Abstract:
Pumping under the present invention includes movement of material, in a first embodiment fluid and in a second embodiment a piston assembly, between first and second positions including detection of said material at each position. Control circuitry and supporting mechanical and fluid coupling responsive to material position toggles the pump into alternate modes of operation driving the material toward each point. The pump arrangement has fewer moving parts than traditional pumps and enjoys higher reliability for its simplified design.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to pumping devices and particularly to a pumping device having limited moving mechanical parts. 
     All pumps of whatever type are subject to mechanical wear. In the case of a recirculating pump, where the outlet fluid eventually returns to the inlet, a rotary gear pump has been generally used. Because it is a constant volume pump, it should be sized according to the expected fluid demand. A recirculating pump is especially vulnerable to any dirt or debris in the fluid. Further, a recirculating pump is not easily movable because of the required driving unit used in conjunction with a recirculating pump. The driving unit, mechanical coupling, and recirculating pump itself all combine to reduce reliability and increase maintenance costs. A recirculating pump is usually not expected to have a high delivery rate, but reliability is of the utmost importance. In particular, as used in oil drilling operations a recirculating pump must operate to maintain operation of the entire oil well. Once the recirculating pump fails, the entire oil well must be shut down for repair or replacement of the recirculating pump. 
     Air driven pumps have the liability of a mechanical shuttle arrangement built into the pump itself, and the shuttle arrangement is a typical cause for pump failure. The mechanical constraints of the shuttle valve often put a limit on pump configuration. Pump discharge pressure typically cannot be raised much without sacrificing output volume. Many air driven pumps also use a diaphragm along with the shuttle valve and this introduces an additional source of potential mechanical failure. 
     SUMMARY OF THE INVENTION 
     A pump under one embodiment of the present invention comprises an air source for coupling to air pressurized relative to ambient air pressure, a first chamber including an inlet and an outlet, and a second chamber including an inlet and an outlet. An air pressure conduit network couples, in a first state, the air source and the first chamber and couples, in a second state, the air source and the second chamber inlet. A transfer conduit network couples, in a first state, the first chamber outlet and the second chamber inlet. The transfer conduit couples, in a second state, the second chamber outlet and the first chamber inlet. A control drives into selected states each of the air pressure conduit network and the transfer conduit network to cause exchange of fluid between the first and second chambers. 
     A pump under the present invention provides suction of a fluid body and discharge of a fluid body obtained by suction, and includes at least one power cylinder having slidably and sealably disposed therein a piston defining a first and second chamber of the pumping cylinder. A pressurized air conduit network couples, in a first state, a source of pressurized air and the left chamber while concurrently opening for exhaust the right chamber. In a second state of air said conduit network, said network couples the source of pressurized air to the right chamber while concurrently opening the left chamber for exhaust. A pumping cylinder, including a piston slidably disposed therein and mechanically coupled to the pumping cylinder piston, defines a chamber of the pumping cylinder. A discharge port and a suction port fluidly coupled to the pumping cylinder chamber accomplish alternate suction of the fluid body and discharge of the fluid body obtained by suction. 
     The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation of the invention, together with further advantages and objects thereof, may best be understood by reference to the following description taken with the accompanying drawings wherein like reference characters refer to like elements. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a better understanding of the invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which: 
     FIG. 1 illustrates a first embodiment of the present invention applied as a recirculating pump maintaining a sealing liquid against a double mechanical seal in a primary pumping system. 
     FIG. 2 illustrates a control circuit responsible for operation of the pump under the present invention. 
     FIG. 3 illustrates a second embodiment of the present invention operating as a shuttle pump. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 illustrates a first embodiment of the present invention applied as a recirculating pump maintaining a sealing liquid, e.g., oil, pressurized against a double mechanical seal of a primary pumping system. For example, such primary pumping system might be as found in oil well drilling transfer pumps. Transfer pumps carry abrasive material and desirably include a sealing liquid maintained at controlled pressure against double acting seals to avoid excessive deterioration thereof. The first illustrated embodiment of the present invention finds application in an oil well drilling system maintaining sealing liquid at controlled pressure against a double mechanical seal of a centrifugal pump. 
