EP3140545B1 - Integrated unit for use in pump station - Google Patents

Integrated unit for use in pump station Download PDF

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Publication number
EP3140545B1
EP3140545B1 EP15725398.0A EP15725398A EP3140545B1 EP 3140545 B1 EP3140545 B1 EP 3140545B1 EP 15725398 A EP15725398 A EP 15725398A EP 3140545 B1 EP3140545 B1 EP 3140545B1
Authority
EP
European Patent Office
Prior art keywords
housing
exterior wall
motor
pump station
wall portion
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP15725398.0A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP3140545A2 (en
Inventor
Charles Armstrong
Alan BARNARD
Lee DERBYSHIRE
John LINDOP
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SA Armstrong Ltd
Original Assignee
SA Armstrong Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by SA Armstrong Ltd filed Critical SA Armstrong Ltd
Priority to PL15725398T priority Critical patent/PL3140545T3/pl
Publication of EP3140545A2 publication Critical patent/EP3140545A2/en
Application granted granted Critical
Publication of EP3140545B1 publication Critical patent/EP3140545B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B17/00—Pumps characterised by combination with, or adaptation to, specific driving engines or motors
    • F04B17/03—Pumps characterised by combination with, or adaptation to, specific driving engines or motors driven by electric motors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/06—Control using electricity
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/06—Control using electricity
    • F04B49/065—Control using electricity and making use of computers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B53/00—Component parts, details or accessories not provided for in, or of interest apart from, groups F04B1/00 - F04B23/00 or F04B39/00 - F04B47/00
    • F04B53/08—Cooling; Heating; Preventing freezing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B53/00—Component parts, details or accessories not provided for in, or of interest apart from, groups F04B1/00 - F04B23/00 or F04B39/00 - F04B47/00
    • F04B53/16—Casings; Cylinders; Cylinder liners or heads; Fluid connections
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2201/00—Pump parameters
    • F04B2201/04—Carter parameters
    • F04B2201/0403—Carter housing temperature
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2203/00—Motor parameters
    • F04B2203/02—Motor parameters of rotating electric motors
    • F04B2203/0205—Temperature

