Baker Hughes Corporation

Hughes Tool Company LLC

Centrilift

John Michael Leuthen

Jerald Ray Rider

Dick Lee Knox

Tom G Yohanan

Brown Lyle Wilson

Sheldon Plitt

Bryan D Schulze

Jim E Layton

Robert Dan Allen

Fang Zheng Peng

James Edward Layton

Howard G Thompson

Renato L Pichilingue

Michael C Underwood

Kevin W Lockyear

Patrick B Cochran

Amin A Moghadas

Brian D Schulze

Jerald Rider

Systems and methods for controlling potentially damaging inrushes of current to the capacitor bank of an electric drive system when the voltage on the capacitor bank is low. In one embodiment, a variable speed drive has a converter that converts AC power to DC power, a capacitor bank that receives the DC power, and an inverter that converts the DC power stored by the capacitor bank to AC output power. The converter has three sections that rectify the phases of three-phase input power. Each section has at least one controlled rectifier component, and the rectifier components have switches connected to them in parallel. When the voltage on the capacitor bank is low, the controlled rectifiers and switches are controlled to prevent dangerously high inrushes of current to the capacitor bank.

Systems and methods for limiting current inrush in electric drive systems

A system for detecting a backspin condition of a motor in an electrical submersible pump is described herein. The system comprises a variable speed drive for powering the motor via a power cable; and a controller, the controller having a memory, a computer processor, and a computer program product stored on the memory and executable by the processor. The computer program product comprises the instructions of: monitoring an input current or impedance on the power cable to determine changes in motor current impedance, comparing changes in the motor current impedance to a historical threshold value for backspin events to determine whether the motor is backspinning; impeding operable power to the motor when it is determined the motor is backspinning; supplying a low AC voltage to the motor after it is determined the motor is backspinning; and determining whether or not the motor has stopped backspinning by monitoring the low AC voltage.

Device, computer program product and computer-implemented method for backspin detection in an electrical submersible pump assembly

An electrical submersible pumping (ESP) system can include a pump located in a wellbore, a motor attached to the pump, a power source located at the surface, a cable electrically coupling the power source and the motor, and a current sensor. The ESP system can also include a controller communicating with the current sensor to calculate a voltage drop associated with the cable responsive to an impedance of the cable. The controller can also control a power source output voltage responsive to the calculated voltage drop. For example, the controller can adjust the power source output voltage to minimize a cable current while maintaining a minimum motor voltage. The controller can also control a motor shaft speed by changing a power source output voltage frequency to compensate for changing slip and adjust the power source output voltage to minimize the cable current while maintaining a minimum motor voltage.

System, method and program product for cable loss compensation in an electrical submersible pump system

A device and method can detect, and also break, an occurrence of gas lock in an electrical submersible pump assembly in a well bore based upon surface or downhole data without the need for operator intervention. To detect an occurrence of gas lock, an instantaneous value is monitored using a sensor. Then a controller compares the instantaneous value to a threshold value over a predetermined duration to thereby detect the occurrence of gas lock in the electrical submersible pump assembly. Sensors can include, for example, a differential pressure gauge, a pressure gage located in a pump stage located toward the inlet, a fluid temperature sensor located toward the discharge, a free gas detector located near the pump discharge, an electrical resistivity gage, a flow meter located within surface production tubing, and a vibration sensor attached to a tubing string to measure a vibration signature.

Device and method for gas lock detection in an electrical submersible pump assembly

Systems and methods for providing electrical power and to downhole oil production equipment such as electrical submersible pumps, wherein the outputs of multiple power modules are individually filtered before being added together to obtain a high voltage output that is provided to the downhole equipment. In one embodiment, an electrical drive system includes multiple power modules and corresponding filters. Each of the power modules is configured to receive an input power signal and to provide a corresponding pulse width modulated or stepped intermediate signal. The signal output by each power module is individually filtered to remove at least a portion of high-frequency components in the signal. The power modules and filters are coupled together in a configuration in which the filtered signals of the power modules are added to produce an output drive signal that is used to drive equipment such as an electrical submersible pump.

System and method for adding voltages of power modules in variable frequency drives

Systems and methods for using variable speed drives to restart downhole submersible pump motors. In one embodiment, a downhole pump is controlled using a variable speed drive that includes a control system configured to detect interruptions in the operation of the pump system. After an interruption that requires the restart of the pump motor, the control system determines the reverse rotational speed of the pump motor and restarts the motor when this speed is sufficiently low. The control system may be configured to reduce the output voltage of the variable speed drive and sweep through a range of output frequencies to determine the frequency at which the current drawn by the motor is lowest. This is the frequency at which the drive's output matches the speed of the motor and the apparent impedance of the motor is highest. When the speed is low enough, the motor is restarted.

Systems and methods for reducing pump downtime by determining rotation speed using a variable speed drive

Systems and methods for reducing harmonic distortion in a power system resulting from non-linear loading on the power system. The power at an interface with a power source is measured, and then distortion in the waveforms of the supplied power is identified. Cancellation signals which cancel all or part of the distortion are then generated and injected at the interface. In one embodiment, the power is sampled to determine the waveform, and then a Fast Fourier Transform is performed on the waveform to convert it to the frequency domain. Harmonics of the fundamental frequency can then be identified, and conjugates of the harmonics generated. An inverse Fast Fourier Transform is performed on the conjugates to generate a signal which is amplified to produce the cancellation signal.