     In FIG. 1, an air powered recirculator 10 maintains a sealing liquid 12 pressurized relative to a double mechanical seal 14 of a plurality of centrifugal pumps 16 (one such pump 16a being shown in FIG. 1). Recirculator 10, in the particular embodiment of in FIG. 1, accommodates eight such centrifugal pumps 16. Pump 16a and corresponding double mechanical seal 14a is shown in FIG. 1 and remaining centrifugal pumps 16b-16h are shown schematically and by block diagram in FIG. 1. While illustrated for service of eight such centrifugal pumps 16, it will be understood that recirculator 10 may be modified to support fewer than eight pumps 16, e.g., by plugging appropriate supply and drain manifolds, and to support more than eight pumps 16 by increasing the drain manifold inlets and the supply manifold outlets as will be apparent given the disclosure herein. 
     Recirculator 10 includes chambers or tanks 20a and 20b. Each tank 20 includes an inlet 22 at an upper portion thereof and a drain 24 at a lower portion thereof. Recirculator 10 further includes spool valves 30a, 30b, and 30c with a network of conduits coupling valves 30, tanks 20, and pumps 16 as described more fully hereafter. A first portion of the conduit network selectively and alternately applies air pressure to the inlets 22 while the remaining portion provides a fluid 12 transfer path between tanks 20 and including seals 14. Generally, when one of tanks 20 is draining, under air pressure applied to its inlet 22, the other tank 20 is refilling with sealing liquid 12 applied to its inlet 22 and originating from the draining tank 20. 
     As illustrated in FIG. 1, tank 20b is presently draining with air pressure applied at the inlet 22b and liquid 12 forced out drain 24b. Also in FIG. 1, tank 20a is presently filling with a source of recirculated sealing liquid 12 provided at inlet 22a. Sealing liquid 12, as transferred under pressure between tanks 20a and 20b, passes by mechanical seals 14 of centrifugal pumps 16, e.g., past seal 14a of pump 16a. Because sealing liquid 12, when present at each seal 14, is controllably pressurized, sealing liquid 12 performs the desired function sealing with respect to operation of pumps 16. Once past the mechanical seals 14, sealing liquid 12 returns to a &#34;filling&#34; one of tanks 20. 
     Each of tanks 20a and 20b further includes a level detection switch 26, illustrated individually as switches 26a and 26b, respectively. When the level of sealing liquid 12 in a given tank 20 passes below the corresponding level switch 26, the tank 20 is considered &#34;empty&#34; and the switch 26 changes state. When sealing liquid 12 in a given tank 20 rises above the corresponding level switch 26, level switch 26 changes state. The state of switches 26a and 26b represent a measure of volume of sealing liquid 12 in each of tanks 20a and 20b, respectively, relative to a reference &#34;empty&#34; volume. In the illustrated example of FIG. 1, each of level switches 26 are located near the corresponding drains 24, and therefore represent volume of sealing liquid 12 relative to an &#34;empty&#34; condition though not allowed to literally empty completely of fluid 12. 
     Each of spool valves 30a-30c are driven by a corresponding one of solenoids 32, individually designated 32a-32c, respectively. A control signal 230, individually 230a-230c, applied to each solenoid 32 dictates operation in a selected state. Each of spool valves 30 include fluid ports 34, 36, and 38, designated individually by subscript. For example, spool valve 30a includes ports 34a, 36a, and 38a. 
