SUBMERSIBLE PUMP DETECTION SYSTEM
20230160389 · 2023-05-25
Assignee
Inventors
Cpc classification
F04D15/0218
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
G01N2021/945
PHYSICS
F04D13/086
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F04D15/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The invention relates to an apparatus, system, and method for detecting a layer of contaminants, such as hydrocarbons, on the surface of accumulated water within a confined area that is periodically evacuated by a pump. The detection of contaminant layers may be accomplished through the use of an optical detection system comprising a light source, a plate having conductive, capacitive, positional and/or reflective properties, and a capacitive, pressure, optical, or ultrasonic sensor capable of distinguishing between oil and water, with the plate positioned at a distance equal to the desired minimum detectable hydrocarbon layer thickness. Dissipation of turbulence and agitation of the accumulated water may be achieved with a stilling tube. Additional sensors may detect high, intermediate, and low levels, as well as trigger optical sensor measurement. An integrated controller may determine the state of media within the confined area.
Claims
1. A submersible pump detection apparatus comprising: a sensor in electric communication with a submersible pump, said sensor configured to detect a level of a fluid within a confined area; and a stilling tube having a first opening disposed above a second opening, and a middle portion disposed therebetween, said sensor being disposed within said middle portion, wherein said stilling tube is configured to stabilize the fluid within an area proximate said sensor so that said sensor can register an accurate reading of a property of the fluid.
2. A submersible pump detection apparatus comprising: a sensor in electric communication with a submersible pump, said sensor configured to detect a level of a fluid within a confined area; and a sensing plate electrically and/or optically coupled to said sensor, said sensing plate including a surface having a longitudinal area capable of maintaining a fluid on said surface due to the surface tension of the fluid, such that said sensor may detect a property of the fluid.
3. A submersible pump detection apparatus comprising: a sensor in electric communication with a submersible pump, said sensor configured to detect a level of a fluid within a confined area; a sensing plate electrically and/or optically coupled to said sensor, said sensing plate including a surface having a longitudinal area capable of maintaining a fluid on said surface due to the surface tension of the fluid, such that said sensor may detect a property of the fluid; and a stilling tube having a first opening disposed above a second opening, and a middle portion disposed therebetween, said sensor and said sensing plate being disposed within said middle portion, wherein said stilling tube is configured to stabilize the fluid within an area proximate said sensor so that said sensor can register an accurate reading of a property of the fluid.
4. A modular sensing unit comprising: first, second, and third sensors, wherein each sensor is adapted to sense a property of one or more media at a distinct location, each sensor being disposed at a separate location to sense said one or more media and being at least partially embedded within an insulating block, wherein said sensors further comprise a unitary device having plug-and-play connection, adapted to be installed and/or removed within a pump detection system.
Description
DESCRIPTION OF DRAWINGS
[0022] Non-limiting and non-exhaustive embodiments of the present disclosure are described with reference to the following drawings. In the drawings, like reference numerals refer to like parts throughout the various figures unless otherwise specified.
[0023] For a better understanding of the present disclosure, reference will be made to the following Detailed Description, which is to be read in association with the accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations, wherein:
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
[0030]
DETAILED DESCRIPTION
[0031] Non-limiting embodiments of the invention will be described below with reference to the accompanying drawings, wherein like reference numerals represent like elements throughout. While the invention has been described in detail with respect to the preferred embodiments thereof, it will be appreciated that upon reading and understanding of the foregoing, certain variations to the preferred embodiments will become apparent, which variations are nonetheless within the spirit and scope of the invention.
[0032] The terms “a” or “an”, as used herein, are defined as one or as more than one. The term “plurality”, as used herein, is defined as two or as more than two. The term “another”, as used herein, is defined as at least a second or more. The terms “including” and/or “having”, as used herein, are defined as comprising (i.e., open language). The term “coupled”, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically.
[0033] Reference throughout this document to “some embodiments”, “one embodiment”, “certain embodiments”, and “an embodiment” or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of such phrases or in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation.
[0034] The term “or” as used herein is to be interpreted as an inclusive or meaning any one or any combination. Therefore, “A, B or C” means any of the following: “A; B; C; A and B; A and C; B and C; A, B and C”. An exception to this definition will occur only when a combination of elements, functions, steps or acts are in some way inherently mutually exclusive.
