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Detection Of Vortex At The Deep Well Submersible Pumps By Using Fuzzy

Logic Controller And Impacts On Pump Operating Characteristics

Conference Paper · October 2016

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 IHANAS 2016
International Human and Nature Sciences: Problems and Solution Seeking Congress
October 7 – 9, 2016 Sarajevo

DETECTION OF VORTEX AT THE DEEP WELL SUBMERSIBLE

PUMPS BY USING FUZZY LOGIC CONTROLLER AND IMPACTS
ON PUMP OPERATING CHARACTERISTICS
Akif DURDU*
Nuri ORHAN**
Sedat ÇALIŞIR***

Abstract

Today, submersible deep well pumps are the most commonly used type of pump
purpose of irrigation from groundwater sources. For these pumps, one of the major
factors affecting the performance is the dynamic water level changing in wells. Changes
of input water-speeds of pump are tracked according to water level in the well. Different
types of vortex which is based on water movements may occur in entrance of the pump.
The resulting vortex and types depend on submergence, well diameter and pump
parameters such as flow rate, diameter, suction inlet-section and shape.

In this study, the test unit equipped for research purposes was used in a deep well.
According to the dynamic water level of submersible pump, changes in pressure, flow
rate and noise were automatically saved. Fuzzy logic controller as a method of
intelligent control methods was applied in this study in order to determine the consisting
of the vortex.

At the end, it is shown that the vortex in the well is automatically detected by depending
on the value of submergence, pressure, flow rate and noise.

Key words: Submersible Deep Well Pumps, Vortex, Fuzzy Logic Controller,
Submergence

*
Asst. Prof. Selçuk University, durdu.1@selcuk.edu.tr
**
Research Assistant, Selçuk University, nuriorhan@selcuk.edu.tr
***
Prof. Dr. Selçuk University, scalisir@selcuk.edu.tr

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1. INTRODUCTION

Today, submersible deep well pumps are the most commonly used for irrigation from
groundwater sources. Productivity and economic life of pumps is an important issue.

Vortex is moving whirl generated by turning and pitting of water or air. The vortex
frequently occurs in pump-intake due to unfavorable flow conditions or low submersion
depth (Chen, 2012:55). According to different energy levels, vortex formation are
classified and shown in Figure 1. The center of vortex is appeared as sharply after
increasing of the power of vortex (Kirst, 2010:285). The potential of vortex cavitation
and air-inlet vortex at the pump-intake is changed by depending on mean value of flow-
velocity and submersion depth. In case of formation of cavitation-vortex depending on
the depth of submergence, determination of the beginning of cavitation vortex is
important for the observation of the various types of vortex. The economic life and
efficiency of the pump are affected by interaction of wings of pump and air when the
vortex cavitation occurs (Nagahara, 2001:1). If the air enters to the pump after
formation of vortex, there can exist a cavitation (Konuralp, 2013:5).

Figure 1. Vortex classification (Anonymous 1998)

Cavitation adversely affects performance in pumping applications, additionally it causes
wear of pump components and seriously reduction in pump life. Many factors affect the
occurrence of cavitation. An important one of them is the cavitation depending on
reduction of water level (submergence). Water movements (vortex) in different shapes
consists that pump intake or suction line at the entrance with the decreasing water level.

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Vortex for water level of 230 mm is show in Figure 2.a. Submergence vortex with air-
inlet at water level of 230 mm is show in Figure 2.b.

a) Air-inlet vortex b) Submerged (Air-inlet) vortex

Figure 2. Vortexes are formed at different water levels (Okamura,2007:3)

The knowledge of whether or not there exists a vortex in submersible pumps running
meters deep is important. In this study, fuzzy logic controllers are used for
automatically detection of discontinuous (air-inlet) vortex or continuous (air-inlet)
vortex at low submergence according to the conditions of well dynamic water level,
pressure, flow-rate and noise of experimental environment.

2. METHODOLOGY

2.1. Fuzzy Logic Control

Zadeh proposed a method of modeling human by using fuzzy logic series. Some
properties of fuzzy logic are i) uses accurate information in a systematic way, ii)
expanded state of Boolean logic which allows relative accuracy values between values
of completely right and completely wrong, iii) an ideal approach for modelling the
system including uncertainty. Fuzzy logic evaluates the uncertain information and gives
an output according to evaluated information.