     In addition, spool valve 30b contains air exhaust ports 40b and 42b. Valves 30a and 30c are identical. Valve 30 operation is as follows: without power applied to the solenoid of valve 30a, port 36a is connected to port 34a and port 38a is blocked. With power applied to the solenoid of valve 30a, port 36a is connected to port 38a and port 34a is blocked. As shown in FIG. 1, power is presently applied to the solenoid 32a of valve 30a. Accordingly, port 36a is connected to port 38a and port 34a is blocked. Further, as presently illustrated in FIG. 1, power is not applied to the solenoid 32c of valve 30c. Accordingly, port 36c is connected to port 38c and port 34c is blocked. 
     Valve 30b does not have a blocked port at any time. Operation of valve 30b is as follows: with no power applied, port 36b connects to port 34b and port 38b connects to exhaust port 40b. With power applied, however, port 36b is connected to port 38b and port 34b connects to exhaust port 42b. In FIG. 1, valve 30b is shown presently with no power applied. 
     With power applied, each valve 30 operates in a powered state. With no power applied, each valve operates in an unpowered state. As shown in FIG. 1, valve 30a is in its powered state and valves 30b and 30c are in their unpowered state. When tank 20b eventually empties and tank 20a is filled, the control-signal to each spool valve 30a, 30b, and 30c changes, i.e., spool valve 30a enters its powered state and valves 30b and 30c go to their unpowered state. 
     Recirculator 10 receives pressurized air at its air regulator/filter 50. Conduit 52 couples air regulator/filter 50 to port 36b of spool valve 30b. Conduit 54 couples port 34b of spool valve 30b, inlet 22b of tank 20b, and port 34a of spool valve 30a. Conduit 56 couples port 38b of spool valve 30b, inlet 22a of tank 20a, and port 38a of spool valve 30a. Conduit 58, including an isolation valve 58a and strainer 58b, couples drain 24a of tank 20a and port 34c of spool valve 30c. Conduit 60, including an isolation valve 60a and strainer 60b, couples drain 24b of tank 20b and port 38c of spool valve 30c. 
     Port 36c of spool valve 30c couples directly to a common chamber of manifold 62. Manifold 62 distributes sealing liquid 12 as received from spool valve 30c among eight manifold 62 ports 62a-62h. Each of manifold 62 ports 62a-62h couple to a corresponding one of pumps 16a-16h. For example, conduit 64a couples port 62a to mechanical seal 14a of centrifugal pump 16a. Similar conduits 64b-64h couple manifold 62 ports 62b-62h to corresponding ones of pumps 16b-16h as illustrated schematically in FIG. 1. 
     Each of pumps 16 couple by one of conduits 68a-68h to inlet ports 66a-66h of a drain manifold 66. For example, conduit 68a couples seal 14a and drain manifold 66 inlet 66a. Similar conduits 68b-68h couple corresponding ones of seals 14b-14h with inlets 66b-66h of drain manifold 66. Each of conduits 68 terminate, i.e., just prior to a common chamber of manifold 66, with an oil filter 70 and line restriction 72. For example, conduit 68a terminates at filter 70a and line restriction 72a. Each oil filter 70 removes debris picked up in what is referred to as the &#34;stuffing box&#34;, i.e., picked up at the seal 14 of pump 16. Restrictions 72 are small relative to the corresponding conduit 68. The degree of restriction provided by each of restrictions 72a-72h in conjunction with the regulated air pressure and sealing liquid 12 viscosity determines the sealing liquid 12 flow rate individually for each of centrifugal pumps 16a-16h, respectively. Conduit 80 couples the common chamber of manifold 66 to port 36a of spool valve 30a. 
     FIG. 2 illustrates control circuit 100, responsible for detecting and comparing the condition of level switches 26a and 26b, and then appropriately driving solenoids 32a-32c to place spool valves 30a-30c into an appropriate state. In FIG. 2, control circuit 100 senses, by way of switches 26a and 26b, fluid 12 level in each of tanks 20a and 20b, respectively. NAND gates 200a-200d connect to form an RS latch 202. An exclusive OR gate 204 provides an enable signal 206 to latch 202. Switches 26a and 26b provide respective first and second inputs to exclusive OR gate 204. Further, switch 26a applies as an input 207a to gate 200a and switch 26b applies as an input 207b to gate 200d. 
