Abstract:
In a rotodynamic pump, a seal chamber conditioning valve mechanism is positioned at least partially within the seal chamber of the pump to selectively and intermittently deliver fluid to or discharge contents from the seal chamber to modify the condition or content of the seal chamber and effectively protect the mechanical seal from failure due to, for example, built up solids or the presence of air. The conditioning valve mechanism may be actuated by a control device in communication with monitoring apparatus that determines the condition of the seal chamber, and particularly the mechanical seal face.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    This invention relates to rotodynamic pumps of the type typically used for processing or handling slurries. Specifically, this invention relates to structures and methods for controlling the conditions and content of a chamber surrounding the mechanical seal arrangement used with equipment such as rotodynamic pumps. 
         [0003]    2. Description of Related Art 
         [0004]    Rotodynamic pumps generally comprise an impeller which is connected to a drive shaft, and a pump casing in which the impeller rotates. Fluid processed by the pump can move to the area between the impeller and the drive side of the casing, around the drive shaft. Therefore, a mechanical seal arrangement is provided for sealing the drive shaft from leakage of fluid around the drive shaft. The mechanical seal of the drive shaft is often cooled and/or lubricated with a liquid flushed near the seal. Sometimes, the fluid used for flushing the system is that which is being processed by the pump. Thus, flushing systems in conjunction with mechanical seals in clear water and chemical processing pumps are well known. 
         [0005]    Exemplar flushing systems are disclosed in U.S. Pat. No. 5,605,436 to Pedersen and U.S. Pat. No. 5,772,396 to Rockwood. The &#39;396 patent exemplifies a seal construction where soft seal faces are employed an annulus is formed between the seal rotating face and the stationary stuffing box. One resulting effect of the &#39;396 configuration is a high potential for dry running at the seal face if flushing of the seal is not continuously maintained. 
         [0006]    In rotodynamic pumps that process fluid with entrained solids, i.e., slurries, the mechanical seal is also subject to wear from solids coming into contact with the seal. In certain rotodynamic pumps that are used for processing slurries, an expanded area, or seal chamber, may be provided around the mechanical seal. The enlarged seal chamber, defined generally between the back of the impeller and the pump casing, provides a stilling chamber and seal environment which is relatively high in pressure, low in air and low in turbulence. The seal chamber also provides an area through which fluid that is processed by the pump can be circulated at a lower velocity and, hence, higher pressure, to cool and/or clean the seal mechanism. 
         [0007]    In some systems, the cooling fluid is pumped into the seal chamber at increased pressures to keep the flushing fluid moving out of the seal chamber toward the pump casing. In others, a fluid is caused to circulate in a sweeping manner in the seal chamber to cool the seal faces, as disclosed in U.S. Pat. No. 5,195,867 to Stirling. In the &#39;867 patent, pumped fluid is circulated through the seal chamber at a low velocity and relatively high pressure to increase the likelihood that the seal chamber will operate in a positive pressure and to reduce the likelihood of air collecting, since air will always pass from a high pressure area to a low pressure area. 
         [0008]    With certain types of slurries, however, particularly those that contain high concentrations of air, solids or a suspension of air and solids, pockets of air can collect in the area of the seal faces and cause a dry running condition. Further, collection of solids about the seal faces can cause wear on the mechanical seal or, if the solids accumulate to a large enough size, the accumulated large solids can break off the surfaces within the seal chamber and damage the seal faces. Failure of the mechanical seal can, therefore, be caused by dry running conditions, by wear due to exposure to solids accumulated in the seal chamber or by actual damage brought about by collision with large agglomerations of solids. 
