U.S. patent application number 16/443034 was filed with the patent office on 2020-12-17 for turbine pumps.
The applicant listed for this patent is CECO ENVIRONMENTAL IP INC.. Invention is credited to Erik BURACHINSKY, William PARRY, Steve ROSE, Jan STUIVER.
Application Number | 20200392960 16/443034 |
Document ID | / |
Family ID | 1000004200156 |
Filed Date | 2020-12-17 |
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United States Patent
Application |
20200392960 |
Kind Code |
A1 |
STUIVER; Jan ; et
al. |
December 17, 2020 |
TURBINE PUMPS
Abstract
Embodiments of pumps are disclosed along with systems and
methods relating thereto. In an embodiment, the pump includes a
casing assembly that includes a central axis, an upstream connector
that is configured to engage with a first connector on a fluid
line, and a downstream connector that is configured to engage with
a second connector on the fluid line. In addition, the pump
includes an impeller rotatably disposed within the casing assembly.
Further, the pump includes a driver assembly coupled to the casing
assembly and annularly disposed about the impeller. The driver
assembly is configured to rotate the impeller about the central
axis.
Inventors: |
STUIVER; Jan; (De Knipe,
NL) ; BURACHINSKY; Erik; (Dallas, TX) ; PARRY;
William; (Dallas, TX) ; ROSE; Steve; (Dallas,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CECO ENVIRONMENTAL IP INC. |
Dallas |
TX |
US |
|
|
Family ID: |
1000004200156 |
Appl. No.: |
16/443034 |
Filed: |
June 17, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04D 3/00 20130101; F04D
13/06 20130101 |
International
Class: |
F04D 13/06 20060101
F04D013/06; F04D 3/00 20060101 F04D003/00 |
Claims
1. A pump comprising: a casing assembly, wherein the casing
assembly includes a central axis and comprises: an upstream
connector that is configured to engage with a first connector on a
fluid line; and a downstream connector that is configured to engage
with a second connector on the fluid line; an impeller rotatably
disposed within the casing assembly; and a driver assembly coupled
to the casing assembly and annularly disposed about the impeller;
wherein the driver assembly is configured to rotate the impeller
about the central axis.
2. The pump of claim 1, wherein the impeller comprises an outer
housing, a central hub, and a plurality of vanes engaged with and
extending between the central hub and the outer housing.
3. The pump of claim 2, wherein the outer housing, the central hub,
and the plurality of vanes of the impeller are formed as a
monolithic member.
4. The pump of claim 3, wherein the impeller comprises
fiberglass.
5. The pump of claim 2, wherein the outer housing is cylindrical in
shape and includes a radially inner cylindrical surface and a
radially outer cylindrical surface, and wherein each of the
plurality of vanes is engaged with the radially inner cylindrical
surface.
6. The pump of claim 5, wherein the casing assembly comprises a
suction casing and a discharge casing, wherein the suction casing
comprises a throughhore that is flush with the radially inner
cylindrical surface of the outer housing of the impeller.
7. The pump of claim 5, wherein the central hub includes a first
end and a second end opposite the first end, wherein the first end
of the central hub includes a hemispherical surface.
8. The pump of claim 5, comprising a plurality of magnets coupled
to the radially outer cylindrical surface of the outer housing of
the impeller, wherein the driver assembly is configured to induce a
varying magnetic field to rotate the impeller and the plurality of
magnets about the central axis.
9. The pump of claim 1, further comprising a thermal transfer
assembly comprising: a body annularly disposed about the driver
assembly; and a cooling coil disposed about the body, wherein the
cooling coil comprises an elongate tube that is configured to
receive a flow of cooling fluid therethrough.
10. The pump of claim 9, wherein the casing assembly comprises a
suction casing and a discharge casing, wherein the body of the
thermal transfer assembly is disposed axially between the suction
casing and the discharge casing.
11. A system, comprising: a first pipe section; a second pipe
section; and a pump mounted between the first pipe section and the
second pipe section, wherein the pump comprises: a casing assembly
including a central axis; an impeller rotatably disposed within the
casing assembly; and a driver assembly coupled to the casing
assembly and annularly disposed about the impeller; wherein the
driver assembly is configured to rotate the impeller about the
central axis to pump fluid from the first pipe section to the
second pipe section.
12. The system of claim 11, wherein the impeller comprises: a
cylindrical outer housing; a central hub disposed within the outer
housing; and a plurality of impeller vanes engaged with and
extending between the central hub and the outer housing.
13. The system of claim 12, further comprising: a diffuser disposed
within the casing assembly, axially adjacent the impeller, wherein
the diffuser is configured to straighten a flow of fluid flowing
from the impeller; and wherein the diffuser comprises: a
cylindrical outer housing; a central hub disposed within the outer
housing of the diffuser; and a plurality of diffuser vanes engaged
with and extending between the central hub of the diffuser and the
outer housing of the diffuser.
14. The system of claim 11, further comprising a thermal transfer
assembly comprising: a body mounted to the casing assembly and
disposed annularly about the driver assembly; and a cooling coil
disposed about the body, wherein the cooling coil comprises an
elongate tube that is configured to receive a flow of cooling fluid
therethrough.
15. The system of claim 14, wherein the cooling coil is fluidly
coupled to the first pipe section and the second pipe section.
16. A method of pumping a fluid through a fluid line, the method
comprising: mounting a pump between a pair of pipe sections of the
fluid line, wherein the pump comprises: a casing assembly including
a central axis; an impeller rotatably disposed within the casing
assembly; and a driver assembly coupled to the casing assembly and
annularly disposed about the impeller; rotating the impeller about
the central axis with the driver assembly; and flowing a fluid
through the pair of pipe sections and the pump while rotating the
impeller
17. The method of claim 16, further comprising: straightening a
flow of the fluid with a diffuser disposed axially adjacent the
impeller
18. The method of claim 16, wherein rotating the impeller
comprises: inducing a varying magnetic field with the driver
assembly; and attracting a plurality of magnets with the varying
magnetic field.
19. The method of claim 16, further comprising: flowing a cooling
fluid through a coil that is wrapped about a body of a thermal
transfer assembly, wherein the body is mounted to the casing
assembly and is disposed annularly about the driver assembly.
20. The method of claim 19, wherein flowing the cooling fluid
through the coil comprises: flowing a stream of fluid from a
downstream section of the pair of pipe sections to the coil; and
flowing the stream of fluid through the coil after; and flowing the
stream of fluid from the coil to an upstream section of the pair of
pipe section after flowing the stream through the coil.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND
[0003] Fluid pumps may include an impeller that is rotated to
pressurize a fluid (e.g., a liquid), Typically the impeller is
driven by a motor or other suitable driver. In some circumstances,
a pump may be used to pressurize fluid that is corrosive,
particularly to metallic materials. In such a service, metallic
components of the pump that come into contact with the fluid may
experience corrosion, thereby decreasing the lifespan thereof.
SUMMARY
[0004] Some embodiments disclosed herein are directed to a pump. in
an embodiment, the pump includes a casing assembly that includes a
central axis, an upstream connector that is configured to engage
with a first connector on a fluid line, and a downstream connector
that is configured to engage with a second connector on the fluid
line. In addition, the pump includes an impeller rotatably disposed
within the casing assembly. Further, the pump includes a driver
assembly coupled to the casing assembly and annularly disposed
about the impeller. The driver assembly is configured to rotate the
impeller about the central axis.
[0005] Other embodiments disclosed herein are directed to a system.
