Submersible Pump Self-Test via Remote Controller

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Solution Overview

Problem

Submersible pumps installed in closed chambers or underground locations are difficult to access for testing, making it challenging to ensure proper installation and operation, especially in applications with hydrocarbons or contaminants, which poses safety and cost risks.

Innovation Solution

A self-test method and system that allows remote testing of submersible pump systems, including pumps, floats, probes, and circuitry, using a main controller and remote monitor for communication, enabling the system to check operational status and performance without physical access, with specific steps for dual and single pump systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If remote self-test is implemented, then safety and cost risks are reduced, but device complexity increases

Engineering Contradiction:

Improvesafety and cost risksVSAvoiddevice complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The pump system performs self-testing automatically without requiring external intervention. The controller executes pre-programmed test sequences that activate pumps, probes, and floats, then monitor their operation and report results back to the user interface, enabling the system to service and verify itself autonomously

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

A remote monitor acts as an intermediary device positioned in or adjacent to the sump, communicating with the main controller via wired or wireless connections. This intermediary enables remote testing capabilities while isolating the user from the confined space, reducing safety risks without requiring direct human access

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If physical access to confined spaces is required for testing, then measurement precision is improved, but ease of operation deteriorates

Engineering Contradiction:

Improvesystem testing accuracyVSAvoidease of operation

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

Physical access and manual testing procedures are replaced with an automated electronic testing system. The controller electronically activates and monitors pump motors, probes, and floats through electrical signals, eliminating the need for physical access to the confined space while maintaining comprehensive system verification

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system incorporates feedback mechanisms where sensors and probes monitor pump operation, float movement, and probe functionality during self-test sequences. Results are fed back to the controller which interprets the data and communicates test outcomes to the user interface, enabling accurate remote assessment of system status

Inventive Principle:

Principle #23Feedback

3Reliability

If comprehensive system testing is performed, then reliability is improved, but time consumption increases

Engineering Contradiction:

Improvesystem reliabilityVSAvoidtime consumption

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The controller executes pre-programmed test sequences that systematically verify pump operation, probe functionality, and float operation before actual use. By performing these comprehensive checks automatically during scheduled intervals or upon system activation, the system ensures reliability without requiring extended manual testing time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The self-test function can be executed periodically at scheduled intervals or triggered by specific events such as system activation or user request. This periodic automated testing maintains system reliability over time without requiring continuous or frequent manual intervention, optimizing the balance between thoroughness and time efficiency

Inventive Principle:

Principle #19Periodic action

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

Enables remote and safe testing of submersible pump systems, ensuring proper installation and operation, reducing costs and risks associated with accessing confined spaces, and facilitating preventive maintenance by identifying connectivity issues and system functionality problems.

Implementation Method 1

The pump disclosed in the '281 patent employs a conductivity probe via which it can be determined whether oil or water is present in the sump (as oil and other hydrocarbons are nonconductive)

Methodology Applied

Scientific EffectElectrical Conductivity: Conduction (electrical)

Data Source

PatentUS10323647B2Self-test methods and systems for submersible pump systems

Publication Date: 2019.06.18 IND FLOW SOLUTIONS OPERATING LLC

AI summary

The present invention relates to methods and systems for implementing a self-test for sump system components using two-way communications between a main controller and each of the system components to check system operation and status. The self-test system is designed to remotely or locally test the installation of field wiring, system functionality and performance of equipment located in an elevator pit, a transformer vault, a transformer moat, a confined space or any other pit/ditch/sump. The benefits of this technology are: 1) ensure proper installation, 2) exercise the system that might otherwise be dormant for years, 3) avoid the costs and risks associated with entering a confined space, and 4) create an easy to implement preventative maintenance program.