     The output of exclusive OR gate 204 is high only when the state of switch 26a is different from that of switch 26b. Once the enable signal to latch 202 is present, latch 202 responds to the inputs 207 provided by switches 26a and 26b. Inputs 207 to latch 202, therefore, can only be recognized by latch 202 when either tank 20a or tank 20b is &#34;empty&#34; as indicated by the corresponding one of switches 26a and 26b. Tanks 20a and 20b are never &#34;empty&#34; concurrently. When tank 20b is empty, it is assumed that tank 20a is full. At all intermediate points, i.e., when both tanks 20a and 20b contain fluid, the exclusive OR gate 204 disables latch 202. Accordingly, the Q output 208 and NOT Q output 210 of latch 202 remain stable, i.e., in the same state that existed at the time the exclusive OR gate 204 last detected one of tanks 20a and 20b as being &#34;empty.&#34; 
     As fluid 12 transfers from, for example, tank 20b to tank 20a, tank 20b eventually becomes &#34;empty&#34; and tank 20a eventually becomes &#34;full.&#34; At the time that exclusive OR gate 204 detects an &#34;empty&#34; signal from switch 26b, exclusive OR gate 204 generates an enable signal for latch 202 causing the outputs 208 and 210 of latch 202 to reverse state. Tank 20b then begins to fill. Once tank 20b fills and tank 20a empties, the cycle repeats. 
     An AC power source, including an AC line voltage 220 and neutral voltage 222, applies to a network of solid state relays 224, individually 224a-224c. In particular, a load A output 230a includes the neutral voltage 222 and a switched AC line voltage 220, i.e., switched via solid state relay 224a. Similarly, a load B output 230b includes neutral voltage 222 and a switched line voltage 220, i.e., switched via solid state relay 224b. Finally, output 230c includes neutral voltage 222 and to a switched line voltage 220, i.e., switched via solid state relay 224c. Latch 202 Q output 208 drives solid state relays 224b and 224c while latch 202 NOT Q output 210 drives solid state relay 224a. As may be appreciated, outputs 208 and 210 may also drive additional solid state relays 224 if needed. With control circuit 100 outputs 230a-230c coupled to corresponding ones of solenoids 32a-32c, as shown in FIG. 1, control circuit 100 responds to the level of fluid 12 in tanks 20a and 20b to appropriately drive valves 30a-30b and accomplish alternating transfer of fluid 12 between tanks 20a and 20b. 
     FIG. 1 illustrates initial conditions where tank 20b is &#34;full&#34; of sealing liquid 12 and tank 20a is &#34;empty&#34;, i.e., below level switch 26a. Additional initial conditions also illustrated in FIG. 1 show spool valve 30a port 36a coupled to port 38a. Spool valve 30b couples its ports 36b and 34b and couples its port 38b to ambient air. 
     In operation of the embodiment illustrated in FIG. 1, tank 20b is initially filled with sealing liquid 12. Air pressure applied via spool valve 30b at inlet 22b of tank 20b forces sealing liquid 12 in tank 20b through its drain 24b and, via conduit 60 and spool valve 30c into manifold 62. Air pressure in conduit 54, i.e., as applied to inlet 22b of tank 20b, is blocked at port 34a of spool valve 30a. In such condition, sealing liquid 206 flows from tank 12 under regulated air pressure through isolation valve 60a, strainer 60b, spool valve 30c, manifold 62, conduits 64, mechanical seals 14 of pumps 16, through conduits 68, into manifold 66 and returns to tank 20a by way of spool valve 30a and inlet 22a. Because drain manifold 66 pressure is atmospheric, sealing liquid 12 simply flows to spool valve 30a and drains into empty tank 20a. As tank 20a fills with sealing liquid 12, air existing in tank 20a exhausts through conduit 56 to ports 38b and 40b of spool valve 30b. 