In an embodiment, the system includes a first pipe section, a
second pipe section, and a pump mounted between the first pipe
section and the second pipe section. The pump includes a casing
assembly including a central axis. In addition, the pump includes
an impeller rotatably disposed within the casing assembly. Further,
the pump includes a driver assembly coupled to the casing assembly
and annularly disposed about the impeller. The driver assembly is
configured to rotate the impeller about the central axis to pump
fluid from the first pipe section to the second pipe section.
[0006] Still other embodiments disclosed herein are directed to a
method of pumping a fluid through a fluid line. in an embodiment,
the method includes (a) mounting a pump between a pair of pipe
sections of the fluid line. The pump includes a casing assembly
including a central axis, an impeller rotatably disposed within the
casing assembly, and a driver assembly coupled to the casing
assembly and annularly disposed about the impeller. In addition,
the method includes (b) rotating the impeller about the central
axis with the driver assembly. Further, the method includes (c)
flowing a fluid through the pair of pipe sections and the pump
during (b).
[0007] Embodiments described herein comprise a combination of
features and characteristics intended to address various
shortcomings associated with certain prior devices, systems, and
methods. The foregoing has outlined rather broadly the features and
technical characteristics of the disclosed embodiments in order
that the detailed description that follows may be better
understood. The various characteristics and features described
above, as well as others, will be readily apparent to those skilled
in the art upon reading the following detailed description, and by
referring to the accompanying drawings. It should be appreciated
that the conception and the specific embodiments disclosed may be
readily utilized as a basis for modifying or designing other
structures for carrying out the same purposes as the disclosed
embodiments. It should also be realized that such equivalent
constructions do not depart from the spirit and scope of the
principles disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a detailed description of various exemplary embodiments,
reference will now be made to the accompanying drawings in
which:
[0009] FIG. 1 is a side view of a pump system according to some
embodiments;
[0010] FIG. 2 is a side cross-sectional view of a pump for use in
the pump system of FIG. 1 according to some embodiments;
[0011] FIGS. 3 and 4 are side cross-sectional views of a suction
casing and a discharge casing, respectively, of the pump of FIG.
2;
[0012] FIG. 5 is a side cross-sectional view of an impeller of the
pump of FIG. 2;
[0013] FIG. 6 is a side cross-sectional view of a thermal transfer
assembly of the pump of HG.
[0014] FIG. 7 is a side cross-sectional view of a. diffuser of the
pump of FIG. 2;
[0015] FIG. 8 is an exploded assembly view of the pump of FIG.
2;
[0016] FIGS. 9 and 10 are exploded assembly views of portions of
the pump of FIG. 2;
[0017] FIG. 11 is a cross-sectional view of the pump system of FIG.
1;
[0018] FIGS. 12 and 13 are schematic side views of embodiments of a
thermal transfer system for use with the pump of FIG. 2 according
to some embodiments;
[0019] FIG. 14 is side cross-sectional view of a wax mold core for
manufacturing an impeller of the pump of FIG. 2 according to some
embodiments; and
[0020] FIGS. 15 and 16 are sequential perspective views of a
molding process utilizing the wax mold core of FIG. 14 according to
some embodiments.
DETAILED DESCRIPTION
[0021] The following discussion is directed to various exemplary
embodiments. However, one of ordinary skill in the art will
understand that the examples disclosed herein have broad
application, and that the discussion of any embodiment is meant
only to be exemplary of that embodiment, and not intended to
suggest that the scope of the disclosure, including the claims, is
limited to that embodiment.
[0022] The drawing figures are not necessarily to scale. Certain
features and components herein may be shown exaggerated in scale or
in somewhat schematic form and some details of conventional
elements may not be shown in interest of clarity and
conciseness.
[0023] In the following discussion and in the claims, the terms
"including" and "comprising" are used in an open-ended fashion, and
thus should be interpreted to mean "including, but not limited to .
. ." Also, the term "couple" or "couples" is intended to mean
either an indirect or direct connection. Thus, if a first device
couples to a second device, that connection may be through a direct
connection of the two devices, or through an indirect connection
that is established via other devices, components, nodes, and
connections. In addition, as used herein, the terms "axial" and
"axially" generally mean along or parallel to a given axis (e.g.,
central axis of a body or a port), while the terms "radial" and
"radially" generally mean perpendicular to the given axis. For
instance, an axial distance refers to a distance measured along or
parallel to the axis, and a radial distance means a distance
measured perpendicular to the axis. Further, when used herein
(including in the claims), the words "about," "generally,"
"substantially," "approximately," and the like mean within a range
of plus or minus 10%.
[0024] As previously described, pumps may include an impeller that
is driven or rotated by a separate driver or motor. Typically, the
motor and/or the pump is supported on separate base or foundation
(e.g., a concrete pad). Therefore, the location of pumps within a
facility is typically determined by the available floor spacing for
the motor foundation. As a result, additional lengths or runs of
piping (or other conduit) may be called for to fluidly couple the
fluid lines to the potentially distally disposed pump. Accordingly,
embodiments disclosed herein include pumps (e.g., turbine pumps)
including an integrated motor or driver that are configured to be
coupled within and along a fluid line or pipe. Thus, through use of
the embodiments disclosed herein, a foundation or base for the pump
(or the associated motor) is no longer included, and the
arrangement of the pumps within a facility is greatly
simplified.
[0025] Referring to FIG. 1, an embodiment of a pump system 1000 is
shown. Generally speaking, system 1000 includes turbine pump 800
(or more generally "pump 800") that is disposed along a fluid line
920. In particular, pump 800 is coupled between and in-line with a
pair of pipe or conduit sections 920a, 920b such that a central or
longitudinal axis 805 ("axis 805") of pump 800 is aligned with a
central axis 925 of fluid line 920. In this embodiment and as will
be described in more detail below, pump 800 is configured to induce
or drive a flow of fluid along fluid line 920 in a flow direction
950 from pipe section 920a to pipe section 920b. Thus, pipe section
920a may be referred to herein as an "upstream pipe section," and
pipe section 920b may be referred to herein as a "downstream pipe
section."
[0026] Referring now to FIGS. 2, generally speaking, turbine pump
800 comprises a casing assembly 100, an impeller assembly 200, a
driver assembly 300, a diffuser 500, and a thermal transfer
assembly 400 all concentrically disposed along axis 805. Driver
assembly 300 and thermal transfer assembly 400 are mounted to
casing assembly 100 and impeller assembly 200 and diffuser 500 are
disposed within casing assembly 100. In general, during operations
impeller assembly 200 is rotated about axis 805 by driver assembly
300 to pressurize a fluid (e.g., a liquid) within fluid line 920
(see e.g., FIG. 1) so that the fluid is flowed from upstream pipe
section 920a toward and through downstream pipe section 920b along
flow direction 950 as previously described. As will be described in
more detail below, some or all of the components of pump 800 may be
constructed from non-metallic materials so as to decrease the
overall weight of pump 800 and to avoid corrosion due to contact
with potentially corrosive fluids flowing therethrough (e.g., salt
water).
[0027] Referring now to FIGS. 2-4 and 8, casing assembly 100
includes a first or suction casing 102 and a second or discharge
casing 120. Referring specifically to FIGS. 3 and 9, suction casing
102 includes a first or upstream end 102a, a second or downstream
end 102b opposite upstream end 102a, and a throughbore 104
extending axially between ends 102a, 102b. In addition, suction
casing 102 includes a first or upstream connector 106 at upstream
end 102a, a second or downstream connector 108 proximate to
downstream end 102b, a cylindrical body 103 extending axially
between connectors 106, 108, and a cylindrical projection or lip
107 extending axially from downstream connector 108 to downstream
end 102b. A seal gland 114 extends radially inward into lip 107
that receives a sealing member (e.g., O-ring) 150 therein.