         [0009]    Known flushing or cooling systems for mechanical seals are not structured to address these problems. For example, known systems may include one or more flushing apertures positioned near the seal faces to cool or lubricate the seal face, but such apertures are not structured to control the amount of flushing liquid delivered to the seal face, and actual damage to the seal face can occur if, for example, cooling liquid strikes a high temperature seal that has been running under dry conditions. Nor are known flushing systems structured or positioned to remove or condition solids accumulations in the seal chamber. Additionally, known flushing systems, when flushed with a solids-containing fluid in close proximity to a seal face, can cause wear or damage. These known flushing systems need to operate continuously to allow the seal to function. Failure or interruption of the flushing system will ultimately cause the seal to fail. 
         [0010]    Therefore, it would be advantageous in the art to provide a seal chamber conditioning mechanism for modifying the condition or content of the seal chamber, particularly responsive to known conditions in the seal chamber that might potentially cause damage to the mechanical seal, such as dry running conditions or potentially damaging solids accumulation. Further, it would be beneficial to provide a system which operates intermittently to clean and/or condition the seal chamber in order to minimize the dilution of the slurry mixture, and one which operates as needed depending on the conditions of the seal chamber. 
       BRIEF SUMMARY OF THE INVENTION 
       [0011]    In accordance with the present invention, a valve mechanism, positioned in the seal chamber of a rotodynamic pump, is structured to provide selective modification of the contents or condition of the seal chamber to assure proper operation and condition of the mechanical seal at all times, thereby improving the seal life of the pump. While the seal chamber conditioning valve mechanism of the present invention is described for use in a centrifugal pump of the slurry type, the valve mechanism may be adapted for use in other types of equipment that use mechanical seals. including for example, clear liquid pumps and turbines. 
         [0012]    The valve mechanism of the present invention is comprised of a housing that is positioned, at least partially, in the seal chamber of a rotodynamic pump to effect delivery of fluid to the seal chamber, including the seal faces of the mechanical seal. The valve mechanism further comprises a first end having a selectively movable valve and valve seat which are oriented inwardly to the seal chamber. In an exemplar embodiment of the invention, the valve is biased by spring means to be registered against the valve seat. Other devices for selectively moving the valve relative to the valve seat may be implemented. 
         [0013]    A second end of the housing, opposite the valve seat, is positioned to reside outside the seal chamber, and is preferably accessible from outside the pump casing of the pump. An opening at the second end provides access to the biased valve such that the valve can be manually operated. Additionally, the opening at the second end of the housing may preferably be threaded to receive a similarly threaded conduit, such as a hose or pipe fitting, that delivers fluid to the valve housing. The fluid delivered by the conduit is pressurized to cause the valve to disengage from the valve seat, thereby providing fluid to the seal chamber. The fluid may be provided from, for example, a pressurized tank or source other than the pump. Alternatively, the conduit may be connected at its other end to the outlet of the pump so as to deliver fluid processed by the pump to the valve for delivery to the seal chamber. As used herein, “fluid” may include both liquid, gas or mixtures thereof. The valve mechanism may include a pressure and flow limiting device that modifies the flow of fluid through the valve. 
         [0014]    The valve is generally conically shaped, thereby effecting a conical-like spray of fluid into the seal chamber. Consequently, the positioning of the valve mechanism in the seal chamber and the conical-like spray pattern produced by the valve enables fluid to be delivered about the surfaces of the seal chamber to flush down and remove accumulated solids from the surfaces of the seal chamber. The valve mechanism is also directed to spray in the direction of the seal face of the mechanical seal to provide cooling and lubrication of the seal face. The valve mechanism is also positioned in the seal chamber to enable the conical-like spray of the valve to break up large air bubbles and to disperse the toroidally-shaped air bubble mass that may form about the pump shaft at high air concentrations. The dissipation of air bubbles from the area causes the seal chamber environment to improve by modifying the seal chamber condition to a more homogeneous mixture of fluid and solids. 
         [0015]    The valve mechanism, as noted above, is selectively operable manually or by introduction of pressurized fluid to the second end of the valve mechanism. As such, the valve mechanism can be manually actuated to open the valve and thereby effect a discharge from the seal chamber as may be required to modify the solids or gas (e.g., air) content of the seal chamber. 
