Direct air displacement pump for liquids with smart controller

Abstract

A pumping system for liquids, comprising of a direct air displacement pump, which does not require a liquid level sensor mounted inside the pump body. It includes a smart controller which is able to drive and estimate the pump status (full or empty) with sensors mounted above ground.

Claims

1. A direct air displacement pumping system for liquids comprising of a direct air displacement pump, a smart controller, a line restriction connected at the compressed air line and a line restriction with a pressure sensor or a pressure switch connected at the discharge line.

2. A direct air displacement pumping system for liquids comprising of a direct air displacement pump, a smart controller, a line restriction with a pressure sensor or a pressure switch connected at the compressed air line and a line restriction with a pressure sensor or a pressure switch connected at the discharge line.

3. A direct air displacement pumping system for liquids comprising of a direct air displacement pump, a smart controller, a line restriction with a pressure sensor or a pressure switch connected at the bubbler line and a line restriction with a pressure sensor or a pressure switch connected at the discharge line.

4. A direct air displacement pump as claimed in claim 1, claim 2 and claim 3, comprising of a cylindrical pump body, having a top port and a bottom port; a floating ball mounted inside the pump body which acts as a bottom port check valve when the pump is empty and as a top port check valve when the pump is full of liquid; a check valve which acts as a liquid intake only from the liquid container towards the pump body and, finally, another check valve which acts as a liquid discharge only from the pump body towards the discharge line.

5. A smart controller as claimed in claim 1, comprising of a computer, or a PLC (programmable logic controller), or a smart relay, or an electric circuit, or an electronic circuit, or a mechanical actuating system, or a combination thereof, connected with a pressure sensor or pressure switch mounted at the discharge line of the pumping system, also connected with an air actuated or solenoid actuated or mechanically actuated air valve which controls the pump body state (pressure or exhaust).

6. A smart controller as claimed in claim 2 and claim 3, comprising of a computer, or a PLC (programmable logic controller), or a smart relay, or an electric circuit, or an electronic circuit, or a mechanical actuating system, or a combination thereof, connected with a pressure sensor or pressure switch mounted at the airline of the pumping system, also connected with a pressure sensor or pressure switch mounted at the discharge line of the pumping system, also connected with an air actuated or solenoid actuated or mechanically actuated air valve which controls the pump body state (pressure or exhaust).

5. A direct air displacement pump as claimed in claim 4, comprising of aluminium, or copper, or brass, or stainless steel, or plastic, or polyethylene, or polypropylene, or urethane, or glass, or plexiglass, or a combination thereof.

6. A direct air displacement pump as claimed in claim 4, suitable for liquids.

7. A set of multiple direct air displacement pumps as claimed in claim 1, claim 2 and claim 3, combined with a smart controller as claimed in claim 5.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is a diagrammatic representation of the direct air displacement pump for liquids with smart controller according to the first aspect.

[0017] FIG. 2 is a diagrammatic representation of the direct air displacement pump for liquids with smart controller according to the second aspect.

[0018] FIG. 3 is a diagrammatic representation of the direct air displacement pump for liquids with smart controller according to the third aspect.

[0019] FIG. 4 is a graph representation of the pressure change related to the time.

[0020] FIG. 5 is a graph representation of the pressure change related to the time.

DESCRIPTION OF THE EMBODIMENTS

[0021] In FIG. 1, FIG. 2 and FIG. 3 one can identify the following: [0022] 01: Air compressor [0023] 02: Air filter [0024] 03: Pressure regulator [0025] 04: Line restriction [0026] 05: Pressure sensor [0027] 06: Air valve [0028] 07: Exhaust [0029] 08: Liquid intake [0030] 09: Liquid intake check valve [0031] 10: Discharge line check valve [0032] 11: Pump body [0033] 12: Liquid to be pumped [0034] 13: Pressure sensor [0035] 14: Line restriction [0036] 15: Liquid discharge

DETAILED DESCRIPTION OF THE DRAWINGS

[0037] According to a first aspect, as shown in FIG. 1, an air compressor (01) provides compressed air to the network (dashed line). The compressed air passes through a filter element (02) and a pressure regulator (03). The regulated air pressure has to be higher than the discharge line head measured from the bottom end of the pump.