[0028] Connectors 106, 108 may be any suitable device or structure
for coupling with a corresponding connector or device on fluid line
920 or within pump 800 (see e.g., FIG. 1), such as, for example,
flanges, couplings, threaded connectors, etc. In this embodiment,
connectors 106, 108 comprise flanges. Upstream connector 106
includes a planar engagement face or surface 106a, and downstream
connector 108 includes a planar engagement face or surface 108a.
Engagement surface 108a of downstream connector 108 includes an
axially extending circumferential groove or channel 112. In
addition, a plurality of bolt holes 116 and bolt holes 118 may be
provided through upstream connector 106 and downstream connector
108, respectively. Note that only one of the bolt holes 116 and one
of the bolt holes 118 are visible in FIGS. 2 and 3 due to the
arrangement of the cross-sectional views shown therein.
[0029] A radially extending downstream facing annular shoulder 109
("shoulder 109") is disposed within throughbore 104 such that
throughbore 104 includes a first or upstream section 104a extending
axially from upstream end 102a to shoulder 109 and second or
downstream section 104b extending axially form shoulder 109 to
downstream end 102b. Downstream section 104b has a larger inner
diameter than upstream section 104a.
[0030] Referring specifically to FIGS. 4 and 10, discharge casing
120 includes a first or upstream end 120a, a second or downstream
end 120b opposite upstream end 120a, and a throughbore 124
extending axially between ends 120a, 120b. In addition, discharge
casing 120 includes a first or upstream connector 128 proximate to
upstream end 120a, a second or downstream connector 126 at
downstream end 120b, a cylindrical body 123 extending axially
between connectors 128, 126, and a cylindrical projection or lip
127 extending axially from upstream connector 128 to upstream end
120a. A seal gland 134 extends radially inward into cylindrical
projection 127 that receives a sealing member (e.g., O-ring) 152
therein.
[0031] Connectors 126, 128 may similar to connectors 106, 108,
previously described for suction casing 102 (see e.g., FIGS. 2 and
3). Thus, connector 126, 128 may be any suitable device or
structure for coupling with a corresponding connector or device on
fluid line 920 or within pump 800. In this embodiment, connectors
126, 128 comprise flanges. Downstream connector 126 includes a
planar engagement face or surface 126a, and upstream connector 128
includes a planar engagement face or surface 128a. Engagement
surface 128a of upstream connector 128 includes an axially
extending circumferential groove or channel 132. In addition, a
plurality of bolt holes 140 and bolt holes 142 may be provided
through upstream connector 128 and downstream connector 126,
respectively, Note that only one of the bolt holes 140 and one of
the bolt holes 142 are visible in FIGS. 2 and 4 due to the
arrangement of the cross-sectional views shown therein.
[0032] A radially extending annular projection 136 ("projection
136") is disposed within throughbore 124 so that throughbore 124
includes a first or upstream section 124a extending axially from
upstream end 120a to projection 136 and second or downstream
section 124b extending axially from projection 136 to downstream
end 120b. Projection 136 defines a first or upstream facing annular
shoulder 137 and a second or downstream facing annular shoulder
139. Upstream section 124a has a larger inner diameter than
downstream section 124b. Also, a radially extending annular recess
138 is disposed within downstream section 124b of throughbore
124.
[0033] Referring now to FIGS. 2, 5, 8, and 9, impeller assembly 200
generally includes an impeller 202, a pair of impeller wear rings
220a, 220b and a magnet assembly 230. Referring specifically to
FIG-S. 5 and 9, impeller 202 comprises an outer housing 204, a
central hub 206 disposed within outer housing 204, and a plurality
of impeller vanes 208 (or more simply "vanes 208") extending
between central hub 206 and outer housing 204.
[0034] In this embodiment, outer housing 204 is a cylindrical
member that includes a first or upstream end 204a, a second or
downstream end 204b opposite upstream end 204a. In addition, outer
housing 204 includes a radially outer cylindrical surface 201 and a
radially inner cylindrical surface 203 both extending axially
between ends 204a, 204b. In other embodiments, outer housing 204
(or a portion thereof), may be non-cylindrical in shape,
[0035] Referring specifically to FIGS. 5 and 9, central hub 206 is
a solid member (non-hollow) that is disposed within outer housing
204 along axis 805 and includes a first or upstream end 206a, a
second or downstream end 206b opposite upstream end 206a. Upstream
end 206a is proximate upstream end 204a of outer housing 204, and
downstream end 206b is disposed at downstream end 204b of outer
housing 204. In this embodiment, central hub 206 is generally.sup.,
conical in shape and thus includes a varying cross-section between
ends 206a, 206b. In particular, the circumference and diameter of
central hub 206 progressively increase between ends 206a and 206b.
In addition, in this embodiment upstream end 206a includes a
rounded or hemispherical surface 207. Without being limited to this
or any other theory, the hemispherical surface 207 may reduce
turbulence for the fluid flowing within outer housing 204 and the
generally conical shape of central hub 206 may progressively
decrease the flow area within outer housing 204 for fluids flowing
from upstream end 204a toward downstream end 204b. This decrease in
the flow area may increase the localized flow rate along axis 805
and the pressure of the fluid flowing through impeller 202 during
operations. It should be appreciated that other shapes and profiles
are contemplated for central hub 206. For example, in some
embodiments, central hub 206 may include non-linear cross-section
changes (e.g., a parabolic).
[0036] Vanes 208 extend generally radially from central hub 206 to
radially inner cylindrical surface 203 of outer housing 204. In
some embodiments, vanes 208 are circumferentially spaced (e.g.,
uniformly circumferentially spaced) about axis 805. In addition,
all or some of the vanes 208 may be axially spaced from one another
along axis 805. In this embodiment, there are total three vanes
208, that are circumferentially spaced approximately 120.degree.
from one another about axis 805; however, other numbers and spacing
are contemplated for vanes 208 in other embodiments. In addition,
each of the vanes 208 of this embodiment extend generally helically
(e.g., along a constant or varying helical pitch) about central hub
206 between ends 206a, 206b..
[0037] As best shown in FIG. 5, in this embodiment, each of the
vanes 208 is generally curved between central hub 206 and radially
inner cylindrical surface 203 of outer housing 204. In particular,
each vane 208 generally curves in an upstream direction, or toward
upstream ends 206a, 204a of central hub 206 and outer housing 204
when moving radially outward from central hub 206 toward radially
inner cylindrical surface 203. However, it should be appreciated
that vanes 208 may extend generally linearly between central hub
206 and radially inner cylindrical surface 203 in other
embodiments. In addition, in this embodiment the axial thickness of
each vane 208 generally decreases when moving from central hub 206
toward radially inner cylindrical surface 203. However, again, in
other embodiments, the axial thickness of vanes 208 may be
generally constant between central hub 206 and radially inner
cylindrical surface 203. Further, while not specifically shown it
should be appreciated that the axial thickness of each vane 208 may
vary (e.g., increase and/or decrease) or may remain generally
constant between its corresponding upstream and downstream ends.
Still further, in some embodiments local cross-sectional variations
may be included along vanes 208 to optimize flow characteristics
through impeller 202 during operations.