Fuzzy logic control has three steps such as fuzzification, fuzzy inherence and
defuzzification (Dupre, 2006:2). These are stated as follows:

1) Fuzzification: No information is lost in this process and the real value is only
converted to a degree of the membership function. Membership functions described for

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input variables are used to determine the degree of accuracy of the actual value. Each
input value must be converted a form within the applied rules.

2) Fuzzy Inherence: all inputs received by the system are evaluated by using IF-THEN
rules to determine the accuracy of values. A part of the input data is used to assign
particular values for a specific response. All fuzzy results obtained from mechanism of
the result are collected to a particular outcome. Different techniques are used to find the
most relevant results. The models of Mamdani, Takagi Sugeno and Tskamoto are given
as example models.

3) Defuzzification: After processing the rules, an internal defuzzification mechanism in

which a proposed action is converted to a real value is executed. This step is required to
control the physical system by using the discrete signals.

2.2. Experimental Environment

In this study, widely used in agricultural irrigation 3'' submersible pump is used. This
pump features of is shown in Table 1. Pump experiments are made in Deep Well Pump
Test Tower of Agricultural Machinery and Technology Engineering at the Department
Faculty of Agriculture Selcuk University. (Figure 3). Figure 4 shows a simulation and
defined terms of typical deep well submersible pump placed in a well.

Figure 3. Deep Well Pump Test Tower (Selcuk University)

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Figure 4. A simulation and defined terms of typical deep well submersible pump placed in a well

Technical specifications of the equipment’s used in test tower are described in Table 1.

Table 1. Technical specifications of the equipment’s used in test tower

Equipment Technical Specifications
Pump Nominal diameter 6'', radial wheel, 4.5 mm terminal opening
Electric Machine Suver, 380 V, 8.2 A, 50 Hz, 2869 1/min, 4,5 kW, shaft diameter :25 mm, water-
cooler, 3x2.5mm2 cable cross-section
Flow meter S MAG 100 TİP, DN 80/HR/316 electromagnetic flow meter, 220 V power supply,
digital indicator Adjustable between 4-20 m/A plus. Operational flow-rates 1 – 280
m3/h, operational pressure 16 bars.
Manometer WİKA, 0-10 bar, 4-20 m/A output.
Level Sensor Hydrotechnik model, 010 type/1,5 V
Power analyzer KAEL brand Mülriser 05-PC-TFT type mains power analyzer
Noise Sensor CT-2012 model, input 4 mA, DC 24V power supply output indicator. Sound level
Transmitter model : TR-SLT1A4, Measurement range:30-80 dB, 50-100 dB, 80-130
dB, output 4-20 mA, 90-260 ACV 50Hz/60Hz, Operation temperature 0-50 0C.
Temperature Truck model, 10-24 VDC, -50...100 0C, 4-20mA output.
Sensor
Computer Asus Intel core i7.

The height of test assembly with deep wells equipment is 10 m(See Figure 3). In the test
assembly, Plexiglas pipe (4 m), well screen pipe (2 m) and steel casing pipe (2 m) are
arranged to track experimental tests. Submersible pump is mounted as Figure 5.

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Figure 5. Submersible pump and connection of the camera

The standard of EN ISO 9906 is used for measurements and calculations of the pump
operating characteristics and the standard of EN ISO 3740 is measurement of the noise
level (Anonymous, 2014; Anonymous, 2007). Noise meter which is next to the drain
header has remained stationary throughout the whole measurement. Two cameras for
side-view and top-view are used to view the formation of vortex. The place of the
camera for top-view is changed according to the water level and the camera angle. Side
camera is connected to outside of the transparent pipe in order to track the pump-inlet
and the formation of vortex (See Figure 5).

The experiments with submergence pump in 188 cm were carried out at the constant
hydraulic load. Drawdown is measured with level meter and the following equation is
used for the calculation of submergence
S= 188-d (1)
where S is submersible depth (cm) and d is submergence (cm).

