Note: Descriptions are shown in the official language in which they were submitted.
CONTROLLED WELL PUMPING AND DISTRIBUTION SYSTEM
[0001] (intentionally left blank)
BACKGROUND OF THE INVENTION
[0002] Water production on remote wells for livestock and other
applications has long
been problematic. Water production of remote wells for the livestock industry
typically has several problems such as low production rates of solar pumping
systems
on deep wells, failure rates and associated maintenance costs, and additional
challenged with windmill water production systems including access and waste.
Many
within the industry have resorted to using generators which can require
repeated trips
to a remote well site to fuel and start a generator to pump enough water to
satisfy
livestock water consumption needs.
[0003] Solar power can be an effective answer, but presents its own
challenges. 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.
1
Date Recue/Date Received 2021-11-12
Water production capabilities will be decreased or can cease in 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. Additionally, as long as there is sunlight the pump will continue
to operate
after the distant storage tank is full. The water that is pumped will overflow
from the
tank onto the ground. This condition will continue as long as there is
sunshine unless
an operator travels to the pump location and turns the pump off In arid areas
of the
world a good deal of the water that is spilled onto the ground is absorbed
into the
atmosphere and lost. The remaining water seeps back into the ground, but can
take
several years to reach static ground water levels and charge the ground water
supply.
[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 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
2
CA 2959339 2017-06-05
the area by some lifting device so that lubrication, oil change maintenance
and repairs
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.
[0006] The point of use generator, though often the least expensive up
front, can
overall be a 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 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.
[0007] The livestock industry in particular has long been challenged by
a need for and
a lack of efficient solutions to water distribution over elevations on grazing
lands,
especially in arid and dry regions around the world. Where water can be
distributed
across grazing lands to targeted locations near feeding areas, the water will
be utilized
more efficiently by the livestock. Livestock that must travel long distances
to
watering locations such as troughs naturally will collect in greater herds to
make the
trip from the feeding location to the watering location. Large herds of
livestock
arriving to drink at the same time result in a high demand on the water in the
troughs
and storage tanks.
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[0008] Pipe lines are often installed to deliver water across a
landscape to supply
water to areas supporting livestock. Commonly the source of water, usually a
well,
storage pond or tank, is located at a lower elevation than the location where
the water
is needed. When this is the case a water delivery technology such as a pump is
required to pump the water to the higher elevations where one or more storage
tanks
and/or troughs are located. In an off-grid setting, one solution is using a
solar powered
pump to pump water by solar energy to higher elevation distant storage tanks.
The
solar powered pump will pump water, from the well, pond or a local storage
tank to
the distant storage tank filling the storage vessel for livestock use.
[0009] 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 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 well pumping and control system of the
present invention.
[00010] While a few devices are available to control pump operation based
on the
water level in a local storage tank where the well or pump are in close
proximity to
such storage tank, there is a need for water level control devices to control
pump
operation based on water levels in distant storage tanks often several miles
from the
pump location. See, for example, the system detailed in U.S. Patent No.
8,457,798.
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SUMMARY OF THE INVENTION
[00011] (intentionally left blank)
Description of the Invention
[00012] In one aspect, the present disclosure relates to an improved well
pump and
controller system which can monitor various attributes, such as a water
pressure,
storage water, or other attributes, of the system. The system can be suitable
for
providing electric power to a pump. Aspects of the invention may be suitable
for
applications such as remote water wells such as livestock wells where utility
power
may not be available. As will be described, the present invention is capable
of
controlling water pumping processes automatically without requiring an on-site
operator.
[00013] In another aspect, the present invention addresses the problems of
prior
systems by eliminating over-pumping of countless gallons of ground water.
Distribution of water according to the present system will result in greater
pasture
efficiency, less intense livestock water consumption and the ability to
utilize pasture
areas that are either underutilized or not used by livestock due to their
distance from
water.
Date Recue/Date Received 2021-11-12
[00014] Water distribution systems using elevation to create water
pressure for
distribution to lower elevations are known. In rural settings, however, the
source of
water, e.g. well heads, ponds, etc., are usually not situated at optimal
elevation for
such distribution. The present invention provides an economical and efficient
system
for delivering water or other fluids to a higher elevation storage tank at a
significantly
greater distance from the fluid source than have previously been achieved in
conventional ranching practice in order to permit much greater range of
controlled
distribution to and from that higher elevation storage tank to one or more
remote
locations.
[00015] The present invention can prevent waste of ground water, reduce
fuel
consumption and emissions due to the repeated trips to well sites and/or due
to an
unmanned generator, increase water production as needed for livestock, convert
formerly unusable areas to usable pastures, and reduce operating costs,
benefitting
both the natural environment and user.