[0038] In some embodiments the generally helical configuration of
vanes 208 may vary along the axial direction (e.g., along axis 805,
between ends 206a, 206b) and/or along the radial direction (e.g.,
radially between central hub 206 and radially inner cylindrical
surface 203 of outer housing 204). For instance, in some
embodiments vanes 208 may have a varying helical pitch along the
axial length between ends 206a, 206b. Generally speaking, as the
helical pitch increases the vanes 208 axially advance a greater
distance along axis 805 for a given amount of angular twist about
axis 805. Thus, in some embodiments the helical pitch of vanes 208
at the first end 206a is different from the helical pitch of vanes
208 at second end 206b. Additionally or alternatively, in some
embodiments vanes 208 may have helical pitch which varies as a
function of radial position between central hub 206 and radially
inner cylindrical surface 203. For example, the helical pitch of
vanes 208 may increase and/or decrease when moving radially from
the attachment central hub 206 and the radially inner cylindrical
surface 203. However, it should be appreciated that other
variations of the helical pitch of vanes 208 (as well as other
parameters) are contemplated herein.
[0039] Referring still to FIGS. 5 and 9, in this embodiment, outer
housing 204, central hub 206 and vanes 208 are all formed as a
monolithic piece or member (i.e., impeller 202). Thus, in some
embodiments, outer housing 204, central hub 206, and vanes 208 may
comprise the same material(s) (e.g., fiberglass). During
operations, the impeller 202 (including outer housing 204, central
hub 206, and vanes 208) generally rotates about axis 805 to
increase the pressure and velocity of the fluid flowing
therethrough. In this embodiment, impeller 202 is symmetrical about
axis 805 such that its rotating moment of inertia is concentric
about axis 805. In addition because vanes 208 are monolithically
formed with outer housing 204 and central hub 206 as previously
described, fluids flowing through impeller 202 (e.g., between ends
204a, 204b of outer housing 204 are prevented from flowing between
outer housing 204 and vanes 208 and between vanes 208 and central
hub 206. Accordingly, the fluid is forced to flow in a generally
helical or twisting path about axis 805 between vanes 208 as it
flows axially between ends 204a, 204b of outer housing 204.
[0040] Referring still to FIGS. 5 and 9, each impeller wear ring
220a, 220b includes an annular base 222 including a central
aperture 221 extending axially therethrough, and a cylindrical
sleeve 223 extending axially from annular base 222. Each of the
impeller wear rings 220a, 220b are disposed on outer housing 204 of
impeller 202, such that wear ring 220a is disposed over upstream
end 204a of outer housing 204, and wear ring 220b is disposed over
downstream end 204b of outer housing 204. In particular, upstream
end 204a of outer housing 204 is received within wear ring 220a
such that radially outer cylindrical surface 201 is engaged with
the corresponding cylindrical sleeve 223 and upstream end 204a is
engaged with the corresponding annular base 222. Similarly,
downstream end 204b of outer housing 204 is received within wear
ring 220b such that radially outer cylindrical surface 201 is
engaged with the corresponding cylindrical sleeve 223 and
downstream end 204b is engaged with the corresponding annular base
222. In addition, once mounted to outer housing 204 as described
above, central apertures 221 in wear rings 220a, 220b are aligned
with radially inner surface 203. Thus, in this embodiment central
apertures 221 are flush with radially inner cylindrical surface
203.
[0041] Referring still to FIGS. 5 and 9, magnet assembly 230
comprises a cylindrical ring or sleeve 232, and a plurality of
magnets 240 mounted to sleeve 232. In particular, sleeve 232.
includes an axially extending radially inner cylindrical surface
231 and an axially extending radially outer cylindrical surface
233. The plurality of magnets 240 are mounted to radially outer
cylindrical surface 233. In particular, magnets 240 are uniformly
circumferentially spaced along radially outer cylindrical surface
233 relative to axis 805. In this embodiment, magnets 240 are
permanent magnets; however, it should be appreciated that in other
embodiments magnets 240 may comprise electrically conductive
materials (e.g., aluminum bars) such as may found within an
induction rotor, or may comprise one or more electro-magnetic coils
(e.g., conductive coils or windings, such as cooper, surrounding a
ferromagnetic or ferromagnetic core, such as iron).
[0042] As best shown in FIG. 5, magnet assembly 230 is disposed
about outer housing 204 of impeller 202 such that radially inner
surface 231 of sleeve 232 is engaged with radially outer
cylindrical surface 201 of outer housing 204. in addition, in this
embodiment, sleeve 232 is positioned axially between wear rings
220a, 220b such that sleeve 232 is axially spaced from cylindrical
sleeves 223 of each ring 220a, 201), Further, in this embodiment,
sleeve 232 is generally axially centered between ends 204a, 204b of
outer housing 204. Sleeve 232 may be secured to radially outer
cylindrical surface 201 of outer housing 204 in any suitable
fashion. For example, in some embodiments, sleeve 232 may be
secured to outer housing 204 via a friction fit. In addition, in
other embodiments, sleeve 232 may be welded, brazed, adhered (e.g.,
with an adhesive) or otherwise secured to outer housing 204.
[0043] Referring again to FIG. 2, during operations, impeller
assembly 200 is disposed axially between suction casing 102 and
discharge casing 120. In particular, a pair of casing wear rings
210a, 210b are disposed within throughbores 104, 124 of casings
102, 120, respectively. Each casing wear ring 210a, 210b includes
an annular base 212 including a central aperture 211 extending
axially therethrough, and a cylindrical sleeve 213 extending
axially from base 212 Casing wear ring 210a is received within
downstream section 104b of throughbore 104 of suction casing 102
such that the corresponding annular base 212 is engaged with
annular shoulder 109 and the corresponding central aperture 211 is
generally aligned and flush with upstream section 104a of
throughbore 104. Similarly, casing wear ring 210b is received
within downstream section 124b of throughbore 124 of discharge
casing 120 such that the corresponding base 212 is engaged with
upstream facing annular shoulder 137.
[0044] As shown in FIG. 2, impeller assembly 200 is received within
casing assembly 100 such that impeller wear ring 220a is received
within casing wear ring 210a and impeller wear ring 220b is
received within casing wear ring 210b. In particular, cylindrical
sleeves 223 of wear rings 220a, 220b may slidingly engage with
cylindrical sleeves 213 of casing wear rings 210a, 210b,
respectively, and central apertures 221 and 211 of wear rings 220a,
220b, and 210a, 210b, are generally flush with one another along
axis 805. As will be described in more detail below, during
operations, impeller assembly 200 rotates about axis 805 within
casing assembly 100 such that wear rings 220a, 220b rotate within
and relative to casing wear rings 210a, 210b, respectively.
Accordingly, direct contact between outer housing 204 of impeller
and casings 102, 120 is avoided, and wear rings 210a, 210b, 220a,
220b may be considered wear parts that are replaced at regular
intervals.
[0045] Referring still to FIGS. 2 and 10, driver assembly 300 is
annularly disposed about magnet assembly 230 and is axially
positioned between suction casing 102 and discharge casing 120. In
particular, as shown in FIG, 2 driver assembly 300 is disposed over
the cylindrical projections 107, 127, and is axially disposed
between planar engagements faces 108a, 128a of connectors 108, 128
of casings 102, 120, respectively. In addition, a sealing sleeve
330 is disposed radially between cylindrical projections 107, 127
of casings 102, 120 and driver assembly 300, such that sealing
members 150, 152 are radially compressed within seal glands 114,
134 of casings 102, 120 (see e.g., FIGS. 3 and 4). Thus, fluids are
prevented (or at least restricted) from flowing between seal sleeve
330 and cylindrical projections 107, 127 during operations.
