U.S. patent application number 16/830475 was filed with the patent office on 2020-10-01 for high flow and low npshr horizontal pump with priming module.
This patent application is currently assigned to Baker Hughes, a GE Company, LLC. The applicant listed for this patent is Baker Hughes, a GE Company, LLC. Invention is credited to Jordan Kirk, Leslie Reid, Deric Thomas, Matthew Walls.
Application Number | 20200309135 16/830475 |
Document ID | / |
Family ID | 1000004764936 |
Filed Date | 2020-10-01 |
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United States Patent
Application |
20200309135 |
Kind Code |
A1 |
Kirk; Jordan ; et
al. |
October 1, 2020 |
High Flow and Low NPSHr Horizontal Pump with Priming Module
Abstract
A horizontal pumping system has a motor, a pump driven by the
motor and a priming module. The pump has a discharge on a first end
of the pump, a suction end on a second end of the pump, and a
plurality of stages between the suction end and the discharge. Each
of the plurality of stages includes an impeller and a diffuser that
encases the impeller. Each diffuser is an independent pressure
vessel. The priming module may be a wet priming module or a dry
priming module. The priming module permits the use of the
horizontal pumping system in many applications in which the liquid
is not naturally present at the pump intake.
Inventors: |
Kirk; Jordan; (Tulsa,
OK) ; Walls; Matthew; (Tulsa, OK) ; Thomas;
Deric; (Tulsa, OK) ; Reid; Leslie; (Tulsa,
OK) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Baker Hughes, a GE Company, LLC |
Houston |
TX |
US |
|
|
Assignee: |
Baker Hughes, a GE Company,
LLC
Houston
TX
|
Family ID: |
1000004764936 |
Appl. No.: |
16/830475 |
Filed: |
March 26, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62824782 |
Mar 27, 2019 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04D 1/06 20130101; F04D
13/02 20130101; F04D 29/106 20130101; F04D 9/04 20130101; F04D
15/0022 20130101 |
International
Class: |
F04D 9/04 20060101
F04D009/04; F04D 13/02 20060101 F04D013/02; F04D 1/06 20060101
F04D001/06; F04D 15/00 20060101 F04D015/00; F04D 29/10 20060101
F04D029/10 |
Claims
1. A horizontal pumping system comprising: a motor; a pump driven
by the motor, wherein the pump comprises: a discharge on a first
end of the pump; a suction end on a second end of the pump, wherein
the discharge is between the suction end and the motor; and a
plurality of stages between the suction end and the discharge; and
a priming module.
2. The horizontal pumping system of claim 1, wherein the priming
module comprises a dry priming module.
3. The horizontal pumping system of claim 2, wherein the dry
priming module comprises: a priming valve positioned at or near the
suction end; a vacuum generator connected to the priming valve; and
a check valve positioned at or near the discharge end.
4. The horizontal pumping system of claim 3, wherein the vacuum
generator comprises a vacuum pump.
5. The horizontal pumping system of claim 3, wherein the vacuum
generator comprises a compressed air driven venturi.
6. The horizontal pumping system of claim 1, wherein the priming
module comprises a wet priming module.
7. The horizontal pumping system of claim 6, wherein the wet
priming module comprises: a priming reservoir; and a priming line
connected between the priming reservoir and the suction end.
8. The horizontal pumping system of claim 7, wherein the wet
priming module further comprises a fill line connected between the
priming reservoir and the discharge.
9. The horizontal pumping system of claim 1, wherein each of the
plurality of stages comprises: an impeller; and a diffuser that
encases the impeller, wherein each diffuser is an independent
pressure vessel.
10. The horizontal pumping system of claim 1, wherein the
horizontal pumping system further comprises a shaft assembly and
wherein the shaft assembly is driven by the motor and wherein each
impeller of the plurality of stages is connected to the shaft
assembly.
11. A horizontal pumping system comprising: a motor; a pump driven
by the motor, wherein the pump comprises: a discharge on a first
end of the pump; a suction end on a second end of the pump, wherein
the discharge is between the suction end and the motor; and a
plurality of stages between the suction end and the discharge,
wherein each of the plurality of stages comprises: a diffuser,
wherein each diffuser is an independent pressure vessel; and an
impeller within the diffuser; and a priming module, wherein the
priming module is configured to supply liquid to the suction end of
the pump.
