Submersible Pump Bypass System for Air Purging
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Solution Overview
Problem
Submersible pumps often experience 'air-lock' or 'vapor-lock' conditions due to entrapped air, leading to reduced performance or catastrophic failure, especially in wells with fluctuating water levels and gases like Hydrogen Sulfide, as existing solutions like bypass holes in the discharge head result in significant pressure loss and performance degradation.
Innovation Solution
The implementation of bypass holes in the diffuser of the bottom impeller stage and a housing bypass hole radially outward from the impeller stages allows air to exit while minimizing performance loss, enabling effective purging of air without the need for submerging the pump or creating a pressure differential, and can be placed in any pump stage with minimal impact on system performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bypass hole is located in the discharge head of the pump above all impellers, then air can be purged from the pump, but significant pressure loss and performance degradation occur
Solution Approach 1:
The bypass system is segmented into multiple components: a bypass hole in the diffuser of the bottom impeller stage, a bypass passage in the housing, and a check valve. This segmentation allows the system to purge air effectively while minimizing pressure loss by distributing the function across multiple strategic locations rather than relying on a single high-pressure discharge hole.
Solution Approach 2:
The bypass hole in the bottom impeller stage diffuser provides a preliminary escape route for air at the lowest pressure point in the pump. By allowing air to escape early in the pumping process rather than waiting for high-pressure discharge, the system prevents air-lock conditions while maintaining pump performance.
2Reliability
If the pump is submerged deeper to create pressure differential, then air can be forced through the check valve, but installation complexity and operational constraints increase
Solution Approach 1:
The bypass system is designed to be self-activating based on pressure differential that naturally occurs during pump operation. The check valve automatically opens when pressure differential exceeds a threshold, eliminating the need for external control systems or complex installation procedures. The system serves itself by using its own operating conditions to trigger air purging.
Solution Approach 2:
The check valve is designed to respond to changes in pressure differential parameter. When the pressure differential across the check valve exceeds a predetermined threshold, the valve opens to allow air escape. This parameter-based control simplifies the system by using inherent operational parameters rather than external control mechanisms.
3Reliability
If a bypass hole is created in the pump housing, then air can exit the pump, but the risk of clogging and system failure increases
Solution Approach 1:
The check valve acts as an intermediary between the bypass passage and the pump interior. It controls air escape while preventing water and debris from entering the bypass passage and causing clogs. This intermediary component protects the bypass system from harmful factors while maintaining its air purging function.
Solution Approach 2:
The check valve design allows selective passage of gases while blocking liquids and particulates. The valve structure functions as a porous-like barrier that permits air molecules to pass through while excluding larger water droplets and debris, thereby preventing clogging in the bypass passage.
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
This solution effectively purges air from the pump, maintaining performance and preventing failure, with negligible pressure loss and reduced risk of clogging, as illustrated by comparable performance graphs with both small and large bypass holes compared to prior art systems.
Implementation Method 1
you must be able to do one of two things: One must either submerse the pump in the well far enough below the water level so that the pressure differential created will force the air through the closed check-valve
Implementation Method 2
The check valve is designed to open when the pressure differential across the check valve exceeds a predetermined threshold
Data Source
AI summary
A submersible pump, and method of making the submersible pump, is disclosed. The pump comprises a housing, a plurality of impeller stages serially disposed in the housing from a bottom impeller stage to a top impeller stage, an impeller stage bypass hole extending through one of the diffusers and a housing bypass hole extending through the housing radially outwardly from one of the impeller stages.