Hybrid intake screen assembly

An intake screen assembly including an intake member, a screen support member, and a screen member coupled to the screen support member. The screen member may be formed from a material, such as copper-nickel, that is different from a material, such as stainless steel, used to form the intake member and/or the screen support member. The intake screen assembly may include corrosion protection members for preventing contact between the components of the screen assembly that are formed from dissimilar materials. The assembly may be formed by coupling the screen support member to the intake member, and coupling the screen member to the screen support member.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the invention relate to intake screen assemblies.

2. Description of the Related Art

Water collection systems are typically used to provide water to end users such as manufacturing plants, cities, irrigation systems, and power generation facilities located adjacent a body of water such as a river, lake, or salt water bodies. The end users may employ this type of system as an alternative to drilling water well or buying water from a municipality. Additionally, use of these systems may be determined by the location of the end user, for example remote locations where water from a municipal source and/or electrical power to operate pumps is not readily available. These water collection systems have the ability to adapt to varying conditions and deliver water efficiently and economically.

These water collection systems typically use an inlet pipe adapted to transport water from a position submerged in a body of water to the end user adjacent the body of water. An inlet pipe is submerged in the body of water and the end of the inlet pipe is typically coupled to an intake screen assembly which typically has a plurality of filtering members. The filtering members are configured to prevent waterborne debris and aquatic life, of a certain size, from entering the inlet pipe.

A common intake screen assembly generally comprises large cylindrical screens with a closure on one end and a pipe connection on the other end. A typical construction for large intake screen assemblies is a flanged tee section with two screen cylinders that are cantilevered from opposite ends of the tee section, and with solid closures such as flat plates, cones, or dished heads on the distal ends of each screen cylinder. The separate components of the assemblies are usually welded together.

The material used to fabricate the separate components is generally stainless steel. However, where certain aquatic animals, such as zebra mussels, are present the preferred material is a copper-nickel alloy. Since copper-nickel alloys are more expensive than stainless steel, it is preferred to supply a hybrid assembly where only the cylindrical screen portion is formed from copper-nickel and the remainder of the assembly is formed from stainless steel.

Traditionally the hybrid assembly has been accomplished by fabricating a copper-nickel cylindrical screen and bolting it the rest of the stainless steel components. There are two potential problems with the hybrid assembly. First, in high loading situations, significant reinforcement of the cylindrical screen is required since the copper-nickel material is not as strong as the stainless steel material. The reinforcing must be designed to transfer through the bolts, which may increase the cost and complexity of manufacture. Second, the cylindrical screen must be bolted to the stainless steel components using gaskets and isolation sleeves to prevent contact of the two dissimilar metals, thereby preventing galvanic corrosion. These additional corrosion protection measures may also increase the cost and complexity of manufacture.

Therefore, there is a need for new and improved hybrid intake screen assemblies.

SUMMARY OF THE INVENTION

In one embodiment, an intake screen assembly comprises an intake member; a screen support member coupled to the intake member; and a screen member coupled to the screen support member, wherein the screen support member and the screen member are formed from different materials. The intake member and/or the screen support member may be formed from stainless steel, and the screen member may be formed from copper-nickel.

In one embodiment, a method of forming an intake screen assembly comprises coupling a screen support member to an intake member; and coupling a screen member to the screen support member. The screen support member and the screen member may be formed from different materials.

In one embodiment, an intake screen assembly comprises an intake member; a support structure coupled to the intake member, wherein the support structure includes, a plurality of circumferential supports; and a plurality of straight bars coupled to the circumferential supports that extend from a first end of the support structure to a second end of the support structure in a zig-zag pattern around the circumference of the support structure; and a plurality of filter members coupled to the support structure for filtering fluid flow into the intake member.

