Downhole power generation system and optimized power control method thereof

Patent metadata

Field	Value
Publication number	US-11454094-B2
Application number	US-201816608009-A
Country	US
Kind code	B2
Filing date	Apr 24, 2018
Priority date	Apr 24, 2017
Publication date	Sep 27, 2022
Grant date	Sep 27, 2022

Abstract

A downhole power generation system is disclosed, which includes a turbine generator system. The turbine generator system includes a turbine, a generator coupled with the turbine and having an AC-DC rectifier, and an optimized power control unit. The turbine is driven by flow of a downhole fluid to rotate. The generator converts rotational energy from the turbine to electrical energy and outputting a direct current voltage. The turbine generator system is coupled to a load via the optimized power control unit. The optimized power control unit controls to regulate an output voltage of the generator and provides a regulated output voltage to the load so that the turbine generator system has an optimized power output. An optimized power control method for a downhole power generation system is also disclosed.

First claim

What is claimed is:

1. A downhole power generation system, comprising:
a turbine generator system comprising:
a turbine driven by a flow of a downhole fluid to rotate;
a generator coupled with the turbine and having an AC-DC rectifier, wherein the generator is configured for converting rotational energy from the turbine to electrical energy and outputting a direct current voltage; and
an optimized power control unit via which the turbine generator system is coupled to a load, wherein the optimized power control unit includes a switch configured to disconnect the generator from the load, a voltage measuring device configured to measure a first voltage of the generator when the generator is connected to the load and measure a second voltage of the generator when the generator is disconnected from the load, and a voltage regulator configured to regulate an output voltage of the generator based on the first measured voltage and the second measured voltage to provide a regulated output voltage to the load so that the turbine generator system has an optimized power output.

2. The downhole power generation system of claim 1 , wherein the optimized power output targets on a maximum power output or a maximum system efficiency of the turbine generator system.

3. The downhole power generation system of claim 1 , wherein the downhole power generation system comprises a plurality of turbine generator systems comprising a plurality of turbines, a plurality of generators and a plurality of optimized power control units, and the plurality of turbines in the plurality of turbine generator systems are so positioned physically that one or more of the plurality of turbines is exposed to the downhole fluid.

4. The downhole power generation system of claim 3 , wherein rotational speeds of the plurality of turbines and amounts of power generated from the plurality of turbine generator systems depend on physical positions of the plurality of turbines.

5. The downhole power generation system of claim 1 , wherein the switch is configured to repeatedly disconnect the generator from the load, the voltage measuring device is configured to repeatedly measure the first voltage of the generator when the generator is connected to the load and repeatedly measure the second voltage of the generator when the generator is disconnected from the load, and the voltage regulator is configured to regulate the output voltage of the generator based on the repeated measurement of the first voltage and the second voltage.

6. A downhole power generation system comprising:
a turbine generator system comprising:
a turbine driven by a flow of a downhole fluid to rotate;
a generator coupled with the turbine and having an AC-DC rectifier, wherein the generator is configured for converting rotational energy from the turbine to electrical energy and outputting a direct current voltage; and
an optimized power control unit via which the turbine generator system is coupled to a load, wherein the optimized power control unit is configured for controlling to regulate an output voltage of the generator and providing a regulated output voltage to the load so that the turbine generator system has an optimized power output, wherein the optimized power control unit is configured for measuring a first voltage of the generator when the generator is connected to the load, disconnecting the generator from the load and measuring a second voltage of the generator after disconnection, and reconnecting the generator with the load and regulating the output voltage of the generator based on the first measured voltage and the second measured voltage for optimized power control.

7. The downhole power generation system of claim 6 , wherein the measured second voltage includes an open circuit voltage of the generator, the open circuit voltage of the generator being defined as a constant no load voltage of the generator after the disconnection.

8. The downhole power generation system of claim 6 , wherein the measured second voltage includes a cutoff voltage of the generator, the optimized power control unit configured for measuring the measured cutoff voltage after a predetermined cutoff time.

9. The downhole power generation system of claim 8 , wherein the optimized power control unit is configured for repeating the steps of disconnecting, measuring the measured cutoff voltage, reconnecting and regulating until the measured cutoff voltage of the generator approaches a constant value.

10. The downhole power generation system of claim 8 , wherein the optimized power control unit is configured for regulating the output voltage so that the output voltage is constant for different flow rates of the downhole fluid.

11. The downhole power generation system of claim 6 , wherein the optimized power control unit is configured for regulating the output voltage so that the output voltage is constant for different flow rates of the downhole fluid.

12. An optimized power control method for a downhole power generation system, wherein the downhole power generation system comprises one or more turbine generator systems each comprising a turbine, and a generator coupled with the turbine and having an AC-DC rectifier, the optimized power control method comprising:
harvesting hydro energy from a flow of a downhole fluid via the one or more turbines in the one or more turbine generator systems;
converting one or more rotational energies from the one or more turbines, by the one or more generators in the one or more turbine generator systems, to one or more electrical energies and outputting one or more direct current voltages;
controlling to regulate an output voltage of each of the one or more generators, wherein the controlling includes:
measuring a first voltage of each of the one or more generators by a voltage measuring device when the one or more generators are connected to one or more loads;
disconnecting the one or more generators from the one or more loads, measuring a second voltage of each of the one or more generators after disconnection, and reconnecting the one or more generators with the one or more loads; and
regulating the output voltage of each of the one or more generators by a voltage regulator based on the measured first voltage and the measured second voltage; and

providing the regulated output voltage of each of the one or more generators to the loads so that each of the one or more turbine generator systems has an optimized power output.

13. The optimized power control method of claim 12 , further comprising repeating the steps of measuring the first voltage, disconnecting the one or more generators, measuring the second voltage, and reconnecting the one or more generators, wherein regulating the output voltage by the voltage regulator is based on the repeated measurement of the first voltage and the second voltage.

14. An optimized power control method for a downhole power generation system, wherein the downhole power generation system comprises a turbine generator systems comprising a turbine, and a generator coupled with the turbine and having an AC-DC rectifier, the optimized power control method comprising:
controlling to regulate an output voltage of the generator, the generator configured to convert rotational energy from the turbine, the turbine driven by a flow of a downhole fluid; and
providing a regulated output voltage of the generator to a load so that the turbine generator system has an optimized power output, wherein controlling to regulate the output voltage of the generator comprises:
measuring a first voltage of the generator when the generator is connected to the load;
disconnecting

Assignees

• Gen Electric
• Baker Hughes A Ge Co Llc

Inventors

• Chen Yunzheng
• Liao Yi
• Mao Saijun
• Xue Ming
• Brazil Stewart Blake
• Qi Xuele

Classifications

• F05B2270/20

  to optimise the performance of a machine · CPC title

• F05B2220/7062

  of the direct current (D.C.) type · CPC title

• F03B13/02 Primary

  Adaptations for drilling wells · CPC title

• E21B41/0085 Primary

  Adaptations of electric power generating means for use in boreholes · CPC title

• F03B13/00 Primary

  Adaptations of machines or engines for special use; Combinations of machines or engines with driving or driven apparatus (if the apparatus aspects are predominant, see the relevant subclasses for such apparatus, e.g. H02K7/18); Power stations or aggregates (incorporating only machines or engines of positive-displacement type F03C; hydraulic engineering aspects E02B; {combinations with wind energy converters F03D9/008}) · CPC title