Abstract:
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.

Description:
TECHNICAL FIELD OF THE INVENTION  
         [0001]    The present invention is directed, in general, to borehole production power systems and, more specifically, to low harmonic borehole production power systems allowing variable speed operation of artificial lift equipment.  
         BACKGROUND OF THE INVENTION  
         [0002]    In borehole production systems that employ artificial lift equipment such as electrical submersible pumps (ESPs), variable speed operation is typically achieved by either quasi-sine wave “six-step” modulation, which produces fifth and seventh harmonics of significant magnitude, or pulse width modulated (PWM) drives, in which sinusoidal load currents are produced by varying the “width” or duration of high frequency square waves in order to vary the operating speed of a motor coupled to the drive via a power cable and, optionally, a step-up transformer.  
           [0003]    However, pulse width modulation often produces ringing or resonance in the transmitted power, resulting in extremely high peak voltages that may, over time, degrade or destroy the power cable insulation, cause vibration damage to the pump, or cause other undesirable side effects. Sine wave filters used to smooth the pulse width modulated output are expensive and complex.  
           [0004]    There is, therefore, a need in the art for improved system of powering artificial lift equipment within a borehole in a manner allowing variable speed operation.  
         SUMMARY OF THE INVENTION  
         [0005]    To address the above-discussed deficiencies of the prior art, it is a primary object of the present invention to provide, for use in a borehole production system, first and second networks of switching devices, each of which are an insulated gate bipolar transistor with an intrinsic reverse-biased clamping diode, that 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 the 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.  
           [0006]    The foregoing has outlined rather broadly the features and technical advantages of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features and advantages of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art will appreciate that they may readily use the conception and the specific embodiment disclosed as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. Those skilled in the art will also realize that such equivalent constructions do not depart from the spirit and scope of the invention in its broadest form.  
           [0007]    Before undertaking the DETAILED DESCRIPTION OF THE INVENTION below, it may be advantageous to set forth definitions of certain words or phrases used throughout this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or” is inclusive, meaning and/or; the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like; and the term “controller” means any device, system or part thereof that controls at least one operation, whether such a device is implemented in hardware, firmware, software or some combination of at least two of the same. It should be noted that the functionality associated with any particular controller may be centralized or distributed, whether locally or remotely. Definitions for certain words and phrases are provided throughout this patent document, and those of ordinary skill in the art will understand that such definitions apply in many, if not most, instances to prior as well as future uses of such defined words and phrases.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]    For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, wherein like numbers designate like objects, and in which:  
         [0009]    [0009]FIG. 1 depicts a borehole production system including a converter/inverter system according to one embodiment of the present invention;  
         [0010]    [0010]FIG. 2 is a circuit diagram for a main circuit structure employed within a converter/inverter system according to one embodiment of the present invention;  
         [0011]    [0011]FIG. 3 illustrates an output voltage waveform for one power phase from a converter/inverter system according to one embodiment of the present invention;  
         [0012]    [0012]FIG. 4 is a plot of optimal initial switching angles as a function of modulation index for converter/inverter switching networks according to one embodiment of the present invention; and  
         [0013]    [0013]FIG. 5 is a diagram of a control system for converter/inverter switching networks according to one embodiment of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0014]    [0014]FIGS. 1 through 5, discussed below, and the various embodiments used to describe the principles of the present invention in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the invention. Those skilled in the art will understand that the principles of the present invention may be implemented in any suitably arranged device.  
         [0015]    [0015]FIG. 1 depicts a borehole production system including a converter/inverter system according to one embodiment of the present invention. Borehole production system  100  includes an electrical submersible pump and motor assembly  101  lowered into a borehole  102  using a production tubing string  103 . A three-phase power cable  104  carries three-phase power into the borehole  102  to the motor within assembly  101  from a surface location.  
         [0016]    At the surface, a three-phase power source  105 , such as a generator or a connection to a local power grid, is coupled to power cable  104  by a converter/inverter system  106 . Converter/inverter system  106  is constructed and operates in the manner described below to regulate the operating speed of the motor/pump assembly.  
         [0017]    Those skilled in the art will recognize that the complete structure and operation of a borehole production system is not depicted in the drawings or described herein. Instead, for simplicity or clarity, only so much of the borehole production system as is unique to the present invention or necessary for an understanding of the present invention is depicted and described.  
         [0018]    [0018]FIG. 2 is a circuit diagram for a main circuit structure employed within a converter/inverter system according to one embodiment of the present invention. A discrete implementation of the circuit depicted is employed for each phase of the three-phase power system including power source  105 , power cable  104  and the motor within motor/pump assembly  101 .  
         [0019]    Circuit  200  is a simplified topology multi-level converter/inverter including a plurality of series-connected electrical energy storage devices, capacitors C 1 -C 4  in the exemplary embodiment, defining nodes V1-V5 each having distinct steady-state voltage levels, preferably of relatively fixed value, at the terminals thereof. Networks  201  and  202  of switching devices selectively connect nodes V1-V5 to a conductor carrying a sinusoidal input voltage V ac     —     in  and to a conductor for an output voltage V ac     —     out  based on control or switching signals Csp 1 -Csp 4 , Csn 1 -Csn 4 , Isp 1 -Isp 4 , and Isn 1 -Isn 4 .  