[00016] In another aspect, the present invention is directed to an
automatic pump
controller and system designed and capable of preventing overflows at distant
storage
tanks. The system can include a distribution pump controller, sometimes
referred to
herein as a "system controller" or simply as a "controller," one or more
monitoring
devices which may include a pressure sensing device, a float switch, a solar
array or
other power source, water distribution piping, at least one water storage tank
or
vessel, and a pump, such as a well pump, deep well pump, submersible deep well
pump, or the like, that provides water to the water storage vessel along with
custom
software and an assembly of electrical components and hardware assembled in an
6
CA 2959339 2017-06-05
enclosure, which may be a NEMA rated enclosure to protect the components from
the
elements.
[00017] The controller can be compatible with solar, DC and/or AC power
sources
and/or pump motors. However, it will be apparent to one of ordinary skill in
the art
that the system could be adapted for use with other types of power sources
such as
propane, combustion engines, other motors, or the like without departing from
the
scope of this disclosure.
[00018] According to a preferred embodiment, the power source includes a
solar array.
In case night time operation is needed when solar power is unavailable, the
controller
may be battery powered or capable of operation on an AC electrical source such
as an
electric generator, utility power, or other power source. In one example, if
AC power
operation is desired, the controller can be equipped with a cord and plug that
can be
plugged into an electric generator. The controller will then be supported by
AC power
and will perform the same functions as when the controller is supported by
solar
power.
[00019] According to a preferred embodiment, the power source includes a
generator,
such as propane or other generator. In such embodiments, the controller may be
capable of starting and stopping the generator.
[00020] According to a preferred embodiment, the controller can be
adapted to monitor
water pressure that is developed on the water distribution piping and storage
tank
water level. When the water level in a distant storage tank decreases, a
slight drop in
water pressure can be detected in the water piping even from several miles
away. This
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CA 2959339 2017-06-05
drop in pressure can be monitored by the system's pressure sensing device. The
pressure sensing device can include, for example, a switch or pressure
transducer.
[00021] When the pressure drops to the preset pressure set point, an
electrical signal
can be sent to the system controller. In a preferred embodiment, this low
pressure
signal should be continuous for a preset time to confirm the level in the tank
is
actually low and not a result of wind moving the water in a sloshing motion.
Once the
preset time has elapsed without any interruption of the low pressure signal
from the
pressure switch or pressure transducer, the system's microprocessor can turn
on the
pump for a preset time. The pump can deliver water to the distant storage tank
for a
preset time. Once the time has expired, the pump can shut off automatically.
As water
is used or consumed, the process can repeat.
[00022] The present disclosure contemplates and includes, in certain
embodiments of
the invention, continuously monitoring the water level in the storage vessel
with
monitoring devices. The present disclosure also includes field sensors to
monitor
critical operating and environmental conditions. The controller may be capable
of
analyzing the conditions to control system operation and to prevent hazards to
both
pump and power source. Embodiments may further include the capability of
alerting
of the existence of a system issue needing to be addressed, such as providing,
for
example, maintenance or troubleshooting messages or system status. The alert
or
notification can be displayed on an LCD screen at a 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.
8
CA 2959339 2017-06-05
[00023] In some embodiments, the monitoring devices can include devices
for
monitoring one or more of a water level in the one of more water storage
vessel, a
flow rate of the pump, and operating conditions of a power source. The
monitoring
device can be a float switch or a pressure sensing device, such as a switch or
pressure
transducer.
[00024] In embodiments including a generator, the monitoring device can
operate to
relay the water level in the water storage vessel to the system control and
start the
generator and the pump when the water level reaches a preset low level. The
system
control can monitor 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 can be provided.
[00025] It is therefore an object of this present invention to provide a
well pumping
and control system which will significantly enhance water production
capabilities at
remote well sites.
[00026] It is another object of this present invention to provide a well
pumping and
control system which will significantly enhance the reliability of water
production at a
remote well site.
[00027] It is a further object of this present invention to provide a
well pumping and
control system which can conserve ground water resources, improve power
efficiency, and reduce the undesirable emissions from vehicular traffic to a
well site
and from unmanned generators.
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CA 2959339 2017-06-05
[00028] It is a still another object of this present invention to provide
a well pumping
and control system which reduces or eliminates health and safety hazards
associated
with technicians performing maintenance tasks on a windmill water production
system at remote locations.
[00029] It is a still another object of this present invention to provide
a well 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 energy source.
[00030] In one aspect, the present invention provides a well 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.
[00031] 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
CA 2959339 2017-06-05
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 can cease
operation 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 can relay 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.
[00032] The
system control can be capable of storing and transmitting at least one
operating condition for display at the system, at least one remote location,
or both.
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CA 2959339 2017-06-05
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.
[00033] The present invention can also include a method of operating a
well pump and
control system, with the system including a system controller, one or more
monitoring
devices which may include a pressure sensing device or float switch, a power
source
which may include a solar array, electric generator, or other power source,
water
distribution piping, at least one water storage tank or vessel, and a pump
that provides
water to the water storage vessel along with custom software and an assembly
of
electrical components and hardware assembled in an enclosure, which may be a
NEMA rated enclosure to protect the components from the elements. The one or
more monitoring devices may be for monitoring at least one of a water level in
the
water storage vessel, a flow rate of the pump, and operating conditions of the
solar
array, generator, or other power source.
