Note: Descriptions are shown in the official language in which they were submitted.
WELL WATCHMAN PUMPING AND CONTROL SYSTEM
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority and benefit to an
application, which
was originally filed as United States Nonprovisionat Patent Application Serial
No.
12/822,077, on June 23, 2010, but which was converted to a provisional
application
by the Request Under 37 C.F.R. I .53(c)(2) For Conversion of a Utility
Application to
a Provisional Application on June 22, 2011.
BACKGROUND OF THE INVENTION
I. Field of the Invention
[0002] The present invention relates to a intelligent well watchman
pumping and
control system which monitors storage water levels typically at remote water
wells
such as livestock wells where utility power is not available, and then
provides
electrical power to a well pump on demand as it monitors and analyzes critical
equipment safety conditions as well as maintenance and production parameters
controlling the water pumping process automatically without the requirements
of an
on-site operator.
2. Description of the Invention
[0003] Water production on remote wells for livestock and other
applications have
long been problematic in the livestock indnstry with the typical low
production rates
of solar pumping systems on deep wells and failure rates along with the
maintenance
costs and access challenges of windmill water production. Many within the
industry
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have resorted to point of use generators which require repeated trips to the
remote
well site to fuel and start the generator to pump the required water to
satisfy livestock
water consumption needs. Solar power has been seen as an effective answer to
the
challenge, but with solar powered water pumping systems, flow rates on deep
water
wells are typically very low when compared to the flow rates of a standard
deep well
pump supported by AC electrical power. Solar energy production is dependent on
exposure to sunlight. Water production capabilities will be decreased or can
cease in
long times of decreased or no sunlight. In some cases, the water production
rate of a
solar water production system is the primary limiting factor restricting a
livestock
property to realize its full potential. In solar water production systems that
do not
utilize level control, water in excess of the amount that can be held by the
onsite water
storage vessel can spill out of the vessel and be wasted.
[0004] Windmill water production is also a common solution to water
production
issues on remote water well sites. Typically, windmills are very wasteful when
producing water. Unless turned off by an operator, windmills pump as long as
wind
is present. Once the storage vessel is full, excess water generally spills out
onto the
ground wasting the water and the operating efforts of the windmill. Windmills
also
tend to be expensive and difficult to maintain, often involving risky and
hazardous
conditions to the technician performing maintenance.
[0005] The point of use generator, though the least expensive up front, can
overall be
very expensive approach to water production. A generator typically requires an
operator making a trip to the site with a container of fuel, fueling the
generator, and
then starting it along with the deep well pump in the well. Typically, the
operator
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does not wait the several hours that it takes the generator to consume the
fuel, but
leaves the site understanding that when the generator has consumed all of the
fuel, it
will stop running. Allowing the generator to run out of fuel under an
electrical load in
this manner is extremely hazardous to both the generator and the deep well
pump,
often shortening the operating life of each piece. This practice further can
lead to
expensive repairs or early replacements of either the generator or the well
pump.
[0006] U.S. Pat. Nos. 4,744,334 and 1,632,188 and 6,699,019 describe
methods and
apparatus for the pumping and transfer of ground water to the surface for
livestock
consumption needs. The invention disclosed in U.S. Pat. No. 4,744,334
generally
suffers from a limited water production capability as compared to the
invention of the
well watchman pumping and control systems water production capabilities. The
windmill water pumping inventions disclosed in U.S. Pat. Nos. 1,632,188 and
6,699,019 suffer in areas of accessibility for maintenance operational
dependability
cost of repairs and water conservation when compared to the invention well
watchman pumping and control system.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a well watchman pumping and
control
system, which comprises a propane or other, similar fuel combustion engine
driven
electric generator and a cast of field sensors to automatically produce an on-
demand
electrical power supply sufficient to support an in-ground well water pump for
filling
a water storage vessel to a predetermined level, while continuously monitoring
the
water level in the storage vessel with the field sensors monitoring critical
operating
and environmental conditions and analyzing the conditions to control system
operation, to prevent hazards to both pump and generator. The present
invention
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further includes the capability to provide an alert to provide, for example,
maintenance or troubleshooting messages or system status. The alert or
notification
can be displayed on an LCD screen at the control panel, or can be relayed to a
location remote from the system, such as a text message, e-mail or other
notification
sent to an operator. The present invention thus can prevent waste of ground
water,
reduce fuel consumption and emissions due to the repeated frequencies of trips
to well
sites and/or due to an unmanned generator, and increase water production as
needed
for livestock, benefitting both the natural environment and operating costs to
the user.
