VARIABLE SPEED RECONFIGURABLE PUMP/TURBINE CLUSTERS

Abstract

A hydraulic rotating machinery (HRM) system provides optimal energy efficiency over a very wide conditions of service (COS) range by configuring a plurality of variable speed HRMs in a cluster. The HRMs are interconnected by one or more valves that can be actuated by a controller to configure and vary a flow path through which a process fluid flows from an inlet to an outlet. By actively selecting which of the HRMs are included in the flow path, the interconnections therebetween, and the operating speeds thereof, the controller ensures that the HRM cluster continues to operate at optimal efficiency as the COS fluctuates over a very wide range. The HRMs can be identical to each other, or can vary in design. The HRM system can be implemented for storage and retrieval of green energy. The controller can also monitor the health of the cluster and/or of the associated process.

Claims

1. A hydraulic rotating machinery (HRM) system that is configured to control a process fluid of a process, said process fluid having widely varying conditions of service (COS), the HRM system comprising: a controller; an HRM cluster comprising a plurality of HRMs having variable operating speeds, each of the HRMs being a pump, a turbine, or a hybrid pump/turbine, the operating speeds of the HRMs being controlled by the controller; an HRM plumbing system, the HRMs being interconnectable by the HRM plumbing system to form a flow path through which the process fluid can flow from an inlet of the HRM plumbing system to an outlet of the HRM plumbing system; a plurality of valves included in the HRM plumbing system, the controller being able to actuate the valves so as to control a selection of the HRMs that are included in the flow path and an arrangement in which the HRMs of the selection are included in the flow path; and non-transient media cooperative with the controller, the non-transient media containing instructions that, when executed by the controller, cause the controller to: accept information regarding at least one of a status of the process and the COS of the process fluid; and according to said information, control the operating speeds of the HRMs and the selection and arrangement of the HRMs in the flow path so as to continuously satisfy at least one requirement of the process while ensuring that the HRMs in the flow path operate substantially at their optimal hydraulic efficiency points over said widely varying COS of the process fluid.

2. The HRM system of claim 1, wherein all of the HRMs in the plurality of HRMs are identical to each other.

3. The HRM system of claim 1, wherein the plurality of HRMs includes pumps and turbines, all of the pumps in the plurality of HRMs being identical to each other, and all of the turbines in the plurality of HRMs being identical to each other.

4. The HRM system of claim 1, wherein the controller is able to change the configuration of the flow path such that an interconnection of a pair of the HRMs in the flow path is changed between a parallel interconnection and a serial interconnection.

5. The HRM system of claim 1, wherein the controller is able to change the configuration of the flow path such that an interconnection between four of the HRMs in the cluster is changed between a fully parallel interconnection, a series-parallel interconnection, and a fully series interconnection.

6. The HRM system of claim 1, wherein the process is an energy generating process, and the HRM system is configured to store a surplus energy output of the process when the process is subject to a low energy demand, and to recover said stored energy and supply the recovered energy to the process when the process is subject to a high energy demand.

7. The HRM system of claim 1, wherein the cluster includes at least one HRM that is configured for efficient operation upon a process fluid that is a mixture of a liquid and a gas.

8. The HRM system of claim 1, wherein the cluster includes at least one HRM that is configured for efficient operation upon a process fluid that is a liquid mixed with solids.

9. The HRM system of claim 1, wherein the cluster includes a first pump having first operating characteristics and a second pump having second operating characteristics that are distinct from the first operating characteristics.

10. The HRM system of claim 1, wherein the cluster includes a first turbine having first operating characteristics and a second turbine having second operating characteristics that are distinct from the first operating characteristics.

11. The HRM system of claim 1, wherein the cluster includes a first hybrid pump/turbine having first operating characteristics and a second hybrid pump/turbine having second operating characteristics that are distinct from the first operating characteristics.

12. The HRM system of claim 1, wherein the information received by the controller includes information pertaining to an operating health of an HRM in the cluster, and wherein the instructions, when executed by the controller, further cause the controller to predict a time until failure of the HRM.

13. A method of efficiently controlling a process fluid of a process, said process fluid having widely varying conditions of service (COS), the method comprising: providing a controller; providing a plurality of HRMs having variable operating speeds, each of the HRMs being a pump, a turbine, or a hybrid pump/turbine; interconnecting the HRMs via an HRM plumbing system to form an HRM cluster, the HRM plumbing system comprising a plurality of valves; controlling of the valves by the controller so as to configure a flow path through which the process fluid can flow from an inlet of the HRM plumbing system to an outlet of the HRM plumbing system, said flow path comprising a selection of the HRMs of the cluster arranged in an HRM arrangement; causing the process fluid to flow through the flow path; receiving by the controller of information regarding at least one of a status of the process and the COS of the process fluid; and according to said information, controlling by the controller of the operating speeds of the HRMs and the selection and arrangement of the HRMs in the flow path so as to continuously satisfy at least one requirement of the process while ensuring that the HRMs in the flow path operate substantially at their optimal hydraulic efficiency points over said widely varying COS of the process fluid.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] FIG. 1 illustrates control of a process fluid by an HRM in an example of the prior art;

