Pump Apparatus Pneumatic Venturi Phase Control
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Solution Overview
Problem
Existing pump apparatus for handling abrasive and reactive drill chippings in drilling operations face challenges in scalability, energy efficiency, and operational flexibility due to the need for multiple units and lack of true integration, leading to increased energy consumption and reduced control over throughput and line velocities.
Innovation Solution
A scalable pump apparatus with multiple pumping elements, each with a housing, material inlet, and discharge outlet, controlled by pneumatic means using a venturi for pressure cycling, allowing selective operation of elements and phase control to manage throughput and energy use, with separate discharge lines to prevent back pressure and optimize airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple pump apparatus are mounted to meet maximum throughput demand, then the throughput capacity is improved, but the energy consumption and footprint increase
Solution Approach 1:
The pump apparatus is divided into multiple independent pumping elements (first and second elements) that can operate autonomously. Each element has its own housing, inlet valve, outlet valve, and venturi system, allowing individual control and operation. This segmentation enables the system to activate only the necessary number of elements based on current throughput requirements, avoiding the energy waste of running all elements at full capacity continuously.
Solution Approach 2:
The system implements dynamic control of pumping elements through phase control mechanisms. The control means can operate elements in different phases (in-phase or out-of-phase) and selectively activate or deactivate elements based on demand. This dynamic operation allows the system to adapt its energy consumption to match actual throughput requirements, improving overall energy efficiency while maintaining the capacity to handle peak demands.
2Productivity
If multiple pump apparatus are mounted to meet maximum throughput demand, then the throughput capacity is improved, but the footprint and air plant size increase
Solution Approach 1:
Multiple pumping elements are integrated into a single unified apparatus with a common control means and shared structural components. The first and second pumping elements are combined within one apparatus, allowing them to share the same footprint space rather than requiring separate installations. This merging approach maintains the throughput capacity of multiple elements while significantly reducing the overall footprint and eliminating the need for multiple separate air plants.
3Ease of operation
If pots are set to operate at optimum irrespective of actual demand, then the operation simplicity is improved, but the energy efficiency deteriorates
Solution Approach 1:
The control means incorporates feedback mechanisms that monitor actual throughput demand and automatically adjust the operation of pumping elements accordingly. The system can detect when demand is low and reduce the number of active elements or adjust their phase relationships to optimize energy consumption. This feedback-driven control maintains operational simplicity while dynamically adapting energy usage to match actual demand conditions.
Solution Approach 2:
The system can change operational parameters such as the number of active pumping elements, their phase relationships, and cycle timing based on demand conditions. By dynamically adjusting these parameters, the system maintains ease of operation through automated control while improving energy efficiency by matching operational intensity to actual throughput requirements rather than running at fixed optimum settings.
4Device complexity
If simple pairing of pots is used, then the device complexity is reduced, but the line velocities are reduced due to slaving
Solution Approach 1:
The control means provides dynamic phase control that allows pumping elements to operate in different phase relationships (in-phase or out-of-phase) depending on system requirements. This dynamic phase control prevents the slaving effect that occurs with simple fixed pairings, as elements can be independently timed to optimize line velocities. The system maintains low complexity through automated control while achieving superior velocity performance through flexible phase management.
Solution Approach 2:
The system uses periodic cycling of pumping elements with controllable phase relationships between elements. By coordinating the periodic operation of multiple elements with optimized phase differences, the system maintains continuous flow and high line velocities without the slaving problems of simple pairings. The periodic action is controlled to ensure that elements operate in a coordinated manner that maximizes throughput velocity while keeping the control system relatively simple.
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 solution enables flexible control over throughput and energy consumption, reducing noise and stalling issues, while maintaining high in-line velocities and efficiency, allowing for variable demand handling with reduced air consumption and footprint.
Implementation Method 1
a venturi adapted to cyclically reduce the housing pressure
Implementation Method 2
the housing is pressurized and the outlet valve is open to discharge said material from said housing
Implementation Method 3
The venturi waste air vents into the delivery line downstream of the outlet valve to provide additional delivery impetus
Data Source
AI summary
Vessels (10, 11, 12 and 13) are associated with an inlet manifold (14) passing to inlets (16), each controlled by a knifegate valve (17). The lower ends of the pots (10) and (12), and pots (11) and (13), pass material through respective outlet knifegate valves (22) to respective first (23) and second (24) delivery lines. The respective knifegate valves (17) and outlet knifegate valves (22) of pots (10) and (11) on the one hand and pots (12) and (13) on the other, are operable by respective common pneumatic actuators (25). Each pot has an ejector assembly (26) having an upper chamber (28), an air injector nozzle (30), and an accelerator tube (31) to create the venturi function. An air cycling valve (32) transitions the upper chamber (28) between a depressurized space and a pressurized space. The accelerator tube (31) exhausts to a delivery line (23 or 24). Ejector assembly (26) air is supplied via air control valve (35). The respective delivery lines (23) and (24) each have an eductor port (37) which allow for air to be ported into the line. The completed load and discharge cycle is governed by a pneumatic PLC and pneumatic timers.