[0008] It is therefore an object of this present invention to provide a
well watchman
pumping and control system which will significantly enhance of water
production
capabilities at remote well sites where utility power is not available.
[0009] It is another object of this present invention to provide a well
watchman
pumping and control system which will significantly enhance the reliability of
water
production at a remote well site.
[0010] It is a further object of this present invention to provide a well
watchman
pumping and control system which can conserve ground water resources, improve
fuel efficiency, and reduce the undesirable emissions from vehicular traffic
to a well
site and from unmanned generators.
[0011] It is a still another object of this present invention to provide a
well watchman
pumping and control system which reduce or eliminate health and safety hazards
associated with technicians performing maintenance tasks on a windmill water
production system at remote locations.
[0012] It is a still another object of this present invention to provide a
well watchman
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pumping and control system which can provide a long life, cheap and dependable
water production system for remote well sites using a domestically produced,
environmentally friendly fuel.
[0013] The present invention provides a well watchman pumping and control
system
that includes an electric generator, a system control, a water storage vessel,
a well
pump that provides water to the water storage vessel, and a monitoring device
for
monitoring a water level in the water storage vessel, a flow rate of the pump,
and
operating conditions of the generator. The monitoring device operates to relay
the
water level in the water storage vessel to the system control and starts the
generator
and the well pump when the water level reaches a preset low level. The system
control monitors the generator and the well pump to protect against operation
under
low flow conditions or operation of the generator or pump during unsuitable
operating
parameters. If the system shuts down, a troubleshooting message indicating any
reasons for shutdown is provided. The monitoring device can be a float switch
or a
water pressure switch. The system can further include a means for monitoring
pump
discharge flow.
[0014] The system can further include at least one of (1) means for
monitoring a fuel
level and means for displaying a low fuel message, (2) means for monitoring an
oil
level and means for displaying a low oil message, (3) means for monitoring
ambient
temperature and means for displaying a low ambient temperature message, (4)
means
for monitoring a typical fill time of the storage vessel by monitoring the
water flow
rate from the pump, the quantity of water required to raise the water level to
the high
level, or the time lapsed between start and stop of the pump, or (5) means for
monitoring electrical output from the generator. The system control ceases
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of the pump and generator at an occurrence of one of the following: (1) after
the fuel
level reaches a preset low fuel level, (2) after the oil level reaches a
preset oil low
level, (3) after the ambient temperature reaches a preset low ambient
temperature, (4)
after the typical fill time has lapsed without the monitoring device
indicating the
water level in the water vessel has reached the high level, or (5) after an
indication
that the electrical output from the generator is outside a preset electrical
output range.
The system control relays an error message at the occurrence of one of the
following:
(1) after the fuel level reaches a preset low fuel level, indicating the
generator requires
fuel, (2) after the oil level reaches a preset oil low level, indicating the
generator
requires oil (3) after the ambient temperature reaches a preset low ambient
temperature, indicating the generator and pump should not be run (4) after the
typical
fill time has lapsed without the monitoring device indicating the water level
in the
water vessel has reached the high level, indicating a leak in the water
storage vessel,
or (5) after an indication that the electrical output from the generator is
outside a
preset electrical output range, indicating an electrical error.
[0015] The system control is capable of storing and transmitting at least
one operating
condition for display at the system, to at least one remote location, or both.
The
operating condition can include one or more of the following: water production
data,
run time of the generator or pump, lapsed time between operation of the
generator or
pump, aggregate amount of water pumped, or maintenance time to clean an air
filter,
oil, or spark plug of the generator. The operating condition can be displayed
on an
LCD screen at the system.
[0016] The present invention also includes a method of operating a well
watchman
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pumping and control system, with the system including an electric generator, a
system
control, a water storage vessel, a well pump that provides water to the water
storage
vessel, and a monitoring device for monitoring a water level in the water
storage
vessel, a flow rate of the pump, and operating conditions of the generator.