DETAILED DESCRIPTION

FIG. 1illustrates an intake screen assembly100according to one embodiment. The intake screen assembly100comprises an intake member or other body shown in the form of a central, flanged tee-section10, a screen support member shown in the form of a cylindrical cage structure20, a closure member shown in the form of a circular plate structure30, and a screen member shown in the form of a curved screen panel40. The right side of the intake screen assembly100is shown with the screen panels40removed to illustrate the underlying cage structure20and its connection to the tee-section10and the plate structure30. The left side of the intake screen assembly100is illustrated with the screen panels40attached to outer surface of the opposite cage structure20, which is hidden from view.

The intake screen assembly100utilizes a separate screen support member for supporting one or more screen members, which provides numerous advantages. By using a separate screen support member, the screen members themselves may be easily replaced without having to significantly disassemble the intake screen structure. Also, the screen support member may be formed from a material that is significantly stronger and/or more cost effective than the material used to form the screen members. The screen support member may further provide a solid base structure capable of withstanding high loading situations, while supporting one or more screen members. The screen members may therefore be formed from numerous other materials that provide significant benefits to the intake screen assembly100, such as repelling certain aquatic life, but which do not necessarily require the support strength as the remaining components of the assembly.

The components of the intake screen assembly100may be formed from different materials or from the same material. The components may be formed from metallic materials, non-metallic materials, and composite materials. The screen member may be formed from one or more materials that are stronger than the materials used to form the screen members. The components of the intake screen assembly100may be formed from dissimilar materials that do not require additional corrosion protection measures.

In one embodiment, the tee-section10, the cage structure20, and/or the plate structure30may be formed from a stainless steel material (such as304or316grade stainless steel), and the screen panels40may be formed from a copper-nickel material. In one embodiment, the tee-section10, the cage structure20, the plate structure30, and/or the screen panels40may be formed from the same material, such as stainless steel or copper-nickel. Appropriate corrosion protection measures may be used when coupling the components of the intake screen assembly100that are formed from dissimilar materials, such as the stainless steel cage structure20and the copper-nickel screen panels40. The corrosion protection members50may be used to prevent direct surface contact between components of the intake screen assembly100of dissimilar materials. In one example, one or more gasket-type and/or washer-type members may be used between adjacent surfaces of the dissimilar material components. In another example, one or more isolation-type sleeves may also be used for isolating the bolt/nut members that are used for forming bolted connections with assembly components of dissimilar materials as described herein.

The tee-section10generally includes a cylindrical lower portion13for supporting the intake screen assembly100when submerged in a body of water, and/or for coupling to a flow line for providing fluid communication to an end user. A cylindrical upper portion15of the tee-section10may be provided for supporting the cage structures20, the plate structures30, and the screen panels40. The cage structures20may be welded to opposite ends of the upper portion15of the tee section10in a cantilevered fashion, and the plate structures30may be welded to the distal ends of the cage structures20. Other connection mechanisms, such as bolting, may be used to connect the components of the intake screen assembly100together.

Although illustrated as a tee-section10, the body of the intake screen assembly100may include other configurations. In one embodiment, the body may be in the form of an L-shaped section for supporting only one cage structure20of the assembly. In one embodiment, the tee-section10may include only the lower portion13for supporting one cage structure20that is horizontally or vertically positioned on top of the lower portion13. Other configurations and shapes of the body may be used with the embodiments described herein.

The cylindrically-shaped cage structure20may be formed from a plurality of bars21(or other similar longitudinal support or reinforcing members) that interconnect a plurality of circumferential supports22(such as ring members). Additional bars, referred to as reinforcing members23, may be provided along the inner and/or outer diameter of the cage structure20. Examples of reinforcing members23are disclosed in U.S. Pat. No. 7,950,527, the contents of which are herein incorporated by reference in its entirety, which describes internal reinforcing helical bars that can be used with the embodiments described herein. In one embodiment, the reinforcing members23may include a plurality of helical bars which traverse the cage structure20. In one embodiment, a first end of at least two reinforcing members23may be coupled to the tee-section10at substantially the same location. The reinforcing members23extend toward the plate structure30in a manner that creates an angle between the two members23. The reinforcing members23may be arranged to have the same contour as the screen panels40, and may contact with the screen panels40as the members23extend from the first end to a second end of the members23. The second end of the reinforcing members23may be coupled to the plate structure30. The members23may form a zig-zag pattern as they traverse the cage structure20. The angles between the reinforcing members23may be any angle necessary for the operation. The larger the angle, the longer the members23may need to be in order to traverse a longer section of the cage structure20. Any number of angles may be used.