     Eventually, tank 20b drains sufficiently and state transition in switch 26b occurs. Control circuitry 100 detects this transition, samples the current state of switches 26a and 26b, manipulates spool valves 30 and toggles operation of recirculator 10 into a second state transferring sealing liquid 12 in tank 20a to tank 20b. 
     The recirculator 10 as illustrated in FIGS. 1 and 2 enjoys significant advantages relative to prior recirculator pumps. First, recirculator 10 is primarily air powered, with the only electric power required, being that needed to operate control circuit 100 and solenoids 32. A sufficient air supply is generally available wherever centrifugal pumps 16 are used, but not necessarily a convenient electrical energy supply. Furthermore, the cubic foot per minute demand of recirculator 10 is relatively low and pressure required is generally less than 100 pounds-per-square inch (PSI). Importantly, recirculator 10 has few mechanical moving parts. In fact, only the solenoid valves 32 and switches 26 mechanically change position. As a result, recirculator 10 has extremely low maintenance costs and high reliability. A single recirculator 10 provides constant sealing fluid 12 pressure across a number of pump 16 &#34;stuffing boxes.&#34; As indicated herein above, the number of pumps 16 supported by a single recirculator 10 may vary by simple modification to recirculator 10. Flow rate may be adjusted individually over a relatively wide range with respect to each centrifugal pump 16. Sealing liquid 12 as applied to pump 16 stuffing boxes is both recirculated and filtered. As a result, the life of mechanical seals 14 is greatly extended. Furthermore, recirculating sealing liquid 12 avoids undesirable environmental discharge of fluid 12. As a result, recirculator 10 enhances environmental criteria at each centrifugal pump 16. 
     FIG. 3 illustrates a second embodiment of the present invention, a shuttle pump 310. Shuttle pump 310 includes cylinders 320, individually, 320a, 320b, and 320c. Pistons 322, individually pistons 322a, 322b, and 322c, reside slidably and sealably in each of the cylinders 320a, 320b, and 320c, respectively. Pistons 322a and 322b define within each of the corresponding cylinders 320a and 320b a left chamber 324 and a right chamber 325, with reference to the orientation of FIG. 3. For example, piston 322a defines a left chamber 324a and a right chamber 325b within cylinder 320a. Piston 322c defines a right chamber 325c within cylinder 320c. 
     Cylinders 320 lie coaxially and pistons 322 couple mechanically with fixed spacing therebetween along a central axis 330. In particular, rod 332 couples in fixed relation pistons 322a and 322b. Rod 332 passes in sliding, sealed relation relative to chambers 325a and 324b at sealed rod support apertures 334 as provided in cylinders 320a and 320b. Similarly, rod 336 couples in fixed relation pistons 322b and 322c and passes in sliding, sealed relation to chamber 325b at support aperture 334 as provided in cylinder 320b. 
     Cylinder 320a further includes proximity switches 326a and 326b detecting given leftward and rightward excursion, respectively, of piston 322a relative to cylinder 320a. Cylinder 320c includes at its right chamber 325c a discharge port 340 and a suction port 342. Intermediate of discharge port 340 and chamber 325c is a check valve 340a. Similarly, intermediate suction port 342 and chamber 325c is a check valve 342a. 
     A four-way open exhaust solenoid valve 350 includes a solenoid 352 driven between first and second states by means of shuttle control 354. In a first state, valve 350 couples its inlet port 356, receiving a source of pressurized air, with a first outlet 358. Outlet 358 couples by means of conduit 360 to the left chambers 324a and 324b of cylinders 320a and 320b, respectively. 