The
method includes monitoring the water level in the water storage vessel with
the
monitoring device, and initiating operation of the generator and well pump
when the
water level reaches a preset low level. The monitoring can include the system
control
receiving a signal from the float switch or pressure switch to commence the
system
starting sequence. The system control generally initiates operation of the
generator
and the pump to pump water to fill the water storage vessel to a preset high
level and
then initiates a shutdown sequence of the generator and pump. The system then
monitors operation of the pump. If the water flow is less than a preset flow
rate, the
method can further include stopping operation of the pump and generator by the
system control. The method can further comprise relaying an error condition.
The
method can further include restarting the well waterman pumping and control
system
after a preset time has elapsed.
[0017] The method can further include at least one of the following: (I)
monitoring a
fuel level and displaying a low fuel message, (2) monitoring an oil level and
displaying a low oil message, (3) monitoring ambient temperature and
displaying a
low ambient temperature message, (4) monitoring a typical fill time of the
storage
vessel by monitoring the water flow rate from the pump, the quantity of water
required to raise the water level to the high level, or the time lapsed
between start and
stop of the pump, or (5) monitoring electrical output from the generator. The
system
control ceases operation of the pump and generator at an occurrence of one of
the
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following: (1) after the fuel level reaches a preset low fuel level, (2) after
the oil level
reaches a preset oil low level, (3) after the ambient temperature reaches a
preset low
ambient temperature, (4) after the typical fill time has lapsed without the
monitoring
device indicating the water level in the water vessel has reached the high
level, or (5)
after an indication that the electrical output from the generator is outside a
preset
electrical output range.
[0018] The system control relays an error message at the occurrence of one
of the
following: (1) after the fuel level reaches a preset low fuel level,
indicating the
generator requires fuel, (2) after the oil level reaches a preset oil low
level, indicating
the generator requires oil (3) after the ambient temperature reaches a preset
low
ambient temperature, indicating the generator and pump should not be run (4)
after
the typical fill time has lapsed without the monitoring device indicating the
water
level in the water vessel has reached the high level, indicating a leak in the
water
storage vessel, or (5) after an indication that the electrical output from the
generator is
outside a preset electrical output range, indicating an electrical error.
[0018a] In accordance with an aspect of the present invention, there is
provided a
water well pumping and control system comprising: an electricity generator; a
system
control; a water storage vessel; a well pump that provides water to the water
storage
vessel; at least one water level monitoring device for monitoring a water
level in the
water storage vessel and a flow rate monitor for the pump; and an ambient
temperature monitoring device for monitoring ambient temperature, the
generator
being operable by the system only when the monitored ambient temperature is
above
a preset low ambient temperature; wherein the at least one water level
monitoring
device relays the water level in the water storage vessel to the system
control, which
starts the generator and the well pump when the water level reaches a preset
low
level; wherein the system control automatically monitors one or more operating
conditions of the generator and the well pump to protect against operation
under low
flow conditions or operation of the generator or pump during unsuitable
operating
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parameters; and wherein, upon an occurrence of the system shutting down, the
system
is configured to provide a troubleshooting message indicating one or more
reasons for
shutdown.
[0018b] In accordance with a further aspect of the present invention, there
is provided
a method of autonomously operating a water well pumping and control system,
the
method comprising: monitoring ambient temperature; operating an electricity
generator, which is controlled by a system control, the generator operating
only when
the monitored ambient temperature is above a preset low ambient temperature;
operating a well pump that provides water to a water storage vessel; operating
a water
level monitoring device for monitoring a water level in the water storage
vessel;
monitoring the water level in the water storage vessel with the water level
monitoring
device; and, signaling the control system to initiate operation of the
generator and
well pump when the water level reaches a preset low level.
[0018c] In accordance with a further aspect of the present invention, there
is provided
a water well pumping and control system comprising: an electricity generator;
a
system control; a water storage vessel; a well pump that provides water to the
water
storage vessel; a water level monitoring device for monitoring a water level
in the
water storage vessel; a flow rate monitor for the pump; and an ambient
temperature
monitor, the generator being operable by the system only when the monitored
ambient
temperature is above a preset low ambient temperature; wherein the water level
monitoring device relays the water level in the water storage vessel to the
system
control, which starts the generator and the well pump when the water level
reaches a
preset low level; wherein the system control automatically monitors one or
more
operating conditions of the generator and the well pump to protect against
operation
under low flow conditions or operation of the generator or pump during
unsuitable
operating parameters; and wherein, upon an occurrence of the system shutting
down,
the system is configured to provide a troubleshooting message indicating one
or more
reasons for shutdown.
