COLUMN PIPE SYSTEM

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application claims priority to U.S. Provisional Patent Application No. 63/730,578 filed on Dec. 11, 2024, entitled “Column Pipe System,” the contents of which are incorporated herein by reference.

BACKGROUND

Field of the Art

The present invention is related to the field of submersible water well pump applications. In particular, the present invention is related to column pipes for use in submersible water well pump applications.

Discussion of the State of the Art

In the water well industry, submersible pumps are commonly used to pump water from varying depths in a well to the surface. These pumps are typically connected to a long pipe, known as a column pipe, which extends from the top of the well to a depth where the pump is located. Water wells have varying depths, and the length of the column pipe depends on the depth of the well. The column pipe serves to hold the weight of the pump and motor, as well as to contain the water being pumped to the surface under pressure. As such, the materials used for the column pipes must be able to support the weight of the pump and motor and withstand the pressures needed to pump the water to the surface.

One of the main problems with traditional column pipes is that they are difficult to adjust in length. If the depth of the pump set changes or if a check valve needs to be set at a different depth, the column pipe must be taken to a machine shop, cut, and rethreaded. This process is time-consuming and costly, and it requires a specialized machine shop and skilled labor.

Traditionally, column pipes in water well applications have been made of steel, stainless steel, or heavy PVC. However, these materials have limitations, particularly in caustic water environments containing high levels of iron bacteria, calcium, magnesium, manganese, and chlorides. These harsh conditions can lead to corrosion and deterioration of the column pipe over time, compromising its structural integrity and leading to premature failure.

Another problem with traditional materials used in water well applications is cost. While stainless steel can be used in high iron bacteria and caustic water conditions, it is extremely expensive compared to other pipe materials and does not resist the build up of iron bacteria.

Previous attempts to solve the problem of depth settings have included sending the column pipe to a machine shop to shorten the threaded joints. However, this solution is still difficult, expensive, and time-consuming.

Another solution has been to use flexible hoses or tubing to connect the pump to the surface. However, the main issue with this style of column pipe is that there is no viable way to add check valves where needed. Further, these materials are not suitable for deep well applications, as they are not strong enough to withstand the high pressures and stresses involved. Additionally, they are prone to kinking and damage, which can lead to leaks and failures.

In the municipal water industry, high-density polyethylene (HDPE) pipes transport water in long, continual, horizontal pipelines known to be corrosion resistant. However, using such long, continual lengths of HDPE pipe in a vertical orientation as a column pipe in a water well application has not been successful because they are difficult to transport and install and because there is no way to install check valves where needed. Further, HDPE has not been used in the water well industry because the fittings that are typically used with HDPE pipelines are not able to withstand the weights and pressures associated with column pipes in the water well industry.

SUMMARY

A column pipe system for use in submersible water well pump applications in accordance with the present invention includes a plurality of pipe sections, each having a length of between 10 and 35 feet, with a typical length of 25 feet. The pipe sections are made of high-density polyethylene (HDPE) and, in particular, may be made of DR9 HDPE or DR7 HDPE. The HDPE pipe sections are strong and durable, able to withstand the high pressures and stresses associated with deep well applications.

The pipe sections are connected using transition fittings and coupling members, which allow the pipe to be easily lengthened or shortened in the field without requiring specialized shops or skilled machinists. The transition fittings comprise three main components: an insert, a HDPE pipe section, and an outer threaded portion. These components are compressed together to form a secure, leak-proof connection between the pipe section and the fitting. The transition fittings may be category 3 transition fittings. The use of category 3 transition fittings makes the column pipe system capable of handling the weight and pressure requirements of the submersible water well pump. The transition fitting may include stainless steel or carbon steel for the insert and the outer threaded portion. For example, stainless steel transition fittings may be used in caustic water environments containing high levels of chlorides or iron bacteria. Carbon steel transition fittings may be used in less caustic water environments where iron bacteria levels are not sufficient to adhere to the fittings or compromise the integrity of the carbon steel.