Definitions

  • the present invention concerns integrated units for use in pump stations, and a related method.
  • the present invention relates to integrated units for use in pump stations that work underground in the delivery of hydraulic fluid.
  • powered roof supports may be used for supporting the mine roof in the region above a cutting machine working at the face.
  • the powered roof supports employ high pressure hydraulic fluid to support the roof load and to advance with a cutting machine as the cutting machine cuts coal from the face.
  • a hydraulic pump station located away from the face is used to supply the hydraulic fluid.
  • the pump station typically comprises tanks serving as reservoirs of hydraulic fluid, and a group of pumping units which are each selectively driven by electric motors.
  • the electric motors are used to drive the pumping units individually into an on or an off state, under control of a pump station system controller.
  • the pump station system controller monitors demand for hydraulic fluid and provides control signals to the electric motors.
  • One such pump station may be used to supply a plurality of powered roof supports, and to supply hydraulic fluid to other machines, for power or cooling purposes, and to perform other pumping jobs such as supplying water or other liquid for dust suppression.
  • the problem of meeting the demand for hydraulic supply is also linked to the responsiveness of the pumping units.
  • responsiveness is limited by the response speed of the motors used to power the pumping units.
  • the distribution of the pumping load across pumping units compensates for slow responsiveness, as no one pumping unit is required to make rapid step changes in its output.
  • responsiveness becomes much more important because the remaining pumping units must try to compensate for the failure. This can require a large and rapid response.
  • a pump station will include a reserve pumping unit which can be employed to provide responsiveness in this sort of situation.
  • the reserve pumping unit is an additional cost and adds complexity to the pump station.
  • US2002101704A1 discloses an automatically operating interlock assembly requiring an electrical cabinet to be closed before connection of the equipment .
  • US3534186A discloses a door interlock system for electrical control cabinets.
  • EP2378059A1 discloses improvements in and relating to long wall hydraulic supply systems.
  • the invention provides a housing for an integrated unit for use in a pump station according to claim 1.
  • an integrated unit for a pump station comprising a motor, a motor controller and an interface to a pump station system controller, wherein the motor, motor controller and interface to the pump station system controller are integrated with one another in a housing, wherein the housing comprises an exterior wall portion that is removably mounted on the housing, and to which an electronic component of the motor controller or interface to a pump station system controller is mounted so as to be located internally to the housing when the exterior wall portion is mounted on the housing, and wherein the exterior wall portion comprises a cooling system for the electronic component.
  • the motor comprises a switched reluctance motor.
  • an integrated unit for a pump station comprising a switched reluctance motor, a motor controller and an interface to a pump station system controller, wherein the motor, motor controller and interface to the pump station system controller are integrated with one another in a housing, wherein the housing comprises an exterior wall portion that is removably mounted on the housing, and to which an electronic component of the motor controller or interface to a pump station system controller is mounted so as to be located internally to the housing when the exterior wall portion is mounted on the housing, and wherein the exterior wall portion comprises a cooling system for the electronic component.
  • a housing for an integrated unit for use in a pump station the housing arrangeable in use to accommodate a motor, a motor controller and an interface to a pump station system controller integrated with one another in a housing, wherein the housing comprises mountings arranged to enable an exterior wall portion thereof to be removably mounted, wherein the exterior wall portion comprises an electronic component mounted thereon and wherein the pump station further comprises an automatically engaging coupling arranged to electrically connect an electronic component mounted on the exterior wall portion to the motor controller or pump station system controller while the exterior wall portion is mounted on the housing, and wherein the automatically engaging coupling is arranged to automatically disconnect the electrical connection between the electronic component and the motor controller or pump station system controller on removal of the exterior wall portion from the housing.
  • the motor comprises a switched reluctance motor.
  • a housing for an integrated unit for use in a pump station the housing arrangeable in use to accommodate a switched reluctance motor, a motor controller and an interface to a pump station system controller integrated with one another in a housing, wherein the housing comprises mountings arranged to enable an exterior wall portion thereof to be removably mounted, wherein the exterior wall portion comprises an electronic component mounted thereon and wherein the pump station further comprises an automatically engaging coupling arranged to electrically connect an electronic component mounted on the exterior wall portion to the motor controller or pump station system controller while the exterior wall portion is mounted on the housing, and wherein the automatically engaging coupling is arranged to automatically disconnect the electrical connection between the electronic component and the motor controller or pump station system controller on removal of the exterior wall portion from the housing.
  • the integrated unit for a pump station may further comprise a pumping unit coupled to the output shaft. If not already described, the housing may be arranged to further accommodate a connector for a power supply, and at least part of an output shaft of a motor arranged therein.
  • the integrated unit for a pump station further comprises a pump station system controller. In one example embodiment the pump station system controller comprises an interface for connection to another pump station system controller external to the integrated unit.
  • a pump station comprising an arrangement of plurality of integrated units as set out above.