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[0019] These and various other objects of the present invention will become
apparent
to those skilled in this art upon reading the accompanying description,
drawings, and
claims set forth herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a front view schematically illustrating the well watchman
pumping
and control system according to the present invention.
[0021] FIG. 2 is an overhead view of the well watchman pumping and control
system.
[0022] FIG. 3 is a front view of exemplary components in the control panel.
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[0023] FIG. 4 is a flow chart showing an exemplary sequence of operation of
the well
watchman pumping and control system.
DETAILED DESCRIPTION OF THE INVENTION
[0024] A well watchman pumping and control system is the overall system
detailed
herein. FIG. 1 illustrates one embodiment of the well watchman pumping and
control
system according to the present invention. As seen in the drawings, the well
watchman pumping and control system is a skid assembly 10 generally including
an
electric generator 11 driven by a propane or other fuel engine that will
accommodate
the electrical power requirements of a well pump 22, which is preferably a
deep
underground well pump. An example of such an electric generator is the EcoGen
series generators available from GENERAC Power Systems of Waukesha, Wisconsin.
A system control panel 12 is electrically connected by a properly sized cord
and plug
assembly 20 for the required electrical load necessary to run the generator
and pump.
The system control panel preferably a NEMA 12, hinged door enclosure and
inside
the panel includes, a display 62 and user input 68, such as a keyboard, touch
screen,
etc., and a system control or processor 60 that enables outputs and receives
and
monitors inputs from a series of field devices including a float switch 14 or
a water
pressure switch 25, a fuel pressure switch 13, and a flow switch 15 as can be
seen on
FIG. 2 of the drawings. The float pressure and flow switches serve to monitor
pumping control variables and system status conditions for an outdoor
application at a
water well site typically where utility power is not readily accessible, such
as on
remote and livestock water wells, reporting the system conditions to the
system
control panel, which in turn controls operation of the pump in response to
such inputs
to maintain the desired water level.
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[0025] The float switch 14 is placed in the target water storage vessel 16
or a pressure
switch 25 is placed into the water pipe 24 between the well discharge and the
water
storage vessel 16 to monitor for predetermined low and full water level
conditions.
The float switch 14 can be any high quality, durable float actuated, magnetic
or
mechanical micro switch rated for 12 volts DC or higher with a at least one
set of
normally open contacts, compatible with the ambient temperatures of the
application.
An example of a preferred water level float switch for this application would
be a
Dayton 3BY80 float switch. This switch is a durable switch compatible with the
ambient temperatures of the application and is generally capable of greater
than ten
thousand cycles over its operating life, for example. The pressure switch 25
can be
any type of durable liquid pressure sensing micro switch, with independent
dual sets
of normally open and normally closed contacts rated for 12 volts DC or higher.
An
example of a preferred water pressure switch for this application would be a
PSW-
852CL pressure switch from OMEGA Engineering of Stamford, Connecticut. The
pressure switch 25 is a durable switch compatible with the ambient
temperatures of
the application. It has a field settable hysteresis and set point
repeatability of +/- 2%
and a greater than ten thousand cycle rated operating life. The float switch
14, or the
water pressure switch 25, is electrically connected by an electrical quick
change cable
and receptacle assembly 18. An example of a preferred assembly would be a Brad
Harrison quick change cable and receptacle assembly model 112020A01F060 with a
1R2006A20A120 and a 1R2004A20A120.
[0026] When the float switch 14 or the water pressure switch 25, detects a
low level
condition in the water storage vessel 16, an electric signal will be sent from
the switch
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to the well watchman pumping and control system control panel 12 where the low
level signal is confirmed by the system control after a preset time to confirm
the
actual low level condition. The system control 12 operates on a pre-programmed
sequence, an example of which follows. Once a low level condition in the
storage
vessel is confirmed, the control panel 12 will begin a system start up
sequence with a
start signal being sent to the skid mounted electric generator 10. The
generator 10
will receive a start signal from the system control panel 12 starting the
electric
generator 11 producing electric power to support an electric motor on an
underground
deep well pump 22.