         [0016]    When an external source of fluid is provided, via a fluid conduit, to the valve mechanism, the configuration of the valve assures that the valve will center properly on the valve seat and will close properly. Application of pressurized fluid to the housing provides a flushing of the valve housing to eliminate the accumulation of solids in the valve housing. 
         [0017]    The spring-loaded construction of the valve, in an exemplary embodiment of the invention, enables the valve to close if excessive pressurization of the valve occurs. That is, the conical spring that seats the valve will close upon itself if the amount of pressure exerted on the valve exceeds a selected load on the conical spring. Automatic closure of the valve mechanism prevents excessive flow of pressurized fluid and prevents excessively high pressure flushing fluid from reaching the seal chamber and seal face, which would introduce undesirable turbulence into the seal chamber. The conical spring about the valve has an added advantage of acting as a restrictive orifice such that as pressure rises in the valve housing and the valve opens, the coils of the spring close together limiting the flow of fluid through the valve mechanism. Thus, the conical spring provides a pressure and flow limiting device. The coil spring is also self-cleaning since solids cannot build up around the spring as it flexes. 
         [0018]    The number of valve mechanisms positioned in the seal chamber may vary. Preferably, however there may be at least three valve mechanisms evenly spaced circumferentially about the drive shaft. As many as six or more valve mechanisms may be evenly spaced about the drive shaft. All of the valve mechanisms may operate similarly to both selectively introduce or discharge fluid from the seal chamber. Alternatively, some of the valve mechanisms may be selectively actuated to discharge contents from the seal chamber while others may be selectively actuated to introduce flushing media into the seal chamber in, for example, an alternating pattern of valves about the drive shaft. Still other valve mechanisms may be used to monitor conditions of the seal chamber, such as pressure, temperature and the presence of, for example, air and excessive solids. 
         [0019]    The seal chamber conditioning valve mechanism of the present invention can be selectively actuated to either discharge contents from or introduce flushing fluid into the seal chamber upon determination of a particular condition within the seal chamber or the seal faces. That is, upon determination, for example, that too much gas is present in the seal chamber, thereby potentially leading to the formation of a gas bubble and dry running of the mechanical seal, some or all of the valve mechanisms may be manually actuated to release gas from the seal chamber, while others may be actuated to introduce flushing fluid into the seal chamber to dissipate the larger air pockets and lubricate or cool the seal face. The determination of the condition or status of the environment within the seal chamber may be monitored by any suitable means, such as a thermocouple. A monitoring element may be positioned in the seal chamber, preferably at or near the seal face. 
         [0020]    It is the unique ability to selectively actuate the seal chamber conditioning valve mechanism of the present invention to modify the condition of the environment within the seal chamber or modify its contents that presents an improvement in preservation and maintenance of the mechanical seal in rotodynamic pumps. That is, the ability to determine stress on or imminent failure of the seal due to adverse conditions in the seal chamber, and to modify the conditions within the seal chamber to save the seal, provides the most significant advantage via the present invention. These and other advantages will become more apparent upon reference to the description provided hereinafter. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0021]    In the drawings, which currently illustrate the best mode for carrying out the invention: 
           [0022]      FIG. 1  is a view in longitudinal cross section of a centrifugal pump illustrating the general elements of the pump, including the seal chamber, and the position of the conditioning valve of the invention; 
           [0023]      FIG. 2  is an enlarged view in longitudinal cross section of the seal chamber of the pump further illustrating the detail of the conditioning valve; 
           [0024]      FIG. 3  is an enlarged view in cross section of the seal chamber conditioning valve of the present invention; and 
           [0025]      FIG. 4  illustrates schematically an embodiment of the invention which employs a system for monitoring conditions within the seal chamber. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0026]      FIG. 1  illustrates, in partial cross section, a centrifugal pump  10  of the type used to process slurries. The pump  10  generally comprises a pump casing  12  which, in turn, comprises a volute casing  14  to which is attached to a suction inlet casing  16 . As shown, the volute casing  14  may preferably comprise a front casing  18  and a back casing  20 . In the particular embodiment of the pump  10  shown, casing liners  22 ,  24  are installed on the inner surface of the front casing  18  and back casing  20 . The pump  10  further comprises a frame plate adaptor  28  that attaches to the back casing  20 . A frame plate liner insert  30  is positioned adjacent the frame plate adaptor  28 . 