  • the pump station comprises a plurality of integrated units, with a plurality of pumping units coupled thereto.
  • Each integrated unit is coupled to a pumping unit.
  • the pump station may comprise a data connection between a pump station system controller and the integrated units so that the integrated units are controllable together to provide a required output according to a variable pumping demand.
  • One of the integrated units may comprise a pump station system controller operable to control one or more of the integrated units in the pump station.
  • one of the integrated units comprises a pump station system controller operable as a master for all of the other integrated units in the pump station.
  • One of the integrated units is operable as a slave, subservient to pump station system controller arranged to act as a master for the integrated units in the pump station.
  • the pump station comprises a plurality of integrated units, with one, two or more of the integrated units, for example each of the integrated units, comprising a pump station system controller that is configurable to operate as a master controller, or as a slave controller subservient to a master controller of another integrated unit.
  • the pump station may be arranged such the data connection is used to designate a master controller from the integrated units.
  • the integrated unit comprises a housing for the connector, motor, motor controller, output shaft and interface to a pump station system controller.
  • the connector is an electrical connector.
  • the connector is arranged to provide an electrical connection, and a physical connection for a power supply line to be mounted on the integrated unit.
  • the connector is at least partially accessible from outside the housing, and is arranged to provide a path for electricity from outside the housing to inside the housing.
  • the output shaft is at least partially accessible from outside the housing for coupling to a pumping unit.
  • the integrated unit comprises a user interface section, arranged to receive user control inputs and to provide operational status information for components of the integrated unit, a pumping unit coupled to the integrated unit, and to pumping units that are operatively connected as part of a pump station.
  • the user interface section comprises a display screen.
  • the user interface section may comprise a touch screen, keyboard, mouse or the like for receiving user control inputs.
  • the motor controller comprises a variable speed drive.
  • the pumping unit comprises a positive displacement pump.
  • a pump station system controller is arranged to monitor the operation of an associated pumping unit coupled to the output shaft, and to receive one or more feedback signals, as well as user control inputs from the user input section.
  • the pump station system controller is arranged to control operation of the integrated unit, including passing drive control signals to the motor controller, based on user control inputs and one or more demand signals related to pumping unit speed, pumping unit flow rate, pumping unit or downstream pressure, and optionally one or more related feedback signals.
  • the housing comprises a plurality of internal compartments. In one example embodiments the housing comprises at least two internal compartments that are physically isolated from one another, completely or in part. In one example the housing comprises a motor compartment, providing internal physical isolation, completely or in part, between the motor and one or more of the motor controller and the pump station system controller. In one example the housing comprises a motor compartment, providing internal physical isolation between the motor and each of the motor controller and the interface for the pump station master controller, completely or in part. In one example embodiment the housing is arranged with a motor compartment including one or more openings between the motor compartment and one or more other compartments in the housing.
  • the housing comprises a motor compartment with openings which are closed by the motor itself, completely or in part, when the motor is arranged in place in the housing.
  • the motor comprises rotor coupled to the output shaft, and a stator arranged around the rotor.
  • the stator comprises an outer jacket, wherein the outer jacket is arranged with the housing to form a motor compartment around the motor, isolating the motor from one or more other compartments in the housing while the motor is in place in the housing, said separation being complete, or partial.
  • compartments may be physically isolated from one another completely, in the sense of there being no connecting path there-between, or may be physically isolated from one another in part so that is a separation feature, such as rib, bar, frame, lattice or the like, wherein a generally open aspect between compartments is provided to give an expansion space for gas in the housing.
  • a separation feature such as rib, bar, frame, lattice or the like
  • an expansion space may be provided in the housing, said space forming a generally interconnected space for gas to move freely between a sub set of the compartments, or all of the compartments.
  • the stator comprises an outer jacket, wherein the outer jacket is arranged, while the motor is integrated into the integrated unit, to provide part of the housing.
  • the outer jacket is arranged to provide internal physical separation between a motor compartment and one or more other compartments in the housing, completely or in part.
  • the outer jacket is arranged to include a projection that extends from the motor as a rib-like projection, or sheet-like projection, arranged to provide complete or partial internal physical separation between compartments in the housing.
  • the projection extends radially from the motor.
  • the projection extends tangentially from the motor or the projection runs along the motor parallel to the axis of the output shaft or the projection runs along the length of the jacket, partially, or alternatively fully along the length of the jacket.
  • the projection is arranged to close an opening between a motor compartment in the housing, and one or more other compartments in the housing, when the motor is arranged in place in the housing.
  • the projection may comprise fixing features to enable one or more other components in the housing to be connected thereto.
  • a plurality of projections are provided on the jacket, with a plurality of the projections as described.