[0035] The drawings featured in the figures are provided for the purposes of illustrating some embodiments of the present disclosure, and are not to be considered as a limitation thereto. The term “means” preceding a present participle of an operation indicates a desired function for which there is one or more embodiments, i.e., one or more methods, devices, or apparatuses for achieving the desired function and that one skilled in the art could select from these or their equivalent in view of the disclosure herein and use of the term “means” is not intended to be limiting.
[0036] As used herein, the term “accuracy” refers to how closely individual measurements agree with the correct, or true, value.
[0037] As used herein, the term “confined area” refers to any defined area that may contain fluid media and which may be evacuated by an active process such as pumping, including but not limited to sumps, moats, transformer vaults, elevator shafts, and other equivalent structures.
[0038] As used herein, the term “precision” refers to a measure of how closely individual measurements agree with one another.
[0039] As used herein, the term “reliability” refers to a level of confidence in detecting contaminants based upon the acceptable calibration of the apparatus and/or system, and based upon the repeatability of the measurements obtained.
[0040] The submersible pump detection apparatus, system and method 100 of the present disclosure can be incorporated into a wide range of pumping installations and applications, can use other components and arrangements to achieve similar objectives, and is described in the context of a detection submersible pump detection system used in contaminant application as an exemplary embodiment as shown in
[0041] As shown in
[0042]
[0043] Submersible Pump Detection System
[0044] As is illustrated in
[0045] In one aspect of the present disclosure, pump detection system 100 may include a stilling tube 110, which may be configured to calm or otherwise dissipate turbulent conditions of the accumulated water within the confines of the stilling tube 110. To achieve this affect, a stilling tube inlet 110a may be located adjacent the lower portion of the confined area 102, as shown in
[0046] Stilling tube 110 may further be configured with a purge opening located at an upper end thereof, to negate pressure effects of air contained within the interior of the stilling pipe 110. The purge opening would therefore allow air to enter and exit the stilling pipe as the accumulated water level changes, so that a pressure differential does not occur across the stilling pipe boundary, allowing the internal level and external level of the accumulated water to remain the same. The purge opening may alternatively be formed by the cumulative effect of openings provided by the system components disposed atop the stilling pipe 110. Additional openings disposed along portions of the stilling tube 110 may be included.
[0047] Furthermore, the stilling tube 110 may be configured to house one or more sensors 130, and/or one or more optical sensors 150 therein. As such, the cross-sectional area, as detailed above, may be further sized in any manner suited to achieve the dissipation of accumulated water, the housing of said one or more sensors 130, the housing of said one or more optical sensors 150, and the space required for the pump detection system 100 to operate reliably, accurately, and precisely. As further detailed below, the one or more sensors 130 and/or the one or more optical sensors 150 may be configured to reliably, accurately, and precisely detect the presence of contaminants, like hydrocarbons, present within the confined area 102. However, an objective of the stilling tube 110 is to promote an immiscible mixture to form (i.e., an emulsion of, for example a hydrocarbon layer on top of a water layer). This is largely achieved by separating the general accumulated water within the confined area from the localized accumulated water adjacent the sensors 130, 150, so that the localized water may settle, turbulent effects may substantially dissipate such as, for example, settling the mixture from foam to a non-emulsion mixture, and sensors 130, 150 may accurately and precisely register a reading of the conditions to determine whether contaminants are present
[0048] Stilling tube 110 may be further configured to electrically couple to a control module device 200. Stilling tube 110, therefore, may further facilitate registration and readings taken by one or more sensors 130. For example, in a preferred embodiment, stilling tube 110 is biased at +12V DC relative to the one or more sensors 130 via an isolated contact 114 connected to the stilling tube 110, as shown in
[0049] In another aspect of the present disclosure, pump detection system 100 may include a sensing plate 140. Sensing plate 140 may be configured to provide a surface upon which accumulated water may collect for the purposes of registering a reading from the one or more optical sensors 150. In accordance with this objective as shown in
[0050] Sensing plate 140 may further be configured to electrically couple to a sensor 130, such as a third sensor 133 shown in
[0051] In another aspect of the present disclosure, pump detection system 100 may include a control module device 200, as shown in
[0052] In the embodiment shown in
[0053] Conductivity Sensor Assembly
[0054] As illustrated in
[0055] The one or more sensors 130 may further be coupled to, and insulated from, the stilling tube 110 wall by a PVC mounting block 112. The mounting block 112 is fitted with probe holes (rods) 113, which provide a press fit for the sensors 130. Electrically isolated feed-through assemblies 115 are disposed at the top of the stilling tube 110 for each of the sensors 130. Additional system components, as shown in
[0056] Under normal operating conditions, the pump will run when the start float 121 is activated and stop when the water level is pumped to the third sensor (stop probe) 131. Under adverse conditions, such as wind and rain, the surface of the water in the confined area 102 may be disturbed and deviate significantly from steady-state levels/conditions. Under such conditions, the accumulated water level sensing accuracy and precision would become compromised, but for the advantageous arrangement as substantially described and shown herein.