[0038] The compressed air passes through a line restriction or orifice (04) and then continues to a larger sized tube. The compressed air is connected to port No1 of a 3-way, 2-position air valve (06). Port No2 of the air valve (06) is connected at the top port of the pump body (11).

[0039] The pump body (11) is submersed in liquid (12) and has two ports, the top port and the bottom port. Inside the pump body there is a floating ball which acts as a check valve at the top port when the pump is full of liquid and as a check valve at the bottom port when the pump is empty. The bottom port of the pump serves as both liquid intake and discharge.

[0040] When the pump is in exhaust mode (the top port is in atmospheric pressure) the pump body is filled with liquid through the check valve (09); check valve (10) is closed as a result of the head pressure at the discharge line.

[0041] When the pump is in pressure mode (the top port is being fed with compressed air) the pump body discharges liquid through the check valve (10); check valve (09) is closed as a result of high pressure at the discharge line.

[0042] The liquid in the discharge line (continuous line) is fed to the customer network (or free flow) through a line restriction or orifice (14). The discharge line pressure just before the restriction (14) is being monitored continuously by the pressure sensor (13).

[0043] According to a second aspect, as shown in FIG. 2, an air compressor (01) provides compressed air to the network (dashed line). The compressed air passes through a filter element (02) and a pressure regulator (03). The regulated air pressure has to be higher than the discharge line head measured from the bottom end of the pump.

[0044] The compressed air passes through a line restriction or orifice (04) and then continues to a larger sized tube. The pressure sensor (05) continuously measures the airline pressure at that point. The compressed air is connected to port No1 of a 3-way, 2-position air valve (06). Port No2 of the air valve (06) is connected at the top port of the pump body (11).

[0045] The pump body (11) is submersed in liquid (12) and has two ports, the top port and the bottom port. Inside the pump body there is a floating ball which acts as a check valve at the top port when the pump is full of liquid and as a check valve at the bottom port when the pump is empty. The bottom port of the pump serves as both liquid intake and discharge.

[0046] When the pump is in exhaust mode (the top port is in atmospheric pressure) the pump body is filled with liquid through the check valve (09); check valve (10) is closed as a result of the head pressure at the discharge line.

[0047] When the pump is in pressure mode (the top port is being fed with compressed air) the pump body discharges liquid through the check valve (10); check valve (09) is closed as a result of high pressure at the discharge line.

[0048] The liquid in the discharge line (continuous line) is fed to the customer network (or free flow) through a line restriction or orifice (14). The discharge line pressure just before the restriction (14) is being monitored continuously by the pressure sensor (13).

[0049] According to a third aspect, as shown in FIG. 3, an air compressor (01) provides compressed air to the network (dashed line). The compressed air passes through a filter element (02) and a pressure regulator (03). The regulated air pressure has to be higher than the discharge line head measured from the bottom end of the pump.

[0050] One branch of the compressed air line (dotted line) passes through a line restriction or orifice (04). The pressure sensor (05) continuously measures the airline pressure at that point. This compressed air line is connected to the bottom port of the pump body (11).

[0051] The second branch of the compressed air line (dashed line) is connected to the port No1 of a 3-way, 2-position air valve (06). The port No2 of the air valve (06) is connected to the top port of the pump body (11).

[0052] The pump body (11) is submersed in liquid (12) and has two ports, the top port and the bottom port. Inside the pump body there is a floating ball which acts as a check valve at the top port when the pump is full of liquid and as a check valve at the bottom port when the pump is empty. The bottom port of the pump serves as both liquid intake and discharge.

[0053] When the pump is in exhaust mode (the top port is in atmospheric pressure) the pump body is filled with liquid through the check valve (09); check valve (10) is closed as a result of the head pressure at the discharge line.

[0054] When the pump is in pressure mode (the top port is being fed with compressed air) the pump body discharges liquid through the check valve (10); check valve (09) is closed as a result of high pressure at the discharge line.

[0055] The liquid in the discharge line (continuous line) is fed to the customer network (or free flow) through a line restriction or orifice (14). The discharge line pressure just before the restriction (14) is being monitored continuously by the pressure sensor (13).

