COMPACT, MODULAR, PUMP OR TURBINE WITH INTEGRAL MODULAR MOTOR OR GENERATOR AND COAXIAL FLUID FLOW

Abstract

A coaxial pump or turbine module includes an integral, modular motor or generator comprising a magnet structure containing radial or axial permanent magnets and/or induction coils detachably fixed to a rotor, and a stator housing detachably fixed to the module housing. Working fluid is directed axially through a flow path symmetrically distributed within an annulus formed between the module housing and the stator housing. The stator housing can be cooled by the working fluid, or by a cooling fluid flowing between passages of the flow path. The flow path can extend over substantially a full length and rear surface of the stator housing. A plurality of the modules can be combined into a multi-stage apparatus, with rotor speeds independently controlled by corresponding variable frequency drives. Embodiments include guide vanes and/or diffusers. The rotor can be fixed to a rotating shaft, or rotate about a fixed shaft.

Claims

1. A sealless pump or turbine module having an integral motor or generator, the module comprising: an inlet located at a proximal end of the module, the inlet being on a central axis of the module; an outlet located at a distal end of the module, the outlet being on the central axis of the module; a module housing surrounding the module; a rotor suspended within the module housing; a motor within the module housing configured to drive a rotation of the rotor, or a generator within the module housing configured to be driven by rotation of the rotor, the motor or generator comprising: a stator within a sealed stator housing, the stator comprising at least one electromagnet directed toward the rotor, said stator housing being removably axially, radially, and rotationally fixable to the module housing; an electrical port formed in the stator housing and configured to form a seal with the module housing when the stator housing is fixed to the module housing, the electrical port providing a sealed passage through which electrical conductors can be directed for interconnection between the at least one electromagnet and apparatus that is external to the module housing; a plurality of magnetic devices assembled in a magnet structure that is removably constrained to be axially fixed and rotationally cooperative with the rotor, the magnetic devices being configured by the magnet structure to pass in proximity to the at least one electromagnet as the rotor rotates; and a flow path symmetrically distributed about the stator housing; the module being configured to direct a flow of working fluid from the inlet through the flow path to the outlet such that the working fluid is symmetrically distributed about the stator housing as it flows past the stator within the flow path.

2. The module of claim 1, wherein the flow path is an annular flow path surrounding the stator housing.

3. The module of claim 1, wherein the flow path comprises a plurality of flow passages arranged symmetrically about the stator housing.

4. The module of claim 1, wherein the rotor is suspended by a rotatable shaft, and the rotor is fixed to the shaft.

5. The module of claim 1, wherein the rotor is suspended by a fixed shaft, and the rotor is configured to rotate about the shaft.

6. The module of claim 5, wherein the rotor is supported on the fixed shaft by a pair of bearings, one of which maintains an axial position of the rotor while the other of which provides radial support of the rotor.

7. The module of claim 5, wherein the rotor is supported axially and radially on the fixed shaft by a single, one-way thrust bearing.

8. The module of claim 5, wherein the rotor is supported on the fixed shaft by at least one bearing that is lubricated by the process fluid.

9. The module of claim 5, wherein the fixed shaft is fixed to at least one of the stator housing and the module housing by threaded attachment.

10. The module of claim 1, wherein the magnetic devices are permanent magnets.

11. The module of claim 1, wherein the magnetic devices are squirrel cage coils.

12. The module of claim 1, wherein the flow path extends over at least 50% of a surface of the stator housing, and at least 90% of the working fluid that flows through the module from the inlet to the outlet is caused to flow through in direct thermal contact with the stator housing.

13. The module of claim 1, wherein the module is configured to require all of the working fluid flowing from the inlet to the outlet to flow through the flow path.

14. The module of claim 1, further comprising: thermal insulation interposed between the flow path and the stator housing; and a cooling fluid path formed between the thermal insulation and the stator housing, the cooling fluid path being in thermal communication with the stator housing and configured to enable an exchange of heat between the stator housing and a cooling fluid flowing through the cooling fluid path.