12. The horizontal pumping system of claim 11, wherein the
plurality of stages comprise: one or more radial flow stages; and
one or more mixed flow stages.
13. The horizontal pumping system of claim 12, wherein the
plurality of stages further comprises on or more axial flow
stages.
14. The horizontal pumping system of claim 11, wherein a first one
of the plurality of stages comprises a first impeller and a second
one of the plurality of stages comprises a second impeller that has
a smaller outer diameter than the first impeller.
15. The horizontal pumping system of claim 11, herein the priming
module comprises a dry priming module.
16. The horizontal pumping system of claim 15, wherein the dry
priming module comprises: a priming valve positioned at or near the
suction end; a vacuum generator connected to the priming valve; and
a check valve positioned at or near the discharge end.
17. The horizontal pumping system of claim 11, wherein the priming
module comprises a wet priming module.
18. The horizontal pumping system of claim 11, wherein the
horizontal pumping system further comprises a shaft assembly and
wherein the shaft assembly is driven by the motor and wherein each
impeller of the plurality of stages is connected to the shaft
assembly.
19. The horizontal pumping system of claim 18, wherein the
horizontal pumping system further comprises a shaft seal module,
wherein the shaft seal module is connected to the discharge of the
pump and wherein the shaft assembly passes through the shaft seal
module.
20. A horizontal pumping system comprising: a motor; a pump driven
by the motor, wherein the pump comprises: a discharge on a first
end of the pump; a suction end on a second end of the pump, wherein
the discharge is between the suction end and the motor; a shaft
seal module connected to the discharge, wherein the shaft seal
module is between the discharge and the motor; and a plurality of
stages between the suction end and the discharge; and a priming
module, wherein the priming module is configured to supply liquid
to the suction end of the pump.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 62/824,782 entitled "High Flow and Low
NPSHr Horizontal Pump with Priming Module" filed Mar. 27, 2019, the
disclosure of which is herein incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to the field of pumping
systems, and more particularly, but not by way of limitation, to an
improved horizontal pump design for use in low net positive suction
head (NPSH) applications.
BACKGROUND
[0003] Horizontal pumping systems are used in various industries
for a variety of purposes. Large split-casing pumps are often used
to move fluids between surface-based storage facilities. For
example, in the oil and gas industry horizontal pumping systems are
used to pump fluids, such as water separated from oil, to a remote
destination, such as a tank, retention pond or disposal well. Many
split casing pumps used in this industry are designed to meet or
exceed the standards set forth in API 610. Although generally
effective, split casing pumps are expensive, difficult to
manufacture and often create large lead times to delivery and
installation.
[0004] As an alternative to split casing pumps, manufacturers have
turned to multistage pumps designed for use in a downhole
environment. These multistage pumps are placed on a skid-supported
frame and used in a horizontal orientation. Typically these
horizontal pumping systems include a pump, a motor, and a suction
housing positioned between the pump and the motor. A thrust chamber
is also included between the motor and the suction housing. The
pump includes a discharge assembly that is connected to downstream
piping.
[0005] Although widely adopted for use in submersible applications,
conventional multistage centrifugal pumps have design requirements
that frustrate use in many surface-based, horizontal applications.
In downhole pumping applications, the pressure of the fluid at the
pump inlet is created by the column of fluid in the wellbore above
the pump. In surface-based pumping systems, however, the net
positive suction head available (NPSH.sub.A) may be much lower. To
match the NPSH.sub.A to the suction pressure required by the pump
(NPSH.sub.R), designers have attempted to incorporate a separate
"boost pump" that charges the fluid to a NPSH.sub.A that matches or
exceeds the NPSH.sub.R required by the horizontal pump. The use of
a separate boost pump is expensive and requires additional space
that may not be available in certain applications.
[0006] In some applications, the pump may be positioned above the
intake liquid level, thereby creating a suction lift configuration.
Pumps that are positioned on berms above retaining ponds must
accommodate suction lift conditions to move fluids out of the
below-grade reservoir. In the past, single-stage centrifugal pumps
have been paired with dry-prime assist mechanisms that evacuate air
from the suction line so that only liquid is available at the pump.