  • the housing comprises a plurality of internal compartments for the motor controller, e.g. two or more of: a motor controller processor compartment, a power electronics compartment, and a filter compartment.
  • the motor controller comprises a plurality of power electronics units in a power electronics compartment.
  • the power electronics units are provided on circuit boards that can be removed and replaced by plug-out and plug-in action, for example by including part of a connector to cooperate with another part of a connector within the housing.
  • one or more, for example each of the compartments for the motor controller is open to an expansion space within the housing.
  • one or more of the power electronic compartments is communicative with an opening in the housing, wherein the housing comprises a removable exterior wall portion that is removably mounted on the housing, and to which an electronic component of the motor controller or pump station system controller is mounted.
  • one or more of the power electronic compartments is communicative with an opening in the housing, wherein the housing comprises a removable exterior wall portion that is removably mounted on the housing, and to which a circuit board carrying an electronic component of the motor controller or pump station system controller is mounted.
  • the electronic component comprises an active component, suitably a rectifier or switching component, preferably a transistor, preferably an insulated-gate bipolar transistor (IGBT).
  • the electronic component comprises a power electronics component, or a power electronics unit comprising a plurality of power electronics components.
  • one or more, for example each of the power electronic compartments is open to an expansion space within the housing.
  • the exterior wall portion is provided with a handle to facilitate removal of the exterior wall portion from the housing.
  • the handle is provided so as to be located externally to the housing when the exterior wall portion is mounted on the housing.
  • the housing comprises mounting features arranged to cooperate with mounting features on the exterior wall portion to in use enable the exterior wall portion to be releasably mounted on the housing.
  • the exterior wall portion is arranged to act as a heat sink for the electronic component mounted thereon.
  • the exterior wall portion has the electronic component mounted in bodily contact thereto, for example with an electrically insulating package of the electronic component in bodily contact with the exterior wall portion.
  • the exterior wall portion may be provided with a thermal bridge layer arranged between the electronic component and exterior wall portion.
  • the exterior wall portion comprises an inner face and an outer face, with the electronic component is mounted on the inner face.
  • the inner face is generally planar, and the electronic component is mounted on the exterior wall portion parallel to the inner face.
  • the cooling system for the electronic component comprises an active cooling system for the electronic component.
  • a cooling system comprises a fluid delivery system.
  • the fluid delivery system comprises a fluid inlet and a fluid outlet provided for the exterior wall portion.
  • the fluid inlet is provided on an outer face of the exterior wall portion.
  • the fluid outlet is provided on an outer face of the exterior wall portion. Both the fluid inlet and the fluid outlet are provided on an outer face of the exterior wall portion.
  • the fluid inlet and fluid outlet are coupled by a fluid pathway formed in the exterior wall portion, for example formed wholly in the exterior wall portion.
  • the fluid pathway does not lie inwardly of the inner face of the exterior wall portion.
  • the fluid pathway comprises a recessed portion of the exterior wall portion.
  • the outer face of the exterior wall portion is generally planar, and the fluid pathway runs within the exterior wall portion in its plane, for example wholly in its plane.
  • the fluid pathway is maintained outside one or more compartments within the housing, so as to be separated from the interior of the compartments, and/or from an expansion space connecting compartments in the housing.
  • the fluid pathway is arranged not to extend beyond the inner surface of the exterior wall portion.
  • the fluid pathway comprises a recess, e.g. a channel, formed in the exterior wall portion, arranged with a cap over it to seal the channel between the fluid inlet and the fluid outlet.
  • the cap comprises a plate. The cap provides an outer face of the exterior wall portion.
  • the electronic component is arranged inwardly in the housing compared to the inward extent of the fluid pathway.
  • the electronic component is arranged to be electrically connected to the motor controller or pump station system controller, away from the exterior wall portion, using a plug-in, push fit or other automatically engaging coupling forming the connection when the exterior wall portion is mounted on the housing.
  • the exterior wall portion may have a plurality of electronic components mounted thereto, the electronic components mounted thereto as set out above.
  • the housing comprises a plurality of exterior wall portions as set out above.
  • the housing may comprise a plurality of exterior wall portions to which the same electronic component is mounted, such that the exterior wall portions are parts of a modular arrangement of electronic components for the integrated unit.
  • the housing comprises exterior wall portions at the front, back, first and second ends, top and bottom, for example forming a generally cuboidal shape.
  • the exterior wall portions comprise openings on at least two faces, for example on three faces.
  • the housing may comprise openings on three generally non-parallel faces, for example on a front face, a top and on a first end face.
  • the housing may comprise openings on only one, two or three of the front face, a top and a first end face. In this way the housing can be positioned against a wall, and next to an interconnected pumping unit on a second end face in use, but remain generally accessible for installation, maintenance and repair work to be performed via the openings.
  • the housing is an explosion-resistant housing.
  • the integrated unit comprises a motor cooling system arranged to enable delivery of cooling fluid to the motor.
  • the motor cooling system comprises a fluid inlet and a fluid outlet provided to the exterior of the housing.
  • the motor cooling system is arranged so that fluid may flow there-through and in doing so carry heat away from the motor and out of the housing.
