Method and apparatus for predicting maintenance needs of a pump based at least partly on pump performance analysis

Abstract

A signal processor is provided comprising one or more signal processor modules configured to: compare signaling containing information about historical data related to the performance of a pump; and provide corresponding signaling containing information about predicted maintenance needs of the pump on a real time basis based at least partly on the signaling compared containing information about the historical data related to the performance of the pump. The one or more signal processor modules may be configured to compare over time the hydraulic power generated by the pump and electric power consumed by a motor driving the pump, including tracking a ratio of hydraulic to electric power. The one or more signal processor modules may be configured to predict maintenance needs based on an algorithm that takes into account a trade-off between the cost of power consumed by a motor driving the pump and the cost associated with the pump maintenance in order to substantially minimize the total cost of operating the pump.

1 . A signal processor comprising:
 one or more signal processor modules configured to:   compare signaling containing information about historical data related to the performance of a pump; and   provide corresponding signaling containing information about predicted maintenance needs of the pump on a real time basis based at least partly on the signaling compared containing information about the historical data related to the performance of the pump.   
     
     
         2 . A signal processor according to  claim 1 , wherein the one or more signal processor modules is configured to compare over time the hydraulic power generated by the pump and electric power consumed by a motor driving the pump. 
     
     
         3 . A signal processor according to  claim 1 , wherein the one or more signal processor modules is configured to track a ratio of hydraulic to electric power. 
     
     
         4 . A signal processor according to  claim 1 , wherein the one or more signal processor modules is configured to predict maintenance needs based on an algorithm that takes into account a trade-off between the cost of power consumed by a motor driving the pump and the cost associated with the pump maintenance in order to substantially minimize the total cost of operating the pump. 
     
     
         5 . A signal processor according to  claim 1 , wherein the corresponding signaling containing information predicting maintenance needs of the pump comprises information about one or more of the following: dynamically adjusting pump clearances, dynamically balancing an impeller and replacing worn parts. 
     
     
         6 . A signal processor according to  claim 1 , wherein the historical data related to the performance of the pump comprises the discharge flow and pressure, intake level, fluid density, pump speed, or motor current, or some combination thereof. 
     
     
         7 . A signal processor according to  claim 1 , wherein the one or more signal processor modules is configured to use non-dimensional quantities to infer the performance of the pump and the trending of the efficiency of the pump. 
     
     
         8 . A signal processor according to  claim 7 , wherein the non-dimensional quantities comprise: the head coefficient, the flow coefficient, the efficiency, the power coefficient, the speed coefficient and the specific speed of the pump. 
     
     
         9 . A signal processor according to  claim 1 , wherein the one or more signal processor modules is configured to adjust the maintenance interval to the rate of wear, or vice versa, so that the total cost of operating the pump is substantially minimized. 
     
     
         10 . A signal processor according to  claim 1 , wherein the one or more signal processor modules is configured to receive the signaling containing information about historical data related to the performance of the pump; to store the signaling containing information about historical data related to the performance of the pump in a historical data database; or both. 
     
     
         11 . A signal processor according to  claim 1 , wherein the one or more signal processor modules is configured to analyze the signaling containing information about historical data related to the performance of the pump using a n-day moving window. 
     
     
         12 . A signal processor according to  claim 1 , wherein the one or more signal processor modules is configured to receive information about maintenance performed of the pump, and to store associated signaling containing information about the maintenance performed in the historical data database. 
     
     
         13 . A signal processor according to  claim 1 , wherein the one or more signal processor modules is configured to use an algorithm that is based at least partly on prolonging the lifetime of the pump, increasing the efficiency of the pump, or both. 
     
     
         14 . A signal processor according to  claim 1 , wherein the one or more signal processor modules is configured to predict maintenance needs based at least partly on an algorithm that takes into account that the fact that maximum efficiency of the pump may only be achieved by reducing the pump's internal clearances and thereby making the internal pressure seal of the pump tighter, and that by doing so the shear rates in the clearance spaces increase and thus the wall friction will increase as well leading to increased wear when the pumped fluids contain abrasive particulate material. 
     
     
         15 . A method comprising:
 comparing signaling containing information about historical data related to the performance of a pump; and   providing corresponding signaling containing information about predicted maintenance needs of the pump on a real time basis based at least partly on the signaling compared containing information about the historical data related to the performance of the pump.   
     