[00034] The method according to some embodiments can include monitoring
the water
level in the water storage vessel with the monitoring device, and initiating
operation
of the 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 can generally
initiate
operation of the pump to pump water to fill the water storage vessel to a
preset high
level and then initiate a shutdown sequence of the pump. In systems including
a
12
CA 2959339 2017-06-05
generator, the control can also start the generator during the system starting
sequence
and stop the generator during the system shutdown sequence.
[00035] The monitoring devices may monitor 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 by the system controller. The method can further comprise relaying an
error
condition. The method can further include restarting the well pumping and
control
system after a preset time has elapsed.
[00036] In some embodiments, the method can further include at least one
of the
following: (1) 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 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.
[00037] In some embodiments, the system controller can relay an error
message at the
occurrence of one of the following: (1) after the fuel level reaches a preset
low fuel
13
CA 2959339 2017-06-05
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.
[00038] In some preferred embodiments, the present disclosure is directed
to a pump
controller system designed and capable of preventing overflows of water in
distant
storage tanks. In some preferred embodiments, aspects of the present
disclosure also
can be adapted to a pump controller system designed and capable of use with
any type
of liquid, such as oil or another liquid in distant storage tanks.
[00038a] In accordance with an aspect of the present invention, there is
provided a
pump and control system for distributing a fluid from a source location to one
or more
remote locations wherein at least one of the remote locations is at an
elevation higher
than that of the source location, the system comprising: a power source; a
controller;
fluid storage vessels at the one or more remote locations, the fluid storage
vessels
including a highest elevation storage vessel and one or more lower elevation
storage
vessels elevationally lower than the highest elevation storage vessel; the
highest
elevation storage vessel having a bottom and being at the elevation higher
than that of
the source location; distribution piping; one or more monitoring devices in
the
distribution piping to sense fluid pressure corresponding to fluid fill levels
in the fluid
14
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storage vessels; and a pump that automatically provides fluid to the fluid
storage
vessels at the remote locations through the distribution piping; wherein the
distribution piping comprises a piping circuit connected to the bottom of the
highest
elevation fluid storage vessel in the piping circuit such that a pressure
change can be
observed throughout the piping circuit as fluid fill level changes in said
highest
elevation fluid storage vessel and the distribution piping further comprises
one or
more connections to the one or more lower elevation storage vessels; and
wherein at
least one of the one or more monitoring devices is situated between the pump
and a
nearest connection of the one or more connections to the one or more lower
elevation
storage vessels.
[0003 8b] According
to an aspect of the invention is a pump and control system for
distributing a fluid from a source location to one or more remote locations
wherein
at least one of the remote locations is at an elevation higher than that of
the source
location, the system comprising: a power source; a controller; fluid storage
vessels
at the one or more remote locations, the fluid storage vessels including a
highest
elevation storage vessel and one or more lower elevation storage vessels
elevationally lower than the highest elevation storage vessel; the highest
elevation
storage vessel having a bottom and being at the elevation higher than that of
the
source location; distribution piping; one or more monitoring devices in the
distribution piping to sense fluid pressure corresponding to fluid fill levels
in the
fluid storage vessels; and a pump that automatically provides fluid to the
fluid storage
vessels at the remote locations through the distribution piping; wherein the
distribution piping comprises a piping circuit connected to the bottom of the
highest
elevation fluid storage vessel in the piping circuit such that a pressure
change can be
Date Recue/Date Received 2021-11-12
observed throughout the piping circuit as fluid fill level changes in said
highest
elevation fluid storage vessel and the distribution piping further comprises
one or
more connections to the one or more lower elevation storage vessels; and
wherein at
least one of the one or more monitoring devices is situated between the pump
and a
nearest connection of the one or more connections to the one or more lower
elevation
storage vessels.
[00039] 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
[00040] FIG. 1 is a front view schematically illustrating the well pumping
and control
system according to one aspect of the present disclosure.
[00041] FIG. 2 is an overhead view of the well pumping and control system.
[00042] FIG. 3 is a front view of exemplary components in the control
panel.
[00043] FIG. 4 is a flow chart showing an exemplary sequence of operation
of the
well pumping and control system of FIG. 1.
[00044] FIG. 5 illustrates a pumping and control system according to
another aspect
of the present disclosure.
[00045] FIG. 6 is a front view of exemplary components in the control
panel.
15a
Date Recue/Date Received 2021-11-12
[00046] FIGS. 7a-7c show front, top, and side views of an exemplary
enclosure for the
control panel of FIG. 6.
[00047] FIG. 8 is a flow chart showing an exemplary sequence of operation
of the
embodiment of FIG. 5 of the present disclosure.
[00048] FIG. 9 is an overview of the system of FIG. 5.