Although these systems work well for single-stage conventional
pumps that are designed to operate in lower NPSHa conditions, there
remains a need for specialized surface pumping systems that are
capable of providing high flow rates in low NPSHa and suction lift
conditions. It is to these and other deficiencies in the prior art
that the present invention is directed.
SUMMARY OF THE INVENTION
[0007] In one aspect, the present invention includes a horizontal
pumping system that has a motor, a pump driven by the motor and a
priming module. The pump has a discharge on a first end of the
pump, a suction end on a second end of the pump, and a plurality of
stages between the suction end and the discharge. Each of the
plurality of stages includes an impeller and a diffuser that
encases the impeller. Each diffuser is an independent pressure
vessel. The priming module may be a wet priming module or a dry
priming module. The priming module permits the use of the
horizontal pumping system in applications in which a suction lift
configuration is present at the pump.
[0008] In another aspect, the present invention provides a
horizontal pumping system that has a motor, a pump driven by the
motor and a priming module. The pump includes a discharge on a
first end of the pump and a suction end on a second end of the
pump, where the discharge is between the suction end and the motor.
The pump further includes a shaft seal module connected to the
discharge and a plurality of stages between the suction end and the
discharge. The priming module is configured to supply liquid to the
suction end of the pump.
[0009] In yet another embodiment, the present invention includes a
horizontal pumping system that has a motor, a pump driven by the
motor and a priming module. The pump has a discharge on a first end
of the pump, a suction end on a second end of the pump, and a
plurality of stages between the suction end and the discharge. The
discharge is between the suction end and the motor. Each of the
plurality of stages includes a diffuser and an impeller, where each
diffuser is an independent pressure vessel. The priming module is
configured to supply liquid to the suction end of the pump.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a side view of a surface pumping system
constructed in accordance with an exemplary embodiment of the
present invention, where the pumping system is positioned above a
retaining pond.
[0011] FIG. 2 is a side perspective of the surface pumping system
of FIG. 1 with a dry prime module.
[0012] FIG. 3 is a side perspective of the surface pumping system
of FIG. 1 with a wet prime module.
WRITTEN DESCRIPTION
[0013] In accordance with an exemplary embodiment, FIG. 1 shows a
side perspective view of a horizontal pumping system 100 deployed
above a liquid source 200. The liquid source 200 can be a retaining
pond, tank, well, reservoir, or other body of liquid in a natural
basin or man-made vessel. An intake line 202 connects the liquid
source 200 to the horizontal pumping system 100. A discharge line
204 conveys the pressurized fluid from the horizontal pumping
system 100 to downstream locations. In some applications, the
liquid source 200 is a man-made retaining pond that holds a volume
of liquid intended for use in downstream hydraulic fracturing
operations. In those applications, the horizontal pumping system
100 is configured to move fluid from the retaining pond 200 to the
pumps and other hydraulic fracturing equipment located at the well
site. As explained below, the horizontal pumping system 100
includes a priming module 206 that permits the use of the
horizontal pumping system 100 to lift fluids from the liquid source
200 under suction lift conditions. As used herein, the term
"priming module" refers to both wet and dry priming mechanisms. As
used herein, "suction lift" refers to the pressure (negative
pressure) on the suction side of the horizontal pumping system 100,
as measured from the center line of the horizontal pumping system
100 down to the surface of the liquid within the liquid source 200
on the suction side of the horizontal pumping system 100.
[0014] Turning to FIG. 2, shown therein is a depiction of the
horizontal pumping system 100 constructed in accordance with a
first embodiment. The horizontal pumping system 100 includes a
motor 102, a thrust chamber 104, and a pump 106. The thrust chamber
104 is connected between the pump 106 and the motor 102. The
various components within the horizontal pumping system 100 are
supported by a frame 108 that may be configured as a skid suitable
for placement on a pad, trailer or any other stable surface capable
of supporting the horizontal pumping system 100. In the embodiment
depicted in FIG. 2, the various components of the horizontal
pumping system 100 are secured to the frame 108 such that the
horizontal pumping system 100 can be lifted, moved and set as a
unitary element without the need to realign the individual
components of the horizontal pumping system 100.
