Patent Application
20240399423
Not applicable.
Not applicable.
The present invention relates to low and medium pressure, high temperature, fluid pressure washers for pressure cleaning surfaces, vessels, piping, tubing, and other structures.
High pressure fluid washing systems are used in a variety of operations, such as cleaning, pipe cleaning, cutting, removal of debris and coatings, to name a few. Most such systems include a fluid source, a drive assembly, a pressurization device, and water blasting equipment, such as a spray gun or spray lance.
The fundamental process is that energy in the form of high-pressure fluid can clean or strip a surface of contaminants by, among other mechanisms, mechanical impingement. Today, pressure washers range from low pressure models (e.g., less than about 2,000 psig (13.8 MPa)) to medium pressure models (greater than about 2,000 psig (13.8 MPa) to less than about 10,000 psig (70 MPa)) to high pressure models (greater than 10,000 psig (70 MPa) up to about 55,000 psig (379 MPa)).
Presently, pressure washers operating at pressures of about 5,000 psig (34 MPa) and higher are often restricted to mechanical or automated systems in which a human does not physically hold or control the water jetting equipment. It will be appreciated that water jetting equipment operating in excess of about 5,000 psig (34 MPa) generates significant reactive forces that may cause the operator to lose control of the jetting equipment, which may result in physical injury or death.
One way to increase the efficiency of contaminant removal or cleaning without increasing the fluid pressure is to add thermal energy to the system. While the mere act of fluid pressurization will increase the fluid temperature, there exist today commercially available low and medium pressure washers with additional fluid heating components. As the fluid temperature increases, component design becomes more complicated. As fluid temperature increases above the ambient phase change (at a particular pressure), additional considerations of safety and design arise. For example, conventional high temperature pressure washers heat the fluid after it leaves the high-pressure pump, rather than heating the fluid before the high-pressure pump. Pressurizing high temperature fluid poses an additional set of problems and issues on the high-pressure pump.
Examples of prior art pressure washers include U.S. Pat. No. 10,843,212, entitled A Pressure Washer And A Method Of Providing A Super-Heated Jet Of Water, which discloses that “[s] ome pressure washers include units for introduction of detergents and other chemicals into the water stream; however, it is desirable to obtain sterilized cleaning water without them, such that use in, for instance, food preparation processes can be implemented. With a sufficiently high temperature super-heated water stream, all process equipment, including pipework, that comes into contact with sterile process materials, can be cleaned, de-greased and sterilized both with the spray jet using water alone whilst not contributing endotoxins, microbial contamination or particles. Merely raising the temperature of water in a conventional pressure washer could cause components to fail, if they were not designed to operate at such high temperatures. In the present invention, the pump (25) supplies a relatively low volume of water at a relatively high pressure to the boiler (13), allowing the boiler (13) to heat that volume of water to a relatively high temperature. In contrast, if a higher volume of water were desired over a given time period, the pump would have to supply it at a comparatively lower pressure (which is undesirable) and/or the boiler would only be able to heat it to a comparatively lower temperature over that same time period (which is also undesirable). Increased working temperatures on a hose (3) will reduce its maximum working pressure; however, by using a PTFE hose as in the present invention, the maximum working pressure at 170 [degrees 338° F.] may be up to 17 MPa [2,466 psi].”
US published application no. 2019/0160497 entitled Hot Water Pressure Washer discloses, now abandoned, “[a] hot water pressure washer employs a high-pressure pump for generating a stream of high-pressure fluid and a hydrodynamic heater operable for heating the fluid stream. The hydrodynamic heater includes an inlet port fluidly connectable to a fluid source and an outlet port fluidly connected to an inlet port of the high-pressure washer. An outlet port of the high-pressure washer is connectable to a handheld wand operable for discharging the fluid stream to atmosphere. A prime mover provides rotational torque for driving the hydrodynamic heater and the high-pressure pump. An unloader valve is used to control distribution of the fluid stream discharged from the high-pressure pump. An exhaust gas recovery heat exchanger operates to transfer heat from the prime-mover exhaust gas to the fluid stream. A pre-heat tank is used to temporarily store a quantity of heated fluid for future use.”