15. The module of claim 1, wherein the stator is configured to rotate independently of the rotor and in a direction that is opposite to a rotation of direction of the rotor.

16. The module of claim 1, further comprising a diffuser that is cooperative with the rotor but is driven by a separate diffuser motor and is thereby able to rotate independently of the rotor.

17. The module of claim 1, wherein the electromagnet of the stator is directed toward a radial periphery of the rotor, and the magnetic devices are fixed near the radial periphery of the rotor.

18. The module of claim 1, wherein the electromagnet of the stator is directed toward a side of the rotor, and the magnetic devices are fixed to the side of the rotor or to a disk that is coaxial with and proximal to the side of the rotor.

19. The module of claim 1, wherein the magnet structure is sealed, thereby excluding the working fluid from reaching the magnetic devices.

20. A multi-stage apparatus comprising a plurality of interconnected modules, each of said modules comprising: an inlet located at a proximal end of the module, the inlet being on a central axis of the module; an outlet located at a distal end of the module, the outlet being on the central axis of the module; a module housing surrounding the module; a rotor suspended within the module housing; a motor within the module housing configured to drive a rotation of the rotor, or a generator within the module housing configured to be driven by rotation of the rotor, the motor or generator comprising: a stator within a sealed stator housing, the stator comprising at least one electromagnet directed toward the rotor, said stator housing being removably fixable axially, radially, and rotationally to the module housing; an electrical port formed in the stator housing and configured to form a seal with the module housing when the stator housing is fixed to the module housing, the electrical port providing a sealed passage through which electrical conductors can be directed for interconnection between the at least one electromagnet and apparatus that is external to the module housing; a plurality of magnetic devices assembled in a magnet structure that is removably constrained to be axially fixed and rotationally cooperative with the rotor, the magnetic devices being configured by the magnet structure to pass in proximity to the at least one electromagnet as the rotor rotates; and a flow path symmetrically distributed about the stator housing; the module being configured to direct a flow of working fluid from the inlet through the flow path to the outlet such that the working fluid is symmetrically distributed about the stator housing as it flows past the stator within the flow path.

21. The apparatus of claim 20, wherein at least two of the motors or generators of the modules can be independently controlled so as to cause the corresponding rotors to rotate at different rates.

22. The apparatus of claim 21, wherein the two, independently controlled motors or generators are controlled by separate variable frequency drives.

23. The apparatus of claim 20, wherein the modules are configured such that the apparatus as a whole is able to continue functioning as a pump or as a turbine despite failure of at least one of the modules included in the apparatus.

24. The apparatus of claim 20, further comprising control electronics that provide shared support to at least two of the modules.

25. The apparatus of claim 20, wherein the plurality of interconnected modules includes at least three interconnected modules.

26. The apparatus of claim 20, wherein the magnet structure in each of the modules is sealed, thereby excluding the working fluid from reaching the magnetic devices.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0068] FIG. 1 is a cross-sectional illustration drawn to scale of a prior art two-stage integral motor pump cooled by a dedicated cooling flow;

[0069] FIG. 2A is a cross-sectional, simplified illustration of a single-stage module of the present invention having a radial motor design;

[0070] FIG. 2B is a cross-sectional illustration from the side drawn to scale of a two-stage embodiment of the present invention having an axial motor design;

[0071] FIG. 2C is an exploded sectional view from the side drawn to scale of one of the rotor assemblies in an embodiment similar to FIG. 2B;

[0072] FIG. 2D is an exploded perspective view drawn to scale of the rotor assembly of FIG. 2C drawn to scale;

[0073] FIG. 2E is an exploded perspective sectional view drawn to scale of the rotor assembly of FIG. 2C.

