Pump Prime Maintenance via Bypass Line and Controller
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Solution Overview
Problem
Existing pumping systems face issues with maintaining prime and detecting leaks, particularly in suction-lift pumps, where leaks often lead to air entrainment and damage to pump seals due to malfunctioning wet switches and frequent loss of prime during idle states.
Innovation Solution
A system with a bypass line and controller that allows fluid to flow from the discharge line to the suction line when the pump is idle, utilizing a pressure tank and flow meter to maintain prime and detect leaks by measuring fluid volume and pressure changes, preventing air intrusion and ensuring continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a wet switch is used to detect dry conditions and activate a vacuum pump, then priming detection is improved, but the system reliability deteriorates due to wet switch malfunction and air intrusion
Solution Approach 1:
The patent removes the wet switch component from the system entirely, replacing it with a bypass line that continuously maintains prime. This extraction eliminates the source of malfunction while preserving the essential function of prime maintenance through passive hydraulic connection.
Solution Approach 2:
The bypass line enables the pump to self-maintain its prime condition through continuous fluid circulation from discharge to suction, eliminating the need for external vacuum pumps or electronic sensors. The system serves itself by using its own output pressure to maintain its input condition.
2Use of energy by moving object
If the pump is allowed to transition to an idle state, then energy consumption is reduced, but prime is lost due to leaks in the foot valve or suction fittings
Solution Approach 1:
The bypass line maintains continuous fluid circulation even when the pump is idle, ensuring that the prime condition is continuously preserved. This continuous action prevents air intrusion during idle periods while minimizing energy consumption compared to running the full pump system.
3Stability of the object's composition
If a bypass line is added to maintain prime during idle states, then prime stability is improved, but device complexity increases
Solution Approach 1:
The bypass line is integrated into the existing pump system by connecting to the discharge line and utilizing the pump's own output pressure. This merging approach adds minimal components while leveraging existing system elements to achieve prime stability.
4Stability of the object's composition
If the control valve is actuated to permit fluid flow through the bypass line, then prime maintenance is improved, but energy consumption increases due to continuous circulation
Solution Approach 1:
The control valve is actuated periodically or on-demand based on system conditions rather than continuously. This periodic action maintains prime stability while minimizing energy consumption by allowing the valve to remain closed during periods when prime is already stable.
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 effectively maintains pump prime and detects leaks, preventing damage to seals and ensuring continuous operation by using a bypass line and controller to manage fluid flow and pressure, thereby reducing system disturbances and extending pump lifespan.
Implementation Method 1
a bypass line extends from the suction connector to the discharge connector... The bypass line includes a control valve operable to selectively permit fluid to flow through the bypass line from the discharge line to the suction line
Implementation Method 2
The system may include a pressure tank connected to the bypass line
Implementation Method 3
The system may include a flow meter positioned between the suction line and the control valve. The controller may be configured to generate an alert if an aggregate volume of fluid flowing through the flow meter exceeds a preselected threshold
Data Source
AI summary
A system for maintaining a prime of a pump includes a suction line, a discharge line, a pump line, a bypass line, and a pressure tank connected to the bypass line. The pump line includes a pump, an inlet in communication with the suction line, and a discharge in communication with the discharge line. The pump is operable to propel fluid from the suction line to the discharge line through the pump line. The bypass line extends from the suction line to the discharge line. The bypass line includes a control valve operable to selectively permit fluid to flow through the bypass line from the discharge line to the suction line.