This invention relates to the field of vacuum pumps. In particular thermal control of vacuum pumps with a screw type configuration.
Screw pumps usually comprise two spaced parallel shafts each carrying externally threaded rotors, the shafts being mounted in a pump body such that the threads of the rotors intermesh. Close tolerances between the rotor threads at the points of intermeshing and with the internal surface of the pump body, which acts as a stator, causes volumes of gas being pumped between an inlet and an outlet to be trapped between the threads of the rotors and the internal surface and thereby urged through the pump as the rotors rotate.
Prior art screw pumps use a water cooling jacket around sections of the machine in order to remove the heat of compression. However, the inlet of the machine does not have any cooling system since, at low pressures, there is little heat of compression to be removed from the inlet. As the pressure increases any additional heat is dispersed from the inlet by the increased gas flow through it. Where the pump is located in a cold environment, surface temperatures within the inlet of the pump may reduce significantly and form cold spots such that gaseous waste products from the evacuation chamber condense into liquid pools in these cooler regions. These pools can be formed from highly corrosive acid or base fluids and can lead to damage of the pump components, which, in turn, can reduce the life of the device.
Double ended screw pumps are known where a single inlet serves two outlets, the rotors being mounted in a co-linear fashion. In such a pump a disparity in temperature between the inlet and the outlet sections of the pump is more pronounced and concentricity of the bores within the housing components becomes important. If the housing components move out of alignment the rotor is more likely to clash with the stator as the already small tolerances reduce even further or are eliminated.
Screw pumps are increasingly being utilised in a broad range of applications. For example within a pharmaceutical process area the same pump may be required to perform numerous different applications. Whilst the configuration of a pump may be tailored to a particular application, once the application is altered, ideal conditions will no longer be present and the pump will not be performing at peak/optimum efficiency.
It is an aim of the present invention to overcome some of the aforementioned problems associated with screw pump technology.
According to one aspect of the present invention there is provided a pump comprising:
The first temperature sensor may be located at the stator, whereas the second temperature sensor may be located either in the exhaust plenum or within the housing, in fluid communication with process gas in an exhaust portion of the rotor, alternatively it may be situated in the gear box of the pump
The thermal control means may comprise first and second control means for controlling the temperature of any fluid in the first and second channels respectively. Either thermal control means at least one of each of a variable speed flow pump, a thermostatic control valve and a heat exchanger. They may be arranged to control the temperature of the fluid in the respective channels dependant on the magnitude of one or more of the sensors' outputs. The thermal control means may include/be controlled by a microprocessor.
One of the thermostatic control valves may comprise a mechanical differential temperature valve. This valve may comprise a third fluid channel in thermal communication with the second fluid channel. A flow restrictor may be provided within this third fluid channel to control the rate of fluid therethrough. The position of this flow restrictor may be governed by signals received from the first and second sensors via signal receptors which may also form part of the valve. Each signal receptor may comprise a sealed component, the volume of which may expand in use. The degree of expansion being dependent on the magnitude of the signal received and determining the relative position of the restrictor within the third fluid channel. The sealed component of the signal receptor may comprise an expandable bellows. The flow restrictor may comprise a spindle and a seat. The spindle acting co-operatively with the seat to open and close an aperture to control the flow of fluid therethrough.
The pump may be of any known form, for example but not strictly limited to; a screw pump, a claw pump or a Roots pump.
According to a further aspect of the present invention there is provided a double-ended pump comprising at least one rotor, comprising:
According to a further aspect of the present invention there is provided a valve comprising:
According to a further aspect of the present invention there is provided a method for releasing the rotors of a pump that have seized due to the presence of deposits of a substance which has solidified on the internal working surfaces of the pump on cooling, comprising the steps of:
According to a further aspect of the present invention there is provided a method for controlling a clearance between a rotor and stator within a pump, of the present invention, the method comprising the steps of:
The method steps may be repeated automatically at predetermined time intervals in order to manage perturbations in the configuration of the pump over time. The predetermined temperature difference may be modified at predetermined time intervals to cause the clearance between components to be altered such that cumulative deposits can be dislodged from the surfaces of the components of the pump.