[0074] FIG. 2F is a front perspective view drawn to scale of one of the stator assemblies of an embodiment similar to the embodiment of FIG. 2B;

[0075] FIG. 2G is a side perspective view drawn to scale of the stator assembly of FIG. 2F;

[0076] FIG. 2H is a simplified cross-sectional view of an embodiment that includes an annular flow path through the annular space;

[0077] FIG. 2I is a cross-sectional view similar to FIG. 2H, but including an additional concentric layer of thermal insulation and a concentric cooling annular passage;

[0078] FIG. 2J is a simplified cross-sectional view of an embodiment that includes a plurality of flow paths that are equally distributed about the coil housing of the motor or generator and insulated therefrom;

[0079] FIG. 3 is a cross-sectional view drawn to scale of an embodiment similar to FIG. 2, but including a separate cooling flow path (cooling path not drawn to scale);

[0080] FIG. 4 is a cross-sectional view drawn to scale of an embodiment similar to FIG. 2, but including guide vanes in the process flow path;

[0081] FIG. 5 is a perspective view drawn to scale of the outer housing of the pump of FIGS. 2C through 2G;

[0082] FIG. 6A is a cross-sectional view from the side drawn to scale of a two-stage embodiment of the present invention having a modular motor design;

[0083] FIG. 6B is a cross-sectional view from the side drawn to scale of one of the rotor and magnet structure assemblies of the embodiment of FIG. 6A;

[0084] FIG. 6C is an exploded cross-sectional view from the side drawn to scale of the rotor and magnet structure of FIG. 6B;

[0085] FIG. 6D is an exploded perspective view drawn to scale from the side and front of the rotor and magnet structure of FIG. 6C;

[0086] FIG. 6E is an exploded perspective view drawn to scale from the side and rear of the rotor and magnet structure of FIG. 6D;

[0087] FIG. 6F is an exploded perspective view drawn to scale from the side and front of one of the stator assemblies of FIG. 6A shown with the rear plate removed;

[0088] FIG. 6G is an exploded perspective view drawn to scale from the side and front of the stator assembly FIG. 6F shown with the rear plate welded in place;

[0089] FIG. 6H is an exploded perspective view drawn to scale from the side and rear of the stator assembly with welded rear plate of FIG. 6G;

[0090] FIG. 6I is a perspective view drawn to scale of the outer housing of the pump of FIGS. 6A through 6H;

[0091] FIG. 7A is a perspective view drawn to scale of a four-module pump of a design that differs from the pump of FIGS. 6A through 6H, but incorporates the same modular stator and magnet structure designs that are included in the pump modules of FIGS. 6A through 6H;

[0092] FIG. 7B is a cross sectional view drawn to scale from the side drawn to scale of a single module of the pump of FIG. 7A; and

[0093] FIG. 7C is an exploded cross sectional view drawn to scale from the side drawn to scale of the module of FIG. 7B.

DETAILED DESCRIPTION

[0094] The present invention is a sealless motor pump or sealless generator turbine that is configured as a module having a concentric flow design. As an example, a pump embodiment 200 of the present invention is illustrated in FIG. 2A. It can be seen in the figure that the housing 204 of the motor coils 212, i.e. the stator housing 204, is surrounded by the housing 218 of the module, forming an annular space 202 therebetween. According to the present invention, the working fluid is distributed about the annular space 202, either among a plurality of flow passages or through a single annular flow passage. The distribution of the working fluid in the annular space 202 can be symmetric about the stator housing 204. In the embodiment of FIG. 2A, the annular space 202 serves as an annular flow passage 202 through which the working fluid flows from the inlet 222 to the outlet 224.

[0095] In the embodiment of FIG. 2A, the annular flow passage 202 is in direct thermal contact with the housing 204 of the motor coils 212. This configuration is suitable for applications where the working fluid is relatively cool. In the illustrated embodiment, the working fluid is directed by the rotor 206 to pass through the annular flow passage 202 over and around the motor coil housing 204 of the module, so that the motor coils 212 are directly cooled by the discharge of the rotor 206, and do not require a separate, dedicated cooling fluid.

[0096] In embodiments, the concentric design of the present invention is implemented as a self-contained, highly compact module that can be used alone, as shown in FIG. 2A, or combined with a plurality of identical modules to form a multi-stage pump or turbine, as shown in FIG. 2B. This modular approach enables extension of the design to an arbitrary number of stages without adding additional complexity or complications to the design, operation, and maintenance of the apparatus. In particular, high stage counts do not raise any issues regarding shaft size, shaft deflection, roto-dynamics, bearing loads, motor alignment, or alignment between stages.

