DESC:
FORM 2

THE PATENT APPLICATION ACT 1970
(39 of 1970)
&
THE PATENT RULES, 2003

PROVISIONAL /COMPLETE SPECIFICATION
(See section 10 and rule 13)

TITLE OF THE INVENTION: A WATER FILLED ELECTRICAL MOTOR IN A SUBMERSIBLE PUMP SETTING

1. APPLICANT (S):

a. NAME: DUKE PLASTO TECHNIQUE PVT. LTD.
b. NATIONALITY: INDIA
c. ADDRESS: N.H.27, Deesa Highway, Badarpura, Palanpur-385511 (North Gujarat) - India

PREAMBLE TO THE DESCRIPTION: FILING OF COMPLETE SPECIFICATION AFTER PROVISIONAL SPECIFICATION (Provisional Application No.: 3658/MUM/2015)
The following specification particularly describes the invention and the manner in which it is to be performed.

2. DESCRIPTION

A WATER FILLED ELECTRICAL MOTOR IN A SUBMERSIBLE PUMP SETTING

[001] The present subject matter relates to electric motors and more particularly to electric motor in a submersible pump-set setting.

[002] Submersible pumpsets are generally used for pumping water. While in some cases a submersible pump-set may be employed for pumping fluids other than water, for example, circulating oil in a cooler, most applications employ the submersible pumpsets for pumping ground water from deep water reservoirs. The submersible pumpsets employ electrical motor; that enables pumping by actuating levers of a pump deployed in the submersible pumpsets. The submersible pumpsets remains submersed into water.

[003] Relating to the schematic depiction of the conventional electric submersible pumpset (ESP), 100 and its various components in Figure 1, the numerals labeled with the figure of a conventional ESP (100) and its associated controlling components mainly represent: (101) a centrifugal pump. The centrifugal pump 101 may be single stage or multi stage in nature, (103) a squirrel-cage induction motor, (105) a housing of the submersible pump assembly, (107) a permanent water level required for placement of the pump, (109) well casing driven to depth necessary to reach below permanent water level, (111) a water intake screen, (113) a check valve/ball valve/switch valve, (115) a main switch and (117) a starter used on 2 or 3-wire pumps. The electric submersible pump (100) in FIGURE 1 comprises of a centrifugal pump driven by an electric motor. The centrifugal pump and the motor are assembled inside single housing, called as pump housing, submersed below the water level, within the well casing. The pump housing is a cylinder, usually about 3-10 inches in diameter and 2-4 feet long structure. During operation, the pump raises the water upward through the piping, to the water tank.

[004] The cost of the submersible pumpsets and operational efficiency thereof, greatly depend on motors used by the submersible pumpsets. Operational efficiency and cost effectiveness of the submersible pumpsets may be improved by improving the motor and enabling the submersible to receive or deploy such improved motors. One of the problem with present day submersible pumpsets is that, they use motor that does not efficiently use the energy supplied to it. One reason being that these motors do not operate in an optimal environment and neither are these motors configured to dynamically optimize the operation based on the environment. Furthermore these motors consume enormous amount of energy to change the status from stationary to moving and from rotating to stationary.

[005] One of the reasons, for huge waste of energy to change status of the motor is inertia. Because of the inherent inertia of a rotor of the motor, the motor draws huge power from an electric source which is driving the motor. When the rotor is rotating, the inertial energy gets converted into the kinetic energy of the rotor which eventually gets wasted. Conventionally, the motor employed in submersible pumpsets, generally employ non-magnetic rotors thereby increasing the power consumption and power threshold. Usually, enameled winding are used, using oil or resin as a coolant, which causes the cost of manufacture to be higher. Further, any repair or re-winding becomes difficult.

[006] There is therefore needed an electric submersible pump providing better power efficiency, reparability while keeping the costs low.

SUMMARY OF THE INVENTION
[007] An electric submersible pump, deploying a rotor made of a permanent magnet using water as a coolant is disclosed. Providing such rotor helps in reducing power consumed by the motor, while changing its status as it takes relatively lower threshold to move the rotor due to its magnetic characteristics. Providing the rotor according to an embodiment herien also, opens a new avenue for controlling the motor more effectively. The motor rotates, when a current flows through its coils, causing a generation of magnetic field due to the current, by changing direction of the current the direction of the magnetic field is changed, which eventually results in rotating the rotor.