U.S. Pat. No. 9,285,040 entitled High Pressure Fluid System discloses “[a] high pressure fluid system including enhanced safety, maintenance and servicing features. The system can include a CAM assembly module, having a valve seat assembly, seal cartridge assembly and inlet manifold, that is easily installed in and removed from a frame and/discharge manifold as a single unit. A discharge manifold can isolate different pressure rated passageways of the system, and multiple rupture discs associated with the same. A discharge manifold end plate can be included to provide ease of repair of discharge outlets and to establish a plumbing system for the rupture discs. A quick coupler can facilitate connection between a plunger of the seal cartridge assembly and a cross head stub connected to a power frame. A lubrication valve assembly can provide and meter lubrication from a high pressure inlet source to a plunger and packing of the seal cartridge assembly.”
The inventions disclosed herein are directed to improved medium and high pressure, high temperature pressure washers and methods of use.
A brief summary of the inventions that indicates their nature and substance may be understood from the scope of the subject matter encompassed by the appended claims and their equivalents, which are incorporated herein by reference for all purposes of this summary. Also, a brief summary of the inventions that indicates their nature and substance may be understood from the scope of the subject matter encompassed by any claims that may be issued from this application and their equivalents, which claims also are incorporated herein by reference for all purposes of this summary. This Brief Summary Of The Invention is not intended to and does not summarize all the inventions that are enabled by this specification.
The following figures form part of the disclosure of inventions and are included to demonstrate further certain aspects of the inventions. The inventions may be better understood by reference to one or more of these figures in combination with the detailed description of certain embodiments presented herein.
While the inventions disclosed herein are susceptible to various modifications and alternative forms, only a few specific embodiments have been shown by way of example in the drawings and are described in more detail below. The figures and detailed descriptions of these embodiments are not intended to limit the breadth or scope of the inventive concepts or the appended claims in any manner. Rather, the figures and detailed written descriptions are provided to illustrate the inventive concepts to a person of ordinary skill in the art and to enable such person to make and use the inventive concepts illustrated and taught by the specific embodiments.
The figures described above, and the written description of structures and functions below, are not presented to limit the scope of the inventions disclosed herein, or the scope of the appended or issued claims. Rather, the figures and written description are provided to teach a person skilled in this art to make and use the inventions for which patent protection is sought.
A person of skill in this art that has benefit of this disclosure will understand that the inventions are disclosed and taught herein by reference to specific embodiments, and that these specific embodiments are susceptible to numerous and various modifications and alternative forms without departing from the inventions we possess. For example, and not limitation, a person of skill in this art that has benefit of this disclosure will understand that the figures and/or embodiments that use one or more common structures or elements, such as a structure or an element identified by a common reference number, are linked together for all purposes of supporting and enabling our inventions, and that such individual figures or embodiments are not disparate disclosures. A person of skill in this art having benefit of this disclosure immediately will recognize and understand the various other embodiments of our inventions having one or more of the structures or elements illustrated and/or described in the various linked embodiments. In other words, not all embodiments of our inventions are described or illustrated in this application, and one or more of the claims to our inventions may not be directed to a specific, disclosed example. Nonetheless, a person of skill in this art that has benefit of this disclosure will understand that the claims are fully supported by the entirety of this disclosure.
People skilled in this art will appreciate that not all features of a commercial embodiment are described or shown for the sake of clarity and understanding. Persons of skill in this art will also appreciate that the development of an actual commercial embodiment incorporating one or more aspects of the present inventions will require numerous implementation-specific decisions to achieve the developer's ultimate goal for the commercial embodiment. Such implementation-specific decisions may include, and are not limited to, compliance with system-related, business-related, government-related, and other constraints, which may vary by specific implementation, location and from time to time. While a developer's efforts might be complex and time-consuming in an absolute sense, such efforts would be, nevertheless, a routine undertaking for those of skill in this art that have benefit of this disclosure.