[0015] As used herein, the terms "upstream" and "downstream"
provide relative positional references to components within the
horizontal pumping system 100 based. Upstream components will be
understood to be positioned closer to the suction end 112, while
downstream components are positioned at a greater distance from the
suction end 112 in the direction of fluid flow away from the
suction end 112. Although the preferred embodiments are depicted in
connection with a horizontal pumping system 100, it will be
appreciated that the preferred embodiments may also find utility in
other pumping systems, including surface-mounted vertical pumping
systems.
[0016] The pump 106 includes one or more turbomachinery stages 110,
a suction end 112 and a discharge 114. As depicted, the pump 106 is
configured as an "end-suction" pump in which the suction end 112 is
positioned on the opposite end of the pump 106 from the thrust
chamber 104. The discharge 114 is positioned between the stages 110
and the thrust chamber 104. Generally, the motor 102 drives the
pump 106 through one or more shafts (not visible) that extend
through the thrust chamber 104 and discharge 114 to the stages 110.
The motor 102 can be configured as a 4-pole motor that operates at
half the rotational speed of a conventional 2-pole motor with an
equivalent electrical input frequency. In one embodiment, the motor
102 is configured to rotate at no more than about 1,750 revolutions
per minute (RPM). In other embodiments, the motor 102 is an
internal combustion engine that produces torque to drive the pump
106. In certain embodiments, it may be desirable to deploy
gearboxes, torque converters, clutches, or additional transmission
components between the motor 102 and the pump 106. In yet other
embodiments, the motor 102 is configured as a 2-pole electric
motor.
[0017] The discharge 114 includes a shaft seal module 116 that
supports and seals the shaft as it enters the discharge 114. The
shaft seal module 116 includes one or more shaft seals (not shown)
that prevent high pressure fluid from being released from the
discharge 114 through the shaft seal module 116.
[0018] Pumped fluids are provided to the suction end 112 from the
intake line 202 and pressurized by the pump stages 110. Each of the
pump stages 110 includes a diffuser 118 and an impeller 120
contained within the diffuser 118. Unlike conventional multistage
surface pumping systems, the diffusers 118 are not contained within
a separate external housing. In this way, the diffusers 118 are
each configured as an independent pressure vessel that can be sized
without restriction to a common external housing found in
conventional multistage pumps. This permits the diffuser 118 and
the impeller 120 to be enlarged (e.g., a larger outer diameter) and
configured for optimal operation under low net positive suction
head (NPSH) conditions while also providing high flow rate
operation. Additionally, this permits each stage 110 to be sized
differently from the other stages 110 in the pump 106. For example,
it may be desirable to use a larger diffuser 118 and impeller 120
on the stage 110 closest to the suction end 112 to manage lower
NPSH at the suction end. In higher pressure applications, the pump
106 may optionally include an external housing (not depicted) that
reinforces the various components of the pump 106 against elevated
internal pressures. In some embodiments, the pump 106 includes a
plurality of pump stages 110 and each diffuser 118 within the
plurality of pump stages 110 is a different size than the other
diffusers 118 within the pump 106.
[0019] In some embodiments, the stages 110 are configured as large,
mixed flow stages. Suitable stages 110 are found in vertical
turbine pump applications often used in steam-based power
generation facilities. The impellers 120 are designed to provide an
increase in the pressure of the pumped fluid while minimizing
cavitation. In other embodiments, the stages 110 are configured as
radial flow stages or axial flow stages. In yet other embodiments,
the pump 106 includes a combination of mixed flow stages 110,
radial flow stages 110 and axial flow stages 110. In these
embodiments, the diffusers 118 and impellers 120 within the stages
110 may be different sizes, and in particular, may have outer
diameters that are different sizes.