[0097] More specifically, FIG. 2B illustrates a two-stage pump embodiment 220 wherein a central axis of the motor 212 in each stage 200 is substantially collinear with the stationary shaft 208 about which the rotor 206 is rotated, such that the process fluid from the rotor 206 flows axially over the stator housing 204 through the annular flow passage 202 formed between the stator housing 204 and the pump housing 218 in each stage 200. While only two stages 200 are shown in FIG. 2B for convenience of illustration, it will be understood that embodiments are extendable to an arbitrary number of pump stages 200.

[0098] In some multi-stage embodiments, the rotor 206 in each stage 200 is independently driven, such that the rotor speed of each stage 200 can be separately controlled. For example, a separate variable frequency drive (VFD) 216 can be dedicated to the control of each stage 200 of the pump.

[0099] In the embodiment of FIG. 2B, in each stage 200 of the pump 220 a plurality of permanent magnets 210 are directly attached to a rear side of the rotor 206, and are caused to pass close to electromagnetic coils 212 of an adjacent stator 212 as the rotor 206 is rotated. Rotors 206 in other embodiments include induction motors that utilize non-permanent magnets 210 such as squirrel cage rotor coils in which currents are induced by the stator electromagnets 212 during pump or turbine operation. Torque is thereby transmitted directly from the electromagnet motor coils 212 to the rotor 206, or electromagnetic energy is transferred from the rotor to the generator coils, without the use of a rotating shaft. In embodiments, the motor coils 212 are sealed from the working fluid using static sealing methods (not shown), which eliminates any need for dynamic mechanical seals, and avoids the problems of alignment, leakage, and/or maintenance that would otherwise arise therefrom.

[0100] Axial and radial locating of the rotor 206 in each stage is provided in the embodiment of FIG. 2B by product-lubricated bearings 214. By using individual bearings 214 for each rotor stage 200, the bearings 214 in each stage 200 can be designed to handle the loads from that stage only, and the risk of overloading bearings from combined stage loading in a multistage arrangement 220 is completely eliminated. Using the working fluid as a lubricant for the bearings 214 in embodiments eliminates the need for an external oil lubrication system and greatly simplifies the overall pump design and maintenance.

[0101] FIGS. 2C through 2E are, respectively, an exploded sectional view from the side, an exploded perspective view, and an exploded perspective sectional view of one of the rotor assemblies in an embodiment similar to FIG. 2B. In the illustrated embodiment, the magnets 210 are included in a magnet structure 252 that further comprises a magnet back iron 236 and a magnet structure cover plate 238. The assembled magnet structure 252 is installed in an annular cavity 240 provided in the rotor 206.

[0102] FIGS. 2F and 2G are front and side perspective views, respectively, of one of the stator assemblies of the embodiment of FIGS. 2B through 2E. The stator coil (not shown) is wound on a form 242 within a coil cavity 250 and covered by a stator cover plate 244. The electrical leads from the coil 212 are directed through an electrical port 246 that extends from the interior of the coil cavity 250 through a stator rear flange that is sealed to the pump or turbine housing 200. In embodiments the stator coil 212 is potted within the coil cavity 250.

[0103] In some embodiments, such as FIG. 2A, the rotor 206 in each stage is fixed to a rotating shaft 208. In other embodiments, such as FIG. 2B, the shaft 208 in each stage is inserted through the hub of the rotor 206 and fixed to the motor or generator coil housing 204, and the rotor 206 rotates about the shaft 208, e.g. on bearings 214. This approach facilitates easy assembly and maintenance without special tools. In similar embodiments, the shaft 208 is threaded or otherwise supported by the pump or turbine module housing 218, or by any combination of the pump or pump module housing 218 and the motor or generator stator housing 204.