In one embodiment, the length and/or diameter of the cage structure20may be within a range of about 6-12 inches to about 8-12 feet. In one embodiment, the length of the cage structure20may be the same dimension as the diameter of the cage structure20, thereby forming a square cylinder arrangement. Although illustrated as a cylindrical cage structure20, the screen support member of the intake screen assembly100may also include other configurations and shapes, such as a substantially flat-sided screen support structure/member.

The flat, cylindrical plate structures30may be coupled to the ends of the cage structures20, such as by welding, to form sealed closed ends of the intake screen assembly100. Other embodiments may include dished head members or fabricated cone members for coupling to the ends of the cage structures20. U.S. Pat. No. 7,950,527, the contents of which are herein incorporated by reference in its entirety, illustrates a cone-shaped end cap117that can be used with the embodiments described herein. Various other shapes and configurations of closure members may also be used with the embodiments described herein. In one embodiment, the cage structure20(or screen support member) and the plate structure30(or end closure member) may be integrally formed as a single piece component of the intake screen assembly100.

The screen panels40are operable to filter and/or repel debris, aquatic life, and other matter from the fluid flow into the intake screen assembly100. The screen panels40may be directly coupled to the outer surface of the cage structures20, the tee section10, and/or the plate structures30. As illustrated inFIG. 1, three partially cylindrical screen panels40may be used to enclose the cage structure20. Any number of screen panels40may used with the embodiments described herein. Although illustrated as curved screen panels40, the screen members of the intake screen assembly100may also include other configurations and shapes, such as a substantially flat-sided screen panel/member.

In one embodiment, the screen panels40may be coupled to each other, such as by bolting or other connection mechanisms, to form a sleeve that can form an interference fit around the cage structure20. In one embodiment, the ends of one or more screen panels40may be coupled together in a segmented fashion, such as by using a hinged connection. The screen panels40may be rotatable about each hinged connection for installation around the cage structure20. In one embodiment, the screen panels40may be coupled to the tee section10at one end and to the plate structure30at the opposite end using a bolted connection. In one embodiment, the screen panels40may be coupled to the cage structure20at one or more locations using bolted connections. In one embodiment, the screen panel40may be in the form of a unitary cylindrical sleeve. The unitary cylindrical sleeve may be installed by sliding the sleeve over the cage structure20. The unitary cylindrical sleeve may be retained using an interference fit or a bolted connection. In one embodiment, the sleeve may be heated and thereby expanded to slide over the cage structure20, and subsequently cooled to form the interference fit to the cage structure20. In one embodiment, the cage structure may be cooled and thereby contracted to slide the sleeve over the cage structure20, and subsequently heated to form the interference fit with the sleeve. In one embodiment, the screen panel40may be in the form of a sheet of material. The sheet of material may be assembled by tightly wrapping the sheet of material around the cage structure20to form an interference fit or by using a bolted connection as described herein. In one embodiment, the screen panel40may include a plurality of spaced wires, ribs, mesh, and/or perforated sheets. As stated above, appropriate corrosion protection measures, such as gasket, washer, and/or isolation sleeve type members, may be used for the connections between the components of dissimilar materials.

The intake screen assembly100may also include a primary and/or secondary flow modifier disposed within the assembly. The flow modifies may include tubular members configured to evenly distribute the fluid flow through the assembly100. U.S. Pat. Nos. 7,950,527, 6,712,959, and 6,051,131, the contents of which are herein incorporated by reference in their entireties, disclose screen assemblies with primary and secondary flow modifiers that may be used with the embodiments described herein.