[0046] In this embodiment driver assembly 300 defines a plurality
of windings or coils 304 of conductive wire (e.g., conductive coils
or windings, such as cooper, surrounding a ferromagnetic or
ferromagnetic core, such as iron) that are disposed or arranged
circumferentially about axis 805. Generally speaking, during
operations, electrical current may be routed through the conductive
coils 304 so as to induce varying magnetic fields. As will be
described in more detail below, the induced magnetic fields within
driver assembly are configured to drive rotation of impeller
assembly 200 about axis 805 within casing assembly 100 during
operations.
[0047] It should be appreciated that driver assembly 300 may
include alternative designs in other embodiments. For instance, in
some embodiments, windings 304 may be replaced with a plurality of
permanent magnets arranged circumferentially around axis 805, or a
plurality of electrically conductive members (e.g., aluminum bars)
such as might be used within an induction motor.
[0048] Referring now to FIGS. 2, 6, and 9, thermal transfer
assembly 400 includes heat sink or body 402 and a cooling coil 420
circumferentially wrapped around body 402. Body 402 includes a
first or upstream end 402a, a second or downstream end 402b
opposite upstream end 402a, and a throughbore 401 extending axially
between ends 402a, 402b that is defined by a radially inner
cylindrical surface 407. In addition, body 402 includes a first or
upstream connector 404 proximate upstream end 402a, a second or
downstream connector 406 proximate downstream end 402b, and a
radially outer cylindrical surface 403 extending axially between
connectors 404, 406. Connectors 406, 408 may comprise any suitable
structure or device for mating with another component or member.
For instance, in this embodiment connectors 404, 406 comprises
flanges that each include a plurality of mounting bores 410
extending axially therein (note: only one of the mounting bores 410
are visible in each of the connectors 404, 406 in FIGS. 2 and 6 due
to the arrangement of the cross-sectional views shown therein)
Further, in this embodiment body 402 includes a first or upstream
lip 409a extending axially upstream connector 404 to upstream end
402a, and a downstream second lip 409b extending axially from
downstream connector 406 to downstream end 402b. Lips 409a, 409b
may also be generally referred to herein as "axial projections
409a, 409b."
[0049] Cooling coil 420 comprises an elongate tube or conduit that
is wrapped (e.g., helically) about radially outer surface 403 of
body 402. Cooling coil 420 may comprise any suitable material, and
in some embodiments may comprise a conductive material (e.g., a
metal) so as to conduct thermal energy away from body 402 during
operations. As will be described in more detail below, during
operations a cooling fluid (e.g., diverted fluid from fluid line
920, a separate cooling fluid, etc.) is flowed or routed through
cooling coil 420 to facilitate convective heat transfer, In this
embodiment, cooling coil 420 comprises includes a circular
cross-section; however, other cross-sections are contemplated
(e.g., elliptical, rectangular, square, etc.).
[0050] Body 402 may be constructed from any suitable material, and
in sonic embodiments may be made of a material having a high
thermal conductivity (e.g., having a coefficient of thermal
conductivity above 5-W/m.degree. K). In addition, in sonic
embodiments, body 402 may be made from a non-magnetic or possibly a
weakly magnetic material (e.g., aluminum, 316 stainless, nickel
alloys, alumina filled epoxy, etc.). In some embodiments, there may
be intimate contact between cooling coil 420 and radially outer
cylindrical surface 403 of body 402 since increased contact areas
and compressive forces may increase the heat flow capacity between
body 402 and cooling coil 420 during operations. In some
embodiments, ridges, fins or other suitable projections may be
disposed along body 402 (particularly along radially outer surface
403) to increase the circumferential contact area between each
segment of cooling coil 420 and body 402. In addition, in some
embodiments, increased contact may be achieved between cooling coil
420 and body 402 by tightly wrapping cooling coil 420 around body
402 and/or by applying an external clamp (not shown) around the
perimeter of cooling coil 420.
[0051] Referring again to FIG. 2, thermal transfer assembly 400 is
engaged axially between connectors 108, 128 of casings 102, 120,
respectively. In particular, upstream connector 404 on body 402 is
engaged with planar engagement surface 108a on downstream connector
108 of upstream casing and downstream connector 406 on body 402 is
engaged with engagement surface 128a on upstream connector 128 of
discharge casing 120. In addition, upstream lip 409a is received
within circumferential groove 112 in planar engagement face 108a,
and downstream lip 409b is received within circumferential groove
132 in planar engagement face 128a. Further, a plurality of
fasteners 160 (e.g., bolts) are received within aligned pairs of
the bolt holes 118 on connector 108 of suction casing 102 and the
mounting bores 410 on upstream connector 404 and within aligned
pairs of the bolt holes 140 on upstream connector 128 and the
mounting bores 410 on downstream connector 406. In this embodiment,
the fasteners extend through bolt holes 118, 140 and are threadably
engaged with the corresponding mounting holes 410 so as to secure
body 402 axially between each of the casings 102, 120.
[0052] In this embodiment, when thermal transfer assembly 400 is
mounted between casings 102, 120 as described above, radially inner
surface 407 of body 402 may contact (or is closely positioned) to
driver assembly 300 (particularly coils 304). Thus, as will be
described in more detail below, heat which is generated within
coils 304 during operations may be transferred (e.g., conducted,
radiated, etc.) to body 402 and then further transferred away from
pump 800 via cooling coil 420 as noted above.
[0053] Referring still to FIGS. 2, 7, and 9, diffuser 500 comprises
an outer housing 502, a central hub 506, and a plurality of
diffuser vanes 508 (or more simply "vanes 508") extending between
central hub 506 and outer housing 502.
[0054] In this embodiment, outer housing 502 is a cylindrical
member that includes a first or upstream end 502a, a second or
downstream end 502b opposite upstream end 502a. In addition, outer
housing 502 includes a radially outer cylindrical surface 504 and a
radially inner cylindrical surface 503 both extending axially
between ends 502a, 502b. In other embodiments, outer housing 502
(or a portion thereof), may be non-cylindrical in shape.
[0055] Referring still to FIGS. 2, 7, and 9, central hub 506 is a
solid member (non-hollow) disposed within outer housing 502 along
axis 805 and includes a first or upstream end 506a, a second or
downstream end 506b opposite upstream end 506a. Upstream end 506a
extends axially past upstream end 502a of outer housing 502, and
downstream end 506b is disposed at downstream end 502b of outer
housing 502. In addition, central hub 506 includes a first or
upstream section 507 extending axially from upstream end 506a, and
a second or downstream section 509 extending axially from upstream
section 507 to downstream end 506b. Upstream section 507 is
generally cylindrical in shape, while downstream section 509 is
generally conical in shape. Thus, of diffuser 500 may include a
varying cross-section between ends 502a, 502b. In this embodiment,
the circumference and diameter of central hub 506 is generally
constant within upstream section 507, and generally decreases when
moving axially within downstream section 509 from upstream section
507 to downstream end 506b. In addition, in this embodiment
downstream end 506b includes a rounded or hemispherical surface
510. Without being limited to this or any other theory, the
hemispherical surface 510 may reduce turbulence for the fluid
flowing within outer housing 502 and the generally conical shape of
downstream section 509 of central hub 506 may progressively
increase the flow area within outer housing 502 for fluids flowing
from upstream end 502a toward downstream end 502b. It should be
appreciated that other shapes and profiles are contemplated for
central hub 506. For example, in some embodiments, central hub 506
may include non-linear cross-section changes (e.g., a
parabolic).