[00049] FIG. 10 is an alternative embodiment which includes at least two
pumps.
DETAILED DESCRIPTION OF THE INVENTION
[00050] FIG. 1 illustrates one embodiment of the well pumping and control
system
according to the present invention. As seen in the drawings, the well pumping
and
control system can be a skid assembly 10 generally including an electric
generator 11
driven by propane or other fuel engine that will accommodate the electrical
power
requirements of a pump 22, which is preferably a deep underground well pump.
An
example of such an electric generator is an EcoGen series generator available
from
GENERAC Power Systems of Waukesha, Wis. 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 12
is preferably in an enclosure, which may be a NEMA, hinged door enclosure, and
inside the panel includes a display 62, 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
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water well site typically where utility power is not readily accessible, such
as on
remote and livestock water wells and reports 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.
[00051] 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. 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, Conn. 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
17
CA 2959339 2017-06-05
change cable and receptacle assembly model 112020A01F060 with a
1R2006A20A 120 and a 1R2004A20A120.
[00052] 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
to the well 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. According to a preferred embodiment, 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 II producing electric power to support an electric motor on
an
underground deep well pump 22.
[00053] According to a preferred embodiment, 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
18
CA 2959339 2017-06-05
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 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.
[00054] According
to a preferred embodiment, 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, Ind. and an example of a thermally actuated
flow
switch for this application would be a FST-211-SPST switch from OMEGA
Engineering of Stamford, Conn. 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
19
CA 2959339 2017-06-05
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 15 for a preset time, then a
signal will
be sent from 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.
[00055] According
to a preferred embodiment, 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 pumping and control system 10, clearing the
condition
CA 2959339 2017-06-05
and allowing immediate operation but still monitoring any no flow condition
reoccurrence.
[00056] According to a preferred embodiment, 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 (32° F.) 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 (40° F.)) 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.
[00057] According to a preferred embodiment, 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, Conn. 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
21
CA 2959339 2017-06-05
112020A01F060 with a 1R2006A20A120 and a 1R2004A20A120 cable and
receptacle assembly.
[00058] According to a preferred embodiment, 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 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.
[00059] According to a preferred embodiment, the well pumping and control
system
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
22
CA 2959339 2017-06-05
prompts are resettable by pressing the system reset button inside the system
control
panel 12.
[00060] According to a preferred embodiment, the well pumping and control
system
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 water 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.
[00061] According to a preferred embodiment, 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
23
CA 2959339 2017-06-05
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 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.
[00062] FIG. 3 is a front view of exemplary components in the control
panel. FIG. 3
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.
[00063] FIG. 4 is a flow chart showing an exemplary sequence of operation
of the well
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
24
CA 2959339 2017-06-05
is indicated at a low level, the method proceeds from step 110 to step 120. At
step
120, the ambient temperature surrounding the well 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 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.
[00064] 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
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.
[00065] 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
CA 2959339 2017-06-05
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.
[00066] 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.
[00067] 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
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.
26
CA 2959339 2017-06-05
[00068] 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
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.
[00069] The well pumping and control system, according to such
embodiments, 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 pumping and control system 10 water production
capabilities that exceed those of wells supported only by solar powered water
production systems, and potentially allowing the user of the well pumping and
control
system 10 opportunities for greater livestock grazing and production
capabilities
where water is currently the limiting factor.
27
CA 2959339 2017-06-05
[00070] Operating the well 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
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 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.
[00071] The use of the well pumping and control system 10 in place of a
non-
intelligent electrical generator also can provide many additional advantages.
A full
28
CA 2959339 2017-06-05
command of the water production operation will be taken by the well 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 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).
[00072] In another aspect, the present disclosure is directed to a pump
controller and
system capable of preventing overflows at distant storage tanks as shown in
FIG. 5.
The system can include a distribution pump controller 560, sometimes referred
to
herein as a "pump controller," "system controller," "system control," or
simply as a
"controller," one or more monitoring devices which may include a pressure
sensing
device 515, 525 or float switch 514, a power source which may include one or
more
solar arrays 530, generator 511, or other power source, water distribution
piping 524,
at least one water storage tank or vessel 516, which may be located at an
elevation
above the pump and/or water source, and a pump 522 that provides water to one
or
more water storage vessels 516.
[00073] FIG. 5 illustrates a pumping and control system according to
another aspect of
the present disclosure. As seen in the drawing, the pumping and control system
can
29
CA 2959339 2017-06-05
be a skid assembly 510 generally including a power source 511. The power
source
511 may include DC power from one or more solar arrays 530 and is sufficient
to
power a pump 522. A system control panel 512 may be electrically connected by
a
properly sized cord and plug assembly 520 sized for the required electrical
load
necessary to run the power source and pump. The system control panel 512 can
include a system control or processor 560 that enables outputs and receives
and
monitors inputs from one or more monitoring devices. The monitoring devices
may
include a float switch 514 or a water pressure sensing device 525, and/or a
flow
switch 515. The float, pressure sensing device, and flow switch may serve to
monitor
pumping control variables and may report conditions to the system control
panel 512,
which in turn may control operation of the pump in response to inputs.
