Downhole power generation system and method

Patent metadata

Field	Value
Publication number	US-11555380-B2
Application number	US-201816608030-A
Country	US
Kind code	B2
Filing date	Apr 24, 2018
Priority date	Apr 24, 2017
Publication date	Jan 17, 2023
Grant date	Jan 17, 2023

Abstract

A downhole power generation includes a power generation module for providing power to a load. A turbine is driven by flow of a downhole fluid to rotate. A generator is coupled with the turbine for converting rotational energy from the turbine to electrical energy, and an AC-DC rectifier is coupled with the generator for converting an alternating voltage from the generator to a direct voltage. A power conversion circuit couples the AC-DC rectifier with the load. The power conversion circuit is configured for providing a first power to the load when the load is in a working mode and providing a second power to the load when the load is in a non-working mode. The second power is less than the first power. A downhole power generation method is also disclosed.

First claim

What is claimed is:

1. A downhole power generation system, comprising:
a power generation module for providing power to a load, comprising:
a turbine driven by flow of a downhole fluid to rotate,
a generator coupled with the turbine for converting rotational energy from the turbine to electrical energy, and
an AC-DC rectifier coupled with the generator for converting an alternating voltage from the generator to a direct voltage; and

a power conversion circuit coupling the AC-DC rectifier with the load, the power conversion circuit including a first DC-DC converter coupled to the load by a first electrical connection and providing a first power to the load when the load is in a working mode and a second DC-DC converter coupled to the load by a second electrical connection and providing a second power to the load when the load is in a non-working mode, the second power being less than the first power.

2. The downhole power generation system of claim 1 , further comprising:
a power converter controller communicatively coupled with the first DC-DC converter and the second DC-DC converter respectively and configured for respectively controlling the first DC-DC converter and the second DC-DC converter to switch between the working mode and the non-working mode.

3. The downhole power generation system of claim 1 , wherein the power generation module comprises:
a boost circuit coupling the AC-DC rectifier with at least one of the first DC-DC converter and the second DC-DC converter.

4. The downhole power generation system of claim 3 , wherein the boost circuit comprises:
a first step-up converter for increasing the direct voltage from the AC-DC rectifier;
a second step-up converter for further increasing the increased direct voltage from the first step-up converter; and
a capacitor coupled between the first step-up converter and the second step-up converter for power buffer.

5. The downhole power generation system of claim 3 , further comprising: a power storage device between the boost circuit and at least one of the first DC-DC converter and the second DC-DC converter.

6. The downhole power generation system of claim 5 , wherein the power storage device is a capacitor.

7. The downhole power generation system of claim 3 , further comprising:
an energy storage device coupled between the boost circuit and at least one of the first DC-DC converter and the second DC-DC converter via a step-up converter.

8. The downhole power generation system of claim 1 , wherein the downhole power generation system comprises a plurality of power generation modules, the power conversion circuit couples the AC-DC rectifier in each power generation module with the load, and the plurality of turbines in the plurality of power generation modules are so positioned physically that one or more of the turbines is exposed to the downhole fluid and the flow of the downhole fluid drives the one or more of the turbines to rotate.

9. The downhole power generation system of claim 8 , wherein rotational speeds of the one or more of the turbines and the direct voltages generated from the plurality of power generation modules depend on the e physical positions of respective turbines of the one or more of the turbines.

10. The downhole power generation system of claim 8 , wherein the downhole fluid flows within a casing, and the plurality of turbines are spacedly arranged at an inner circumferential wall of the casing or deployed closer to the center of the casing.

11. The downhole power generation system of claim 8 , further comprising: a power storage device between each of the power generation modules and at least one of the first DC-DC converter and the second DC-DC converter.

12. The downhole power generation system of claim 8 , further comprising: energy storage device coupled between each of the power generation modules and at least one of the first DC-DC converter and the second DC converter via a step-up converter.

13. The downhole power generation system of claim 12 , wherein the energy storage device is a battery.

14. The downhole power generation system of claim 1 , wherein the load is a sensor.

15. A downhole power generation method, comprising: driving one or more turbines, by flow of a downhole fluid, to rotate;
converting one or more rotational energies from the one or more turbines, by one or more generators, to one or more electrical energies respectively;
converting one or more alternating voltages from the one or more generators, by one or more AC-DC rectifiers, to one or more direct voltages respectively;
converting the one or more direct voltages, by controlling a first DC-DC converter connected to a load by at least a first electrical connection, to a first power and providing the first power to the load when the load is in a working mode; and
converting the one or more direct voltages, by controlling a second DC-DC converter connected to the load by at least a second electrical connection, to a second power and providing the second power to the load when the load is in a non-working mode, wherein the second power is less than the first power.

16. The downhole power generation method of claim 15 , further comprising:
increasing the one or more direct voltages, by one or more boost circuits, to obtain one or more increased direct voltages, wherein the first DC-DC converter converts the one or more increased direct voltages to the first power and the second DC-DC converter converts the one or more increased direct voltages to the second power.

17. The downhole power generation method of claim 15 , further comprising:
providing additional power to the load when the one or more electrical energies generated from the one or more turbines is not enough for the load.

18. The downhole power generation method of claim 15 , further comprising: storing one or more excessive electrical energies generated from the one or more turbines in an energy storage device when the one or more electrical energies generated from the one or more turbines is excessive for the load.

Assignees

• Gen Electric
• Baker Hughes A Ge Co Llc

Inventors

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

Classifications

• H02M7/00

  Conversion of AC power input into DC power output; Conversion of DC power input into AC power output · CPC title

• F03B13/02

  Adaptations for drilling wells · CPC title

• E21B41/0085 Primary

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

• H02K11/049

  Rectifiers associated with stationary parts, e.g. stator cores · CPC title

• H02J1/082

  DC supplies with two or more different DC voltage levels · CPC title