Pump Testing for Predicting Lifetime and Wear Conditions

A method for controlling a pump comprising:

• initializing the pump for operation in an application;
• performing a pump test by calculating an initial MPI by performing the steps of:
• operating the pump at operating speed for a minimum operating interval;
• initiating a pump braking function;
• continuously monitoring pump speed starting at initiation of pump braking function;
• reading an initial time, ti, when the pump speed decreases to an initial pump speed close to and less than the operating speed;
• storing the initial pump speed for time ti;
• reading an end time, te, when the pump speed decreases to a final pump speed close to and greater than a critical speed;
• determining a mechanical power index (MPI) as:
• MPI=initial pump speed−final pump speed/te−ti;
• and
• using the MPI to determine a pump deterioration state.

A system for performing a pump test comprising:

• a pump controller configured to execute a pump test, to transmit command signals configured to communicate pump control functions to a pump via a communications interface, and to process data received from the pump via the communications interface;
• and
• a data acquisition and control interface configured to communicate between the pump and the pump controller over the communications interface, the data acquisition and control interface comprising a speed sensing signal path to a speed sensor mounted in proximity to the pump to sense a pump speed;
• where the pump controller includes computer program instructions to perform the pump test when executed by the pump controller, the pump test comprising the steps of:
• calculating an MPI by:
• operating the pump at operating speed for a minimum operating interval;
• initiating a pump braking function;
• continuously monitoring pump speed starting at initiation of pump braking function;
• reading an initial time, ti, when the pump speed decreases to an initial pump speed close to and less than the operating speed;
• storing the initial pump speed for time ti;
• reading an end time, te, when the pump speed decreases to a final pump speed close to and greater than a critical speed;
• determining a mechanical power index (MPI) as:
• MPI=initial pump speed−final pump speed/te−ti;
• and
• using the MPI to determine a state of deterioration of the pump.