[0057] Optical Sensor Assembly
[0058] As shown in
[0059] Turning now to
[0060] As an air medium is nonconductive, and does not provide for dispersion of the light source,
[0061] Modes of Operation
[0062] In a first mode of operation, stilling tube 110, may be configured to maintain a level surface under all external conditions. In a second mode of operation, the stilling tube may be configured to sense the water level at three points: the stop level (first probe level 172), an intermediate stop level (second probe level 173), and an oil-sensing level (third probe level 174), which correspond to first, second, and third sensors 131, 132, and 133, respectively. In one embodiment, sensors 131, 132, 133 may detect a difference in conductivity between water (conductive) and hydrocarbons or air (insulative), thereby determining whether the surface of the water is above (high conductivity) or below (low conductivity) the sensor tip. The stop probe 131 may be set at a level (first probe level 172) that is proximate and above said pump inlet level 171, which ensures contaminants do not pass within pump inlet 103 of the pump 101. As previously mentioned, under normal operating conditions, the pump will run when the start float 121 is activated and stop when the water level is pumped to the third sensor (stop probe) 131.
[0063] A third mode of operation, stilling tube 110 and associated components of third sensor 133 and optical sensor 150 may be configured to detect hydrocarbon layers. This is achieved via the oil sensing level probe 140 and an optical sensor 150 which can detect the difference between water and hydrocarbons. A suitable optic sensor 150 is configured to sense water, oil, and/or anything that disperses the light source. If the optic sensor 150 does not distinguish between oil and water, the optical sensor 150 will generally activate through the introduction of media that cause dispersion of the optic sensor's light source. However, air and oil are nonconductive and cannot disperse the light source. If the light source is dispersed, PLC 150 input 2 is energized by z signal from the optical sensor 150 so as to turn on. If the light source 150 is not dispersed, oil is present, and a signal is not present at input 5, so as to turn off the PLC 150 due to loss of conductivity between the stilling tube 110 and the oil probe protruding plate 140. The system will then go into a hydrocarbon alarm.
[0064] The proper functioning of the optical sensor 150 requires that an optical signal pass through a homogeneous layer of liquid and be reflected into an optical detector. Thus, for a thin layer of hydrocarbons to be properly detected, it must fill the gap between the optical probe and the plate 140 that has a reflective surface and/or reflective properties. The ⅛″ thick plate 140 is factory set at a distance equal to the desired minimum detectable layer thickness, which may be 1/16″. In operation, as the pumping cycle occurs, the water level will drop below the oil-sensing-level probe 133, causing the input signal to change to a low state and triggering the optical sensor 150 to take a reading. This occurs quickly due to the high-speed programmable logic controller (PLC) 210 and its fast solid-state relay 160. If the gap between the sensor 150 and plate 140 is filled with hydrocarbons, the sensor will trigger the hydrocarbon alarm and pumping will be stopped immediately. If, however, water or air partially fills this gap, the hydrocarbon layer will not be accurately detected and the alarm indicating the presence of hydrocarbons will not be activated. This reinforces the need for a calm surface on the liquid to be sensed and the purpose of the stilling tube 110. Upon detecting a layer of hydrocarbons, the PLC will alter the pumping cycle to run between the start float 121 and the intermediate stop level probe 132, keeping the thin layer of oil at a safe distance from being discharged while still pumping water. The intermediate stop level probe 132 is factory set at a height that will facilitate keeping hydrocarbons battered by rain from entering through the water into the suction area of the pump.
[0065] Signal Processing Circuitry
[0066]
Alternative Embodiments
[0067] In an alternative embodiment as illustrated in
[0068] In an alternative embodiment, communications hardware may be added to the system to effect internet connectivity for remote monitoring and/or control. The communications hardware may take the form of, for example, an ethernet adapter, a Wi-Fi adapter, or a cellular or other radio frequency transceiver.
[0069] In an alternative embodiment, the system may be fitted with solar power and battery backup.
[0070] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein can be applied to other embodiments without departing from the spirit or scope of the invention. It is therefore desired that the present embodiments be considered in all respects as illustrative and not restrictive, reference being made to the appended claims as well as the foregoing descriptions to indicate the scope of the invention.