Systems and methods for reducing distortion in a power source using an active harmonics filter

A device, method, and program product detect and break an occurrence of gas lock in an electrical submersible pump assembly in a well bore based upon surface or downhole data without the need for operator intervention. The system provides the ability to flush the pump and return the system back to production without requiring system shutdown. In addition, the system provides an algorithm for controlling a pump operating speed of the electrical submersible pump assembly to maximize production from the well bore.

Device, method and program product to automatically detect and break gas locks in an ESP

Systems and methods for providing ride-through for interruptions in the power supplied to drives that are used to control equipment such as downhole submersible pumps. In one embodiment, a variable speed drive includes converter and inverter sections, a capacitor bank and a control system. The drive shuts down the converter section upon detecting a disruption in the AC input power and continues to generate output power by drawing on the energy stored in the capacitor bank. When the AC input power returns (or begins to return) to normal, the drive resumes operation of the converter section in a controlled manner (e.g., by presetting the firing angle of the SCR's in the converter to match the voltage across the capacitor bank.) The drive thereby limits the current that recharges the capacitor bank and prevents sudden inrushes of current that could damage the drive.

Systems and methods for power ride-through in variable speed drives

First and second networks of switching devices, each of which are an insulated gate bipolar transistor with an intrinsic reverse-biased clamping diode, are controlled to selectively connect a sinusoidal input voltage and an output to different nodes within a series of capacitors during different portions of input and output voltage cycles to produce a stepped sinusoidal output voltage. The topology requires a low part count, produces relatively low harmonics without filtering when powering artificial lift equipment within a borehole, and scales up to medium voltages without a step-up transformer. During variable speed operation of the lift equipment, optimized switching angles for controlling the switching devices during the voltage cycles may be selected based on modulation producing the desired speed and phase measurements.

Low harmonic diode clamped converter/inverter

A sine wave filter including an inductor for each phase (three inductors) and three delta- or Y-connected capacitors is employed within a borehole power system, coupled within a three phase power system at the surface between the output of a variable frequency drive and a three phase power cable transmitting power to a borehole location, and boosts the output voltage of the drive. The sine wave filter is designed to have a resonant frequency higher than the maximum operational frequency of the drive, and a Q such that, at the maximum operational frequency of the drive, the filter provides a voltage gain equal to the ratio of the desired voltage to the drive's maximum output power at the maximum operational frequency. The sine wave filter also smooths the voltage waveform of a pulse width modulated variable frequency drive.

Method for boosting the output voltage of a variable frequency drive

A variable speed controller is provided which utilizes a combination of pulse width modulation and fixed pulse control, such as a conventional six-step control, in order to generate multiphase sinusoidal power signals for use by downhole wellbore equipment, such as electrical submersible pumps. A controller is utilized to monitor at least one DC voltage level of the rectifier and/or inverter circuit of a variable speed controller. The DC level is compared to an optimum DC level. A triggering threshold is established. Once the triggering threshold is surpassed, the controller is utilized to switch between a conventional six-step mode of control and a pulse width modulation mode of control in order to better respond to a positive transient voltage condition. The pulse width modulation mode of operation provides for real time counteracting of the positive transient condition. Once the controller determines that the transient condition has subsided, control is returned to the conventional six-step control mode of operation.

Method and apparatus for pulse width modulation of a power supply for

A method and circuit for detecting rapid increase in line voltages applied to variable speed drives utilizing a phase controlled converter. A three phase alternating current line voltage is applied to a full wave bridge rectifier to generate a direct current signal. A buffer amplifier having a high input impedance is coupled to the output of the rectifier and a diode is utilized to ensure that only positive voltage transients are detected. Positive voltage transients output through the buffer amplifier rapidly charge a capacitor through the low output impedance of the buffer amplifier and that charge is permitted to bleed off slowly through an associated resistor. The rate of change of the capacitor charge level is compared to a preset voltage level and increases beyond that preset level are utilized to trigger an inhibit signal which momentarily resets the delay angle of the switching devices within the phase controlled converter. In this manner, a rapid increase in the average slope of the input line voltage, whether or not preceded by a decrease, may be detected and removed from the input of a variable speed drive.

Protection circuit and method for variable speed drives utilizing phase

A protection circuit for a power transistor cuts off the transistor if an overcurrent condition occurs. The protection circuit includes control transistors that are switched on and off to alternately supply positive voltage to the base of the power transistor to turn it on and negative voltage to turn it off. A control circuit provides signals to the control transistors to turn them on and off. A latch has an input connected across the collector and emitter of the power transistor for monitoring the voltage. If the voltage exceeds a threshold level at the latch, the latch will provide a disabling output to the control circuit to turn off the power transistor.

Overcurrent protection circuit for power transistors

An SCR firing circuit allows the firing point to be changed. The firing circuit includes a ROM which has an output for each gate of each SCR. The ROM is programmed to fire the SCRs in a desired sequence. The ROM is driven by a counter, which counts pulses from an oscillator, the frequency of which is variable. The difference between the zero cross of the waveform and the ROM output is compared and averaged. The comparator output is summed with a variable DC demand voltage. The sum is applied to an integrator, which provides an integrated output to the oscillator to change the frequency of the oscillator if the firing point is changed.

Growing community of inventors

Claremore, OK, United States of America

John Michael Leuthen