Further, the use of a singular term, such as, but not limited to, “a,” is not intended as limiting of the number of items. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise. Also, the use of relational terms, such as, but not limited to, “top,” “bottom,” “left,” “right,” “upper,” “lower,” “down,” “up,” “side,” and the like are used in the written description for clarity in specific reference to the figures and are not intended to limit the scope of the invention or the scope of what is claimed.
Reference throughout this disclosure to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one of the many possible embodiments of the present inventions. The terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise.
Furthermore, the described features, structures, or characteristics of one embodiment may be combined in any suitable manner in one or more other embodiments. In the following description, numerous specific details are provided, such as examples of programming, software modules, user selections, network transactions, database queries, database structures, hardware modules, hardware circuits, hardware chips, etc., to provide a thorough understanding of embodiments of the disclosure. Those of skill in the art having the benefit of this disclosure will understand that the inventions may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the disclosure.
The description of elements in each figure may refer to elements of proceeding figures. Like numbers refer to like elements in all figures, including alternate embodiments of like elements. In some possible embodiments, the functions/actions/structures noted in the figures may occur out of the order noted in the block diagrams and/or operational illustrations. For example, two operations shown as occurring in succession, in fact, may be executed substantially concurrently or simultaneously, or the operations may be executed in the reverse order, depending upon the functionality/acts/structure involved or desired.
In general, we have invented improved medium to high pressure, high temperature pressure washers in which a booster pump, such as reciprocating pump, multi-stage reciprocating pump, centrifugal pump, positive displacement pump or the like, draws a fluid, such as, but not limited to, ambient temperature water, or a water-based cleaning solution, from a replenishable source and pressurizes the fluid about 55 psig (379 kPa) to about 200 psig (1,379 kPa) and preferably to between about 90 psig (621 kPa) and about 180 psig (1,241 kPa). The outflow of the booster pump (i.e., low pressure fluid) may be communicated to a fluid heater, such as a direct fired, or electrical heater, so that the temperature of the incoming pressurized fluid is increased above ambient to between about 180° F. (82° C.) and about 375° F. (191° C.), and preferably between about 200° F. (93° C.) and about 325° F. (163° C.). In one preferred embodiment, the booster pump may be controlled, such as by an operator or a controller, such that that the low-pressure fluid leaving the booster pump has a pressure greater than the vapor pressure of the fluid exiting the heater. For example, if the system is configured to heat water to 180° F. (82° C.), the booster pump may be set, controlled, or operated to pressurize the fluid to greater than about 55 psig (379 kPa) and preferably to about 90 psig (621 kPa), so that the heated water remains in its liquid state within system. For 325° F. (163° C.) fluid, the booster pump may pressurize the water to greater than about 135 psig (931 kPa), and preferably to about 180 psig (1,241 kPa). It is preferred, but not required, that the booster pump not pressurize the fluid to greater than about 250 psig (1,724 kPa).
It will be appreciated that a fluid heater operating at 250 psig (1,724 kPa) or less is easier and cheaper to design, build, and safer to operate than a fluid heater that operates at 250 psig (1,724 kPa) or higher. In our inventions, the low pressure, heated water may be passed to a medium and/or high-pressure pump that increases the fluid pressurization to between about 2,500 psig (17 MPa) and about 5,000 psig (34 MPa) (e.g., medium pressure, high temperature fluid) or to between about 5,001 psig (34 MPa) and about 10,000 psig (70 MPa) (e.g., high pressure, high temperature fluid), at flow rates from about 1 gpm (3.8 l/min) up to about 10 gpm (37.9 l/min). Suitably modified direct acting reciprocating piston or plunger pumps, such as triplex pumps or the like, may be suitable for this application. The medium or high pressure and heated fluid is then passed to a manifold for distribution to fluid washing/blasting equipment, such as one or more spray nozzles or spray lances, to provide hot, pressurized fluid, such as steam or wet steam, for cleaning.