[00074] FIG. 6 is a front view of exemplary components of the control
panel 512.
FIG. 6 shows components of the interior 550 of the controller panel 512,
including
controller 560, relays 557, 558, 559, terminals 569, 570, 571, and fuses 572.
The
control panel 512 can also include an LCD screen 562, inputs 564, outputs 566,
user
inputs 568 (such as keyboard, entry keys, etc.), and/or push buttons 577 and
can have
a height y and a width x. For exemplary purposes only, the height y could be
14.75
inches and the width x could be 12.88 inches. The elements shown in FIG. 6
should
not be limiting in any manner, and are provided herein as an exemplary
configuration.
[00075] FIGS. 7a-7c show front, top, and side views of an exemplary
enclosure 575 for
the control panel of FIG. 6. The enclosure 575 may be a NEMA rated hinged door
enclosure.
CA 2959339 2017-06-05
=
[00076] According to some embodiments, the pump controller 560
can be used for
controlling the pump 522 to distribute water or other fluid from a well or
reservoir or
storage vessel across a landscape to a distant storage vessel 516, such as one
located
at or across an elevation that can be higher than the well, reservoir or
storage vessel.
The pump controller can include a set of electrical and electronic components,
which
are typically located in a weather tight enclosure. While it can be otherwise
located,
the pump controller is typically installed at a convenient location, which can
be at or
near a solar array, generator 511, or other power source that electrically
supports the
pump 522. The array and controller 560 are also typically near the location of
the
distribution pump 522, but can also be otherwise located.
[00077] The pump controller 560 can operate with either a DC
power input or an AC
power input, and may be designed to automatically accept a particular power
source,
such as, for example, accepting the AC input as the priority power source when
AC is
connected. The pump 522 can be located in a well, reservoir, or storage vessel
or in a
fluid piping circuit fed from a source, such as one of the sources mentioned
herein.
As will be apparent to one of ordinary skill in the art, the pump 522 may also
be
otherwise located without departing from thc scope of this disclosure.
[00078] In a preferred embodiment, the controller 560 may be
electrically connected to
one or more solar arrays 530. One array may be dedicated to provide power to
the
pump and a second array, which may be smaller, may be dedicated to provide
power
to the control circuitry, thus electrically supporting the control system. The
pump
power feed can be connected to the power relay output 571 of the controller
560. As
shown in FIG. 9, the discharge of the pump 522 may feed into a piping circuit,
and a
3'
CA 2959339 2017-06-05
check valve 578 may be located on the discharge line coming out of the pump.
The
check valve 578 does not have to be precisely positioned for each use, but
generally
being closer to the discharge port 582 of the pump can, in some embodiments,
prevent
fluid from draining back through a distribution piping circuit or network 580.
[00079] According to some embodiments, the pump controller is designed to
operate in
multiple modes and may include a mode selector switch 576 operable to select
an
Automatic, Off, or Manual mode. Further, according to some embodiments, the
pump controller 560 can be a standalone solar pump controller, can be
automatic, or
can be combined with a well pumping and control system, such as that described
in
pending U.S. Patent Application No. 13/167,328.
[00080] In a preferred embodiment, the pump controller 560 can receive DC
power
from either a combination of battery and solar charger panels, a dedicated set
of 12-
volt solar panels (typically used for charging 12-volt automobile or Deep
Cycle
batteries), or the like.
[00081] In some embodiments, when the Controller's selector switch 576 is
set in
automatic mode and used as a standalone controller for a solar distribution
pumping
system, the controller 560 can, through preprogrammed settings, automatically
turn
the pump 522 on or off depending on environmental factors and/or sensor
feedback.
For example, the Controller 560 in automatic mode could be programmed to do
one
or more of the following:
I. Power ON at sunrise and power OFF at sunset.
2. Power ON at sunrise or when sunlight is present and power
OFF with
loss of sun light. As the controller powers ON when sunlight is present,
32
CA 2959339 2017-06-05
the controller 560 can be powered on, with the operation being in the
state that the selector switch is set (i.e., auto, manual or off).
3. Monitor static water pressure in the distribution piping 580 through a
pressure switch or pressure transducer 525 located at the discharge of
the pump that is controlled by the controller. Static water pressure will
change in the distribution piping as the fluid level in the distant storage
vessel falls or rises.
4. Display, e.g. on the text screen and/or in text messages, at the
controller operation state (i.e. Manual, Auto, OFF), pump status (On
/Off), and/or the percent of fluid level in the distant storage tank (0-
100% full)
[00082] The controller 560 can include several electrical components as
shown in FIG.
6, which may be mounted in an enclosure 575, which is preferably weather
tight.
Electrical components of the controller may include one or more of:
= A Microprocessor controller that may have digital and analog inputs
and digital outputs.