[0020] For example, a pump 106 might include a large radial flow
"inducer" stage 110 adjacent the suction end 112, a small radial
flow stage 110 downstream from the large radial flow stage 110, a
large mixed flow stage 110 downstream from the small radial flow
stage 110, and a small mixed flow stage 110 downstream from the
large mixed flow stage 110. In a modification of this embodiment,
the pump 106 may further include one or more axial flow stages 110
downstream from the mixed flow stages 110
[0021] In the embodiment depicted in FIG. 2, the priming module 206
of the horizontal pumping system 100 is a dry prime module 122. The
dry prime module 122 is generally configured to evacuate air and
other gases out of the intake line 202 so that the NPSHa at the
suction end 112 matches the NPSHr for the initial stages 110. In
exemplary embodiments, the dry prime module 122 includes a vacuum
generator 124, a priming valve 126 positioned at or near the
suction end 112, and a check valve 128 positioned at or near the
discharge 114. The vacuum generator 124 may include a vacuum pump
(shown in FIG. 2) or a compressor-driven venturi system (not shown
in FIG. 2).
[0022] The check valve 128 may be a conventional flapper-style
valve that closes the discharge 114 when fluid is not being pumped
through the horizontal pumping system 100, or when sufficient
suction is applied by the vacuum generator 124 through the
horizontal pumping system 100. When the vacuum generator 124 is
activated, air in the horizontal pumping system 100 and intake line
202 is evacuated and vented to the atmosphere or storage tank. Once
a sufficient negative pressure has been applied through the
horizontal pumping system 100, liquid is drawn from the liquid
source 200 to the suction end 112 through the intake line 202. When
the liquid reaches the priming valve 126, a buoyant float within
the priming valve 126 is lifted by the rising liquid level. The
priming valve 126 can be configured to automatically throttle or
turn off the vacuum generator 124, or to power on the motor 102 of
the horizontal pumping system 100 to initiate the pumping
operation. In this way, the dry prime module 122 is well-suited to
extend the operating range of the horizontal pumping system 100 to
situations in which a suction lift condition is present at the
suction end 112.
[0023] Referring to FIG. 3, shown therein is an alternate
embodiment in which the horizontal pumping system 100 includes a
wet prime module 130 in place of, or in addition to, the dry prime
module 122. The wet prime module 130 includes a priming reservoir
132 located at or above the suction end 112 that includes a volume
of liquid sufficient to prime the horizontal pumping system 100.
The priming reservoir 132 is connected to the suction end 112 with
a priming line 134. A valve 136 on the priming line 134 controls
the flow of fluid from the priming reservoir 132 to the suction end
112. The valve 136 can be manually or automatically controlled. In
some embodiments, the wet prime module 130 includes a check valve
(not shown) in the intake line 202 or suction end 112 that prevents
priming fluid from draining out of the system. The priming
reservoir 132 can be filled through a fill line 138 that is
connected to the discharge 114 of the horizontal pumping system
100, or provided with priming fluid from an external source. Prior
to startup, the valve 136 can be opened to flood the suction end
112 and the intake line 202. Once the system has been primed, the
motor 102 can be energized to initiate the pumping operation. Once
the horizontal pumping system 100 has been activated, the valve 136
can be closed to prevent further drainage from the wet prime module
130.
[0024] In other embodiments, the wet prime module 130 may include
an independent wet prime trash pump that feeds the suction end 112
of the horizontal pumping system directly from the liquid source
200.
[0025] Thus, the surface pumping system 100 is well suited to pump
large volumes of fluid between surface facilities under negative
suction lift conditions. Suitable applications include the movement
of fluids between storage containers, retention ponds and naturally
occurring bodies of water. Because the surface pumping system 100
is configured for high volume operation, the surface pumping system
100 can also be used to provide the fluid feed on hydraulic
fracturing operations from a sub-grade liquid source 200. In these
applications, the surface pumping system 100 can be used to
transfer "frac" fluid from a storage facility to the high pressure
triplex pumps commonly used in hydraulic fracturing operations.
[0026] It is to be understood that even though numerous
characteristics and advantages of various embodiments of the
present invention have been set forth in the foregoing description,
together with details of the structure and functions of various
embodiments of the invention, this disclosure is illustrative only,
and changes may be made in detail, especially in matters of
structure and arrangement of parts within the principles of the
present invention to the full extent indicated by the broad general
meaning of the terms in which the appended claims are expressed. It
will be appreciated by those skilled in the art that the teachings
of the present invention can be applied to other systems without
departing from the scope and spirit of the present invention.
* * * * *