The use of shorter pipe sections and transition fittings allows the column pipe to be easily adjusted in length to accommodate changes in check valve depth or pump position in the field. This eliminates the need to take the pipe to a machine shop for cutting and rethreading, saving time and money.

The pipe sections are connected to the transition fittings using a heat fusion process, which creates a seamless, permanent bond that is secure, leak-proof, and resistant to failure. The resulting column pipe assembly is designed to be used in a vertical orientation, extending from the top of the well to the top of the submersible pump and motor. The heat fusion bonding process ensures a strong and reliable connection between the transition fittings and the HDPE pipe sections, allowing the column pipe to support the weight of the pump and motor while also containing the water being pumped to the surface under pressure.

In one example, the invention is a column pipe system for use in submersible water well pump applications. The system includes a pipe section made of a first material and having a first end and a second end; a first transition fitting coupled to the first end of the pipe section; and a second transition fitting coupled to the second end of the pipe section. The first transition fitting and the second transition fitting each comprise an external threaded section made of a second material that is different from the first material. The first material may be high-density polyethylene (HDPE) (e.g., DR9 HDPE or DR7 HDPE), and the second material may be steel (e.g., stainless steel or carbon steel). The column pipe system may further include a pipe coupling having internal threads and/or a check valve having internal threads. The pipe coupling and/or check valve may be threadedly attached to the external threaded section of the first transition fitting or the second transition fitting. The first transition fitting and the second transition fitting may be category 3 transition fittings. The first transition fitting and the second transition fitting may be fusion-bonded to the first end and the second end of the pipe section, respectively. The pipe section may have a length that is less than 35 feet.

In another example, the invention is a column pipe system for use in submersible water well pump applications. The system includes a plurality of pipe sections coupled together to form an elongated discharge pipe having a vertical orientation. Each one of the pipe sections is made of a first material and has a first end and a second end. The system further includes a respective plurality of first end transition fittings. Each one of the first end transition fittings is fixedly coupled to the first end of a respective one of the pipe sections. The system further includes a respective plurality of second end transition fittings. Each one of the second end transition fittings is fixedly coupled to the second end of a respective one of the pipe sections. Each one of the first end transition fittings and each one of the second end transition fittings has an external threaded portion made of a second material that is different from the first material. The first material may be HDPE (e.g., DR9 HDPE or DR7 HDPE) and the second material may be steel (e.g., stainless steel or carbon steel). The system further includes a respective plurality of coupling members. Each one of the coupling members is coupled to one of the first end transition fittings and one of the second end transition fittings. The respective plurality of coupling members may include a plurality of pipe couplings and at least one check valve.

In yet another example, the invention is a column pipe system for use in submersible water well pump applications. The system includes a first pipe section made of a first material and having a first proximal end and a first distal end; a second pipe section made of the first material and having a second proximal end and a second distal end; a first transition fitting fixedly coupled to the first distal end; and a second transition fitting fixedly coupled to the second proximal end. The first transition fitting may be fixedly coupled to the first distal end by fusion bonding, and the second transition fitting may be fixedly coupled to the second proximal end by fusion bonding. The first transition fitting and the second transition fitting each have an external threaded portion made of a second material that is different from the first material. The first transition fitting and the second transition fitting may each include an insert made of the second material, and a center section made of the first material, where the center section may be sandwiched between the insert and the external threaded portion. The first material may be HDPE and the second material may be steel. The system may further include a pipe coupling having internal threads. The pipe coupling may be threadedly attached to the first transition fitting and the second transition fitting. The column pipe system may further include a check valve having internal threads. The check valve may be threadedly attached to the first transition fitting and the second transition fitting. The first pipe section, the first transition fitting, the second transition fitting, and the second pipe section may be arranged in order in a vertical configuration.