= A three position maintained selector switch that may be electrically
connected to a 12 volt common, a digital input to the microprocessor
controller for manual ON, and a digital input into the microprocessor
controller for an Auto ON.
= An AC power cord with a male plug to connect to an electrical
generator AC output.
33
CA 2959339 2017-06-05
= One DC power supply with an AC input and a DC output, to provide
DC control power when plugged into an AC source such as a
generator.
= One control relay 557 that may be used for two purposes.
o First to switch AC power ON at the input of the DC
power supply.
o Second to input a signal representing "AC present" to
the Microprocessor controller. The relay energizes
instantly when AC power is present.
= Two power relays 558, 559:
o One relay for the purpose of energizing and de-
energizing DC power to the pump based on fluid/water
pressure and level in the distant storage vessel. The
power relay's coil is electrically connected to an output
from the microprocessor controller.
o One relay for the purpose energizing and de energizing
AC power to the pump based on fluid/water pressure
and level in the distant storage vessel. The power
relay's coil is electrically connected to an output from
the microprocessor controller.
= A fuse 572 on the DC output of the DC power supply, to protect the
power supply from overload.
34
CA 2959339 2017-06-05
= A cast of terminal blocks 569, 570, 571 for the purpose terminating
wires between the AC power cord, solar arrays 530, the pressure
sensing device 525 and wiring internal to the controller 560.
= A solar array 530 to provide DC power to the system control 560.
= A solar array 530 to provide DC power to the pump 522.
[00083] The system control 560 can operate on a pre-programmed sequence,
an
example of which follows: Once a low level condition in the storage vessel is
confirmed, the control panel 512 begins a system start up sequence with a
start signal
being sent to a power source 511, such as a generator. Such a configuration
may be
particularly suitable for embodiments including a generator which may be
mounted
onto a skid assembly 510. The power source 511 can receive a start signal from
the
system control panel 512 starting and can produce electric power to support an
electric motor on the pump 522, which may be a deep underground well pump. It
will
be apparent to one of ordinary skill in the art, however, that other types of
power
sources 511 or pumps 522 will be suitable for use without departing from the
scope of
the present disclosure.
[00084] According to a preferred embodiment, sensing device 525 is a high
resolution
pressure sensor with high repeatability. The pressure sensing device 525 can
be a
pressure switch, but where higher pressure resolution is needed a pressure
transducer
may be preferred. Static fluid pressure in a vessel changes as the level of
fluid/water
rises or lowers in the vessel. In one example, water pressure will change
approximately 0.433 psi for each foot of change in elevation. With a piping
circuit
CA 2959339 2017-06-05
580 connected to the bottom of the storage vessel 546, the same pressure
changes are
also seen throughout the piping system 580 as the fluid/water level changes.
[00085] According to a preferred embodiment, the high resolution pressure
sensing
device 525 monitors the change in pressure due to the fluid level. Sensing
this change
in pressure in the piping system 580 allows the controller 560 to identify a
fill level
point in the storage vessel. When the fluid level in the storage vessel 5-1-6
drops, the
pressure in the piping circuit 580 lowers in direct proportion. A set point
can be
selected and programmed in the controller 560 to recognize the storage vessel
fluid
level based on the fluid pressure change. When the controller 560 sees that
the set
point is met, the controller 560 can enable the pumping process in response.
[00086] According to a preferred embodiment, the controller 560 will not
start the
pump instantly on a low pressure input signal. Wind sloshing the fluid/water
in an
open-air higher elevation storage tank could cause enough change in pressure
to
enable an input signal, but pressure changes that result from the wind cycle
on and off
very quickly. For this reason, some embodiments may include a timer in the
controller 560 that can be enabled when the pressure signal is enabled and can
reset if
the pressure signal cycles off According to some embodiments, the low pressure
signal must be enabled continuously, with no interruption, for the entire
duration of
the timer before the controller 560 will turn on the pump 522. This pump ON
delay
timer setting can be set by the installer in software or, in a preferred
embodiment, by
the operator using a switch on the controller. In a preferred embodiment a 30
to 90
second delay is typically sufficient to prevent the controller from starting
the pump
when pumping is not desired.
36
CA 2959339 2017-06-05
[00087] According to a preferred embodiment, once the pump 522 has turned
on,
pressure will increase dramatically, due to the pressure introduced from the
operation
of the pump. A pump ON timer can be enabled in the software when the pump
turns
on and can allow the pump to remain on only for a preset time. This time can
be
selected by the installer, and can be determined by volume of water needed and
the
flow rate of the pump. For example, if the storage vessel need is 1000 gallons
of
fluid/water and the pump flow rate is 10 gallons per minute the timer setting
will be
¨100 minutes.