     In the first state of solenoid valve 350, a second port 362 couples to exhaust port 364 and exhaust port 368 is blocked. Conduit 366 couples second outlet 362 to the right chambers 325a and 325b of cylinders 320a and 320b, respectively. Thus, in the first state of solenoid valve 350, pressurized air appears in the left chambers 324a and 324b of cylinders 320a and 320b while cylinders 320a and 320b exhaust air from the right chambers 325a and 325b by way of exhaust outlet 364. 
     In the second state, valve 350 couples its inlet port 356 to port 362, thus pressurizing chambers 325a and 325b of cylinders 320a and 320b, respectively. In this second state, valve 350 allows escape of air through port 358 to the now open exhaust port 368 from the left chambers 324a and 324b of cylinders 320a and 320b, respectively. Exhaust port 364 is blocked. 
     Cylinders 320a and 320b are considered the &#34;power&#34; cylinders and cylinder 320c the &#34;pumping&#34; cylinder. When pressurized air is applied to the inlet port 356 of valve 350, given the device state illustrated in FIG. 3, the left chambers of the &#34;power&#34; cylinders are pressurized while the right chambers of the &#34;power&#34; cylinders are opened to the atmosphere. As the pistons 322a and 322b move to the right, eventually piston 322a engages proximity switch 326b. Shuttle control 354 responds by driving solenoid valve 350 into its opposite state. This introduces pressurized air into the right chambers 325a and 325b of the &#34;power&#34; cylinders 320a and 320b and allows the left chambers 324a and 324b of the &#34;power&#34; cylinders 320a and 320b to exhaust. The assembly of pistons 322 then moves leftward in the view of FIG. 3. Eventually, piston 322a engages proximity switch 326a and shuttle control 354 drives valve 350 into its opposite state and the cycle repeats. Pistons 322 thereby shuttle alternately leftward and rightward. 
     As pistons 322 move rightward, fluid present in right chamber 325c of cylinder 320c is forced out through check valve 340a to discharge port 340a. Suction check valve 342a is forced to a closed position. Similarly, as pistons 322 move leftward, chamber 325c of cylinder 320 fills with fluid as drawn in through the suction port 342. In this manner, fluid is alternately drawn into suction port 342 and discharged from discharge port 340. 
     In this second embodiment of the present invention, control 354 is substantially identical to control 100 described above for the first embodiment of the present invention. The second embodiment, however, requires only one relay following the Q output of the RS latch and one relay following the NOT Q output of the RS latch. As may be appreciated, the condition sensed in the second embodiment of the present invention is cylinder position, as opposed to fluid level in the first embodiment. In each embodiment, the control device is a mechanism detecting position of a material and causing shuttle of such material alternately between two points. 
     By stacking additional &#34;power&#34; cylinders, i.e., similar to cylinders 320 and 320b and coupled for coordinated movement with pistons 322a and 322b, magnification of the pumping and suction pressure is achieved. Also, when the &#34;power&#34; pistons have a greater diameter relative to the &#34;pumping&#34; piston, e.g., six and one-half inches versus five inches diameter, then the output pressure may be computed as 2(61/2/5) 2  (input air pressure). Thus, assuming an input pressure of 120 PSI, the output pressure is 405 PSI. Thus, either or both piston stacking and relative diameter of power/pumping piston ratio can be changed to achieve a pressure or volume change. 
     Using the control 354 and air operated piston pump arrangement of the shuttle pump 310, the shuttle mechanism is external to the pump. Accordingly, piston and cylinder layout is simplified and made more flexible. 
     Shuttle pump 310 is powered primarily by pressurized air, requiring only sufficient electrical energy to operate shuttle control 354 and solenoid 352 of valve 350. The relatively few moving parts required in shuttle pump 310 support a substantially reduced cost of manufacture and maintenance cost. 
     It will be appreciated that the present invention is not restricted to the particular embodiment that has been described and illustrated, and that variations may be made therein without departing from the scope of the invention as found in the appended claims and equivalents thereof.