  • Z The motor cooling system is arranged so that fluid may flow over an outer jacket of the motor and in doing so carry heat away from the motor and out of the housing.
  • the fluid inlet and fluid outlet of the motor cooling system are may be in fluid communication with a motor compartment of the housing.
  • a void is provided so that fluid may flow there-through.
  • the motor cooling system may comprise a void in a motor compartment, at least partially surrounding the motor.
  • the motor cooling system may comprise a void in a motor compartment, the void formed between the motor and the housing in which the motor is arranged.
  • the automatically engaging coupling is arranged to electrically connect an electronic component mounted on the exterior wall portion to the motor controller or pump station system controller on mounting, including re-mounting of the exterior wall portion of the housing.
  • the automatically engaging coupling is a multi-part coupling with one part carried by any one of: the exterior wall portion; the electronic component mounted on the exterior wall portion; a circuit board carrying the electronic component mounted on the exterior wall portion.
  • the automatically engaging coupling is a multi-part coupling with another part carried by any one of: the housing; the motor controller; the pump station system controller; a circuit board or bus coupled to the motor controller; a circuit board or bus coupled to the pump station system controller.
  • the housing comprises a plurality of exterior wall portions as set out above, arranged to function as set out above when mounted on the housing and on removal from the housing.
  • the exterior wall portions are parts of a modular arrangement of electronic components for a pump station, for example for a motor controller.
  • the integrated unit comprises a motor controller including a plurality of modular units, each comprising one or more electronic components mounted on an exterior wall portion of the housing.
  • the electronic component is arranged to be electrically connected to the motor controller or pump station system controller, away from the exterior wall portion, using a plug-in, push fit or other automatically engaging coupling forming the connection when the exterior wall portion is mounted on the housing.
  • a housing as set out above In one example embodiment there is provided a housing as set out above. In one example embodiment there is provided a housing for assembly into an integrated unit as set out above.
  • a method of manufacturing an integrated unit for use in a pump station comprising a connector for connection to a power supply, a motor arranged to provide mechanical drive to an output shaft for coupling to a pumping unit associated with the pump station, a motor controller arranged to supply the motor with power from the connector to thereby control the motor, and an interface for a pump station system controller, the method comprising assembling the connector, motor, motor controller, output shaft and interface for a pump station system controller as an integrated unit.
  • a method of operating a pump station comprising a motor, a motor controller and an interface for a pump station system controller, the motor, motor controller and pump station system controller integrated with one another in a housing, wherein the housing comprises an exterior wall portion that is removably mounted on the housing, and to which an electronic component of the motor controller or interface for a pump station system controller is mounted so as to be located internally to the housing when the exterior wall portion is mounted on the housing, the method comprising method comprising a providing cooling to the electronic component using a cooling system provided by the exterior wall portion.
  • the invention provides a method of fitting or assembly according to claim 15, the method performed using a housing suitable for accommodating a motor, a motor controller and an interface for a pump station system controller integrated with one another in a housing, the housing comprising mountings to enable an exterior wall portion thereof to be removably mounted, wherein the exterior wall portion comprising an electronic component mounted thereon and wherein the pump station further comprises an automatically engaging coupling, the method comprising mounting the exterior wall portion to thereby electrically connect the electronic component mounted on the exterior wall portion to the motor controller or interface for the pump station system controller.
  • the method further comprises removal of the exterior wall portion from the housing to thereby automatically disconnect the electrical connection between the electronic component mounted on the exterior wall portion and the motor controller or interface for the pump station system controller.
  • FIGs 1, 2 , 3 , 7 and 9 shows the exterior of an integrated unit 1, with Figures 4 through 6 , 8 , 10 and 11 showing section views of the integrated unit 1 so that interior features can be seen and understood.
  • the integrated unit 1 comprises a connector 10 for connection to a power supply, such as an electrical power supply operating at 1140V AC, and is rated for operation at 300kW. Power from the connector 10 is arranged to pass to a motor 20 so as to provide mechanical drive to an output shaft 30. The output shaft 30 is in use coupled to a pumping unit in the form of a positive displacement pump (not shown) that is associated with the integrated unit 1.
  • a motor controller is arranged to control the supply of power from the connector 10 to the motor 20 to thereby control the motor 20.
  • An interface for a pump station system controller is provided to interface with the motor controller, so that the integrated unit 1 can be operated with the mechanical drive supplied to the output shaft 30 by the motor 20 matched to demand from the pumping unit.
  • the pumping unit is envisaged working with the integrated unit 1 to supply pressurised hydraulic fluid, for example an emulsion of water and oil to powered roof supports or other mining machinery, for example pressurised to 300-400 bar.
  • the integrated unit 1 is arranged so that the connector 10, motor 20, motor controller, output shaft 30 and interface for the pump station system controller are provided as an integrated unit.
  • the integrated unit 1 has the connector 10, motor 20, motor controller, output shaft 30 and interface for a pump station system controller provided integrated with one another within a housing 40.