     
         16 . A method according to  claim 15 , wherein the method comprises comparing over time the hydraulic power generated by the pump and electric power consumed by a motor driving the pump. 
     
     
         17 . A method according to  claim 15 , wherein the method comprises tracking a ratio of hydraulic to electric power. 
     
     
         18 . A method according to  claim 15 , wherein the method comprises predicting maintenance needs based on an algorithm that takes into account a trade-off between the cost of power consumed by a motor driving the pump and the cost associated with the pump maintenance in order to substantially minimize the total cost of operating the pump. 
     
     
         19 . A method according to  claim 15 , wherein the corresponding signaling containing information predicting maintenance needs of the pump comprises information about one or more of the following: dynamically adjusting pump clearances, dynamically balancing an impeller and replacing worn parts. 
     
     
         20 . A method according to  claim 15 , wherein the historical data related to the performance of the pump comprises the discharge flow and pressure, intake level, fluid density, pump speed, or motor current, or some combination thereof. 
     
     
         21 . A method according to  claim 15 , wherein the method comprises using non-dimensional quantities to infer the performance of the pump and the trending of the efficiency of the pump. 
     
     
         22 . A method according to  claim 21 , wherein the non-dimensional quantities comprise: the head coefficient, the flow coefficient, the efficiency, the power coefficient, the speed coefficient and the specific speed of the pump. 
     
     
         23 . A method according to  claim 15 , wherein the method comprises adjusting the maintenance interval to the rate of wear, or vice versa, so that the total cost of operating the pump is substantially minimized. 
     
     
         24 . A method according to  claim 15 , wherein the method comprises receiving the signaling containing information about historical data related to the performance of the pump; to store the signaling containing information about historical data related to the performance of the pump in a historical data database; or both. 
     
     
         25 . A method according to  claim 15 , wherein the method comprises analyzing the signaling containing information about historical data related to the performance of the pump using a n-day moving window. 
     
     
         26 . A method according to  claim 15 , wherein the method comprises receiving information about maintenance performed of the pump, and storing associated signaling containing information about the maintenance performed in the historical data database. 
     
     
         27 . A method according to  claim 15 , wherein the method comprises using an algorithm that is based at least partly on prolonging the lifetime of the pump, increasing the efficiency of the pump, or both. 
     
     
         28 . A method according to  claim 15 , wherein the method comprises predicting maintenance needs based at least partly on an algorithm that takes into account that the fact that maximum efficiency of the pump may only be achieved by reducing the pump's internal clearances and thereby making the internal pressure seal of the pump tighter, and that by doing so the shear rates in the clearance spaces increase and thus the wall friction will increase as well leading to increased wear when the pumped fluids contain abrasive particulate material. 
     
     
         29 . Apparatus comprising:
 means for comparing signaling containing information about historical data related to the performance of a pump; and   means for providing corresponding signaling containing information about predicted maintenance needs of the pump on a real time basis based at least partly on the signaling compared containing information about the historical data related to the performance of the pump.   
     
     
         30 . Apparatus according to  claim 29 , wherein the apparatus comprises means for comparing over time the hydraulic power generated by the pump and electric power consumed by a motor driving the pump. 
     
     
         31 . Apparatus according to  claim 29 , wherein the method comprises tracking a ratio of hydraulic to electric power. 
     
     
         32 . Apparatus according to  claim 29 , wherein the method comprises predicting maintenance needs based on an algorithm that takes into account a trade-off between the cost of power consumed by a motor driving the pump and the cost associated with the pump maintenance in order to substantially minimize the total cost of operating the pump. 
     
     
         33 . A signal processor according to  claim 1 , wherein the one or more signal processor modules is configured to extrapolate information related to the performance of the pump to a Best Efficiency Point, thus providing an efficiency measure at a common point. 
     
     
         34 . A method according to  claim 15 , wherein the method comprises extrapolating information related to the performance of the pump to a Best Efficiency Point, thus providing an efficiency measure at a common point. 
     
     
         35 . Apparatus, including a computer-readable storage medium, having computer-executable components for implementing a method comprising:
 comparing signaling containing information about historical data related to the performance of a pump; and   providing corresponding signaling containing information about predicted maintenance needs of the pump on a real time basis based at least partly on the signaling compared containing information about the historical data related to the performance of the pump,
 when executed on a signal processor running on a computer device.