Floatless Pneumatic Pump Control for Fouling-Prone Leachate Wells
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Solution Overview
Problem
Existing submersible well pumps for landfills suffer from frequent failures due to mechanical floats fouling and sticking, requiring manual oversight and disassembly for maintenance, which increases exposure to hazardous chemicals and introduces human error.
Innovation Solution
A floatless pneumatic fluid pump system with a control system that uses pressurized gas to manage liquid flow without mechanical floats, allowing operation in various bore orientations and enabling remote monitoring and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical floats are used for liquid detection, then the pump can operate in vertical orientation, but the float is prone to fouling and sticking resulting in frequent pump malfunction
Solution Approach 1:
The patent removes the mechanical float component from the pump system entirely. Instead of using a float for liquid level detection, the system employs a floatless design where the pump chamber itself serves as the detection mechanism. When liquid enters the pump chamber through the inlet check valve, it directly activates the pumping mechanism without requiring a separate float component, thereby eliminating fouling and sticking issues associated with traditional floats.
Solution Approach 2:
The patent replaces the mechanical float system with a pneumatic control system. The floatless pump uses pressure differential and pneumatic actuation to detect liquid presence and control the pumping cycle. This substitution of mechanical components with pneumatic/hydraulic principles eliminates the complexity and reliability issues of mechanical floats while maintaining the liquid level detection function.
2Adaptability or versatility
If mechanical floats with linkages are used, then the pump can detect liquid levels, but the pump is only functional in vertical orientation and quickly fouls in non-vertical orientations
Solution Approach 1:
The floatless pump design creates a universal pumping mechanism that can operate effectively in multiple orientations (vertical, deviated, and horizontal). The pump chamber and check valve system are designed to function regardless of orientation, allowing the same pump design to be deployed in various well configurations without modification. This multi-functional capability eliminates the limitation of vertical-only operation while maintaining reliable performance across different orientations.
Solution Approach 2:
Instead of having the float rise with liquid to trigger pumping (vertical-dependent mechanism), the floatless design inverts the approach by having liquid pressure directly act on the pump chamber diaphragm or piston. This inversion of the detection mechanism allows the pump to respond to liquid presence based on pressure differential rather than gravitational float movement, enabling operation in any orientation without fouling issues.
3Ease of repair
If float failures require pump removal and disassembly for maintenance, then the pump can be repaired, but human exposure to hazardous chemicals increases resulting in safety incidents
Solution Approach 1:
By removing the float component entirely from the pump system, the patent eliminates the primary source of failures that would require pump removal and disassembly. The floatless design with its simpler internal structure (primarily check valves and pneumatic components) reduces maintenance requirements and allows for easier in-situ repairs or replacements, minimizing the need to expose workers to hazardous landfill chemicals.
Solution Approach 2:
The floatless pump design incorporates features that reduce maintenance needs and enable self-diagnosis or automated monitoring. The pneumatic control system can detect operational status and liquid levels without mechanical components that wear or foul, reducing the frequency and complexity of maintenance interventions required in hazardous environments.
4Extent of automation
If manual oversight is required for pump operation, then the pump can be monitored, but greater opportunities for human error arise interrupting pump operation
Solution Approach 1:
The floatless pump system incorporates pneumatic and electronic feedback mechanisms that automatically monitor liquid levels, pump chamber pressure, and operational status. This feedback enables automated control of the pumping cycle, liquid level regulation, and system diagnostics without requiring continuous manual oversight, thereby reducing human error while maintaining reliable operation.
Solution Approach 2:
The replacement of mechanical float-based manual operation with pneumatic and electronic control systems enables automated pump operation. The pneumatic actuation and electronic sensing systems can autonomously respond to liquid level changes and operational conditions, eliminating the need for manual intervention and reducing opportunities for human error that would interrupt continuous pump operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enhances reliability and safety by reducing maintenance needs, allowing operation in non-vertical orientations and enabling remote monitoring, thus minimizing human exposure to hazardous conditions.
Implementation Method 1
the pneumatic inlet control valve/vent valve controls the flow of pressurized gas to the fill cavity to force liquid/viscous leachate into a distal end of the free-hanging discharge tube and up to the discharge check valve
Implementation Method 2
the inlet check valve is configured to allow one way passage of the liquid/viscous leachate into the fill cavity and prevent said liquid/viscous leachate from returning to the wellbore
Implementation Method 3
said discharge check valve operably serves to connect to the fluid outlet discharge line and prevent discharged liquid/viscous leachate from returning to the fill cavity
Data Source
AI summary
An improved pump device and control system for removal of liquid, such as viscous leachate, from a bore. A pump device includes a casing with an inlet check valve on a lower portion thereof and a discharge check valve on an upper portion thereof positioned within the casing. A fill cavity within the casing is connectable to a source of pressurized gas. As liquid/viscous leachate accumulates within the bore it enters the fill cavity through the inlet check valve. As pressurized gas is introduced to the fill cavity it displaces liquid/leachate from the fill cavity into and through a discharge tube and upward through the discharge check valve to remove the liquid/leachate from the fill cavity. The pump does not comprise a float. Control systems and devices provide for improved automated, semi-automated, and manual monitoring and control of pump device operation.