[0056] Referring specifically now to FIG. 7, vanes 508 extend
generally radially outward from central hub 506 to radially inner
surface 503 of outer housing 502. Each vane 508 includes a first or
upstream end 508a and a second or downstream end 508b opposite
upstream end 508a. Upstream end 508a is proximate upstream end 502a
of outer housing 502 and downstream end 508b is proximate
downstream end 502b of housing 502. In some embodiments, vanes 508
are circumferentially spaced (e.g., uniformly circumferentially
spaced) about axis 805. In this embodiment, there are total four
vanes 508, that are circumferentially spaced approximately
90.degree. from one another about axis 805; however, other numbers
and spacing are contemplated for vanes 508 in other embodiments. In
addition, each of the vanes 508 of this embodiment are configured
to generally convert a twisting or helical flow pattern for a fluid
(e.g., such as a fluid that has flowed across impeller 202
previously described) into a generally axial or laminar flow
pattern. That is, vanes 508 are configured to straighten the fluid
flowing from impeller 202. Thus, in this embodiment, each vane 508
extends generally helically at upstream end 508a, but then
progressively transitions to a generally axial orientation at
downstream end 508b. In one embodiment, the upstream end 508a vanes
508 may generally correspond (e.g., having a similar or equal
helical angle, pitch, etc.) to the helical direction or shape of
vanes 208 of impeller 202 (see e.g., FIGS. 2 and 5) such that fluid
flowing past impeller 200 is efficiently captured by diffuser 500,
during operations.
[0057] Referring still to FIG. 7, in this embodiment, vanes 508
extend generally helically along portions of central hub 506
proximate to upstream end 508a and couple with radially inner
surface 503 of housing 502. In addition, in this embodiment the
axial thickness of each vane 508 generally decreases when moving
from central hub 506 toward radially inner surface 503. However,
again, in other embodiments, the axial thickness of vanes 508 may
be generally may be constant between central hub 506 and radially
inner surface 503. Further, while not specifically shown it should
be appreciated that the axial thickness of each vane 508 may vary
(e.g., increase and/or decrease) or may remain generally constant
between its corresponding upstream and downstream ends 508a, 508b,
respectively. Still further, in some embodiments local
cross-sectional variations may be included along vanes 508 to
optimize flow characteristics through diffuser 500 during
operations. Also, in substantially the same manner as was
previously described for the vanes 208 of impeller 200, in some
embodiments the general helical shape of vanes 508 of diffuser 500
(e.g., for the portion of vanes 508 proximate upstream end 508a)
may vary (e.g., in helical pitch) along the axial direction and/or
the radial direction with respect to axis 805.
[0058] In this embodiment outer housing 502, central hub 506, and
vanes 508 are all monolithically formed as a single piece or member
(i.e., diffuser 500). Thus, in some embodiments, outer housing 502,
central hub 506, and vanes 508 may comprise the same material(s)
(e.g., fiberglass). During operations, fluid is flowed over the
diffuser 500 (including outer housing 502, central hub 506, and
vanes 508) to transition the flow pattern of the fluid from helical
or twisting to laminar (or more laminar). Because vanes 508 are
monolithically formed with outer housing 502 and central hub 506 as
previously described, fluids flowing through diffuser 500 (e.g.,
between ends 502a, 502b of outer housing 502) are prevented from
flowing between outer housing 502 and vanes 508 and between vanes
508 and central hub 506. Accordingly, the fluid is forced to flow
over vanes 508 as it flows axially between ends 502a, 502b of
housing 502.
[0059] Referring again to FIG. 2, diffuser 500 is inserted within
downstream section 124b of throughbore 124 in discharge casing 120
during operations. In particular, diffuser 500 is inserted axially
into downstream section 124b of throughbore 124 from downstream end
120b of casing 120 until upstream end 502a of outer housing 502
engages with downstream facing annular shoulder 139, and upstream
end 506a of central hub 506 approaches downstream end 206b of
central hub 206 along axis 805. Thereafter a retaining ring 520 is
inserted within throughbore 124 (particularly downstream section
124b) and is radially expanded into annular recess 138. Thus,
during operations, diffuser 500 is prevented from axially
translating out downstream section 124b of throughbore 124 by
engaging with retaining ring 520.
[0060] Referring now to FIGS. 1 and 11, during operations, turbine
pump 800 is mounted within a fluid line (e.g., fluid line 920). In
particular, in this embodiment, pump 800 is mounted within pump
system 1000 between upstream section 920a and downstream section
920b of fluid line 920 so that axes 805, 925 are generally aligned
with one another as previously described. More specifically, as
best shown in FIG. 11, in this embodiment, upstream connector 106
on suction casing 102 is engaged with a corresponding connector
910a on upstream section 920a and downstream connector 126 on
discharge casing 120 is engaged with a corresponding connector 910b
on downstream section 920b. Connectors 910a, 910b include a
plurality of bolt holes 912 that are aligned with the plurality of
bolt holes 116, 142 on casings 102, 120, respectively. As a result,
during operations, fasteners (e.g., bolts) (not shown) are inserted
through aligned pairs of the bolt holes 912 in connector 910a and
bolt holes 116 in connector 102 and through aligned pairs of bolt
holes 912 in connector 910b and bolt holes 142 in downstream
connector 126. In addition, while note shown, it should be
appreciated that a suitable sealing member (or members) (e.g., a
gasket, O-ring, etc.) may be disposed between the engaged
connectors 910a, 116 and 910b, 126 so as to prevent fluids flowing
within fluid line 920 and pump 800 from leaking during
operations.
[0061] Upstream section 920a and downstream section 920b of fluid
line 920 each include a corresponding flow bore 922a and 922b,
respectively. When pump 800 is mounted between sections 920a, 920b
as described above, flow bore 922a of upstream section 920a is in
fluid communication with flow bore 922b of downstream section 920b
through the throughbore 104 of suction casing 102, the outer
housings 204, 502 of impeller 202 and diffuser 500, respectively,
(as well as the central apertures 211, 221 of wear rings 210, 220
on either side of impeller 202), and the throughbore 124 of
discharge casing 120. In addition, as shown in FIG. 10, when pump
800 is mounted between sections 920a, 920b as described above,
upstream section 104a of throughbore 104 (see e.g., FIG. 3),
central apertures 211, 221 of wear rings 210a, 210b, 220a, 220b,
respectively, projection 136 within throughbore 124, and radially
inner surfaces 203, 503 of outer housings 204, 502 of impeller 202
and diffuser 500, respectively, are all generally flush with the
radially inner surface defining the flow bore 922a within upstream
section 920a. Without being limited to this or any other theory,
fluids may experience less disturbance due to the flush orientation
of fluid flow bore 922a and the above noted surfaces within pump
800 during operations, so that pump 800 may operate an a higher
level of efficiency during operations.
[0062] Referring still to FIGS. 1 and 10, during operations, driver
assembly 300 induces a varying magnetic field to thereby rotate
impeller 202 about axis 805 within casing assembly 100 as
previously described above. As impeller 202 rotates about axis 805,
turbine pump 800 produces fluid flow through fluid line 920 from
upstream section 920a to downstream section 920b in flow direction
950. During these operations, diffuser 500 remains generally
stationary, and serves to transition the fluid flowing from
impeller from a helical or twisting flow to a more laminar flow
downstream of turbine pump 800 as previously described above.