[008] According to one aspect, the motion of a motor is controlled by variable frequency drive (VFD), due to which power consumption is reduced, thereby provide the optimal efficiency of the pump-set. The pump-set is provided with a pressure sensor at the outlet of the pipe, which sense the pressure of flow of water flowing through the pipe and send signal to microcontroller of the controller. Based on the feedback signal of pressure sensor received by microcontroller from the pressure sensor, the microcontroller decide the movement of motor by using variable frequency drive (VFD).

[009] In another aspect, a dry sensor is also used and placed with motor in the bore well which sense the availability of water in the bore well if the water level is below the pump set, dry sensor will operate and send the signal to microcontroller and microcontroller disconnect the power supply to the motor by operating relay, and stop motor to operate at dry condition (when availability of water is below a set limit).

[0010] According to a further aspect, an embodiment herein provides optimally controlling of change in the direction of magnetic field, to synchronize it with the rotating magnetic field of the permanent magnet. By optimally controlling and synchronizing, the efficiency of the submersible pump-set is increased. According to one aspect, embodiments herein provide better ways of optimally controlling and synchronizing the magnetic field, generated due the driving current and the permanent magnetic field of the rotor, which rotates along with the rotor, by providing a variable frequency drive (VFD).

[0011] In one of the embodiment, the embodiments provides an electric submersible pump-set (ESP). The electric submersible pump-set comprises at least one motor and at least one magnetic rotor. The magnetic rotor operates efficiently by using variable frequency drive (VFD) of the motor. The motor of the submersible pump-set operates on magnetic pole synchronous with the magnetic flux frequency speed principle with less power losses. In other words, the rotor of the electric motor of submersible pumpset rotates with the same, speed as of windings and therefore it achieves synchronous speed and consequently the overall power consumption gets reduced. As per an embodiment herein the efficiency of electric submersible pump-set (ESP) is raised upto 85 to 98%.

[0012] In one aspect, water is used as a coolant in the motor as compared to oil/resin. Further, providing submersible pumpset with the magnetic rotor, wherein the electric motor works on magnetic pole synchronous with magnetic flux frequency speed principle results in less power losses. In another aspect, the rotor rotates with the same speed as of the windings of the motor thereof, and hence achieves virtually zero slip, supporting the increase in the frequency of the motor.

[0013] In one aspect, a submersible pumpset is disclosed with a magnetic rotor, wherein the efficiency of the pumpset is increased. In one embodiment the efficiency may reach up to 85% to 98% by involving variable frequency drive. The submersible pumpset as per an embodiment herein comprises an electric motor, which works on magnetic pole synchronous with magnetic flux frequency speed principle with slip loses or zero slips, thereby less power losses resulting providing energy efficiency system.

[0014] In another aspect the motor of the submersible pump-set with a magnetic rotor, wherein the rotor rotates with the same speed as of the windings of the motor thereof, and hence achieves virtually zero slip, supporting the increase in the frequency of the motor.

[0015] In another aspect, embodiments herein relate to the submersible pumpset with the magnetic rotor, wherein the magnetic fluxes are induced as in the induction motors and wherein the motor is directly plugged in with the variable frequency derive (VFD).

[0016] It shall become clear to a person, after reading this specification, that the following discussion is intended only for illustration purpose and that the subject matter may be practiced without departing from the spirit of the present subject matter.

[0017] For the purpose of illustrations, following discussion explains the present subject matter with an example of submersible pumpset, however it shall become clear to a person, after reading this specification, that the subject matter may be practiced without departing from the spirit of the present subject matter, for other forms of submersible pumpset. Further, the present subject matter explains for example, a submersible pumpsets comprises at least one motor and at least one magnetic rotor. The magnetic rotor operates efficiently by using variable frequency drive (VFD) of the motor. The motor of the submersible pumpset operates on magnetic pole synchronous with the magnetic flux frequency speed principle with less power losses, however it shall become clear to a person in the art, that scope of the present subject matter may extend for other form of submersible pumpset.

[0018] Embodiment here disclose a submersible pumpset, wherein submersible pumpset characterized by the use of magnetic rotor in the submersible motor of the pump assembly. Thereby the present system may achieve efficiency in terms of power consumption and water discharge capacity at a very low voltage.

[0019] In another aspect, the submersible pumpset as per an embodiment herein works on magnetic pole synchronous with magnetic flux frequency speed principle, with less power losses. The rotor rotates with the same speed as of windings, hence nearer to zero slip. The magnetic fluxes are induced as in the induction motors. The motor of the instant electric submersible pumpset (ESP) is directly plugged in with the variable frequency drive (VFD) and at pre-set frequency, the controller maintains the speed. In an embodiment herein the Controller is connected to the main panel which receives 3 phase input at about 415 (with a variation of -15%, + 10%) voltage and thereafter it converts them into alternate current (AC) to run the drive, which in conversion provides alternate current (AC) supply output to the motor.