[0027] Once the generator 11 has started, the ON condition will be
confirmed at the
system control panel 12 receiving a signal of the output from the electric
generator 11.
Once the electric generator output is confirmed at the system control panel
12, a
preset run time can be allowed to elapse allowing the engine of the electric
generator
11 to warm up. After the preset warm up period is completed the system control
panel 12 will turn on the electric power to the underground deep well pump 22,
which
can be any DC or sixty cycle AC electric motor driven submersible pump rated
for the
installation and compatible with the environmental conditions of the
installation. The
pump 22 is electrically connected to the system control panel by a cord and
plug
assembly 20, producing a water flow from the underground deep well pump 22
through a water pipe 24 to the water storage vessel 16, filling the water
storage vessel
16 to a predetermined full level as signaled by the float switch 14 position
of 45
degrees above horizontal position or the water pressure switch 25, pressure
setting.
When the water level in the water storage vessel 16 reaches a full condition
as
measured by the float switch 14 at a predetermined position or the water
pressure
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switch 25 at a preset pressure setting, a signal will be sent from the float
switch 14 or
the water pressure switch 25, to the system control panel 12 to begin a
controlled
shutdown process of the underground deep well pump 22 and electric generator
11.
The electrical supply to the well pump 22 will be turned OFF by the system
control
panel 12. The electric generator 11 will continue to run for a preset time to
allow the
electric generator 11 to warm down with no load and then it will shut off
ready for the
next fill cycle process to begin.
[0028] A flow switch 15 is located in the water pipe 24 between the well
discharge
and the water storage vessel 16. An example of a mechanical switch is a Dwyer
F.S.-
2 vane flow switch available from DWYER Instruments Inc. of Michigan City,
Indiana and an example of a thermally actuated flow switch for this
application would
be a FST-211-SPST switch from OMEGA Engineering of Stamford, Connecticut.
The flow switch 15 can be any temperature, magnetic or mechanically actuated
micro
switch rated for 12 volts DC or higher with a at least one set of normally
closed
contacts capable of sensing the lowest water flow level of the installation.
The flow
switch 15 is durable and compatible with the ambient temperatures of the
application,
can have a field adjustable set point, and generally is rated as a greater
than ten
thousand cycle operating life. The flow switch is electrically connected to
the system
control panel by an electrical quick change cable and receptacle assembly 19.
An
example of a preferred quick change cable and receptacle assembly would be a
Brad
Harrison model 113020A01F060 with a 1R3006A20A120 and a 1R3004A20A120.
The flow switch 15 will confirm water flow within a preset time after the well
pump
is turned on. If no water flow is sensed or if water flow stops through the
flow switch
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15 for a preset time, then a signal will be sent fiom the flow switch 15 to
the system
control panel 12 to turn off the electrical power being supplied to the
underground
deep well pump 22 protecting it from operating in a no flow condition due to a
frozen
water pipe 24, a weak water supply in the well or any other condition that
could
prevent water from flowing when the underground deep well pump 22 is ON.
[0029] An alarm or other fault condition notification can be sent, for
example, via text
message or other indicator on the LCD screen 62 inside the system control
panel 12 to
indicate the no flow condition and can be automatically forwarded to a central
control
or operator, such as wirelessly, via e-mail, text, or other notification.
After a preset
time period has elapsed to allow a well to recharge with ground water seepage
or to
allow frozen water pipes 24 to thaw, the system control panel 12 will
automatically
initiate a new start up sequence still providing no flow pump protection by
means of
the flow switch 15. This sequence will repeat until the water storage vessel
16 has
reached a full level as measured by the float switch 14 in the water storage
vessel 16
or the water pressure switch 25 in the water pipe. A reset button inside the
system
control panel 12 thereafter can reset the text message and the well watchman
pumping
and control system 10, clearing the condition and allowing immediate operation
but
still monitoring any no flow condition reoccurrence.