Overall, the column pipe system of the present invention provides a simple, reliable, and cost-effective solution to the problems associated with traditional column pipes used in the water well industry. Unlike threaded couplings, which require the pipe to be cut and threaded in the field, the transition fittings allow the pipe to be easily adjusted in length without specialized equipment or skilled labor. Additionally, the heat fusion process creates a stronger, more reliable connection than threaded couplings, which can be prone to leaks and failures.

The column pipe system of the present invention addresses the limitations of traditional column pipe materials, such as steel and heavy PVC, which are susceptible to corrosion and deterioration in caustic water environments containing high levels of iron bacteria, calcium, magnesium, manganese, and chlorides. By utilizing DR9 or DR7 HDPE pipe in combination with category 3 transition fittings, the present invention provides a solution that can withstand these harsh conditions without compromising the structural integrity of the column pipe.

In summary, the column pipe system of the present invention provides an improved column pipe system for submersible water well pump applications that addresses the shortcomings of traditional materials. By combining the corrosion resistance of DR9 or DR7 HDPE pipe with the strength and durability of category 3 transition fittings, the column pipe system offers a solution that can withstand the harsh conditions found in caustic water environments, is more affordable, and can tolerate the weights and pressures found in submersible water well pump applications, thereby extending the life of the column pipe and reducing the need for costly repairs or replacements.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate several embodiments and, together with the description, serve to explain the principles of the invention according to the embodiments. It will be appreciated by one skilled in the art that the particular arrangements illustrated in the drawings are merely exemplary and are not to be considered as limiting of the scope of the invention or the claims herein in any way.

FIG. 1 is a diagram of a submersible water well system that includes a column pipe, in accordance with an embodiment of the present invention.

FIG. 2 is a front view of a section of pipe having transition fittings coupled to both ends, in accordance with an embodiment of the present invention.

FIGS. 3A-3D are front elevation, first end perspective, end elevation, and second end perspective views, respectively, of a transition fitting for use in a column pipe system, in accordance with an embodiment of the present invention.

FIGS. 4A and 4B are exploded views of pipe sections coupled together using a pipe coupling or a check valve, respectively, in accordance with an embodiment of the present invention.

FIG. 5 is a close up view of the connection between two pipe sections, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

The present invention is a column pipe system for use in submersible water well pump applications that includes a plurality of pipe sections with each pipe section having transition fittings attached to both ends thereof. The pipe sections may be made of HDPE and the transition fittings may be category 3 transition fittings. The transition fittings are coupled to both ends of the pipe sections by butt fusion. Each one of the pipe sections may have a length that is less than 35 feet.

The invention is described by reference to various elements herein. It should be noted, however, that although the various elements of the inventive apparatus are described separately below, the elements need not necessarily be separate. The various embodiments may be interconnected and may be cut out of a singular block or mold. The variety of different ways of forming an inventive apparatus, in accordance with the disclosure herein, may be varied without departing from the scope of the invention.

One or more different embodiments may be described in the present application. Further, for one or more of the embodiments described herein, numerous alternative arrangements may be described; it should be appreciated that these are presented for illustrative purposes only and are not limiting of the embodiments contained herein or the claims presented herein in any way. One or more of the arrangements may be widely applicable to numerous embodiments, as may be readily apparent from the disclosure. In general, arrangements are described in sufficient detail to enable those skilled in the art to practice one or more of the embodiments, and it should be appreciated that other arrangements may be utilized and that structural, logical, software, electrical and other changes may be made without departing from the scope of the embodiments. Particular features of one or more of the embodiments described herein may be described with reference to one or more particular embodiments or figures that form a part of the present disclosure, and in which are shown, by way of illustration, specific arrangements of one or more of the aspects. It should be appreciated, however, that such features are not limited to usage in the one or more particular embodiments or figures with reference to which they are described. The present disclosure is neither a literal description of all arrangements of one or more of the embodiments nor a listing of features of one or more of the embodiments that must be present in all arrangements.

Headings of sections provided in this patent application and the title of this patent application are for convenience only and are not to be taken as limiting the disclosure in any way.