[00088] A number of commercially available water pumps may be utilized by
various
embodiments of the present invention. Various types of pumps may be selected
according to a particular application without departing from the scope of this
disclosure. In some embodiments, such pumps can include underground or
submersible pumps, which may be deep pumps or deep well pumps. Examples of
pumps that are well suited for use with aspects of the present disclosure
include
Grundfos SQ Flex series, which is available for example from TP Pump of
Albuquerque New Mexico. These pumps are positive displacement pumps and are
equipped with universal motors accepting either DC or AC power. Other
commercially available pumps are also compatible with various embodiments of
the
present disclosure. According to a preferred embodiment, such pumps are
suitable as
long as they have either universal or DC motors. DC motor pumps are typically
used
with a DC drive sized for the motor. These various types of pumps are
mentioned
herein by way of example only, and as such are not intended as a limitation to
the
scope of this disclosure.
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[00089] As shown in FIG. 9 as further detailed below, aspects of the
present disclosure
may be used with a fluid or water reservoir 501 that is located at an
elevation lower
than the distant storage vessel 505. The reservoir can provide fluid or water
to the
suction side of the pump either through submersion in the fluid or water or
through
piping that can be connected proximate to and/or between the bottom of the
reservoir
and the suction side of the pump 522. However, it will be readily apparent to
one of
ordinary skill in the art that the water reservoir, piping, and pump may be
otherwise
configured such that fluid may be provided to the pump.
[00090] As shown in FIGs. 9, the pump discharge port 582 may be connected
to a
check valve 578; the check valve 578 may be connected to a tee 579 with a
pressure
sensing device 525 mounted at the tee. The tee 579 may be connected to
distribution
piping 580 which can be installed across a landscape to a higher elevation
where a
storage vessel 505 may be located. The piping 580 can be connected to the
bottom of
the storage vessel 505.
[00091] As shown in FIG. 9, across the piping 580 there can be a number
of other
storage vessels, tanks and/or other fluid or water holding receptacles 516 at
elevations
different than the storage vessel 505, such as, for example, lower than the
storage
vessel. These storage vessels, tanks and other receptacles 516 each can have
mechanical means such as float valves 511 installed to control the level of
fluid or
water inside of each and prevent overflow.
[00092] By using the pumping and control system of the present disclosure
in place of
other systems, such as a windmill water production system, a reduction in
maintenance costs and the substantial elimination of the hazards of working at
heights
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CA 2959339 2017-06-05
can be realized. This could conceivably prevent injury to the technicians and
even
death resulting from accidents associated with working at the heights on
windmill
towers along with the conditions involved with such activities.
[00093] In a preferred embodiment, the pumping and control system of the
present
disclosure includes at least one solar array 530 and is capable of reducing
costs in
labor and operation due to reducing the frequency of trips to a well site to
refuel
and/or to start a generator.
[00094] In some embodiments, the pump and control system can also monitor
critical
system dynamic conditions. Controlling the system operations to operate with
respect
to these conditions, can result in safe operation of both the power source 511
and the
pump 522 and will prevent both power source 511 and pump 522 from operating
outside of electrical design tolerance conditions such as over voltage, under
voltage,
generator, low frequency, or the frequency of a generator shutting down under
an
electrical load and consequentially causing shutdown of an electrically
connected
pump motor.
[00095] As previously stated, aspects of the present disclosure can
include custom
software and an assembly of electrical components and hardware assembled in an
enclosure 575, which may be a NEMA rated enclosure, to protect the components
for
the elements. The assembly can include the following electrical components and
hardware, however, it will be readily apparent to one of ordinary skill in the
art that
other such electrical components or hardware could be chosen without departing
from
the scope of this disclosure. By example and without limiting the scope of the
present
disclosure, possible choices of electrical components and hardware can
include:
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CA 2959339 2017-06-05
= A micro-processor controller, an example of which is an IDEC Micro-
Smart relay controller manufactured by the IDEC Corporation
available at Western Switches of Phoenix, Arizona, is utilized with
custom written software as the primary control component.
= A pump controller that can include:
o One or more microprocessor controllers, a suitable
example of which is an IDEC Smart Relay model
FL1E-H12RCE, which can be found at: IDEC
Corporation of Sunnyvale, California.
o One or more AC to DC power supplies, a suitable
example of which is an IDEC model PS5R-SC24,
which can be found at: IDEC Corporation of Sunnyvale,
California.
o One or more control relays, a suitable example of which
is an IDEC model RH3B-U, which can be found at:
IDEC Corporation of Sunnyvale, California.
o One or more power relays or contactors, suitable
examples of which are ABB model AF09Z-220-00-20
or ABB model AF16-30-10-11, which can be located
through: Thomas & Betts of Albuquerque, New
Mexico.
o One or more pressure sensing devices.
CA 2959339 2017-06-05
o A
pressure switch or a pressure transducer. A suitable
example of a pressure switch is WIKA model PSD-30
from WIKA Instrument Corporation of Lawrenceville,
Georgia. A suitable example of a pressure transducer is
a Pro-sense SPT25-20-0150D from Western Switches
of Phoenix, Arizona.