In one of the many possible embodiments of our inventions, the medium/high pressure pump preferably comprises a barrier fluid seal around each plunger through which a barrier fluid, such as water, is continuously circulated during pump operation to provide cooling to the pump, and/or to evacuate any leakage from the pump seal systems. The volume and flow rate of the barrier fluid preferably maintains a substantially constant temperature in the chamber prohibiting any leakage from the inboard seal systems to flash to vapor. Even in catastrophic conditions, the barrier fluid may prohibit the pressurized fluid from flashing to vapor. In addition, the circulating barrier fluid may provide cooling to the plunger and other pump components.
Further, the medium/high pressure pump may have a spring-biased inlet valve assembly with a low opening force (aka cracking pressure) to reduce the opening velocity of the fluid entering through the valve. The discharge valve assembly also may comprise a biasing spring with a low opening force that promotes immediate or substantially instantaneous actuation when the plunger/piston begins its forward (compressive) motion. The main seal of the pressure pump (e.g., each plunger bore) is preferably made of a PEEK material, which is manufactured, or machined to an interference fit with the bore of the plunger stuffing box and the plunger/piston. Once the high-pressure pump begins operation, the interference fit of the seal changes or wears to a zero-clearance fit with the plunger.
Turning now to more detailed descriptions of one of the many possible embodiments incorporating one or more aspects of our inventions,
Fluid from the tank 102 may be passed to a booster pump 112, such as described above, that pressurizes the fluid from atmospheric conditions to a pressure level of between about 100 psig (689 kPa) and less than about 250 psig (1,724 kPa), which for purposes of this disclosure is considered to be low pressurization. A purpose of the booster pump 110 may be to pressurize the fluid above its vapor pressure throughout the system 100 (excluding when the fluid exits the system 100 at wand or lance). In other words, because the temperature of the fluid in the system 100 is increased before the fluid reaches the high-pressure pump 120, the booster pump 110 creates pressurization so that the fluid is always above its vapor pressure. In one embodiment, the booster pump 110 may be run at a pressurization that ensures the fluid will not enter the vapor state within the system 100. A pressure sensor 112, such as an analog pressure gage and/or digital pressure transducer, may indicate or transduce fluid pressure into observable or usable signals.
The low-pressure fluid may leave the booster pump 110 and enter a low pressure heater 114 to increase the thermal energy or temperature of the low-pressure fluid. The heater 114 may be a direct fired heater, such as a Diesel heater, natural gas heater or LPG heater, or may be an electric heater, such as a resistance or induction heater, a microwave heater, or other type of fluid heater. The heater or heating system 114 also may capture waste heat such as flue gas heat, or from other components, such as an internal combustion engine or that powers the system 100 (e.g., exhaust gas heat). Regardless of the type of heater 114 employed, the heater 114 is structurally configured to raise the temperature of the fluid to at least about 200° F. (93° C.) and up to about at least 250° F. (121° C.) and, and preferable up to about 325° F. (163° C.) at flow rates from about 1 gpm (3.8 l/min) to about 10 gpm (37.9 l/min) or more. For purposes of the embodiment of
The heated, low-pressure fluid (i.e., the fluid exiting the heater 114) may then be passed from the heater 114 to a high-pressure pump 120 structurally configured and organized to raise the pressure of the low pressure, heated fluid to between about 2,500 psig (17 MPa) and about 10,000 psig (70 MPa). A conventional triplex pump, such as those available from Heritage pumps, modified as disclosed herein, may be employed as the high-pressure pump 120. The pressure of the fluid exiting the high-pressure pump 120 is preferably measured or transduced 122 and passed to a distribution manifold 124 that distributes the high temperature, medium, or high-pressure fluid to spray washing equipment 126, such as one or more spray guns or spray lances (not shown).
This system 100 may be designed to provide the user/operator with the ultimate in flexibility when pressure cleaning at pressures up to and including 10,000 psig (70 MPa), flows up to and including 10 gpm (37.9 l/min), and temperatures up to and including 312° F. (156° C.). The system 100 may be designed to provide a safer way to handle high temperature pressurized water including steam and wet steam by heating the fluid through the heating system before it is pressurized to about 2,500 psig (17 MPa) or to up about 10,000 psig (70 MPa). The high-pressure pump 120 is preferably designed and configured to tolerate both the Maximum Allowable Working Pressure (MAWP) of about 10,000 psig (70 MPa) and a Maximum Allowable Working Temperature (MAWT) of about 375° F. (191° C.).