Devices that are in communication with each other need not be in continuous communication with each other, unless expressly specified otherwise. In addition, devices that are in communication with each other may communicate directly or indirectly through one or more communication means or intermediaries, logical or physical.

A description of an aspect with several components in communication with each other does not imply that all such components are required. To the contrary, a variety of optional components may be described to illustrate a wide variety of possible embodiments and in order to more fully illustrate one or more embodiments. Similarly, although process steps, method steps, algorithms or the like may be described in a sequential order, such processes, methods and algorithms may generally be configured to work in alternate orders, unless specifically stated to the contrary. In other words, any sequence or order of steps that may be described in this patent application does not, in and of itself, indicate a requirement that the steps be performed in that order. The steps of described processes may be performed in any order practical. Further, some steps may be performed simultaneously despite being described or implied as occurring non-simultaneously (e.g., because one step is described after the other step). Moreover, the illustration of a process by its depiction in a drawing does not imply that the illustrated process is exclusive of other variations and modifications thereto, does not imply that the illustrated process or any of its steps are necessary to one or more of the embodiments, and does not imply that the illustrated process is preferred. Also, steps are generally described once per aspect, but this does not mean they must occur once, or that they may only occur once each time a process, method, or algorithm is carried out or executed. Some steps may be omitted in some embodiments or some occurrences, or some steps may be executed more than once in a given aspect or occurrence.

When a single device or article is described herein, it will be readily apparent that more than one device or article may be used in place of a single device or article. Similarly, where more than one device or article is described herein, it will be readily apparent that a single device or article may be used in place of the more than one device or article.

The functionality or the features of a device may be alternatively embodied by one or more other devices that are not explicitly described as having such functionality or features. Thus, other embodiments need not include the device itself.

Techniques and mechanisms described or referenced herein will sometimes be described in singular form for clarity. However, it should be appreciated that particular embodiments may include multiple iterations of a technique or multiple instantiations of a mechanism unless noted otherwise. Process descriptions or blocks in figures should be understood as representing modules, segments, or portions of code which include one or more executable instructions for implementing specific logical functions or steps in the process. Alternate implementations are included within the scope of various embodiments in which, for example, functions may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those having ordinary skill in the art.

The detailed description set forth herein in connection with the appended drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts described herein may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of various concepts. However, it will be apparent to those skilled in the art that these concepts may be practiced without these specific details. In some instances, well known structures and components are shown in block diagram form in order to avoid obscuring such concepts.

Apparatus

The column pipe system of the present invention includes a plurality of pipe sections coupled together using transition fittings and coupling members. The coupling members may be pipe couplings or check valves. The pipe sections are made of a first material and the transition fittings have external threaded portions made of a second material. For example, the pipe sections may be made of HDPE, and specifically, may be made of DR9 HDPE or DR7 HDPE. The transition fittings are category 3 transition fittings. Transition fittings are fixedly coupled to each end of the pipe sections. For example, the transition fittings may be coupled to both ends of a pipe section using butt fusion.

As shown in FIG. 1, a submersible water well pump system 100 includes a motor 102, a pump intake 104, pump bowls 106, a column pipe 108, a power cable 110, and a check valve 112. Depending on the depth of the well, the total length of the column pipe 108 may be up to 1000 feet, and the column pipe length may be customized to extend between the pump and the ground surface. The column pipe 108 in accordance with the present invention includes a plurality of pipe sections with transition fittings coupled to either end of the pipe sections and coupling members used to attach adjacent sections of pipe together. Each one of the pipe sections in the column pipe may have a length that is less than 35 feet so that the total length of the column pipe can easily be adjusted and customized. For example, each pipe section may be between 10 and 35 feet, or between 15 and 30 feet.