= An AC power relay is used for AC power control and power isolation,
an example is an ABB AF-16-30-1O-1I, made by the ABB
Corporation and available from Western Switches of Phoenix, Arizona.
= A DC power relay is used for DC power control and power isolation,
an example is an ABB AF09Z-22-00-20, made by the ABB
Corporation and available from Western Switches of Phoenix, Arizona.
= A DC power supply, an example is a PS5R-SC24, manufactured by the
IDEC Corporation and available in Sunnyvale, California, is used to
convert AC power to DC control power.
= An AC control relay, an example is an RH-3B-U, manufactured by the
IDEC Corporation and available in Sunnyvale, California, is used to
sense AC power and enable a DC power supply.
= An assortment of readily available terminal blocks, a fuse block, a
three position maintained toggle switch, wires and power cord and
plug all sized for the applicable loads are also used.
= In a preferred embodiment, the assembled devices are mounted in an
enclosure 75. Without limiting the scope of this disclosure, and by
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CA 2959339 2017-06-05
way of example only, one such enclosure is a NEMA rated outdoor
enclosure, an example of which is a Weigmann B121206CH, available
from Western Switches of Phoenix, Arizona.
= According to some embodiments, custom software may be written in
Ladder or Function Block logic. However,
other forms of
programming logic may also be used if compatible. One such example
of ladder logic software suitable for use with aspects of the present
disclosure is Win Ladder by IDEC Corporation.
[00096] FIG. 8 is
a flow chart showing an exemplary sequence of operation of the
embodiment of FIG. 5 of the present disclosure. The exemplary method,
indicated at
600, includes a step 610 of providing DC power from solar or AC power to the
system. If a power source is present, the method proceeds to step 620. At step
620,
the method includes a step of determining whether an AC power source is
switched
on. If an AC power source is switched on, the method proceeds to step 622 and
AC
power is used as a default. If an AC power source is not switched on, the
method
proceeds to step 624 and DC power is used as a default.
[00097] After
steps 622 and 624, the method proceeds to step 630. In step 630, the
controller powers on. The method then proceeds to step 640. In step 640, the
system
checks the position of the pump selector switch 576 to determine whether the
switch
576 is in an AUTO, OFF, or MANUAL position.
[00098] If the
switch 576 is in the AUTO position in step 640, the method proceeds to
step 650. In step 650, the method includes checking whether the low pressure
switch
is closed or, if a pressure transducer is used, whether low pressure is sensed
by the
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CA 2959339 2017-06-05
transducer. If the pressure switch is not closed (or if the pressure
transducer, if used
in lieu of a pressure switch, does not sense a low pressure condition), the
method
proceeds to step 660. If the pressure switch is closed (or if the pressure
transducer, if
used in lieu of a pressure switch, senses a low pressure condition), the
method
proceeds to step 652. In step 652, the method includes checking that pressure
switch
is closed for a preset time. If the preset time lapses with the pressure
switch closed
(or if the pressure transducer, if used in lieu of a pressure switch, senses a
low
pressure), the method proceeds to step 654. In step 654, the pump is powered
on.
The method then proceeds to step 656. In step 656, a timer causes the pump to
remain on for a preset time. Once the preset time has lapsed, the method
proceeds to
step 660.
[00099] If the switch 576 is in the OFF position, the method proceeds to
step 660. At
step 660, the pump is turned off.
[000100] If the switch 576 is in the MANUAL position, the method proceeds
to step
670. At step 670, the pump switches ON until manually switched OFF.
[000101] FIG. 9 is an overview of the system of FIG. 5. As shown in FIG.
9, the system
according to a preferred embodiment can include a supply reservoir 501 which
can be
a tank, spring, pond, well, other water source, or the like, a pump 522, solar
arrays
530, a check valve 578, a pressure sensing device 525, float level-controlled
storage
vessels 516, and a storage tank 505. Fig. 9 also shows the direction of fluid
flow F
through a piping distribution circuit 580.
[000102] FIG. 10 is an alternative embodiment which includes at least two
pumps. As
shown in FIG. 10, the system can include a main pump 522 and one or more
auxiliary
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,
distribution pumps 542. The main well pump 522 can be powered by a power
source
511, which can be, for example, a propane fueled generator or solar arrays
530. The
auxiliary distribution pump 542 can be powered by a power source 511, or can
be, for
example, a solar power source, which can include one or more solar arrays 530.
The
auxiliary pump may tap into a water source, including a water source that does
not
include a well pump. As such, aspects of this embodiment may be particularly
suitable for a reservoir with no well pump or for an older well with a storage
tank that
is close to the well head. In other words, in such an embodiment, the system
can be
used with any water source.
[000103]
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
scope
of the present invention as defined in the appended claims and equivalents
thereof.
As such, aspects of one or more embodiments may be used in conjunction with
aspects of other embodiments to create new embodiments without departing from
the
scope of this disclosure.
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