         [0027]    An impeller  32  is positioned in the pump casing  12  and is secured to a pump shaft  34  that extends through the frame plate adaptor  28 . The pump shaft  34  also extends through a bearing housing  36  in which is located a set of bearings (not shown) which support the pump shaft  34 . The pump shaft  34  is also keyed for attachment to a motor or drive belt mechanism (not shown). The features of a pump bearing housing  36  and motor are well-known in the art and are not discussed in further detail herein, but will be known to those of skill in the art. 
         [0028]    A mechanical seal  40  is positioned about the pump shaft sleeve  58  at the point of extension of the pump shaft  34  through the frame plate adaptor  28 . The mechanical seal  40  prevents fluid from leaking out of the pump  10  and around the pump shaft  34 . In this particular embodiment of a slurry pump  10 , the pump  10  is configured with a seal chamber  42  that comprises an enlarged area about the mechanical seal  40 . The relative positioning of a seal chamber conditioning valve mechanism  44  of the present invention is illustrated in  FIG. 1   
         [0029]    It can be appreciated from the view of the pump  10  in  FIG. 1  that fluid enters the inlet  48  of the pump  10  by suction created by the rotation of the impeller  34  within the casing  12 . The impeller  32  directs the fluid into the volute  14  where it is discharged from an outlet (no shown) tangentially oriented to the volute. The pressure of the processed fluid causes fluid to travel through a gap  50  formed between the back shroud  52  of the impeller and frame plate liner insert  30  of the pump  10 , and into the seal chamber  42 . Solids and gases are typically entrained in the fluid. Solids may then build up in the seal chamber and may even accumulate on the frame plate liner insert  30  and the back shroud  52  of the impeller  34 . This condition causes the seal face temperature to rise. Removal of the solids and gases is then required to keep the seal from failing. The valve mechanism  44  of the present invention thus serves to quickly modify the condition or contents of the seal chamber to allow the seal to continue to operate without leakage until the cause of the problem is corrected. 
         [0030]      FIG. 2  provides an enlarged view of one half of the pump shaft  34  and seal chamber  42 , better illustrating the elements of the mechanical seal  40  and valve mechanism  44 . As previously described, the pump shaft  34  is connected to the impeller  32  by appropriate means, here illustrated as a threaded engagement  56 . A pump shaft sleeve  58  surrounds the pump shaft  34  and is positioned axially between the hub portion  59  of the impeller  32  and a release collar  60 . Both the pump shaft sleeve  58  and release collar  60  rotate with the pump shaft  34 . 
         [0031]    The mechanical seal  40  comprises a mechanical seal sleeve  62  that is positioned about the pump shaft sleeve  58  and rotates with the pump shaft sleeve  58 . A rotating seal face holder  64  is secured to the mechanical seal sleeve, as shown in  FIG. 2 , and rotates with the mechanical seal sleeve  62 . The rotating seal face holder  64  provides support for a mechanical seal rotating face  66  which rotates with the rotating seal face holder  64 . A stationary mechanical seal face  68  abuts the mechanical seal rotating face  66  and thereby defines a seal face  70  therebetween. The stationary mechanical seal face  68  is secured to a mechanical seal gland plate  74  by means of a plurality of drive pins  76 . Though not shown, a plurality of biasing springs are positioned between the mechanical seal gland plate  74  and the stationary mechanical seal face  68  to maintain a tight fit between the stationary seal face  68  and rotating face  66  at the seal face  70 . An o-ring  78  is also positioned between the mechanical seal gland plate  74  and the stationary mechanical seal face  68  to prevent leakage of fluid therebetween. 