[0030] To aid in the prevention of operating in a condition where a frozen
water pipe
may be present, a temperature sensor located inside of the system control
panel 12
will prevent the start up of the system anytime that the temperature has
dropped below
a set temperature (e.g. thirty two degrees Fahrenheit (32oF) or below) and
will not
allow the system the system to begin a startup sequence until the temperature
sensed
inside the control panel 12 has risen to a set temperature (e.g. forty degrees
Fahrenheit
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(40oF)) or the system reset button inside the system control panel 12 is
initiated. A
text message will be displayed of the condition on the LCD screen inside the
system
control panel 12 until the condition has cleared or the reset button inside
the system
control panel 12 has been initiated.
[0031] Fuel pressure is monitored by a pressure switch 13 with a Division 1
Hazardous rating with a least one set of normally closed contacts rated for 12
volts
DC or higher with an adjustable set point range from eight to thirty pounds
per square
inch and at least a maximum working pressure rating of three hundred pounds
per
square inch and rated for outdoor installations. An example of a preferred
pressure
switch would be a PSW12T-AS switch available from Omega Engineering of
Stamford, Connecticut. This pressure switch is electrically connected by an
electrical
quick change cable and receptacle assembly 13. An example of a preferred quick
change cable and receptacle assembly would be a Brad Harrison model
112020A01F060 with a I R2006A20A120 and a 1R2004A20A120 cable and
receptacle assembly.
[0032] The fuel pressure switch 13 is located between the propane 21 tank,
or other
fuel supply, and the pressure regulator 23 supplying the electric generator
11. The
fuel pressure switch 13 monitors the tank fuel level and senses a low fuel
pressure
condition, and will send a signal to the system control panel 12 to initiate a
shutdown
sequence when the fuel pressure drops to the set point of the pressure switch
13 while
the system is running. Once a low fuel pressure level is sensed, a text
message of the
condition will be displayed on the LCD screen inside the system control panel
12 and
the system will be prevented from restarting until the system is refueled to
an
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adequate pressure above the pressure switch 13 set point and the system reset
button
inside the system control panel 12 is initiated, clearing the condition and
the text
message.
[0033] The well watchman pumping and control system 10 further can display
on the
LCD screen inside the system control panel 12 a series of maintenance text
prompts,
including air filter change after five hundred hours of operation, oil change
after five
hundred hours of operation, and/or spark plug change after five hundred hours
of
operation. All maintenance text prompts are based on operating hour interval
times,
recommended by the electric generator 11 manufacturer. Such prompts generally
will
be programmed into the system control inside of the system control panel 12,
and a
text message will be displayed at the end of each of these elapsed times to
notify a
technician/operator to perform the prompted task on the LCD screen inside of
the
system control panel 12. These maintenance text prompts are resettable by
pressing
the system reset button inside the system control panel 12.
[0034] The watchman pumping and control system 10 will display on the LCD
screen
inside the system control panel 12 operational text. Based on the measured
flow rate
of the pump at the installation, a calculated value of total gallons of water
made up to
one million gallons will be displayed as a default on the LCD screen. This
total value
is not resettable by an operator. Once the system has totaled one million
gallons of
water produced the value will change back to zero and start counting up to one
million gallons again, repeating this cycle throughout the systems' life. A
second
water production value will be displayed on the LCD screen inside of the
system
control panel 12 as a secondary default screen, displaying total gallons of
water
pumped since last reset. This is to allow an operator to quantify gallons of
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produced between visits to the well site. In one example operation, a counter
is reset
to zero by pressing the system reset button inside the system control panel 12
for five
seconds. After pressing the system reset button for five seconds, the counter
value
will reset back to zero and will restart totaling gallons of water when the
water
production process starts again.
[0035] Calculations are made based on the water storage vessel 16 capacity
of the
measured underground deep well pump 22 discharge rate and the float switch 14
or
the water pressure switch 25 settings to determine the approximate time
required for
the deep well pump to fill water storage vessel 16 to a desired or necessary
level. The
storage vessels 16 are installed on well sites as needed and generally range
between
10,000 and 40,000 gallons. Storage reserves also range and depend on livestock
loads
and pump flows, and can range, for example, from a system that operates nearly
every
day for 8 hours or more to systems that operate once a week or less. Based on
the
calculations, a time value plus a selected percent of the calculated time will
be
inputted into the system control 60 inside on the system control panel 12.