[0037] FIG. 2 illustrates an embodiment of the present invention in which an HRM cluster stores and then retrieves energy in support of a green energy system;

[0038] FIG. 3A illustrates an HRM cluster comprising two HRMs, where the HRMs are connected in parallel by the HRM plumbing system according to an embodiment of the present invention;

[0039] FIG. 3B illustrates an HRM cluster comprising two HRMs, where the HRMs are connected in series by the HRM plumbing system;

[0040] FIG. 4A is a block diagram of an HRM cluster comprising four HRMs, where the HRMs are connected in parallel by the HRM plumbing system according to an embodiment of the present invention;

[0041] FIG. 4B is a simplified block diagram of the cluster of FIG. 4A, showing the flow path through the cluster;

[0042] FIG. 4C is a block diagram of an HRM cluster comprising four HRMs, where the HRMs are connected in a series-parallel arrangement by the HRM plumbing system according to an embodiment of the present invention;

[0043] FIG. 4D is a simplified block diagram of the cluster of FIG. 4C, showing the flow path through the cluster;

[0044] FIG. 4E is a block diagram of an HRM cluster comprising four HRMs, where the HRMs are connected in series by the HRM plumbing system according to an embodiment of the present invention;

[0045] FIG. 4F is a simplified block diagram of the cluster of FIG. 4E, showing the flow path through the cluster; and

[0046] FIG. 5 is a block diagram that illustrates an exchange of information between a controller and an HRM cluster, a process, and a green energy system;

DETAILED DESCRIPTION

[0047] The present invention is a hydraulic rotating machinery (HRM) system that can provide high energy efficiency over a very wide condition of service (COS) range. In energy storage embodiments, the invention provides maximal round-trip efficiency (RTE) for energy storage and recovery.

[0048] With reference to FIGS. 2 and 3A, the invention comprises a plurality, or cluster 212, of variable speed HRMs 102, 202 having operating speeds that are independently controlled 206 by an HRM controller 200. The HRMs 102, 202 in the cluster 212 are interconnected with each other by an HRM plumbing system 204 that includes an inlet 300, an outlet 302, and one or more valves 104 that can be actuated by the HRM controller 200 to configure a flow path 306 through which a process fluid flows from the inlet 300 to the outlet 302 via one or more of the HRMs 102, 202 in the cluster 212. By actively selecting which of the HRMs 102, 202 are included in the flow path 306, the interconnections therebetween, and the operating speeds thereof, the HRM controller 200 is able to ensure that the HRM cluster 212 continues to operate at optimal efficiency as the COS fluctuates over a very wide range.

[0049] FIGS. 3A-3B illustrate a very simple example of a hypothetical HRM cluster 212 comprising two identical, variable speed pumps 102a, 102b, where the HRM cluster 212 is used to store energy resulting from excess capacity of a green energy source by pumping water into a storage compressor, thereby compressing a gas that is contained within the storage container (not shown). In this hypothetical example, the operating speed of each of the pumps 102a, 102b can be varied so as to maintain optimal hydraulic efficiency when the volumetric flow rate through the pump 102a, 102b is between 30 and 50 cubic feet per minute (cfm), and the output pressure is between 0 and 40 psi higher than the input pressure. As the process begins, the HRM controller 200 has the option of either bypassing one of the pumps 102b and adjusting the speed of the other pump 102a to deliver gas to the storage container at 30-50 cfm. FIG. 3A illustrates the other possibility, which is to cause the valves 104 to interconnect the two pumps 102a, 102b in a parallel configuration to deliver the gas to the storage container at a flow rate of 60-100 cfm. The choice between these two options may depend, for example, on the amount of excess energy that is currently available from the green energy system.

[0050] With reference to FIG. 3B, once the pressure in the storage container reaches 40 psi, the HRM controller causes the valves 104 to reconfigure the pumps 102a, 102b, into a series configuration, and adjusts their operating speeds such that they are each pumping between 30 and 50 cfm over a pressure differential of psi per pump. As the pressure within the storage container continues to rise above 40 psi, the operating speeds of the two pumps 102a, 102b are varied so as to maintain optimum energy efficiency. In the series configuration of FIG. 3B, by controlling the operating speeds of the pumps, optimal efficiency of the HRM cluster 212 can be maintained up to a maximum of 40 psi per pump, i.e. 80 psi total.