  • the housing 40 is explosion-resistant, and an expansion space 80 is provided therein between internal components and compartments so that gas can move within the confines of the housing to account for temperature changes etc.
  • the motor 20 comprises a switched reluctance motor, and the motor controller comprises a variable speed drive.
  • the motor controller comprises a variable speed drive.
  • Induction motors typically also take up much more volume for a given power and torque specification.
  • use of a switched reluctance motor in an integrated unit as described is advantageous, in particular when motor controller and system controllers are closely integrated therewith to provide the drive for the motor.
  • Responsiveness of switched reluctance motors, and their relatively high torque density means that the integrated unit may be operated without a reserve unit provided. In this way the integrated unit can form part of a pump station which includes fewer redundant elements while still enabling a rapid response to large changes in demand, such as changes associated with failure of an other element in the pump station.
  • the motor, and the associated components including the motor controller etc respectively comprise a switched reluctance motor, and associated components for use with a switched reluctance motor.
  • the motor controller comprises a number of circuit elements - a motor controller processor 60, a rectifier 61, a line reactor 62, an EMC filter 63, a capacitor bank 64 and a plurality of power electronics switching elements in the form of insulated-gate bipolar transistors (IGBTs) 65.
  • the motor controller processor 60 is arranged to monitor the operation status of the motor 20 and to provide, through the other components of the motor controller a desired speed for the motor 20.
  • the motor controller processor 60 is further arranged to receive a setting signal, for example a signal representative of a desired speed for the motor 20 from the interface to a pump station system controller, according to the demand for supply of hydraulic fluid from the pumping unit connected to the motor 20 via the output shaft 30 and the corresponding operation speed of the pumping unit required to meet the demand.
  • a setting signal for example a signal representative of a desired speed for the motor 20 from the interface to a pump station system controller
  • the interface for the pump station system controller comprises a pump station controller processor 50 that is arranged to monitor the operation of an associated pumping unit coupled to the output shaft 30, and to receive one or more feedback signals, as well as user control inputs from a user.
  • the interface for the pump station system controller comprises a user interface section that can be used to receive user control inputs and to provide operational status information for a pumping unit coupled to the integrated unit 1.
  • the user interface section comprises a display screen 51, and a mouse 52 for receiving user control inputs.
  • the pump station controller processor 50 may also be used to control other integrated units that are connected to the integrated unit 1 as part of a pump station by operating as a pump station system controller.
  • the integrated unit 1 includes on its front face exterior wall portions 410 that are removably mounted on the housing 40, and to which electronic components of the motor controller 50 are mounted so as to be located internally to the housing 40 when the exterior wall portions 410 are mounted on the housing 40.
  • the exterior wall portions 410 provide a number of advantages for the integrated unit 1, in terms of the arrangements for cooling components of the integrated unit 1, and facilitating removal and replacement of components of the integrated unit 1.
  • the exterior wall portions 410 are used in a cooling system for electronic components of the motor controller, in this case the rectifier 61 and the IGBTs 65.
  • Two exterior wall portions 410, 410' are shown associated with the IGBTs 65, and a further exterior wall portion 410" is shown associated with the rectifier 61.
  • the exterior wall portions 410 are arranged to act as a heat sink for the electronic components mounted thereon. To get good thermal transfer the electronic components are mounted in bodily contact with the inner face of the exterior wall portions 410. Beyond any cooling provided by the thermal mass of the exterior wall portions 410 and the surface area for heat transfer to the environment around the integrated unit 1, the exterior wall portions 410 are part of an active cooling system for the electronic components mounted thereto.
  • the cooling system comprises a fluid delivery system 420 that causes fluid to pass from a fluid inlet 430 to a fluid outlet 431 provided in the exterior wall portion 410, so that between the fluid inlet 430 and the fluid outlet 431 heat can be absorbed from the exterior wall portion and the associated electronic components and thereby removed from the housing 40.
  • the fluid inlet 430 and the fluid outlet 431 are both provided on an outer face of the exterior wall portions 410, and are coupled by a fluid pathway formed as a channel 433 in the exterior wall portions 410 covered with a cap 434 to seal the channel 433 as a closed conduit between the fluid inlet 430 and the fluid outlet 431.
  • Figure 12E shows this arrangement in cross section.
  • the cap 434 is depicted as transparent, in order to show the path of the channel 433 which in use lies under the cap 434.
  • the fluid delivery system is kept entirely separate from the interior of the compartments in the housing 40 which contain the electronic components.
  • the material integrity of the exterior wall portion 410" is relied upon to keep the fluid from leaking into the housing, which can easily be specified and manufactured to a high level of reliability.
  • welds 435 are provided.
  • one or more welds 435 are made around the edge of the cap 434 to couple the cap 434 to the exterior wall portion 410", with the cap located on the exterior wall portion 410" so as to lie over the channel 433.
  • Welds 435 are also provided through apertures 436 provided in the cap 434, to couple the exterior wall 410" portion to the cap 434, for example to reinforce the connection between the two components.
  • the apertures 436 are aligned with the channel 433 so that the welds 436 are provided away from the edges of the cap 434.