DETAILED DESCRIPTION OF THE INVENTION

[0056] According to the first aspect, (FIG. 1), assuming that the pump body is submersed in the liquid, the smart controller is turned off and the air valve is in exhaust mode. As a result, the pump body (11) is full of liquid (12) which has entered through intake (08) and check valve (09).

[0057] We turn on the smart controller. The smart controller gets a reading of the pressure sensor (13) and then sends a command to the air valve (06). The air valve (06) state goes to pressure mode and a slug of air rushes downhole (dashed line). As a result of the restriction (04), it takes some time to the indication of the pressure sensor (13) to increase, as indicated in FIG. 5. The amount of time required to increase the pressure sensor (13) indication at a certain value is indicative of the percentage of liquid that was in the pump vessel before starting the pump discharging process. This amount of time is compared to the average of the preceding attempts. If it is less, this means that the pump vessel happened to have more liquid in it. If it is greater, this means that the pump vessel happened to have less liquid in it. The next pump filling time is extended or reduced accordingly. The conditions that may impact on the pump's filling time are:

[0058] change to the liquid level (12), blockage to the foot valve (09), bacteria build up in the pump inner body (11), change in the liquid viscosity, etc. As the pump starts discharging liquid, the pressure sensor (13) indication rises as a result of the restriction (14), even with a free flow. As the pump vessel empties, the floating ball drops down until it reaches the bottom end and plugs the pump bottom port. At this time, we notice a drop at the pressure sensor (13) indication (pump is empty). The controller sends a command to the air valve (06) and changes its state to exhaust mode (pump is filling). The controller waits for x amount of seconds (as calculated above) to fill the pump and then the same process is repeated.

[0059] The first inventive step is the way the smart controller of the first aspect (FIG. 1) can estimate when the pump is full, as there is no sensor mounted inside the pump body. After the air valve state changes from exhaust mode to pressure mode, it takes a certain amount of time for both the airline going downhole (dashed line) and the pump body (11) to fill with compressed air. This amount of time is short if the pump body is full of liquid and long if the pump body is empty. The smart controller timer starts counting straight after the air valve (06) state changes from exhaust to pressure mode. But the endpoint of this timer is not clearly identified. The line restriction (14) is there to help define this timer endpoint. As a slug of compressed air starts flowing from the air valve through the airline towards the pump body, it takes some time to the pressure sensor (13) indication to increase. With the passage of time, the pump body inner pressure gradually increases and the indication of the pressure sensor (13) increases, as shown in FIG. 5. The timer endpoint can be defined as the point where the pressure sensor (13) indication raises to a certain value.

[0060] According to the second aspect, (FIG. 2), assuming that the pump body is submersed in the liquid, the smart controller is turned off and the air valve is in exhaust mode. As a result, the pump body (11) is full of liquid (12) which has entered through intake (08) and check valve (09).

[0061] We turn on the smart controller. The smart controller gets a reading of the pressure sensor (05) and then sends a command to the air valve (06). The air valve (06) state goes to pressure mode and a slug of air rushes downhole (dashed line). As a result of the restriction (04), the indication of the pressure sensor (05) drops and then increases, as indicated in FIG. 4. The amount of time required to drop the pressure and then increase at a certain value is indicative of the percentage of liquid that was in the pump vessel before starting the pump discharging process. This amount of time is compared to the average of the preceding attempts. If it is less, this means that the pump vessel happened to have more liquid in it. If it is greater, this means that the pump vessel happened to have less liquid in it. The next pump filling time is extended or reduced accordingly. The conditions that may impact on the pump's filling time are: change to the liquid level (12), blockage to the foot valve (09), bacteria build up in the pump inner body (11), change in the liquid viscosity, etc. As the pump starts discharging liquid, the pressure sensor (13) indication rises as a result of the restriction (14), even with a free flow. As the pump vessel empties, the floating ball drops down until it reaches the bottom end and plugs the pump bottom port. At this time, we notice a drop at the pressure sensor (13) indication (pump is empty). The controller sends a command to the air valve (06) and changes its state to exhaust mode (pump is filling). The controller waits for x amount of seconds (as calculated above) to fill the pump and then the same process is repeated.