When the
pump operating time with a confirmed flow at the flow switch 15 exceeds this
inputted value, the system control panel 12 of the well watchman pumping and
control system 10 indicates that the system has exceeded a reasonable run
time,
prompting the operator to check for major a leak in the piping system. The
system
also generally will proceed through a shutdown sequence and will not restart
until an
operator has pressed the system reset button inside the system control panel
12. This
feature is intended to prevent the waste of fuel and preserve ground water.
[0036] FIG. 3 is a front view of exemplary components in the control panel.
FIG. 3
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shows components of the interior 50 of control panel 12, including pump relay
52,
thermostat 54, battery charger 56, relays 58, controller 60, terminals 70,
fuses 72, and
relays 74. Controller 60 includes LCD screen 62, inputs 64, outputs 66, and
user
inputs 68 (such as keyboard, entry keys, etc.). Since additional or fewer
components
can be included in the interior 50 of control panel 12, the elements shown in
FIG. 3
should not be limiting in any manner, and are provide as an exemplary
configuration.
[0037] FIG. 4 is a flow chart showing an exemplary sequence of
operation of the well
watchman pumping and control system. The exemplary method, indicated at 100,
includes a step 110 that analyzes the level of water level in the water
storage vessel.
If the water level indicates a full level, the generator remains off as shown
in step 310.
If the water level is indicated at a low level, the method proceeds from step
110 to
step 120. At step 120, the ambient temperature surrounding the well watchman
system is measured. If the ambient temperature is not above 32, the method
returns to
step 310 with the generator remaining off. If the ambient temperature
surrounding the
well watchman system is above 32, the method proceeds from step 120 to step
140.
Alternatively, the method can be reset, such as pressing a reset button as
shown in
step 130. The method then proceeds from step 130 to step 140. At step 140, the
method measures the engine oil level. If the engine oil level at step 140 is
not okay,
the method returns to step 310 and the generator remains off. If the engine
oil level is
acceptable, the method proceeds from step 140 to step 150. Alternatively, the
engine
oil level indication can be reset such as indicated at step 130 and the method
then
proceeds to step 150.
[0038] At step 150, the method measures the fuel pressure. If the fuel
pressure is not
adequate, the method returns to step 310 and the generator remains off. If the
fuel
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pressure is adequate, the method proceeds to step 160. Alternatively, the fuel
pressure
monitor can be reset such as shown at step 200 and the method can return to
step 160.
[0039] At step 160, the method measures a time interval that lapses to
indicate that a
low water level at the water storage vessel is indicated. For example, as
indicated at
step 160, after sixty continuous seconds have lapsed, the generator will start
and
produce electric power. The method then will proceed from step 160 to step 170
where fuel pressure will be measured. If the fuel pressure is indicated to be
low, the
method proceeds from step 170 to step 180 with the generator disconnecting
electrical
power to the pump and the generator runs for sixty seconds to warm down and
then
proceeds from step 180 to step 310 to switch the generator off. If at step
170, a low
fuel pressure is not indicated, the method proceeds to step 190. At step 190,
the AC
electricity signal to the system control is monitored for two seconds. If this
is
indicated, the method proceeds from step 190 to step 210. If it is not
indicated, the
method proceeds from step 190 to step 310 with the generator switching off.
Alternatively, the method can proceed from step 190 and indicate that a reset
button
has been pressed and the method can return to step 160 to proceed as indicated
above.
[0040] At step 210, the generator operates with no electrical load for
sixty seconds to
warm the engine and the method then proceeds to step 220. At step 220,
electrical
power is sent to the submersible pump motor by way of a system control pump
relay
and the method proceeds to step 230. Alternatively, the reset button can be
pressed as
indicated at step 240 and the method then proceeds to step 180 as detailed
above.
[0041] At step 230, the submersible pump operates for the preset time of
about sixty
seconds to produce water flow to confirm flow at the flow switch preventing
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continued operation in a no flow condition, such as a frozen pipe. The method
then
proceeds from step 230 to step 250 where water flow is monitored at the system
flow
switch. If water flow is not indicated at the system flow switch, the method
proceeds
from step 250 to step 180 as indicated above. Alternatively, if water flow is
not seen
at the system flow switch, the method can be reset as indicated at 240 and
return to
step 230 as indicated above. If water flow is indicated at the system flow
switch, the
method proceeds from step 250 to step 260. At step 260, the generator operates
and
provides electrical power to the submersible pump motor until the storage tank
indicates a full level, or until a preset allowed run time is elapsed, or
until a loss of
flow is indicated at the flow switch.