FIG. 2 depicts one section of pipe 202. The pipe section 202 is made of a first material. For example, the pipe section 202 may be made of HDPE and, more specifically, may be made of DR9 HDPE or DR7 HDPE. The pipe section 202 may be between 10 and 35 feet long and may have an outer diameter between 2 and 12 inches. The section of pipe 202 has a distal end 204 and a proximal end 206. A first transition fitting 208 is coupled to the distal end 204 of the pipe 202 and a second transition fitting 210 is coupled to the proximal end 206 of the pipe 202. The transition fittings 208, 210 are coupled to the pipe using any known attachment procedure, such as HDPE welding or butt fusion.

The transition fittings 208, 210 may be category 3 transition fittings. Category 3 transition fittings ensure that the column pipe system is capable of handling the weight and pressure requirements of the submersible water well pump. The transition fittings 208, 210 include external threaded portions 212 that are made of a second material that is different from the first material that comprises the pipe section 202. The external threaded portion 212 may be made of steel, such as stainless steel or carbon steel. Stainless steel transition fittings may be used in caustic water environments containing high levels of chlorides or iron bacteria. Carbon steel transition fittings may be used in water environments where iron bacteria levels are not sufficient to adhere to the fittings or compromise the integrity of the carbon steel.

FIGS. 3A-3D illustrate a transition fitting 302 that may be used in the column pipe system of the present invention. The transition fitting 302 includes an insert 304, a center pipe section 306, and an outer threaded portion 308. These components 304, 306, 308 are compressed together to form a secure, leak-proof connection between the pipe sections. The center pipe section 306 may be made of the same material as the pipe section 202 and the outer diameter of the center pipe section 306 is approximately equal to the outer diameter of the pipe section 202. The insert 304 and the outer threaded portion 308 of the transition fitting 302 may be made of a second material that is different from the first material that comprises the center pipe section 306. For example, the insert 304 and the outer threaded portion 308 may be made of steel, such as stainless steel or carbon steel.

Sections of pipe 202 with transition fittings 208, 210 attached to either end are coupled together using a coupling member having internal threads. The internal threads of the coupling member are threadedly attached to the external threaded portion 212 of the transition fittings 208, 210. The coupling member may be a pipe coupling or a check valve. As shown in FIG. 4A, two sections of pipe 202 having transition fittings 208, 210 attached to adjacent ends are attached together by screwing the outer threaded portion 212 of each transition fitting 208, 210 into a pipe coupling 402. Similarly, as illustrated in FIG. 4B, two sections of pipe 202 having transition fittings 208, 210 attached to adjacent ends are attached together by screwing the outer threaded portion 212 of each transition fitting 208, 210 into a check valve 404. One of the advantages of the column pipe system in accordance with the present invention is that check valves are easily installed at desired locations along the column pipe.

FIG. 5 depicts a portion of the column pipe in the assembled state. A first pipe section 202 having a transition fitting 208 attached to its distal end is coupled to a second pipe section 202 having a transition fitting 210 attached to its proximal end by using a pipe coupling 402. The pipe coupling 402 includes internal threads that are configured to screw onto the external threads 212 on the transition fittings 208, 210.

Additional Considerations

As used herein any reference to “one embodiment” or “an embodiment” means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

Some embodiments may be described using the expression “coupled” and “connected” along with their derivatives. For example, some embodiments may be described using the term “coupled” to indicate that two or more elements are in direct physical or electrical contact. The term “coupled,” however, may also mean that two or more elements are not in direct contact with each other, but yet still co-operate or interact with each other. The embodiments are not limited in this context.

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present) , and both A and B are true (or present).

In addition, use of the “a” or “an” are employed to describe elements and components of the embodiments herein. This is done merely for convenience and to give a general sense of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

Upon reading this disclosure, those of skill in the art will appreciate still additional alternative structural and functional designs for a system and/or a process associated with the disclosed principles herein. Thus, while particular embodiments and applications have been illustrated and described, it is to be understood that the disclosed embodiments are not limited to the precise construction and components disclosed herein. Various apparent modifications, changes and variations may be made in the arrangement, operation and details of the method and apparatus disclosed herein without departing from the spirit and scope defined in the appended claims.