[0062] The second inventive step is the way the smart controller of the second aspect (FIG. 2) can estimate when the pump is full, as there is no sensor mounted inside the pump body. After the air valve state changes from exhaust mode to pressure mode, it takes a certain amount of time for both the airline going downhole (dashed line) and the pump body (11) to fill with compressed air. This amount of time is short if the pump body is full of liquid and long if the pump body is empty. The smart controller timer starts counting straight after the air valve (06) state changes from exhaust to pressure mode. But the endpoint of this timer is not clearly identified. The line restriction (04) is there to help define this timer endpoint. As a slug of compressed air starts flowing from the air valve through the airline towards the pump body, the indication of the pressure sensor (05) drops as the air line filling rate is small due to the line line restriction (04) and the compressed air temporarily expands. With the passage of time, the pump body inner pressure gradually increases and the indication of the pressure sensor (05) increases, as shown in FIG. 4. The timer endpoint can be defined as the point where the pressure sensor (05) indication raises to a certain value.

[0063] According to the third aspect, (FIG. 3), assuming that the pump body is submersed in the liquid, the smart controller is turned off and the air valve is in exhaust mode. As a result, the pump body (11) is full of liquid (12) which has entered through the intake (08) and the check valve (09).

[0064] Compressed air is trying to go downhole (dotted line), but as the pump body is full of liquid and the floating ball has reached the top end, the top port has been blocked and the pressure sensor (05) indicates the airline pressure as set up by the pressure regulator (03).

[0065] We turn on the smart controller. The smart controller sends a command to the air valve (06). The air valve (06) state goes to pressure mode and compressed air rushes downhole (dashed line). The pump starts discharging liquid and the pressure sensor (13) indication rises as a result of the restriction (14), even with a free flow. As the pump vessel empties, the floating ball drops down until it reaches the bottom end and plugs the pump bottom port. At this time, we notice a drop at the pressure sensor (13) indication (pump is empty). The controller sends a command to the air valve (06) and changes its state to exhaust mode (pump is filling).

[0066] During filling, a tiny amount of compressed air is flowing through the line restriction (04) (dotted line), enters the pump body (11) from the bottom port, exits the pump body (11) from the top port, flows towards the air valve (06) (dashed line) and finally escapes to the atmosphere through the exhaust (07). The amount of pressure drawn in the dotted airline branch is proportional to the level of liquid build inside the pump body (11). However, as the floating ball inside the pump body (11) reaches the top end, it blocks the top port and the pressure sensor (05) indication continues to increase until it reaches the pressure regulator (03) set pressure.

[0067] As a result of this pressure increase, the smart controller senses that the pump body is full of liquid and sends a command to the air valve (06) to change to pressure mode and then the same process is repeated.

[0068] The third inventive step is the way the dotted airline (known also as a bubbler line) informs the smart controller of the liquid level inside the pump body. This bubbler line is mounted outside the pump body and provides information on the liquid level inside the pump body. In conjuction with the floating ball inside the pump body (11), when the pump gets full and the floating ball reaches the top end of the pump body it blocks the top port. The pressure indication of the pressure sensor (05) is no more proportional to the liquid level inside the pump body (11), but ramps up until reaches the maximum airline pressure as set up by the pressure regulator (03). This ramp up of the pressure indication of the pressure sensor (05) provides enough information to the smart controller to sense that the pump body is full and it is time to change the air valve (06) to pressure state.

[0069] The fourth inventive step is the way the smart controller of all the above aspects can estimate when the pump is empty. Let's assume that the air valve (06) is in exhaust mode and the pump body (11) is filling with liquid. The indication of the pressure sensor (13) equals the static head pressure after that point (which can be the atmospheric pressure if we have free flow). As the air valve (06) state changes to pressure mode the pump starts discharging liquid through the discharge line (solid line). If we have a free flow, the indication of the pressure sensor (13) increases as a result of the line restriction (14) as shown in FIG. 5. If a tank is filling, the indication of the pressure sensor (13) increases as a result of overcoming the discharge line friction. If there is a valve closed at the discharge line, the indication of the pressure sensor (13) increases as a result of the applied air pressure inside the pump body. The smart controller waits until the pressure sensor (13) indication drops to a certain percentage (e.g. 10%) above the initial measured pressure (the pressure just before the air valve state changed from exhaust to pressure mode).