Sand and particle separator for fluid pumping systems

#The present invention relates generally to devices for separating particles from fluid. More particularly, it relates to a separator for use with downhole well pumping systems.

#The presence of sand, silt, clay and other foreign particles in fluid, such as water pumped from deep wells, greatly accelerates pump wear. The pumps in wells are frequently located several hundred feet below the surface of the ground and in some instances even several thousand feet. Without a mechanism for separating the particulate matter from the fluid, the pump wears quickly and must be elevated periodically to the ground surface for replacement of worn parts. Pulling up a pump from such depths is both tedious and expensive. In order to avoid this, several systems have been designed to remove particulate material from the fluid prior to the fluid entering the pump.

#Often, the designs of the prior art systems have a separation chamber located at the bottom of the device. Through various mechanisms, particles are removed from the fluid. The fluid is drawn up to the top of the chamber, then into and through a pump that forces the fluid to the surface. The configuration of these systems requires that the pump shroud be large enough that the fluid being pumped can pass around the perimeter of the motor. Furthermore, the well hole must be drilled large enough in diameter that the water can flow around both the pump shroud and the separation chamber so that the fluid can easily reach the inlet to the separation chamber. Since the cost of drilling is directly related to the diameter of the hole being drilled, any increase in system diameter greatly increases the installation cost of the system.

#FIG. 1 shows a prior art sand separation system.

#FIG. 2 shows a cross section of a basic embodiment of the separation system of the present invention.

#FIG. 3 shows a cross section of a second embodiment of the separation system having a spin plate.

#FIG. 1 shows a prior art sand separation system 10. In this prior art system 10, the pump occupies the upper portion of the pump shroud 12 and the pump motor is located below the pump within the shroud 12. The separator unit 14 is located below the pump shroud 12. In this system, the fluid being draw up by the pump must pass around the periphery of the pump motor. Based on this configuration, the diameter of the hole must be large enough for the motor diameter, a flow channel for the cleaned water to pass around the outside of the motor and within the pump shroud 12, as well as have clearance around the pump shroud 12.

#FIG. 2 shows a cross section of a basic embodiment of the separation system 20 of the present invention taking the form of a single shroud 22 for the separation chamber 24 and pumping system 26. Fluid enters the separation chamber 24 through one or more inlet openings 28. The fluid begins to move in a circular path down the separation chamber 24. The rotation of the water tends to force any particulate material to the outside edge of the separation chamber 24. The particulate material continues to move down to a collection cone 30 in the base of the separation chamber 24. At the base of the cone 30 is a screw or auger 32, which draws the particulate material out of the separation chamber 24 and into the particle outlet chamber 34. The screw 32 must provide sufficient pull to draw down the particulate material against the upward forces created by the pump 26 and any frictional forces caused by the particulate material in the fluid. The particle outlet chamber 34 has one or more discharge openings 36 in the base to allow the material to exit the particle outlet chamber 34.

#The fluid remaining in the separation chamber 24 is now free of most of the particulate material. The fluid is drawn upward in the center of the separation chamber 24 and through the clear water passage 38 to the fluid outlet 39 by the pump 26. Located at the base of the shroud 22 is a motor 62, seen in FIGS. 3-5, with a drive shaft 40 extending upward. The drive shaft 40 may extend part way or through the entire length of the shroud 22. The drive shaft 40 may be used to drive many of the features of the separator system 20. For example, the auger or screw 32 is formed onto the perimeter of the drive shaft 40 or is attached thereto. The drive shaft 40 may also be used to drive the pump 26. Depending on the depth of the well and the amount and speed the fluid needs to exit the well, a single pump, a multi-stage pump, as seen in FIG. 5, or a series of serial pumps may be used to draw the water out of the well.