls the water pressure based on one or more dynamic set points, such as, for example, but not limited to, a discharge pressure set point. For example, in the case of a pressure booster, the controller may start a first pump and ramp up its speed with a goal of increasing the pressure in the system to the discharge pressure set point. If the discharge pressure remains below the discharge pressure set point after running the first pump, the controller may cause a second pump to run to get the discharge pressure up to the discharge pressure set point. However, as the flow increases, there friction loss in the piping that transports the water increases. That is, friction loss of the piping is a function of flow, and the friction loss can change rapidly.

Furthermore, in the case of pressure boosters, the different characteristics of each pressure booster, including the different diameter headers, different lengths of headers, different numbers and types of pumps, etc. impacts the dynamic set point for the booster.

To compensate for the fact that friction loss is a function of flow, in some embodiments, the controller performs dynamic set point adjustment (DSA) in which the controller, and its software, adjusts the discharge pressure set point, indicative of the pressure that the system is trying to maintain in the system, for the friction loss in the piping and the flow that the booster pump system is to achieve. With dynamic set-point adjustment (DSA), the controller automatically resets the system discharge pressure based upon system flow and piping friction loss. In some embodiments, the controller performs DSA by monitoring discharge pressure of the booster pump system using a pressure sensor, determining the quantity of pumps operating in the booster pump system, adjusting the discharge pressure set point based on preset pressure adjustments calculated based on the pressure booster packaged characteristics. In some embodiments, these calculations take into account the friction loss in the piping and the target flow that the booster pump system is to achieve. The controller modules the operating pumps to maintain the discharge pressure at the adjusted discharge pressure set point. In some embodiments, during DSA, the controller performs this modulation by automatically staging the pumps and adjusting the pump speed based on discharge pressure control.

In some embodiments, the controller determines the set point based on calculations using the flow rate and the friction loss to compensate for changes in the flow that occur at different times. These calculations result in the setting of the dynamic set point. In some embodiments, these calculations take into account the number of pumps in the booster, as well as other booster characteristics. In some embodiments, different calculations are performed at different flows, which allows the controller to change the discharge pressure set point for each of the flows.

In some embodiments, the preset pressure adjustments are calculated using information regarding the target flow rate based on the VFDs of the pressure booster, which allows the controller to make adjustments to the target discharge pressure set point based on the number of pumps that are operating. More specifically, the calculations are based on the pressure booster package characteristics (e.g., headers, the check valves, isolation valves, etc.) and the frequency of the drives (as the frequency is related to speed). Each booster theoretically could have a different dynamic set point based on what the target flow rate is. In some embodiments, the calculations are completed outside of the controller (e.g., the control panel) programming. Thus, based on the VFD speed at that instant in time, the controller can dynamically adjust the target discharge pressure set point of the booster.

By performing DSA, the controller is able to manage the flow through of the system while still achieving the desired pressure, such as, for example, the pressure desired at the high point in a building.

is a flow diagram of some embodiments of a process for controlling a booster pump system. In one embodiment, the booster pump system includes a pressure booster. In some embodiments, the pressure booster comprises a multi-state variable speed pressure booster having two or more pumps. In some embodiments, the process is performed, at least in part, by processing logic comprising hardware (e.g., circuitry, dedicated logic, etc.), software (e.g., software running on a chip, software run on a general-purpose computer system or a dedicated machine, etc.), firmware, or a combination of the three. In some embodiments, the process is performed by a controller in the booster pump system.

Referring to, the process includes processing logic receiving a discharge pressure reading from a pressure transducer (sensor) (processing block). Processing logic determines if the discharge pressure reading drops below a discharge pressure set point. In some embodiments, the discharge pressure set point is adjustable. If the discharge pressure reading drops below the discharge set point, then processing logic modules one or more booster pumps to operate and maintain the discharge pressure at the discharge pressure set point (processing block).