The thermal controller may comprise a microprocessor which may be embodied in a computer, which in turn is optionally programmed by computer software which, when installed on the computer, causes it to perform the method steps (a) to (e) mentioned above.
The present invention enables a pump to be subject to an improved level of thermal control. This allows benefits to be achieved during operation of the apparatus in terms of providing optimised running clearances enhancing the tolerance of the pump to excessive exhaust back pressures, reducing the occurrence of cold spots in the inlet of the pump, reducing thermal lag in the apparatus and enhancing the likelihood of restart in circumstances where deposits are formed due to cooling.
An example of the present invention will now be described with reference to the accompanying drawings in which:
Screw pumps are illustrated in
The housing 2 is provided as a double skinned construction. The internal skin acts as the stator of the pump. A cavity 6 is provided between the skins of the housing 2 such that a cooling fluid, such as water, can be circulated around the stator in order to conduct heat away from the working section of the pump. This cavity 6 encircles the full length of the stator i.e. over the inlet stator 4 as well as the exhaust stators 5. Cooling fluid is circulated through this cavity to draw heat away from the hot surface. By providing the water jacket over the length of the stator, heat generated towards the exhaust end of the rotor can be redistributed to the earlier stages when necessary. This will enable the temperature gradient to be reduced and allow a more uniform temperature to be maintained over the surface of the pump. Consequently, the ‘cold spots’ found in the prior art can be avoided and condensation of potentially corrosive materials in the rotor inlet are substantially reduced. Furthermore, thermal lag is introduced into the system due to the presence of a complete water jacket which effectively prevents rapid temperature changes in the stator and rotor surfaces e.g. through wind chill effects. The maintenance of a uniform temperature causes all of the stator components to expand at the same rate from a central datum (the shaft) thus concentricity can be maintained and, consequently, the rotor retains its relative position within the stator and clashing of components can be avoided.
Conventional pumps with thermal jackets generally use convection to circulate the thermal liquid through the stator. This can lead to uneven distribution of temperature over the pump, notably, with cooler areas lower down the pump and warmer sections in the upper regions. Such localised cold spots can cause the process gases to condense out, becoming increasingly corrosive. By implementing a circulation pump within the thermal fluid consistent thermal control can be achieved such that local variations in temperature can be minimised.
In some cases, the waste products passing through the pump comprise a waxy or highly viscous substance and deposits are formed on the surfaces of the pump during operation. On shut down of the pump, these deposits cool and may solidify. Where such deposits are located in clearance regions between components, they can cause the pump to seize up. The motor may then provide insufficient torque to overcome this additional friction and cause the rotor to rotate. Additional torque can be applied using a leverage bar inserted into a socket on the shaft, which can then be rotated manually. However such a technique exerts a significant load on the rotor and may cause damage. However, it may not be possible to exert sufficient load to release the mechanism and force the shaft to rotate, under these circumstances it may be necessary to decommission the apparatus and take it out of service either for replacement or repair. An alternative use of the water jacket of the present invention can be implemented in these circumstances where the pump has become seized due to cooling of the rotor. The fluid in the cavity 6 of the housing 2 may be heated to raise the temperature of the stators 4,5 and the rotors 1. This can enhance the pliability of the residue and may assist in releasing the mechanism.