[0104] Certain embodiments include modules 200 having an inverted rotor/stator configuration, whereby the rotor 206 and the stator 212 can both rotate independently from each other in opposite directions. Some embodiments include a plurality of rotors 206 fixed to a common fixed or rotating shaft 208, combined with stators and/or diffusers that rotate individually. In some of these embodiments, the diffusers are implemented in a manner similar to the disclosure of patent application U.S. Ser. No. 15/101,460, which is included herein by reference in its entirety for all purposes.

[0105] In still other embodiments, there is no shaft 208, and instead a wear ring clearance on the front of each rotor 206 acts as the primary radial and axial bearing. Torque is thereby transmitted directly from or to the electromagnet stator coils 212 of the motor to the rotor, or electromagnetic energy is transferred from the rotor 206 to the coils 212 of the generator, without the use of a rotating shaft.

[0106] Fig, 2H is a simplified cross-sectional illustration of an embodiment having an annular flow passage, similar to FIG. 2A, where the cross section is taken through the pump motor coils 212 perpendicular to the primary axis of the motor.

[0107] The embodiments of FIGS. 2A through 2H are suitable for use with relatively cool working fluids, whereby the annular flow passage 202 brings the working fluid into direct thermal contact with the motor or generator coil housing 212, thereby cooling the motor or generator coils. In FIGS. 2A through 2H, more than 80% of the working fluid is brought into thermal contact with the motor or generator coil housing 212, and at least 20% of the motor or generator coil housing 212 is in thermal contact with the annular flow path 202. In various embodiments, more than 90% of the working fluid is brought into thermal contact with the motor or generator coil housing 204, and at least 50% of the motor or generator coil housing surface 204 is in thermal contact with the annular flow path 202.

[0108] With reference to FIG. 2I, in some embodiments where a high temperature working fluid is anticipated, the design of FIG. 2H is modified by including an additional concentric layer of thermal insulation 228 between the annular flow passage(s) 202 and the housing 204 of the motor or generator coils 212. In some of these embodiments, a concentric cooling annular passage 234 is further created between the insulation 228 and the coil housing 204, through which a cooling fluid, such as water or a cooling oil, can be circulated from an inlet 230 to an outlet 232.

[0109] With reference to FIG. 2J, in other embodiments the working fluid is distributed among a plurality of substantially identical flow passages 226 arranged symmetrically within the annular space 202 about the circumference of the stator housing 204. In the embodiment of FIG. 2J, the flow passages 226 are formed by the module housing walls 218. The embodiment of FIG. 2J further includes a concentric annular layer of insulation 228 and concentric cooling annular passage 234, similar to FIG. 2I.

[0110] With reference to FIG. 3, in embodiments a small amount of the working fluid is diverted through a separate cooling path 300, where it is cooled and then circulated through the concentric annular cooling passage 234 in thermal contact with the stator housing 204 to cool the motor coils 212. In similar embodiments, a separate cooling fluid, such as water or a cooling oil, is circulated through the cooling path 300 without diverting any of the working fluid.

[0111] Fluid cooling of the motor or generator coils 212 in various embodiments allows the system to operate with high temperature working fluids, and also enables the system to provide higher performance limits and greater power density in the overall pump or turbine even if the working fluid is not elevated in temperature.

[0112] With reference to FIG. 4, embodiments include guide vanes 400, either in the annular flow space 202 if the flow passage is annular, or elsewhere in the flow path. In the illustrated embodiment, the guide vanes 400 control the flow of the process fluid in a section of the concentric flow path at the end of the motor or generator coils 212, where the flow path turns radially inward toward the central axis of the module. The guide vanes 400 break the flow path into a plurality of separate but symmetric paths until the flow reaches the central axis and flows axially out through the outlet 224 and into the next stage 200. In embodiments, the guide vanes 400 direct the process fluid within the flow path into close proximity with the motor or generator stator housing 204.

[0113] The guide vanes 400 can also provide a casing wall that can be used to route power cables from the sealed motor or generator 212, through the fluid passages 202, and out of the pump casing 218 to the variable frequency control 216. In embodiments, the guide vanes 400 also act as fins to provide additional convective surface area to cool the motor or generator coils 212, and/or to provide space for integral cooling passages 300 connected to an external cooling fluid source.