BRIEF DESCRIPTION OF THE DRAWINGS
[0020] References will be made to embodiments of the invention, examples of which may be illustrated in the accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in the context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
[0021] Figure 1: It is the schematic diagram of one embodiment of a conventional electric submersible pump (100) and it’s various components.
[0022] Figure 2: represents the general schematic plan of a submersible pumpset as per an embodiment herein.
[0023] Figure 3: It represents the complete schematic cross-sectional view of the electric submersible pump as per an embodiment herein., along with its various components.
[0024] Figure 4: is a graphical representation of the efficiency of the submersible pump as per an embodiment herein, wherein the graph is drawn between Head Vs. Discharge.
[0025] Figure 5: It is a graphical representation of the efficiency of the submersible pump as per an embodiment herein over the conventional ones, wherein the graph is drawn between overall efficiency vs. discharge.
[0026] Figure 6: It is a graphical representation of the efficiency of the submersible pump as per an embodiment herein over the conventional ones, wherein the graph is drawn between ampere vs. discharge.
[0027] Figure 7: It is a graphical representation of the efficiency of the submersible pump as per an embodiment herein. The graph is drawn between motor efficiency vs. discharge.

DETAILED DESCRIPTION OF THE INVENTION
[0028] An electric submersible pump, deploying a motor that uses rotor made of a permanent magnet and using water as a coolant is provided. Further, windings comprise of synthetic plastic polymer insulation.

[0029] The following description is set forth for the purpose of explanation in order to provide an understanding of the invention. However, it is apparent that one skilled in the art will recognize that embodiments of the present invention, some of which are described below, may be incorporated into a number of different computing systems and devices. Also, various parameters mentioned herein are exemplary and various others obvious to person skilled in the art may be added. The embodiments of the present invention may be present in hardware, software or firmware. The conditioning, processing or evaluation of operational data may be present in hardware or software made available on a non-transitory computer medium. Structures shown below in the diagram are illustrative of exemplary embodiments of the invention and are meant to avoid obscuring the invention. Furthermore, connections between components within the figures are not intended to be limited to direct connections. Rather, data between these components may be modified, re-formatted or otherwise changed by intermediary components.

[0030] Reference in the specification to “one embodiment”, “in one embodiment” or “an embodiment” etc. means that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

[0031] The illustration of Figure 2 can be understood by the illustrations and explanations described in Figure 2. The Figure 2 discloses the diagrammatic representation of the submersible pumpset as per an embodiment herein. The numerals labeled with the figure of a submersible pump ESP (200) as per an embodiment herein and its associated controlling components mainly represent: (201) a centrifugal pump. The centrifugal pump may single stage or multi stage in the nature, (203) a magnetic rotor induction motor, (205) a housing of the submersible pump assembly, (207) a permanent water level required for placement of the pump, (209) well casing driven to depth necessary to reach below permanent water level, (211) a water intake screen, (213) a check valve/ball valve/switch valve which is operated by stepper motor (not described in figure), as per the input given by microcontroller to stepper motor(not described in figure), (215) a main switch and (217) a controller.

[0032] The microcontroller provides inputs signal to variable frequency drive (VFD), a dry run sensor, pressure sensor. Based on the signal received by microcontroller, the dry run sensor and pressure perform operation by providing the desired input to submersible pumpset and stepper motor. Over current protection is also provide in the controller 217. The pressure transducer (219) which is fit with the outlet pipe of submersible pump and sense the pressure of water flow in the pipe and send the pressure signal to the microcontroller and according to pressure signal, frequency supply to the magnetic rotor induction motor and input voltage to stepper motor is decided by microcontroller, (221) is a dry run sensor, which send the feedback signal to the microcontroller when water level is less than the required level in borewell to protect submersible pump in dry run condition.

[0033] In another embodiment, the submersible pumpset (200) is configured to be engaged with a controller (217). The controller (217) comprises at least one variable frequency drive (VFD) and a protection device. The protection device may comprises relay (not discloses in FIGURE). The motor of electrical submersible pumpset (200) is directly plugged with the controller (217). At programmable frequency or pre-set frequency, the controller maintains the speed. The controller is connected to the submersible pumpset, which receives 3 phase input. In one embodiment the range of voltage is 110 to 415 (-15%,+10%) voltage Controller thereafter converts the input current into direct current to run the drive, which in conversion provides alternate current supply output to the motor.