2.2 Record Actions

Software and automation systems were carried out to record the measured data. The
block diagram of the system is given in Figure 6. As it is shown in the block diagram,
the information received from sensors located in the system is wirelessly transferred to

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the central computer via a data acquisition card and Bluetooth module. The information
stored in central computer for the desired range is recorded with the suitable name that
is given by the operator on the interface of the software. Record action is set to get one
data per second. After the pump enters the regime, the record-process is started and 50-
data is taken from one sensor.

Figure 6. Block Diagram of the Automation System

The measurements at the optimum operating speed of the submersible pump are taken
for 5-7 different dynamic levels at the constant four different range of flow rate (40-50-
55-60 m3/h). The depth of diving is reduced after the first values are recorded at the
determined flow-rate of the pump. The flow-rate changed by downturn in the water
level is reinstated by the valve in measuring pipe. In this way, measurements for five
different submersion depth levels at a flow-rate value are recorded and monitored.

3. TESTS AND RESULTS

Characteristic features of the pump used for testing is given in Table 2. Analyzing the
Table 2, optimum system efficiency at the 14,05 meter of monometric height and the
flow-rate of 48.69 m3/h is obtained by 41,12%. Noise level by 74.49 dBA at the
optimum system efficiency is close to the high value, the drawdown is also increased to
7.5 cm. At the end, it is seen that the drawdown value is increased by increment of the
flow-rate value.

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Table 2. Characteristic features of the pump

Flow Hm Power Noise level System Drawdown
rate (mSS) (kW) (dBA) efficiency (cm)
3
(m /h) (%)
0.00 25.80 3.70 68.64 0.00 0
19.45 21.25 3.99 69.02 28.22 2
30.04 18.85 4.15 74.98 37.14 3.5
40.42 16.26 4.43 74.30 40.40 5.5
48.69 14.05 4.53 74.49 41.12 7.5
56.50 11.43 4.55 70.50 38.67 10
63.00 8.75 4.48 73.63 33.50 12.5
68.56 6.08 4.35 73.17 26.10 14.5
73.26 3.53 4.21 71.71 16.73 16.5
75.20 1.07 4.03 69.71 6.53 18

3.1. Design of the System Via Fuzzy Logic Controller

As previously mentioned, the expert-experience is used to model any state in fuzzy

logic system. Fuzzy logic control system designed in this study provides the information
of continuous or discontinuous vortex formation according to the data received from the
sensors of flow-rate, noise, submersion depth and pressure in the environment.

Depth in the creation of the rule-based fuzzy logic control system is created by four
input-variables named as Submergence (M1), Pressure (M2), Flow-Rate (M3) and
Noise (M4) and two output-variables named as Continuous Vortex (Y1) with
Discontinuous Vortex (Y2). States of input variables and vortexes occured by the
related inputs are shown in Table 3.

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Table 3. State-table occured by the inputs and outputs of fuzzy logic control system
Submergence
Pressure [bar] Flow-Rate [m3/h] Noise [dBA]
Output of the System (cm)
M2 M3 M4
M1
No Vortex 182,5 1,48 40,22 74,56
No Vortex 103 1,41 40,22 72,67
No Vortex 3 1,31 40,43 71,96
Continuous Vortex (Y1) 2 1,30 39,80 79,39
No Vortex 180 1,21 50,18 73,55
No Vortex 117 1,16 50,16 70,40
No Vortex 3 1,04 50,19 72,18
Continuous Vortex (Y1) 2 0,98 47,81 81,96
No Vortex 178,5 1,06 55,20 71,54
No Vortex 135 1,02 55,21 71,91
Discontinuous Vortex (Y2) 4 0,90 55,16 72,51
Continuous Vortex (Y1) 2 0,83 53,01 82,31
No Vortex 177,5 0,86 60,08 69,45
No Vortex 132,5 0,83 60,05 70,13
Discontinuous Vortex (Y2) 5 0,70 60,06 71,11
Discontinuous Vortex (Y2) 4,5 0,70 60,09 71,34
Continuous Vortex (Y1) 3 0,69 59,69 79,03

Membership functions of the designed fuzzy logic system are determined by inputs
variables M1, M2, M3, M4 and outputs variables Y1, Y2. Figure 8 shows membership
functions depending on input and output variables. Rule table of the designed fuzzy
logic system is given in Table 4.