FIGS. 2A and 2Billustrate a support structure600(such as cage structure20) that may be used with the embodiments of the assembly100described herein and vice versa. The support structure600may include one or more circumferential supports622A-D (such as circumferential supports22) and one or more bars624(such as bars21and/or reinforcing members23). The support structure600may be coupled at one end directly to an intake member, such as the tee-section10, and/or via a support member, such as a plate member. A closure member, such as plate structure30, may also be coupled to the support structure600at an opposite end. A plurality of screen members or panels, such as screen panels40, may also be coupled to the support structure600to filter fluid flow into the support structure600.

As illustrated, the bars624may comprise straight tubular-type members. The bars624, however, may be solid, hollow, and/or include circular or polygonal shaped cross sections. A first end626of at least two bars624may be coupled together and/or at the same location to the circumferential support622A (and/or the tee-section10). The opposite or second end628of the at least two bars624may be coupled at different locations to the circumferential support622D (and/or the plate structure30), thereby forming a V-shape or zig-zag configuration. The second end628of the at least two bars624may be similarly coupled together and/or at the same location to the circumferential support622D with the ends of two other bars624. The bars624may form a zig-zag pattern around the circumference of the circumferential supports622A-D. In one embodiment, the bars624may be angled and oriented in the same direction around the circumference of the circumferential supports622A-D. The bars624may be arranged in other types of patterns known in the art. The bars624provide a truss-type support structure operable resist axial (tension and/or compression) and torsional loads applied to the support structure600.

The bars624may be coupled to the circumferential supports622A-D in a non-longitudinal straight line. The bars624may be disposed at an angle relative to the longitudinal axis of the support structure600and/or the central axis of one or more of the circumferential supports622A-D. The first end626and the second end628of each bar624may be coupled to the circumferential support622A and the circumferential support622D, respectively, at different longitudinal locations.

As illustrated inFIG. 2B, the first and second end626,628of the bars624may be coupled to the top or bottom surfaces of the circumferential supports622A,622D. In one embodiment, illustrated inFIG. 2C, the first end626of the bars624may be coupled further from (or closer to) the outer diameter OD of the circumferential support622A, while the second end628of the bars may be coupled further from (or closer to) the inner diameter ID of the circumferential support622D. In one embodiment, the first end626and the second end628of the bars624may be coupled to the inner and/or outer diameters of the circumferential supports622A,622D.

In one embodiment, as illustrated inFIG. 2B, the bars624may contact the inner diameter of the intermediate circumferential supports622B,622C that are disposed between the outermost circumferential supports622A,622D. In one embodiment, the bars624may not contact the inner diameter of the intermediate circumferential supports622B,622C. In one embodiment, the circumferential supports622A-D may include one or more grooves625along the inner surface (and/or along the outer surface) for securing and supporting the bars624along the longitudinal length of the support structure600. In one embodiment, the inner (and/or outer) diameter of the intermediate circumferential supports622B,622C may be oversized and/or undersized relative to the outermost circumferential supports622A,622D to provide and/or prevent contact with the bars624. In one embodiment, the bars624may be disposed through one or more of the circumferential supports622A-D. In one embodiment, one or more clamp-type members may be used to secure the bars624to the circumferential supports622A-D.

One or more bars624may be coupled to the inner diameter and/or outer diameter of one or more circumferential supports622A-D. In one embodiment, a plurality of screen/filter/panel members, such as wires, ribs, mesh, and/or perforated sheets may be coupled to and supported directly by the outer and/or inner surfaces of one or more bars624and/or one or more circumferential supports622A-D. In one embodiment, one or more components (e.g. members/bars23,624, circumferential supports/rings622A-D,22, longitudinal supports120, tee-section10, plate structures30, screen members/panels40, etc.) of the assemblies described herein may be formed integral with or separate from one or more other components of the assemblies. One more components may be coupled to one or more other components by welded, screwed, and/or bolted connections, by simple contact with (e.g. resting against) another component, and/or by other ways known in the art. One or more of the embodiments described herein may be used in whole or part with one or more other embodiments described herein.