Embodiments of high temperature pressure washer systems, including that embodiment 100 illustrated in
Additionally, or optionally, embodiments also may comprise a low temperature mode in which low pressure fluid from the booster pump 110 transits through an un-energized heater 114 to the high-pressure pump 122 to provide unheated pressurized fluid. Alternately or optionally, embodiments may comprise a controllable conduit (not shown) that bypasses the heater 114 entirely.
Embodiments of pressure washers may also comprise a low pressure, high temperature mode in which high temperature, low pressure fluid bypasses the high-pressure pump 120. For example, a controllable bypass conduit 138 (such as through controllable valves) may communicate the low pressure heated fluid to the manifold 124 bypassing the high-pressure pump 120.
As illustrated in
As will described in more detail below, a portion of the booster pump 110 output may be, and preferably is, communicated to the high-pressure pump 120 for use with the barrier fluid seal. For example, a conduit 134 may communicate a portion of the pressurized fluid, such as about 1.5 gpm (5.7 l/min) or about 2 gpm (7.6 l/min) or more, from the booster pump 110 to the high-pressure pump 120 and return the fluid to the tank 102 via conduit 136.
It will be appreciated that embodiments of our inventions may be manually controlled or automatically controlled. By manually controlled, we mean using analog pressure and temperature gages or digital display gages, manual valves, and other operator controlled components. Automatic control may comprise a controller 160 having a microprocessor and/or logic board, memory, a human interface device and/or display, a communication module, and a, preferably, a bi-directional communication system, such as but not limited to a data bus 162.
In
It is contemplated that the controller 160 may transmit and/or receive data wirelessly, such as by electromagnetic transmission, including the Bluetooth® protocol, other packet-based protocols, and even analog protocols. For example, the controller may communicate to remote computers for monitoring and/or controlling the system 100. Additionally, or optionally, the controller 160 may transmit operational information to the Internet for access by remote or adjacent computers for monitoring and/or controlling the system 100.
Persons of skill will appreciate that embodiments like that illustrated as system 100 will require a power source to drive the booster pump 110, the high-pressure pump 120, other equipment, and, optionally, the heater 114. A preferred embodiment may use a Diesel engine, such as, but not limited to, a Kubota 07 series industrial Diesel engine producing about 55 KW of power. The high-pressure pump 120 may be disengageably driven by the engine power take off, and a hydraulic pump connected to the engine may drive the booster pump 110.
Having now described certain general aspects of high temperature systems according to our inventions, we now turn to descriptions of various components that may be used as desired with various other embodiments.
The tank may be fabricated from any convenient material or combination of materials including metals, plastics, and/or composites. It will be appreciated if tank recirculation conduits 410 are employed, such as conduits 136 or 140 illustrated in
The hydraulic drive system 504 may comprise a hydraulic drive or motor 510, a hydraulic fluid filter 512, a reservoir 514, such as a cyclone reservoir, for removing entrained air in the hydraulic fluid, a manifold 516, and associated hoses or plumbing.