The process also includes processing logic causing a controlled increase in the discharge pressure to a point above the discharge pressure set point (processing block) and then processing logic detecting a no flow event has occurred based on a booster pump response with respect to the controlled increase in discharge pressure above a discharge pressure set point (processing block). In some embodiments, processing logic detects a no flow event if after the controlled increase, the discharge The process also detecting a no flow event has not occurred based on a booster pump response with respect to a controlled increase in discharge pressure if the discharge pressure returns to the discharge pressure set point.

is a flow diagram of some embodiments of a process for detecting a no flow event has occurred. In one embodiment, the booster pump system includes a pressure booster. In some embodiments, the pressure booster comprises a multi-state variable speed pressure booster having two or more pumps. In some embodiments, the process is performed, at least in part, by processing logic comprising hardware (e.g., circuitry, dedicated logic, etc.), software (e.g., software running on a chip, software run on a general-purpose computer system or a dedicated machine, etc.), firmware, or a combination of the three. In some embodiments, the process is performed by a controller in the booster pump system.

Referring to, the process includes processing logic receiving a discharge pressure reading from a pressure transducer (sensor) (processing block). The process also includes processing logic controlling the discharge pressure of a booster pump system to increase the discharge pressure to a predetermined amount greater than the discharge pressure set point (processing block). In some embodiments, the predetermined amount greater than the discharge pressure set point is two to five pound per square inch (PSI) higher than the discharge pressure set point. In some embodiments, the discharge pressure set point is adjustable. In some embodiments, the booster pump includes a lag pump and a lead pump, and controlling discharge pressure of the booster pump to increase the discharge pressure comprises ramping up the discharge pressure, by a variable frequency drive (VFD) of a lead pump, to reach the predetermined amount.

Next, processing logic starts a no flow timer (processing block). The no flow timer that a duration by which it expires or otherwise times out. In some embodiments, the duration is set to a predetermined amount (e.g., 30 seconds). Processing logic then determines whether the discharge pressure remains above the discharge pressure set point after the increase in the discharge pressure has ended and the timer has timed out (processing block). In some embodiments, the processing logic determines that the discharge pressure remains above the pressure set point by obtaining a measurement of the discharge pressure using a pressure sensor and comparing the measurement to the discharge pressure set point.

The process also includes processing logic in determining whether the discharge pressure returned to the discharge pressure setpoint (processing block), and if so, processing logic determines that the no flow event did not occur (processing block).

is a flow diagram of some embodiments of another process for controlling a booster pump system. In one embodiment, the booster pump system includes a pressure booster. In some embodiments, the pressure booster comprises a multi-state variable speed pressure booster having two or more pumps. In some embodiments, the process is performed, at least in part, by processing logic comprising hardware (e.g., circuitry, dedicated logic, etc.), software (e.g., software running on a chip, software run on a general-purpose computer system or a dedicated machine, etc.), firmware, or a combination of the three. In some embodiments, the process is performed by a controller in the booster pump system.

Referring to, the process includes monitoring discharge pressure of the booster pump system using a pressure sensor (processing block). In some embodiments, the pressure sensor obtains the pressure measurement at the output of the discharge header of a pressure booster system. The process also includes determines the quantity of pumps operating in the booster pump system (processing block).

Thereafter, processing logic adjusts a discharge pressure setpoint based preset pressure adjustments that are calculated based on the pressure booster packaged characteristics (processing block). In some embodiments, processing logic adjusts a discharge pressure set point based on the piping friction loss and a target flow rate. In some embodiments, processing logic calculates a flow rate based on a variable frequency drive (VFD) of a pump in the booster pump system.

The processing logic also modulates the operating pumps to maintain the discharge pressure at the adjusted discharge pressure set point (processing block). In some embodiments, processing logic modulates the operating pumps by adjusting speed of a pump based on the adjusted discharge pressure set point. In some embodiments, the processing logic automatically resets the discharge pressure based upon system flow and piping friction loss. In some embodiments, this is performed by automatically staging the pumps of a booster system (e.g., a pressure booster) and adjusting the pump speed based on the discharge pressure control.

There is a number of example embodiments described herein.

Example 1 is a method for controlling a booster pump system, where the method includes detecting a no-flow event has occurred based on a booster pump response with respect to a controlled increase in discharge pressure above a discharge pressure set point and shutting down the booster pump system in response to occurrence of the no-flow event.

Example 2 is the method of example 1 that may optionally include that detecting the no-flow event has occurred includes controlling discharge pressure of a pump of the booster pump system to increase the discharge pressure to a predetermined amount greater than the discharge pressure set point, starting a no flow timer that has a duration, and determining that the discharge pressure remains above the discharge pressure set point after increasing the discharge pressure.