         [0032]    The seal chamber conditioning valve mechanism  44  of the present invention is shown positioned through an opening  80  formed in the mechanical seal gland plate  74 . While only one valve mechanism  44  is shown, it is understood that a plurality of such valve mechanisms  44  may preferably be distributed circumferentially around the pump shaft  34  and positioned, as shown, through the gland plate  74 . The valve mechanism  44  may preferably be threadingly received into the opening  80  of the gland plate  74 . An o-ring  82  is positioned between the valve mechanism  44  and the threaded opening  80 . The valve mechanism  44  comprises a housing  90  which has a first end  92  that is oriented toward the interior of the seal chamber  42  and a second end  94  that is positioned external to the pump casing  12  thereby providing access to actuation of the valve mechanism  44 . 
         [0033]    Further detail of the seal chamber conditioning valve mechanism  44  can be seen in  FIG. 3  where, notably, the housing  90  is provided with a threaded neck portion  96  that is received into a correspondingly threaded opening  80  ( FIG. 2 ) in the gland plate  74 . It can also be seen that the housing  90  is formed with an internal bore  98  that extends from the first end  92  to the second end  94  of the valve mechanism  44 . At the first end  92  of the valve mechanism  44 , the internal bore  98  defines a valve seat  100  against which a valve  102  registers when the valve mechanism  44  is in a closed position, as illustrated. 
         [0034]    The valve  102  is connected to a valve stem  106  that is concentrically positioned within the bore  98  of the housing  90 . In the particular embodiment illustrated, the valve stem  106  is a hex flange bolt having a flanged hex head  108  at a first terminal end  110  against which the valve  102  is positioned. A flat washer  112  and locknut  114  are threaded onto the opposing second end  116  of the valve stem  106 . A conically configured spring  120  is positioned to encircle the valve stem  106  and is biased between the flat washer  112  and an inwardly extending shoulder  122  of bore  98 . 
         [0035]    A second end  126  of the housing  90  of the valve mechanism  44  is configured as a threaded female coupling  126  to which a fluid conduit, such as a hose or other pipe fitting (not shown), may be attached for introducing fluid into the valve mechanism  44 . The coupling  126  also provides an opening through which access may be made to the second end  116  of the valve stem  106  for manually actuating the valve  102 , as described more fully below. 
         [0036]    The valve  102  is conically shaped and the valve seat  100  against which the valve  102  registers is configured with a complimentary conical shape. Consequently, when fluid is introduced into the bore  98  of the valve housing  90  through the coupling  126 , the pressure of the fluid causes the valve  102  to move out of registration with the valve seat  100  and a conically shaped spray is produced. 
         [0037]    Referring to  FIG. 2 , it can be seen that the first end  92  of the housing  90  of the valve mechanism  44  is flush with the inner-facing surface  130  of the gland plate  74 . The valve mechanism  44  is, therefore, positioned to provide a conical spray to the gland plate  74  and the seal face  70  to wash away solids, and particularly solids that may have accumulated on those surfaces or structures. The distribution of a plurality of such valve mechanisms  44  circumferentially about the pump shaft  34  ensure that the seal chamber  42  is substantially flushed of solids. The distribution of the valve mechanisms  44  about the pump shaft  34  further assures a comprehensive dissipation of large air pockets that might have formed in the seal chamber  42 , particularly in the area of the seal face  70 . The conical spray provided by the valve  102  breaks larger air pockets into smaller bubbles that are dispersed more effectively into the contents of the seal chamber  42 . The position of the first end  92  of the valve housing  90  flush with the surface  130  of the gland plate  74  also avoids the production of turbulence in the seal chamber when displacement fluid is being introduced by the conical spray. 