[0051] This approach can be extended to clusters of more than two pumps so as to cover even wider COS ranges as needed. For example, with reference to FIGS. 4A-4B, a cluster 212 that includes four identical pumps 102a, 102b, 102c, 102d (collectively 102) as described above could be configured by an HRM controller 200 to be entirely in parallel for container pressures up to 40 psi, as illustrated by FIG. 4A. The flow path for this configuration is illustrated by FIG. 4B. As the pressure differential varies from 40 to 80 psi, the controller 200 can then cause the valves 104 in the HRM plumbing system to reconfigure the pumps 102 into a series/parallel arrangement, as illustrated in FIG. 4C. The flow path 204 for this configuration is illustrated in FIG. 4D. Once the pressure differential rises above psi, the controller 200 can configure the pumps 200 so that they are all in series, thereby enabling the cluster 212 to continue operating at optimum efficiency for pressure differentials from 80 to 160 psi. According to this simple example, by varying both the operating speeds of the pumps and the interconnections between the pumps, the controller 200 is able to ensure that each of the pumps continues to operate at or near its BEP over this entire range. In the same way, this approach can be extended to clusters that include any combination of pumps, turbines, and/or hybrid pump/turbine HRMs (hybrid HRMs).

[0052] In some embodiments, the cluster 212 includes only one type of HRM, for example one type of pump 102 for clusters that are used only for pumping fluids, only one type of turbine 202 for clusters that are used only for generating turboelectric energy, or only one type of hybrid HRM for clusters that are used both for pumping fluids and for generating turboelectric energy. In similar embodiments, the cluster 212 includes a limited range of HRM types, such as a plurality of identical pumps 102 and a plurality of identical turbines 202.

[0053] Limiting the number of different types of HRM that are included in a cluster 212 can simplify the support and maintenance of the cluster 212 and reduces costs, because only a relatively small inventory of spare HRMs is required to enable failed units in the cluster 212 to be quickly replaced. This modular approach also enables the cluster 212 to be readily expanded as need, simply by adding additional HRMs from inventory to the cluster 212, with appropriate extensions to the HRM plumbing system 204 and to the controller 200, thereby enabling the cluster 212 to be readily adapted to changing requirements of the process.

[0054] Other embodiments include clusters comprising a plurality of different types of pumps 102, turbines 202, and/or hybrid HRMs having different BEPs, as well as HRMs that can tolerate different gas fractions and/or solid/liquid ratios. This approach can reduce the number of HRMs that are required to enable the cluster 212 to maintain optimal energy efficiency over a wide range of COS. For example, if the process fluid is normally a liquid, but sometimes also includes gas and/or solids, then an HRM cluster 212 can include at least one pump 102 that is optimized for pumping a pure liquid and another pump 102 that is optimized for pumping a hybrid fluid that includes gas and/or solids mixed with a liquid.

[0055] With reference to FIG. 5, the HRM controller 200 adjusts the HRM operating speeds and interconnections based upon information received from one or more information sources. The information can include, for example, the energy status at any given time of a green energy source such as a solar panel or wind turbine 500, i.e. how much excess energy is available to be stored, or how much previously stored energy is currently needed. The information can also include sensed information regarding energy being consumed 214 by pumps 102 and/or generated 210 by turbines 202 in the cluster 212, as well as information regarding the status of the process 108, such as pressures, flow rates, mass flow rates, geodetic fluid levels, static and dynamic fluid levels, static and dynamic fluid energies, fluid temperatures, fluid densities, fluid phases (gas, liquified, supercritical, solidified), amounts of solids and/or suspensions present in the process fluid, gas fractions, and/or solid/liquid ratios, among others.

[0056] The HRM controller applies a process-dependent algorithm to this information so as to determine which of the HRMs in the cluster 212 should be included in the flow path, how they should be interconnected, and at what speed each of the HRMs should be operated, thereby ensuring that each of the HRMs in the flow path operates at or near its best efficiency point (BEP).

[0057] In embodiments, the HRM controller 200 also monitors 208 the health of the HRMs in the cluster 212, for example by monitoring bearing temperatures, noise levels, vibrations, wear rates, and component deflections. The HRM controller is thereby able to predict when an HRM is nearing failure and should be repaired or replaced. Similarly, in various embodiments the HRM controller 200 monitors 208 the health of the overall process 108 with which the HRM cluster 200 is associated, for example detecting leaks and other problems by monitoring pressures, temperatures, and/or flow rates at various points in the process.

[0058] The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. Each and every page of this submission, and all contents thereon, however characterized, identified, or numbered, is considered a substantive part of this application for all purposes, irrespective of form or placement within the application. This specification is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of this disclosure.

[0059] Although the present application is shown in a limited number of forms, the scope of the invention is not limited to just these forms, but is amenable to various changes and modifications. The disclosure presented herein does not explicitly disclose all possible combinations of features that fall within the scope of the invention. The features disclosed herein for the various embodiments can generally be interchanged and combined into any combinations that are not self-contradictory without departing from the scope of the invention. In particular, the limitations presented in dependent claims below can be combined with their corresponding independent claims in any number and in any order without departing from the scope of this disclosure, unless the dependent claims are logically incompatible with each other.