A hydraulic pump (not shown) may be coupled to the stationary engine, such as to an auxiliary PTO, for supplying pressurized hydraulic fluid to the drive system 504. As is known, hydraulic drive systems typically raise the temperature of the hydraulic fluid during operation. If needed, a fluid to air or fluid to fluid heat exchanger may be incorporated in the hydraulic system to remove heat from the hydraulic fluid. For example, and without limitation, a counter-flow, plate heat exchanger may be employed through which hydraulic fluid passes in one direction while pressurized fluid from the tank or the booster pump passes through in the opposite direction. The tank or pressurized booster pump fluid removes heat from the hydraulic fluid and the heated fluid can be returned to the tank. Alternately or optionally, embodiments of our inventions can use waste heat from the hydraulic fluid to heat the pressure washing fluid thereby reducing the size of or even eliminating an additional heater, such as heater 114 in
Alternately, rather than a hydraulically driven booster pump, the system may utilize electrical motors, such as radial flux or axial flux motors and linear motors. For example, the power source 204 in
The pump 700 may comprise a PTO coupling 714 that is coupled to the stationary engine or coupled though a gear box or transmission. It is preferred that the pump 700 is engageable and disengageable from the stationary engine as desired or required. For example, a hydraulic cylinder (not shown) may be used to engage a PTO lever on the power source 204 to engage and disengage the high pressure pump 700 from the PTO 206. It is preferred that a disengagement lockout be employed to prevent the PTO from prematurely or inadvertently disengaging from the pump 700. For example, if a hydraulic actuation cylinder is employed, a hydraulic circuit with necessary check valves can be used to prevent cylinder from unintentionally backing off, or a mechanical lock can be employed to retain the cylinder in the engaged position until it is desire to de-energize the pump 700.
A fluid inlet 716 with pressure gage or transducer 718 is illustrated feeding fluid, such as heated fluid from the heater to the high-pressure cylinder 720. A high-pressure fluid outlet 722 and associated pressure gage or transducer 724 is shown exiting the cylinder head 720.
FIG. illustrates a barrier fluid seal system in more detail comprising an annular chamber 810 formed between the stuffing box, e.g., 702a and the plunger 902. The annular chamber 810 may be formed by enlarging the stuffing box 702a inside diameter surface in this area, or, more preferably, by providing a chamber insert or lantern ring 902 illustrated in
A chamber insert 902 may be fabricated from a variety of materials including stainless steel or PEEK. The insert 902 may have an inboard end configured to contact the inboard seal system 814, and insert 902 may have an outboard end configured to contact an interference ring 904 and the outboard seal system 812 It is preferred that the chamber insert 902, and preferably the inboard portion of the insert 902, not form a fluid seal with the inside surface of the stuffing box 702a or the plunger 802 to allow high pressure fluid leaking past the inboard seal system 814 to enter the chamber 810.
Additionally, and/or optionally, the outside surface of the insert 902 may be tapered with a reducing diameter toward the inboard end to facilitate channeling of any leaks into the chamber 810. Further, if desired, an outside diameter portion of the insert 902 adjacent the outboard seal system 812 may have an interference fit with the inside surface of the stuffing box 702a-702c to fix the insert 902 in position relative to the seal systems and inhibit leaking into the outboard seal system 812.
As illustrated in
As illustrated in
As fluid circulates through the annular chamber 810, the low-pressure fluid cools the plunger 802 and stuffing box, or at least that portion of the plunger and stuffing box in contact with the fluid, and other pump components. If high-pressure fluid from the cylinder 720 leaks past the primary sealing system 910, 814, the low-pressure fluid (e.g., from the booster pump) keeps the annular chamber 810 above the vapor pressure of the high-pressure fluid. High pressure leaks are entrained in the circulating low-pressure fluid and returned to the tank 102. In this way, conditions in which the high-pressure fluid (e.g., water) is allowed to lower below its vapor pressure and flash to steam within the system is avoided or at least minimized. The outboard sealing system 904, 812 functions to seal the barrier chamber 810 from the outside environment. This is very different from conventional reciprocating plunger pumps in which water is allowed to continually leak over the “packing” to maintain the cooling of the plunger.
It is preferred that the volume or flow rate of barrier fluid continuously flowing through the seal chamber 810 is significantly more than the volume or flow rate of any anticipated leak. For example, it is preferred that the barrier fluid flow rate be about 50 times to about 75 times or even 100 times the anticipated leak flow rate. If a leak rate through or across the inboard seal system is estimated to be about 0.5 ml/sec, then the barrier fluid flow rate through the chamber 810 is preferred to be about 0.5 gpm (1.9 l/min). So, for a triplex pump as described above with three plungers, a flow rate of about 1.5 gpm (5.7 l/min) from the booster pump to the barrier fluid manifold 804 would be needed. A large barrier fluid flow rate compared to a leak rate helps ensure that any leaking heated fluid will be captured by the circulating fluid and quenched so that it doesn't flash to steam if released from the system.