  • the alignment between apertures 436 and channel 433 may be such that the welds are provided through the apertures in a central region of the cap 434, or in a region of the cap which lies between two portions of the channel, such as two adjacent portions, here shown as two portions which extend in side-by-side relation with one another, such as in parallel with one another.
  • the welds may further be provided in alternating arrangement between first and second sides of the channel, moving along the length of the channel, and/or may be provided in alternating arrangement between portions of the channel that extend in side-by-side relation with one another.
  • the exterior wall portion may be manufactured with the channel provided therein, for example with the channel comprising an interior feature of a casting.
  • failure of connectors at the inlet and outlet, and failure of seals made between the inlet/outlet and the exterior wall portion or between inner part and an outer plate of the exterior wall portions are not critical in maintaining fluid separate from the electronic components.
  • mounting features are provided on the housing 40.
  • the mounting features are arranged to cooperate with related mounting features on the exterior wall portions 410 to enable the exterior wall portions to be releasably mounted on the housing 40.
  • the mounting features in the integrated unit 1 comprise threaded fasteners, openings 460 in the exterior wall portions 410 and threaded bores in the housing 40.
  • the exterior wall portions 410 are provided with handles 413 to facilitate removal of the exterior wall portions from the housing once the mounting features have been released from one another.
  • each of the exterior wall portions 410 is an electrical connection system which is arranged to automatically engage, to provide an electrical connection between an electronic component mounted on the exterior wall portion 410 and the motor control processor 60.
  • the electrical connection is made on mounting of the exterior wall portion 410 to the housing 40.
  • the electrical connection system comprises a plug-in, push fit or other automatically engaging coupling with one part fixed to the exterior wall portion 410 and one part fixed within the housing 40.
  • Figures 13B and 13E show the IGBTs 65 physically coupled to the exterior wall portion 410' by mounting screws 651.
  • the IGBTs 65 are electrically coupled to the electrical systems within the integrated unit 1 by electrical connectors 652, using a plug- and-play pin arrangement between the IGBTs 65 and the connectors 652 Flexible flying leads 450 are used to form a further connection from the connectors 652 with the rest of the electrical system within the integrated unit 1.
  • the connectors 652 and flying leads 450 are retained in the housing 40 within a carrier unit 653 that is in use fixed to the housing 40 at, or around the openings 460 for the exterior wall portions.
  • Analogous connection arrangements are suitably provided for other power components, such as the rectifier 61 in conjunction with the exterior wall portion 410" and carrier unit 613, and may also be provided for control or diagnostic signal transmission, for example by a data connector 440.
  • the housing 40 comprises plurality of internal compartments, which may be at least partially physically isolated from one another, while maintaining the expansion space 80.
  • the housing 40 comprises compartments for the motor 20, the elements of the motor controller and the elements of the interface for the pump station system controller.
  • the compartment in which the motor 20 is located is oversized with respect to the motor 20, to enable operation of a motor cooling system.
  • the motor cooling system enables delivery of cooling fluid to the motor 20. Cooling fluid can be passed between a fluid inlet 21 and a fluid outlet 22 provided to the exterior of the housing 40. Cooling fluid passing between the fluid inlet 21 and the fluid outlet 22 can carry heat away from the motor 20 and out of the housing 40.
  • the need for a separate cooling jacket for the motor 20 is eliminated.
  • the material integrity of the housing 40 at its internal compartments is relied upon to keep the fluid from leaking into the rest of the housing 40, and in the motor cooling system failure of connectors at the inlet and outlet, and failure of seals made between the inlet/outlet and the exterior wall portion or between inner part and an outer plate of the exterior wall portions are not critical in maintaining fluid separate from the electronic components within the housing 40.
  • the housing 40 as described above has on its front face exterior wall portions 410 that are removably mounted on the housing 40, which when in place cover over openings in the housing.
  • the top face and a first end face also have removable wall portions 510, 610 respectively which when removed reveal openings by which the interior of the housing 40, and components therein can be accessed for installation, maintenance and repair purposes.
  • the integrated unit 1 can be used as part of a pump station comprising an arrangement of plurality of integrated units.
  • Each integrated unit in the pump station is provided with a pumping unit coupled thereto, and a data connection is provided between the interfaces for the pump station system controllers so that the integrated units are controllable together to provide a required output from the pumping units according to a variable pumping demand.
  • one of the integrated units is configured with its pump station controller processor operating as a master pump station system controller.
  • the other integrated units are configured with their pump station controller processors operating as slaves.
  • the slaves are subservient to the pump station system controller provided by the pump station controller processor that acts as the master.
  • the integrated unit can be arranged so that the data connection is used to designate a master, either in response to a user input, or automatically through a predetermined protocol, for example including facility for seamlessly adding or removing integrated units to the pump station.
  • a separate pump station system controller is used to provide control inputs for all of the integrated units using their interfaces for pump station system controllers.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Details Of Reciprocating Pumps (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Cooling Or The Like Of Electrical Apparatus (AREA)
EP15725398.0A 2014-04-23 2015-04-23 Integrated unit for use in pump station Active EP3140545B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL15725398T PL3140545T3 (pl) 2014-04-23 2015-04-23 Zintegrowana jednostka do zastosowania w stacji pomp