The rotor 1 comprises a threaded section 9 and a separate shaft component 8 as illustrated in
Returning to
By introducing two thermostatic control valves as described, it is possible to control the temperature of the pump rotor relative to the stator temperature. The rotor to stator clearance d (as illustrated in
By providing a temperature control circuit within the rotor it is possible to thermostatically control rotor temperature relative to the stator temperature to optimise rotor/stator clearance d. In its simplest implementation the present invention can be used simply to avoid cold spots and thus eliminate corrosion due to condensation build up as discussed above. In a more sophisticated implementation, input signals can be taken from sensors mounted on each of the stator 4, 5 and the rotor 1 and these signals can be analysed/processed by a closed loop control system to maintain a set temperature, for example to be less than 135° C. This allows a pump using the present invention to safely process materials with a known auto-ignition temperature.
However, as discussed above, the present invention can be used at an even higher level of sophistication to select particular temperatures that will result in a particular clearance d being achieved and maintained.
Under normal steady state operation, a dry pump will attain a particular pumping speed determined by the clearance between the rotor and the stator. If the inlet pressure to the pump is increased more gas will enter the pump. This additional gas will cause the rotors to cool down with respect to the stator and hence the clearance d between these two components will increase. It follows that, at higher pressures, a significant amount of leakage around the rotor will occur. This is particularly problematic when pumping gas species such as helium, which typically result in low pump speeds and gas throughput being achieved when approaching atmospheric pressures. With the control feature of the present invention it is possible to artificially reduce the clearance d between the rotor and the stator. Consequently leakage around the rotor may be reduced and the efficiency of the pump can be improved significantly. In the above example, when pumping helium, it is desirable to maintain a small gap to prevent leakage. However, the same pump could be used, in an alternative application, to pump Argon where a larger gap would be required. By providing a pump that can essentially be optimised during operation to function efficiently under varying conditions, a multi-purpose pump is achieved. This functionality can be used to good effect in fields, such as the pharmaceutical or chemical process industries, where a single pump needs to be used for different applications using the same tooling.
The temperature control can be dynamic within a particular process. On start up there will typically be a greater temperature difference since the temperature of the rotor increases at a faster rate than the stator due to the significant difference in thermal mass of the relative components. However, once the pump has reached a steady state this temperature difference will be reduced. By performing the temperature control dynamically, this early difference can be minimised such that the clearance d can be maintained at an approximately steady value. This, in turn, will lead to a more consistent level of pump efficiency.
The dynamic control of the clearances may be implemented in a cyclic manner when the pump is operating under normal conditions. At predetermined intervals the thermal conditions can be modified to reduce the clearances between the rotor and the stator for a short period of time. This will have the effect of removing/dislodging process deposits that have become adhered to these components. If this is repeated at intervals the cumulative build up of solid matter on the internal surfaces of the pump can be substantially reduced thus preventing seizure of the pump.
Seizure of the pump may be further be avoided by provision of an additional sensor for monitoring either the pressure within the pump or the power consumption of the pump. If either of these values increase significantly, this may be an indication that the clearances are becoming obstructed and that seizure is imminent. By monitoring these values it is possible to initiate a condition of maximum cooling of the rotor component to maximise the clearance between the rotor 1 and the stator 4, 5 and thus prevent seizure of the pump.
Alternatively the thermal control means may be provided by a purely mechanical means as illustrated in
The present invention is not restricted for use in screw pumps and may readily be applied to other types of pump such as claw pumps or Roots pumps. Indeed in some Roots blowers, significantly higher exhaust pressures (in some cases up to 2 to 3 bar) can be experienced. These raised pressures lead to a notable increase in component temperatures within the pump which can, in turn, lead to problems in maintaining appropriate clearances. By implementing dynamic thermal control according to the present invention these clearances can be maintained at consistent levels thus improving the tolerance of the pump to different operating conditions.
A rotor 35 from a Roots blower is illustrated in
It is to be understood that the foregoing represents just a few embodiments of the invention, others of which will no doubt occur to the skilled addressee without departing from the true scope of the invention as defined by the claims appended hereto.
Number | Date | Country | Kind |
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0223769.1 | Oct 2002 | GB | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/GB03/04415 | 10/10/2003 | WO | 1/27/2006 |