Preferably, the inboard seal system and the outboard seal system may each comprise PEEK composite material seals manufactured as an interference fit with the bore of the stuffing box 702a-702c and with the plunger 802. PEEK is a suitable seal material because of its tolerance of the low lubricity of water and its ability to tolerate temperature swings from ambient to about 350° F. (177° C.) or more. Once the high-pressure pump 700 begins operation, such as during a manufacturer break-in or quality control process, the interference fit with the plunger 802 wears to a zero-clearance fit. For 1 inch (4 cm) diameter plungers, a diametrical interference of between about 0.0005 inch (½ mil or 12.7 μm) and about 0.001 inch (1 mil or 25.4 μm) is preferred. Next to the PEEK seal may be a plurality, and preferably two or three, rings of impregnated packing, which rings are tolerant of the pumping temperatures from ambient to about 350° F. or more. A seal system spring 824 provides constant pressure the maintains the integrity of both the inboard and outboard seal systems, as well as the barrier fluid chamber 810.
Similarly, it is preferred that the outlet seating spring 1112 be modified or constructed to provide a minimum seating force (aka cracking force) to minimize the differential pressure across the valve seat on opening. Minimizing the cracking force helps to ensure that the high-pressure fluid is effectively instantaneously passed through the outlet valve assembly 806 and that pressurized fluid, especially heated pressurized fluid at the fluid outlet 1114 remains pressurized above its vapor pressure. For example, and not limitation, for the Heritage Pump Company Model HT-28 mentioned above, an outlet seating spring 1106 preferably is a conical or beehive type spring having a variable spring rate so that the initial or cracking force is low but the return force is greater to ensure rapid seating of the valve. For a high pressure pump with an exit pressure of about 3,500 psig (24 MPa), an outlet spring with about 5 lbf (22 N) to about 7 lbf (31 N) of seating force may be used to provide a minimum cracking force.
Mode selection screen 1304 illustrates five possible modes of operation of a system according to our invention. One gun mode may comprise a (1) high temperature, high pressure mode of about 312° F. (156° C.) and about 5,000 psig (34 MPa) at about 10 gpm (37.9 l/min), or depending on the thermostat setting, a (2) low temperature, high pressure mode of less than 100° F. (38° C.) and about 5,000 psig (34 MPa) at about 10 gpm (37.9 l/min). Two-gun mode may comprise a (3) high temperature, high pressure mode of about 200° F. (93° C.) at about 5,000 psig (34 MPa) and less than about 10 gpm (37.9 l/min) for both guns, or depending on the thermostat setting, a (4) low temperature, high pressure mode of less than 100° F. (38° C.) and about 5,000 psig (34 MPa) and less than about 10 gpm (37.9 l/min) for both guns. The steam mode may comprise a (5) high temperature, low pressure mode of about 312° F. (156° C.) at about 200 psig (1,379 kPa) at about 10 gpm (37.9 l/min).
Once the power source is energized, such as by starting a Diesel engine and reaching operating temperature, the Mode selection screen is enabled, allowing the operating to select the desired mode. After mode selection, the operator may start the system, which energizes the booster pump to circulate cleaning fluid, such as water, through the heater, bypassing the high-pressure pump, to the manifold and back to the fluid tank, unless spray equipment is operated. Fluid is also circulated through the annular chamber of the barrier fluid seal, preferably regardless of whether the high pressure pump is energized. Once the operator is prepared to begin full operation of the system, a push button panel allows the operator to start the high-pressure pump, as required by the mode selected, which energizes the high-pressure pump, such as by energizing a hydraulic cylinder to engage a PTO. The engine may be operated along its entire range of RPMs from idle (about 800 RPM) to its maximum of about 2,400 RPM to generate the desired high pressure pump output pressure. For example, the operator may run the pump at about 1,170 RPM to generate 5 gpm of water flow, or at about 2,250 RPM to generate 10 gpm (37.9 l/min) of water flow. As of this point, the operator may choose to run one tool at 5 gpm (19 l/min) or two tools at 10 gpm (38 l/min).