[0063] Additionally, during the above described operations, thermal
transfer assembly 400 cools driver assembly 300, which may be prone
to heating by the electrical current flowing therein, As previously
described above, thermal transfer assembly 400 may transfer heat
away from driver assembly 300 via body 402 as well as with cooling
coil 420, For instance, referring now to FIGS. 12, in some
embodiments cooling coil 420 may receive a recycle stream of fluid
from fluid line 920 and in particular from downstream section 920b
during operations. in this embodiment, a relatively small amount of
the fluid flowing through fluid line 920 is diverted from
downstream section 920b and is supplied to cooling coil 420 via a
conduit 923 (e.g., tubing). After flowing through cooling coil 420,
the fluid is then recycled back to fluid line 920 via a conduit 924
(e.g., tubing 924), such as at a position upstream of pump 800
(e.g., within upstream section 920a as shown). After being emitted
from cooling coil 420, the fluid may be at an elevated temperature,
and thus, may be routed through a suitable heat exchanger prior to
flowing back into fluid line 920 (e.g., upstream section 920a) as
previously described above.
[0064] Referring to FIG. 13, in other embodiments of turbine pump
800, a separate fluid (that is, a fluid that is not the fluid
flowing through fluid line 920) may be flowed through cooling coil
420 to facilitate heat transfer operations. in particular, in this
embodiment cooling fluid (e.g., air, water, ethyl glycol, oil, or
two-phase evaporative fluids such as R134a, etc.) is supplied to
cooling coil 420 from a self-contained cooling unit 1250 via a
conduit 1252 (e.g., tubing). Once emitted from the cooling coil
420, the cooling fluid may be recycled back to cooling unit 1250
via a conduit 1254 (e.g., tubing) (which may include one or more
heat exchangers, pumps, etc.).
[0065] In some embodiments, components of turbine pump 800 (e.g.,
impeller 202, diffuser 500, etc.) may be manufactured out of
non-metallic materials (e.g., fiberglass, carbon fiber, aramid
fiber) such that the pump 800 may be more effectively utilized to
pump corrosive fluids (e.g., such as salt water). Accordingly, an
example manufacturing process is described below for manufacturing
some or all of the components of pump 800. The manufacturing
process described herein is employs a resin transfer molding (RTM)
process. During RTM molding, reinforcing fibers, such as
fiberglass, are oriented prior to the injection of resin into the
mold, thereby increasing the strength of the molded component in
the direction of fiber orientation. However, it should be
appreciated that the manufacturing process described herein can be
applied to other types of molding processes, such as, for example,
compression molding. During compression molding, the orientation of
the reinforcing fibers is generally less controlled or
uncontrolled, thus causing the compression-molded component to have
a greater thickness than a like RIM-molded component having a given
strength.
[0066] Generally speaking, when manufacturing the components (or
some of the components) of pump 800, a mold core having a shape
that is the inverse of the molded component is disposed inside a
mold cavity. In some embodiments, the mold core may comprise a wax.
For example, the wax comprising the core may comprise a "Blue
Blend" machinable wax, a wax commercially available from
"Machinable Wax.com", Lake Ann, Mich. In some embodiments, the
"Blue Blend" wax has a Specific density of approximately 0.035
pounds/cubic inch, a hardness of 50-55 (Shore I) scale), a flash
point of 575.degree. F., a softening point of 226.degree. F., a
drop melting point of 227.degree. F., and a 5% volumetric shrinkage
rate. In addition, in some embodiments, the wax comprising the mold
core is carveable.
[0067] Referring to FIG. 14, a wax structure 60 is illustrated
which may be used to produce impeller 202 (see e.g., FIG. 5), yet a
similar procedure may be used for diffuser 500 (see e.g., FIG. 7)
as well as other components of pump 800. More particularly, wax
structure 60 has a shape suitable to provide a mold core 62 that is
disposed inside a mold cavity so as to facilitate fabrication of a
RTM-fabricated impeller 202. Thus, the size of mold core 62 may be
defined by the geometry of the desired wax structure 60. In
particular, mold core 62 defines an inverse structure of impeller
202, such that solid regions of mold core 62 defines open regions
or air pockets along impeller 202 that are material-free, while
open regions or air pockets defined by mold core 62 defines solid
structures along impeller 202. In order to prevent cracking as wax
structure 60 cools, mold dies that define the shape of wax
structure 60 may be made of silicon rubber. Silicon rubber
minimizes the dissipation of heat as wax structure 60 hardens
during fabrication of wax structure 60. Additionally, heat lamps
may be selectively used during the fabrication of wax structure 60
to prevent local hardening of the wax, for example at the open end
of the mold which is exposed to ambient air temperatures. This
local heating technique allows the wax to cool slowly, along a
direction from the closed portion (e.g., the base) of mold core 62
towards the open end of mold core 62, thereby minimizing the
possibility of forming cracks in the wax during cooling. Multi-axis
computer numerical control (CNC) machines can mill or otherwise
machine cutouts 64 in wax structure 60 that are in the shape of
impeller vanes 208.
[0068] During operations, reinforcing fibers (not shown), such as
fiberglass fibers, are oriented along a desired direction, placed
along the outer and inner surfaces of mold core 62, and are also
inserted along cutouts 64. As best shown in FIGS. 15 and 16, the
fiberglass-carrying core 62 is placed into a mold cavity 72 that is
defined between a pair of mold dies 74, and a resin is injected
into the mold cavity 72 to form impeller 202. Once the resin
hardens, mold dies 74 may be separated to reveal impeller 202.
[0069] The injected resin may be any suitable resin, such as, for
example a non-corrosive resin (e.g., as a vinyl-ester or epoxy). In
some embodiments, the injected and cured resin has a melting point
of greater than 350.degree. F., and greater than that of wax mold
core 62, such that wax mold core 62 may be melted away without
damaging impeller 202. In some embodiments, the resin may heated to
facilitate the curing thereof, and thus it may be possible to
select a mold curing temperature that concurrently cures and
removes mold core 62. For example, 267.degree. F. may provide a
suitable curing temperature in some embodiments which may melt away
a wax mold core 62 made of Blue Blend wax (e.g., above 227.degree.
F.) without melting the cured resin at 350.degree. F.
[0070] Any residual wax which may remain on impeller 202 after wax
core 62 is melted, may be flushed out of turbine pump 800 during
operations, Without being limited to this or any other theory, the
residual wax may be soft enough such that it may pass through
turbine pump 800 and fluid line 920 during normal operations.
[0071] It should be appreciated that both the molded impeller 202
and diffuser 500 are homogeneous one piece solid components when
produced by the methods described herein above. More particularly
the elements of each component are fabricated as a single integral
structure, free of joints in the form of glue, non-molded resin,
bolts, fasteners, or other discrete connections. For example,
impeller vanes 208 are integrally connected to both outer housing
204 and central hub 206. Likewise, diffuser vanes 508 are
integrally connected to outer surface 502 and central hub 506.
[0072] In the manner described, embodiments disclosed herein
include turbine pumps with integrated motor or drive units (e.g.,
pump 800), which may allow the pumps to be installed and supported
within segments of a fluid line (e.g., fluid line 920). As a
result, a separate support base or foundation for the motor or
drive unit of the pump may be omitted. In addition, some
embodiments of the turbine pumps disclosed herein are constructed
(wholly or partially) of non-metallic materials, such that they may
be used to pump corrosive fluids (e.g., salt water).