[0034] The motor used may be a water filled permanent magnet motor coupled to a centrifugal pump. The motor may be synchronous. The controller comprises a variable frequency drive and is configured to receive an electrical power input. The power input may be received from electrical grid or any other source such as for example solar panels. The input power is received at an input frequency and an input voltage. The variable frequency drive provides power output to the motor at an output frequency and output voltage depending on evaluation of operational conditions of said motor.

[0035] The operational condition of the motor may include the electric power input, input frequency, input voltage, water level of water being pumped and pressure level of output water. Depending on the level of input power characteristics the controller is configured to stabilize the power output to the motor. When the power input increases for example in case of solar panel as power source, during the noon time, the power output can also be increased dynamically by the controller. In doing so the controller may increase the frequency, the voltage or both.

[0036] In figure 3, the basic schematic view of the motor (300) showing components as per an embodiment herein such as motor shaft (301), NEMA couple connection (303), oil seal (Nitrile Rubber) (305), flat cable (3 core) (307), motor housing of 01 FG 200 (inner) (309), permanent magnet rotor (311), stator tube ISS 202 (313), synthetic plastic polymer Insulated winding wire insulation (315), loose segment thrust bearing (317), rubber diaphragm (319), and motor housing of CI FG 200 (outer) (321). Biaxially oriented polypropylene film coated insulation for the wiring may also be used. Here the permanent magnet rotor (311), as compared to Cage motor has advanced features, such as synchronous speed, no rotor copper loss, and higher comparative efficiency therein. Further, any changes in grid voltage and frequency are restrained from passing on the motor because the microcontroller keeps voltage and frequency fixed. Usually voltage changes in grid.

[0037] The motor uses water as a coolant. It comprises of a rotor including a permanent magnet and a stator around said rotor including wiring wound on it. The wiring may be synthetic plastic polymer coated. In one embodiment the wiring is PVC. In another embodiment BOPP insulated wiring may also be used. The use of PVC wiring and water coolant significantly increases the repairability of the motor thereby increasing the life and reducing the cost involved. Further, the motor may be synchronous with controller deciding the wave that is input to the motor.

[0038] While the subject matter may be susceptible to various modifications and alternative forms, specific embodiments have been shown by the way of figures/ examples in the drawings and have been described herein. Alternate embodiments or modifications may be practiced without departing from the spirit of the subject matter. The drawings shown are schematic drawings and may not be to the scale. While the drawings show some features of the subject, some features may be omitted. In some other cases, some features may be emphasized while other are not. Further, the methods disclosed herein may be performed in manner and/or order in which the methods are explained. Alternately, the methods may be performed in manner or order different than what is explained without departing from the spirit, meets and bounds of the present subject matter. It should be understood that the subject matter is not intended to be limited to the particular forms disclosed. Rather, the subject matter is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as described above.

,CLAIMS:3. CLAIMS

We claim: -

1. A water filled electric motor comprising:
a rotor including a permanent magnet;
a stator around said rotor including wiring, wherein the wiring is synthetic plastic polymer coated.

2. The water filled electric motor as in claim 1, wherein the synthetic plastic polymer is polyvinyl chloride.

3. The water filled motor as in claim 1, configured to provide synchronous change in the direction of magnetic field to the rotating magnetic field of the permanent magnet.

4. The water filled motor as in claim 1, further configured to be electrically coupled to a controller including a variable frequency drive for controlling the frequency of the rotor.

5. An electric submersible pump comprising:
a centrifugal pump;
a water filled permanent magnet motor coupled to the centrifugal pump;
a controller comprising a variable frequency drive, wherein
the controller is configured to receive an electrical power input at an input frequency and an input voltage and provide power output to said motor at an output frequency and output voltage depending on evaluation of operational conditions of said motor.

6. An electric submersible pump as in claim 5, further comprising a dry sensor for detecting the condition of water level being pumped going below predefined level wherein said controller is further configured to signal stalling of motor if the water level is below said predefined level.

7. An electric submersible pump as in claim 5, further comprising a pressure sensor for detecting the pressure of water output.

8. The electrical submersible pump as in claim 5, wherein the operational condition of the motor include the electric power input, input frequency, input voltage, water level of water being pumped and pressure level of output water.

9. The electrical submersible pump as in claim 5, wherein the motor is synchronous.

10. The electrical submersible pump as in claim 5, wherein said electrical power input is provided by electrical grid lines or solar panel.

11. The electrical submersible pump as in claim 10, wherein said controller is configured to change said output frequency and said output voltage depending on the time of the day.