         [0038]    The conical shape of the valve  102  also enables an even flow of fluid through the bore  98  of the housing  90  and about the valve stem  106 . This factor assures that solids are flushed from the valve mechanism  44 . The conical shape of the spring  120 , in combination with the conical shape of the valve  102 , further assures that the valve stem  106  remains centered in the housing  90  and the conical shape of the spring  120  provides a pre-loaded condition that assures proper closing of the valve  102  against the valve seat  100 . 
         [0039]    Displacement fluid can be introduced into the coupling  126  of the valve mechanism  44  from a variety of sources. For example, process fluid can be taken from the outlet of the pump and circulated into the valve mechanism  44  by conduit means known in the industry. The displacement fluid can also be in the form of a gas or liquid supplied from an external source, such as a tank. 
         [0040]    The valve mechanism  44  of the present invention is also structured to be manually actuated by accessing the valve stem  106  through the coupling  126 . This may be accomplished by insertion of a tool through the coupling  126  that engages the second end  116  of the valve stem  106 , thereby enabling movement of the valve stem  106  for disengagement of the valve  102  from the valve seat  100 . The manual actuation of the valve mechanism  44  enables the valve mechanism  44  to be opened for discharge of air, fluid and solids from the seal chamber  42  as may be required. Once air, fluid and solids are discharged through the valve mechanism  44 , any residual solids can be flushed from the valve mechanism  44  by closing the valve  102  and introducing fluid, from a fluid conduit connected to the coupling, into the valve housing  90 . 
         [0041]    The conditions of the seal chamber  42  and the seal face  70  may be monitored by any appropriate monitoring apparatus  120  or means to enable the valve  44  to be intermittently actuated as required to modify the conditions or content of the seal chamber  42 . As illustrated schematically in  FIG. 4 , such monitoring apparatus may include, for example, a thermocouple  122  positioned at or near the seal face  70 . The thermocouple  122  is capable of monitoring the temperature at the seal face  70  and producing a signal that is transmitted, such as by wire  126 , to a control device  128  located outside the casing  12  of the pump. The control device  128  is in electrical and/or mechanical communication, such as via wire  132 , with a solenoid valve  136  connected to the conditioning valve mechanism  44 . 
         [0042]    Thus, when data is sent from the thermocouple  122  to the control device  128  concerning the condition of the seal face  70  or the seal chamber  42 , such as temperature, the control device  128  processes the data and determines when it may be appropriate to signal the valve  102  to open via action of the solenoid  136 . The valve  102  opens to either allow discharge of some of the contents of the seal chamber  42  or to allow introduction of fluid through the valve mechanism  44  into the seal chamber. The control device  128  can, therefore, also control a source of fluid to provide that fluid to the valve housing  90  as conditions dictate. One or more control devices  128  can be used to operate a plurality of valves  44 , and the control devices  128  can be made to intercommunicate data between the devices  128 . 
         [0043]    A centrifugal pump may be structured with a plurality of valve mechanisms  44  encircling the pump shaft  34 , as described, where all of the valve mechanisms  44  are actuated at the same time and in the same manner. That is, all valve mechanisms  44  may be simultaneously actuated together to either introduce fluid into the seal chamber  42  or to discharge fluid from the seal chamber  42 . Alternatively, the valve mechanisms  44  may be actuated individually or in alternating series (e.g., every other valve mechanism  44  being actuated to introduce fluid into the seal chamber  42 ) to provide a conditioning effect within the seal chamber  42  that is unique to the current condition of the seal chamber  42 . 
         [0044]    While the seal chamber conditioning valve mechanism of the present invention is particularly suited for modifying the conditions and content of a seal chamber in a centrifugal slurry pump, the valve mechanism of the invention may be adapted for use in any number of other types of pumps and for other purposes. Hence, reference herein to specifics of the structure and positioning of the valve mechanism of the invention is by way of example only and not by way of limitation.