Should the operator wish to add heat to the water, the operator would then turn the heating system to the ON position. The operator has the ability to set the system's thermostat to the desired discharge temperature, ranging from about 125° F. (52° C.) to about 325° F. (163° C.). As the system is operated between its full flow of 10 gpm (37.9 l/min) and may cycle between one tool or two, the manifold bypass valve or dump valve will send any excess high-pressure water back to the water tank.
To generate low pressure wet steam, the operator can select the “WetSteam” push button, which will automatically switch the controllable valves to the bypass position so that the high-pressure pump is bypassed, and the high-pressure pump PTO is disengaged. In this mode, the operator may select a temperature of 325° F. (163° C.) on the thermostat and operate the system at low pressure of about 100 psig (689 kPa) to about 150 psig (1,034 kPa).
While operation of an embodiment with a controller has been described, those of skill that have benefit of this disclosure will appreciate that manual operation of embodiment may implemented in similar fashion.
It will be appreciated that use of our invention may require that the operator (i.e., the worker holding the pressure wand or lance) may be a significant distance from the system, such as greater than 50 feet and upwards of hundreds of feet. Thus, it is contemplated that pressure wands, lances and other discharge equipment comprise one or more information and/or safety features. For example, in a first embodiment, a pressure wand may comprise a plurality of visual displays, such as LEDs, to indicate the temperature of the fluid, the pressurization of the fluid, fluid level in the tank, fuel level in the tank, and/or operation condition of the power source.
Having now disclosed several embodiments of our inventions, it will be appreciated that stationary power sources other than Diesel engines may be employed. For example, natural gas, or gasoline internal combustion engines may be utilized as well as gas turbine engines. These power sources may be used to directly drive the high-pressure pump, and hydraulic pumps, or they may drive an electrical generator to power electric motors to drive the booster and high-pressure pumps. Furthermore, the power source can be an electric motor such as a DC motor or a variable frequency drive AC motor or motors that directly drive the pumps.
It will now also be appreciated that fluid heaters other than a direct fired Diesel heater may be used to great effect. For example, when an internal combustion engine is used as the power source, waste heat from for example, the exhaust gases may be captured by an air to fluid heat exchanger to heat the fluid. Also waste heat from the engine coolant system may be captured with a fluid-to-fluid heat exchanger for the same purpose. The additional sources of heat can be used to reduce the size of or entirely replace the primary heater. If an electrical generator set is used to provide electrical power rather than mechanical power, or if direct grid power is used, the heater may comprise an electric heater or boiler, such as an inductance heater.
Persons of skill having the benefit of this disclose will now understand how to mix and match these various components disclosed herein to create other and further embodiments of our inventions. Further, the various methods and embodiments of the methods of manufacture and assembly of the system, as well as location specifications, can be included in combination with each other to produce variations of the disclosed methods and embodiments. Discussion of singular elements can include plural elements and vice versa.
The order of steps can occur in a variety of sequences unless otherwise specifically limited. The various steps described herein can be combined with other steps, interlineated with the stated steps, and/or split into multiple steps. Similarly, elements have been described functionally and can be embodied as separate components or can be combined into components having multiple functions.
The inventions have been described in the context of preferred and other embodiments and not every embodiment of the invention has been described. Obvious modifications and alterations to the described embodiments are available to those of ordinary skill in the art. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the invention conceived of by the Applicants, but rather, in conformity with the patent laws, Applicants intend to protect fully all such modifications and improvements that come within the scope or range of equivalent of the following claims.
This application for patent claims benefit of and priority to U.S. Provisional Patent Application No. 63/495,285, filed on Apr. 10, 2023, the entire contents of which are incorporated herein by reference for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 63495285 | Apr 2023 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18632085 | Apr 2024 | US |
| Child | 18807437 | US |