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB1407154.2A GB201407154D0 (en) 2014-04-23 2014-04-23 Integrated unit for use in pump station
PCT/GB2015/051198 WO2015162429A2 (en) 2014-04-23 2015-04-23 Integrated unit for use in pump station

Publications (2)

Publication Number Publication Date
EP3140545A2 EP3140545A2 (en) 2017-03-15
EP3140545B1 true EP3140545B1 (en) 2021-03-10

Family

ID=50929081

Family Applications (3)

Application Number Title Priority Date Filing Date
EP15725397.2A Active EP3140544B1 (en) 2014-04-23 2015-04-23 Integrated unit for use in pump station
EP15725396.4A Active EP3140543B1 (en) 2014-04-23 2015-04-23 Integrated unit for use in pump station
EP15725398.0A Active EP3140545B1 (en) 2014-04-23 2015-04-23 Integrated unit for use in pump station

Family Applications Before (2)

Application Number Title Priority Date Filing Date
EP15725397.2A Active EP3140544B1 (en) 2014-04-23 2015-04-23 Integrated unit for use in pump station
EP15725396.4A Active EP3140543B1 (en) 2014-04-23 2015-04-23 Integrated unit for use in pump station

Country Status (6)

Country Link
EP (3) EP3140544B1 (zh)
CN (3) CN106460812B (zh)
AU (3) AU2015250634B2 (zh)
GB (1) GB201407154D0 (zh)
PL (3) PL3140543T3 (zh)
WO (3) WO2015162428A2 (zh)

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US10378326B2 (en) 2014-12-19 2019-08-13 Typhon Technology Solutions, Llc Mobile fracturing pump transport for hydraulic fracturing of subsurface geological formations
CN110513155B (zh) 2014-12-19 2022-09-20 泰福恩技术解决方案有限责任公司 用于地下地质构造的水力压裂的移动发电设备
CN105221409A (zh) * 2015-11-06 2016-01-06 何丹 一种用于扬水站的水泵汲水管装置
CA3035171C (en) * 2016-08-31 2021-08-17 Evolution Well Services, Llc Mobile fracturing pump transport for hydraulic fracturing of subsurface geological formations
US11725582B1 (en) 2022-04-28 2023-08-15 Typhon Technology Solutions (U.S.), Llc Mobile electric power generation system

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Also Published As

Publication number Publication date
PL3140545T3 (pl) 2021-09-06
EP3140544B1 (en) 2021-03-10
WO2015162429A3 (en) 2016-01-21
EP3140545A2 (en) 2017-03-15
EP3140544A2 (en) 2017-03-15
CN106255826B (zh) 2019-11-19
AU2015250634B2 (en) 2018-11-15
WO2015162428A3 (en) 2016-01-07
GB201407154D0 (en) 2014-06-04
AU2015250635B2 (en) 2018-11-22
AU2015250634A1 (en) 2016-11-24
PL3140544T3 (pl) 2021-12-13
EP3140543B1 (en) 2021-11-17
WO2015162427A3 (en) 2016-01-21
CN106460812B (zh) 2020-03-06
WO2015162427A2 (en) 2015-10-29
WO2015162428A2 (en) 2015-10-29
AU2015250633A1 (en) 2016-11-24
CN106232988B (zh) 2019-04-30
CN106460812A (zh) 2017-02-22
PL3140543T3 (pl) 2022-02-21
AU2015250635A1 (en) 2016-11-24
CN106255826A (zh) 2016-12-21
WO2015162429A2 (en) 2015-10-29
EP3140543A2 (en) 2017-03-15
AU2015250633B2 (en) 2018-11-08
CN106232988A (zh) 2016-12-14

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