[0042] The method then proceeds from step 260 to either step 270, 280
or 290. If the
allowed run time has elapsed, the method proceeds from step 260 to step 270.
If the
water storage tank indicates a full level, the method proceeds from step 260
to step
280. If step 260 indicates a loss of flow at the flow switch, the method
proceeds from
step 260 to step 290. If the allowed run time has elapsed at step 270, the
method
proceeds to step 180 as indicated above and then proceeds to switch off the
generator
at step 310. If at step 280 the water storage tank as full, the method
proceeds to step
180 as indicated above and then proceeds to step 310 to switch the generator
off. If a
loss of flow at a flow switch is indicated at step 290, the method proceeds to
step 300.
At step 300, after the preset loss of flow time expires, the generator will
operate for
sixty seconds and shut off. Then, after a preset restart time has expired, the
pumping
process will be restarted and operated until the water storage tank indicates
a full
level. After step 300, the method proceeds from step 300 to step 280 to
indicate that
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the water storage tank is full and then proceeds from step 280 to step 180 as
detailed
above and eventually to step 310 to switch the generator off.
[0043] The present well watchman pumping and control system 10 addresses
several
shortcomings realized in prior systems, including providing the ability to
operate in
both daylight and night hours along with significantly greater flow rates,
giving the
well watchman pumping and control system 10 water production capabilities that
exceed those of wells supported by solar powered water production systems, and
potentially allowing the user of the well watchman pumping and control system
10
opportunities for greater livestock grazing and production capabilities where
water is
currently the limiting factor.
[0044] Operating the well watchman pumping and control system 10 in place
of a
windmill water production system will produce greater flow rates than windmill
powered water production systems and will prevent the waste of ground water
which
is pumped from the ground to a water storage vessel, since windmills have no
level
control capabilities, and once the storage vessel is full, excess water
typically is then
allowed to spill out onto the ground, much of which evaporates into the air
wasting
the precious resource. The maintenance of windmill water production systems
also
can be very expensive and dangerous to the operator and technicians. Typical
frequent maintenance tasks are replacement of the seals at the bottom of the
well
piping requiring the expense of several man hours and the use of a crane type
vehicle.
Servicing the gear box assembly at the top of the windmill pumping system
tower
requires a technician to climb high up to the top of the windmill tower or be
raised to
the area by some lifting device so that lubrication, oil change maintenance
and repairs
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to that portion can be performed. This exposes a technician to the hazards of
working
in conditions at heights with tools, lubricants, and being subject to wind
gusts that can
create an extremely dangerous environment. By the use of the well watchman
pumping and control system 10 in place of windmill water production system,
the
operator will see a reduction in maintenance costs and the substantial
elimination of
the hazards of working at heights to the technicians conceivably preventing
injury and
even death involved in accidents associated with working at the heights on
windmill
towers along with the conditions involved with said activities.
[0045] The use of the well watchman pumping and control system 10 in place
of a
non-intelligent electrical generator also can provide many additional
advantages. A
full command of the water production operation will be taken by the well
watchman
pumping and control system 10. While reductions in labor and operating costs
due to
frequent trips to the well site to refuel to start the generator were the
primary focus of
the invention, a substantial realized benefit to the operator is that the well
watchman
pumping and control system 10 will monitor critical system dynamic conditions.
Controlling the system operations to operate with respect to these conditions,
will
result in safe operation to both the electric generator 11 and the underground
deep
well pump 22 and will prevent both electric generator 11 and underground deep
well
pump 22 from operating in out of electrical design tolerance conditions such
as over
voltage, under voltage, generator, low frequency, or the frequency of the
generator
shutting down under an electrical load (pump motor electrically connected).
[0046] Thus it will be appreciated by those skilled in the art that the
present invention
is not restricted to the particular preferred embodiments described with
reference to
the drawings, and that variations may be made therein without departing from
the
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scope of the present invention as defined in the appended claims and
equivalents
thereof.
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