[0114] FIG. 5 is a perspective view of the exterior of the pump of FIGS. 2C-2G.

[0115] With reference to FIG. 6A, in various embodiments 610 the motor or generator is modular in design, whereby a given motor or generator design can be incorporated into a plurality of different pump or turbine designs. In the example of FIG. 6, the plurality of magnetic devices 210 that are cooperative with the rotor of the motor are incorporated in a detachable magnet structure 600 that can be fixed to and removed from the rotor 206 of the pump 200. Attachment of the magnet structure 600 to the rotor can be by any means known in the art that is able to constrain the magnet structure 600 both axially and rotationally in relation to the rotor. Some embodiments include threaded attachment of the magnet structure to the rotor that constrains the magnet structure both axially and rotationally. In the embodiment of FIG. 6, the magnet structure 600 is attached to the rotor 206 by bolts 602 that constrain the magnet structure 600 to the rotor 206 both axially and rotationally.

[0116] The embodiment of FIG. 6A further includes an electrical port 608 (see FIG. 6H) that provides a sealed conduit extending from the void 250 within the stator housing 204 that contains the stator coil 212 through the rear flange 248 of the stator housing 204, thereby providing a path for electrical leads 606 and/or control lines to extend between the stator coil 212 and the environment external to the pump 200. It can be seen in the figure that the stator housing 204 includes a flange 248 bolted and sealed to a rear end thereof. The flange 248 includes a female socket 604 into which the electrical port 608 is inserted, and with which the electrical port 608 forms an 0-ring seal.

[0117] In embodiments, the magnet structure 600 and/or the stator portion 204 of the motor or turbine that contains the stator coils is/are modular and fully sealed, thereby requiring only mechanical attachment to the housing 200 of the pump or turbine in proximity to each other. In various embodiments, sealed modular magnet structures 600 and/or sealed modular stator assemblies 204 of the present invention can be implemented in different combinations, rendering it unnecessary to configure new instantiations of the magnet structure 600 and/or stator assembly 204 each time a new pump or turbine module is designed.

[0118] FIG. 6B is an enlarged cross sectional view of one of the rotors 206 and magnet structures 600 of FIG. 6A shown as assembled. FIG. 6C is a cross sectional exploded view of the rotor 206 and magnet structure 600 of FIG. 6B. FIGS. 6D and 6E are front and rear exploded perspective views of the rotor 206 and magnet structure 600 of FIG. 6B. FIG. 6F is an enlarged exploded perspective view from the front of one of the stator assemblies of FIG. 6A, shown in relationship to the rear flange 248 of the pump housing. It can be seen that the guide vanes 400 that are located in the exit flow path of the process fluid are fixed to the rear flange 248, wherein the rear plate 244 of the module has been removed to reveal the interior. FIG. 6G is identical to FIG. 6F, except that the rear plate 244 has been welded in place, thereby completing the sealed stator module. FIG. 6H is an enlarged exploded perspective view from the rear of the stator assembly of FIG. 6G. The electrical port 608 that serves as a conduit for the stator coil leads 606 is clearly visible in the figure. FIG. 6I is a perspective view of the fully assembled pump 610 of FIG. 6A.

[0119] FIG. 7A is a perspective view of a four-module pump design 700 that is considerably different from the pump of FIGS. 6A through 6H. FIG. 7B is a cross sectional illustration of a single module 708 of the pump of FIG. 7A, and FIG. 7C is an exploded cross sectional view of the module 708 of FIG. 7B. It can be seen in the figures that a diffuser 702 is included in the illustrated design, and that the rear flange 248, pump rotor 206, stator housing 204 and pump housing 218 are all quite different from the designs shown in FIGS. 6A through 6H. Nevertheless, the pump 700 of FIGS. 7A through 7C incorporates essentially the same modular motor components as are included in FIGS. 6A through 6H. The only small difference is that, in the illustrated embodiment, a snap ring 704 is used to constrain the magnet structure 600 axially, and pins 706 are used to constrain the magnet structure 600 rotationally. However, it is obvious that bolts could be used to constrain the magnet structure, as in FIGS. 6A through 6H, with only a trivial modification to the design.