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Figure 8. Membership functions of the designed fuzzy logic system with inputs variables M 1, M2,
M3, M4 and outputs variables Y1, Y2.

Table 4. Rule table of the designed fuzzy logic system

Input Variables Output Variables
Rule
Numbers M1 M2 M3 M4 Y1 Y2

R1 K B K B B K
R2 K K O K K B
R3 K K O O K B
R4 K K O B B K
R5 K O O B B K
R6 K K B K K B
R7 K K B O K B
R8 K K B K B K

The fuzzy logic system based on the membership functions (Figure 8) and rule table
(Table 4) is tested by using the real data. The obtained results are given in Table 5.

Table 5. Test results of the designed fuzzy logic system with measured values.
Output
Input Variables
Test Variables
Numbers
M1 M2 M3 M4 Y1 Y2
Test 1 2.868 1.37 38.43 83 Yes No
Test 2 23.98 1.37 38.43 83 No No
Test 3 45.91 0.6767 49.76 75.17 No No
Test 4 10.28 0.6767 49.76 75.17 No Yes
Test 5 5.28 0.6767 49.76 79.34 Yes No
Test 6 105.28 0.69 49.76 72.34 No No
Test 7 8.23 0.7 54 72.22 No Yes

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Output
Input Variables
Test Variables
Numbers
M1 M2 M3 M4 Y1 Y2
Test 8 3.426 0.80 57.65 81.29 Yes No

According to Table 5, the results of the fuzzy logic controller are trusted when we
examined the sensor information taken from M1, M2, M3 and M4 and the output based
on it. Top-view and side-view of vortex discontinuous and continuous (immersion
depth) is shown in Figure 9.

a) Side-view of discontinuous vortex b) Top-view of discontinuous vortex

c) Side-view of continuous vortex d) Top-view of continuous vortex

Figure 9. The vortex images obtained in the test

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4. CONCLUSION

Due to an intelligent controller, multiple sensor information received from the

environment could be evaluated easily. In this study, a fuzzy logic controller is used as
an intelligent controller and successful results are obtained. Thus, the machines used in
agriculture will be more efficient and have long working life. In particular, the
cavitation generated by continuous (immersion depth) vortex has negative impact on the
lives of the submersible pump. The fuzzy logic control system helps to determine the
vortex in this study and thereby the cavitation will be reduced. In future studies, the
system based on knowledge of vortex formation can automatically adjust the depth of
the pump by the way of an automation design.

ACKNOWLEDGEMENT

This study was supported by TheScientific and Technical Research Council of Turkey
(TUBITAK, Project No:213O140).

REFERENCES

Anonymous 1998, American National Standard for Pump Intake Design, ANSI/HI 9.8-
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www.pumps.org.

Anonymous 2007, TS EN ISO 3740 Determination of sound power level of the acoustic
-noise source. TSE, Ankara.

Anonymous 2014, TS EN ISO 9906 Rotodynamic pumps - Hydraulic performance

acceptance tests - Category 1, Category 2 ve Category 3. TSE, Ankara.

Chen, Y., C. Wu., B. Wang., M. Du., Three-dimensional Numerical Simulation of

Vertical Vortex at Hydraulic Intake, International Conference on Modern Hydraulic
Engineering, 28 (2012) 55-60, China.

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Dupre M. And Yang S. X. ‘‘Two-Stage Fuzzy Logic-Based Controller for Mobile

Robot Navigation’’, İnternational Conference on Mechatronics and Automation, 2006

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Problems for Extraterrestrial Celestial Bodies, 8. Pump Valve Congress Abstract Book,
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Impeller, CAV2001: sessionB8.006, (2001), Japan.

Nurşen, E.C., Centrifugal Pump in account Cavitation problems and Maximum Suction,
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Zadeh L.A, ‘‘Fuzzy Sets’’, Information and Control, vol 8 pp 338-353, 1965

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