[0073] While some embodiments of the pump 800 described above have
included a magnet assembly 230 that is separately secured to
impeller 202, it should be appreciated that in other embodiments,
magnet assembly 230 (or portions thereof) are integrated or
monolithically formed with impeller 202. For instance, in some
embodiments, magnets 240 of magnet assembly 230 may be molded onto
and/or within outer housing 204 of impeller 202 during an
embodiment of the above described manufacturing process. That is,
the magnets 240 may be placed within the mold cavity along with
core 62 (see FIGS. 15 and 16) so that the resulting impeller 202
may have magnets embedded therein. In addition, some of the
embodiments of pump 800 may supplement or replace cooling coils
420, with other thermal transfer devices. For instance, in these
embodiments, thermal transfer assembly 400 may include a so-called
cooling jacket to channel or flow a volume of cooling fluid about
body 402. For example in some embodiments, body 402 may define or
include a channel or annulus that may receive a flow of cooling
fluid therethrough during operations (e.g., such as cooling fluids
discussed above with respect to FIGS. 12 and 13). in sonic of these
embodiments, the channel or annulus may be subdivided using fins,
baffles, etc. Still further, in some embodiments other heat
transfer components or devices may be used within pump either in
lieu of or in addition to those described above fins, blowers,
fluid baths, etc.).
[0074] Having described various devices and methods, specific
embodiments can include, but are not limited to:
[0075] In a first embodiment, a pump comprises: a casing assembly,
wherein the casing assembly includes a central axis and comprises:
an upstream connector that is configured to engage with a first
connector on a fluid line; and a downstream connector that is
configured to engage with a second connector on the fluid line; an
impeller rotatably disposed within the casing assembly; and a
driver assembly coupled to the casing assembly and annularly
disposed about the impeller; wherein the driver assembly is
configured to rotate the impeller about the central axis.
[0076] A second embodiment can include the pump of the first
embodiment, wherein the impeller comprises an outer housing, a
central hub, and a plurality of vanes engaged with and extending
between the central hub and the outer housing.
[0077] A third embodiment can include the pump of the second
embodiment, wherein the outer housing is cylindrical in shape and
includes a radially inner cylindrical surface and a radially outer
cylindrical surface, and wherein each of the plurality of vanes is
engaged with the radially inner cylindrical surface.
[0078] A fourth embodiment can include the pump of the third
embodiment, wherein the casing assembly comprises a suction casing
and a discharge casing, wherein the suction casing comprises a
throughbore that is flush with the radially inner cylindrical
surface of the outer housing of the impeller.
[0079] A fifth embodiment can include the pump of the third or
fourth embodiment, wherein the central hub includes a first end and
a second end opposite the first end, wherein the first end of the
central hub includes a hemispherical surface.
[0080] A sixth embodiment can include the pump of any one of the
third to fifth embodiments, comprising a plurality of magnets
coupled to the radially outer cylindrical surface of the outer
housing of the impeller, wherein the driver assembly is configured
to induce a varying magnetic field to rotate the impeller and the
plurality of magnets about the central axis.
[0081] A seventh embodiment can include the pump of any one of the
second to sixth embodiments, wherein the outer housing, the central
hub, and the plurality of vanes of the impeller are formed as a
monolithic member.
[0082] An eighth embodiment can include the pump of the seventh
embodiment, wherein the impeller comprises fiberglass.
[0083] A ninth embodiment can include the pump of any one of the
first to eighth embodiments, further comprising a thermal transfer
assembly comprising: a body annularly disposed about the driver
assembly; and a cooling coil disposed about the body, wherein the
cooling coil comprises an elongate tube that is configured to
receive a flow of cooling fluid therethrough.
[0084] A tenth embodiment can include the pump of the ninth
embodiment, wherein the casing assembly comprises a suction casing
and a discharge casing, wherein the body of the thermal transfer
assembly is disposed axially between the suction casing and the
discharge casing.
[0085] In an eleventh embodiment, a system comprises: a first pipe
section; a second pipe section; and a pump mounted between the
first pipe section and the second pipe section, wherein the pump
comprises: a casing assembly including a central axis; an impeller
rotatably disposed within the casing assembly; and a driver
assembly coupled to the casing assembly and annularly disposed
about the impeller; wherein the driver assembly is configured to
rotate the impeller about the central axis to pump fluid from the
first pipe section to the second pipe section.
[0086] A twelfth embodiment can include the system of the eleventh
embodiment, wherein the impeller comprises: a cylindrical outer
housing; a central hub disposed within the outer housing; and a
plurality of impeller vanes engaged with and extending between the
central hub and the outer housing.
[0087] A thirteenth embodiment can include the system of the
twelfth embodiment, further comprising: a diffuser disposed within
the casing assembly, axially adjacent the impeller, wherein the
diffuser is configured to straighten a flow of fluid flowing from
the impeller; and wherein the diffuser comprises: a cylindrical
outer housing; a central hub disposed within the outer housing of
the diffuser; and a plurality of diffuser vanes engaged with and
extending between the central hub of the diffuser and the outer
housing of the diffuser.
[0088] A fourteenth embodiment can include the system of any one of
the eleventh to thirteenth embodiments, further comprising a
thermal transfer assembly comprising: a body mounted to the casing
assembly and disposed annularly about the driver assembly; and a
cooling coil disposed about the body, wherein the cooling coil
comprises an elongate tube that is configured to receive a flow of
cooling fluid therethrough.
[0089] A fifteenth embodiment can include the system of the
fourteenth embodiment, wherein the cooling coil is fluidly coupled
to the first pipe section and the second pipe section.
[0090] In a sixteenth embodiment, a method of pumping a fluid
through a fluid line comprises: mounting a pump between a pair of
pipe sections of the fluid line, wherein the pump comprises: a
casing assembly including a central axis; an impeller rotatably
disposed within the casing assembly; and a driver assembly coupled
to the casing assembly and annularly disposed about the impeller;
rotating the impeller about the central axis with the driver
assembly; and flowing a fluid through the pair of pipe sections and
the pump while rotating the impeller.
[0091] A seventeenth embodiment can include the method of the
sixteenth embodiment, further comprising: straightening a flow of
the fluid with a diffuser disposed axially adjacent the
impeller.
[0092] An eighteenth embodiment can include the method of the
sixteenth or seventeenth embodiment, wherein rotating the impeller
comprises: inducing a varying magnetic field with the driver
assembly; and attracting a plurality of magnets with the varying
magnetic field.
[0093] A nineteenth embodiment can include the method of any one of
the sixteenth to eighteenth embodiments, further comprising:
flowing a cooling fluid through a coil that is wrapped about a body
of a thermal transfer assembly, wherein the body is mounted to the
casing assembly and is disposed annularly about the driver
assembly.
[0094] A twentieth embodiment can include the method of the
nineteenth embodiment, wherein flowing the cooling fluid through
the coil comprises: flowing a stream of fluid from a downstream
section of the pair of pipe sections to the coil; and flowing the
stream of fluid through the coil after; and flowing the stream of
fluid from the coil to an upstream section of the pair of pipe
section after flowing the stream through the coil.
[0095] While exemplary embodiments have been shown and described,
modifications thereof can be made by one skilled in the art without
departing from the scope or teachings herein. The embodiments
described herein are exemplary only and are not limiting. Many
variations and modifications of the systems, apparatus, and
processes described herein are possible and are within the scope of
the disclosure. Accordingly, the scope of protection is not limited
to the embodiments described herein, but is only limited by the
claims that follow, the scope of which shall include all
equivalents of the subject matter of the claims. Unless expressly
stated otherwise, the steps in a method claim may be performed in
any order. The recitation of identifiers such as (a), (b), (c) or
(1), (2), (3) before steps in a method claim are not intended to
and do not specify a particular order to the steps, but rather are
used to simplify subsequent reference to such steps.
* * * * *