[0120] In FIGS. 2B, 4, 6A and 6H, only two pump modules 200 are shown, while the pump 700 of FIG. 7 includes five modules. In general, it can be easily seen that in embodiments any number of the disclosed pump or turbine stages 200 can be combined in series without adding additional complexity or complication to the design, operation, and maintenance of the pump or turbine 200. In particular, high stage counts according to the disclosed design do not raise any issues regarding shaft size, shaft deflection, rotor dynamics, bearing loads, motor alignment, or alignment between stages 200.

[0121] Certain embodiments include at least some drive electronics that are shared between more than one stage. For example, in some embodiments AC power is converted to DC power by a common set of large electronics, which is then distributed to the individual pump or turbine stages as needed. Other embodiments include a plurality of variable frequency drives (VFD's) 216, and in some of these embodiments the motor or generator coils 212 in each stage 200 of the pump or turbine are independently controlled by a dedicated VFD 216 or other controller. One of the key benefits in some of these embodiments is that the first stage can run at lower speeds than the rest of the pump, so as to accommodate low net positive suction head (NPSH) and off-peak conditions. In some applications, varying the speed of only the final stage provides a useful approach for precisely controlling the output pressure and/or flow.

[0122] Providing an individual VFD drive 216 for each stage 200 can also serve as a fail-safe redundancy, whereby if one stage fails, the rest will continue to operate and the pump will continue to function. The continued function after failure of a pump stage may be with reduced head and flow, or the speed of the remaining stages can be increased to compensate for the lost head and flow of the failed stage. This approach creates a failure scenario wherein the pump continues to operate, possibly at reduced head and flow, until an operator, after becoming aware of the stage failure, has time to safely shut down the system. In contrast, the failure of one stage in a traditional pump or turbine typically results in failure of the entire pump or turbine, with a complete loss of performance and a sudden, uncontrolled shutdown of the system.

[0123] In the embodiment of FIG. 2A, the motor is a radial motor that includes permanent magnets mounted about the periphery of the rotor, while the other embodiments that are illustrated in the figures include disk or pancake style rotors 206 that incorporate permanent magnets 210 that are positioned behind the rear surfaces of the rotors 206. Induction motors are used in other embodiments. Some embodiments include variable speed drives that enable the synchronous operating speeds of the pump stages 200 to rise above 3600 rpm.

[0124] In the embodiments that are illustrated in the drawings, the pump stages 200 are centrifugal designs having radial flow rotors 206. Some of these embodiments include rotors with specific speeds up to about 2,000 US units, and ins some embodiments up to 4000 US units and even 5000 US units. Other embodiments include pump stages 200 with radial flux rotor designs.

[0125] In the embodiments that are illustrated in the drawings, combined radial and one-way thrust bearings 214 are used in place of separate axial and radial bearings. The illustrated embodiments include stationary shafts 208 inserted through the hubs of the rotors 206 and threaded into the pump stage housing 218, which facilitate easy assembly and maintenance without special tools. Using a sensor-less motor along with appropriate VFD drives 216 also reduces any requirement for instrumentation on each stage 200 in the illustrated embodiments.

[0126] Certain embodiments of the present invention include modular stages 200 having an inverted rotor/stator configuration, whereby the rotor and the stator can both rotate independently from each other in opposite directions. And some embodiments include stators and/or diffusers that rotate individually, for example with separate motors driving the rotors and diffusers. In some of these embodiments, the diffusers are implemented in a manner similar to the disclosure of patent application U.S. Pat. No. 15/101,460.

[0127] As is well known in the art, roto-dynamic pumps and turbines are often highly similar in their physical designs, such that the difference between a pump and a turbine can sometimes be mainly a question of use rather than structure. Accordingly, while the embodiments that are illustrated in the drawings are pumps, the features of the present invention that are discussed herein with reference to a turbine or to a pump should be understood to refer equally to both, except where the context requires otherwise.

[0128] 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.

[0129] 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 without departing from the spirit thereof. 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.