         [0020]    In the exemplary embodiment, the switching devices (which are referenced in FIG. 2 by the switching signals Csp 1 -Csp 4 , Csn 1 -Csn 4 , Isp 1 -Isp 4 , and Isn 1 -Isn 4  received by the corresponding switching device) within networks  201  and  202  are npn insulated gate bipolar transistors (IGBTs) each having an intrinsic diode connected with reverse bias orientation across the anode and cathode (or source/drain or emitter/collector) of the IBGT. That is, the anode of the intrinsic diode is connected to the cathode or emitter of the IGBT, while the cathode of the intrinsic diode is connected to the anode or collector of the IGBT.  
         [0021]    Switching devices Csp 4 , Csp 2 , Csp 1 , Csn 1 , Csn 2  and Csn 4  are connected in series within network  201 , and switching devices Isp 4 , Isp 2 , Isp 1 , Isn 1 , Isn 2  and Isn 4  are connected in series within network  202 , where the collectors of devices Csp 4  and Isp 4  within both networks  201  and  202  are connected to node V5 and the emitters of devices Csp 4  and Isp 4  within both networks  201  and  202  are connected to node V1. Switching devices Csp 3  and Isp 3  within both networks  201  and  202  are connected between the emitters of devices Csp 4  and Isp 4  within the respective network  201  or  202  and node V4 , while switching devices Csn 3  and Isn 3  within both networks  201  and  202  are connected between the collectors of devices Csn 4  and Isn 4  within the respective network  201  and  202  and node V2.  
         [0022]    The conductor carrying the sinusoidal input voltage V ac     —     in  for the power phase operated on by circuit  200  is connected, via a phase shifting device  203  (an inductor in the example depicted), to the junction within network  201  between the emitter of device Csp 1  and the collector of device Csn 1 . The conductor carrying the stepped sinusoidal output voltage V ac     —     out  for the corresponding power phase is connected to the junction within network  202  between the emitter of device Isp 1  and the collector of device Isn 1 .  
         [0023]    Each network  201  and  202  within circuit  200  also includes series-connected diodes D 1  and D 2  having a common forward bias orientation and connected in parallel with a reverse bias orientation across switching devices Csp 1  and Csn 1  or Isp 1  and Isn 1 , to the collector of device Csp 1  or Isp 1  and to the emitter of device Csn 1  or Isn 1 . The junction between diodes D 1  and D 2  within each of networks  201  and  202  is connected to node V3 , which is a grounded node in the example depicted.  
         [0024]    [0024]FIG. 3 illustrates an output voltage waveform for one power phase from a converter/inverter system according to one embodiment of the present invention. The output voltage V ac     —     out  of circuit  200  has a stepped sinusoidal waveform modeled after, and illustrated in comparison with, a “pure” sinusoidal waveform V ac     —     ref . The output voltage V ac     —     out  is switched between a number of voltage levels (five in the example shown) with a timing determined by two switching parameters, switching angles θ 1  and θ 2 .  
         [0025]    In the single cycle illustrated in FIG. 3, the output voltage V ac     —     out  begins at a neutral or ground voltage level V3 (although voltage level or node V3 need not necessarily be grounded) and is initially switched to a first positive voltage level V4 at a point during the cycle corresponding to switching angle θ 1 , then is switched to a second positive voltage level V5 greater than the first positive voltage level V4 at a point during the cycle corresponding to switching angle θ 2 . The output voltage V ac     —     out  is dropped to the first positive voltage level V4 at a point during the cycle corresponding to π−θ 2 , and then to the neutral or grounded voltage level V3 at a point during the cycle corresponding to π−θ 1 . The output voltage V ac     —     out  is maintained at the neutral or grounded voltage level V3 through the end of the positive half of the cycle.  
         [0026]    During the negative half of the cycle, the output voltage V ac     —     out  similarly begins at the neutral or ground voltage level V3 and is initially switched to a first negative voltage level V2 at a point during the cycle corresponding to π+θ 1 . The output voltage V ac     —     out  is switched to a second negative voltage level V1, having a greater magnitude than the first negative voltage level V2, at a point during the cycle corresponding to π+θ 2 , then is switched back to the first negative voltage level V2 at a point during the cycle corresponding to 2π−θ 2 . The output voltage V ac     —     out  is returned to the neutral or grounded voltage level V3 at a point during the cycle corresponding to 2π−θ 1 , and maintained at that voltage level V3 through the end of the negative half of the cycle.  
         [0027]    Circuit  200  produces the output voltage V ac     —     out  depicted in FIG. 3 by asserting control signals applied to switching networks  201  and  202  in a manner to selectively connect the conductors carrying the input voltage V ac     —     in  and the output voltage V ac     —     out  to the nodes/voltage levels V1-V5. Switching devices Csp 1 -Csp 4  and Csn 1 -Csn 4  within network  201  connect nodes V1-V5 to the input voltage V ac     —     in  to charge capacitors C 1 -C 4 , while switching devices Isp 1 -Isp 4  and Isn 1 -Isn 4  within network  202  connect nodes V1-V5 to the output voltage V ac     —     out  to product the appropriate output voltage level during respective portions of each cycle. The reverse-bias intrinsic diodes within each IGBT act as clamping devices constraining the voltages passed to or from nodes V1-V5 to the respective voltage levels.  
         [0028]    The output voltage levels or nodes V1-V5 and the corresponding necessary control signal/switching device states for the switching devices within networks  201  and  202  to connect a respective input or output voltage V ac     —     in  or V ac     —     out  to that voltage level or node V1-V5 are summarized below in TABLE I (where a logical “1” indicates that the respective control signal and switching device are asserted and on, while a logical “0” indicates that the respective control signal and switching device are not asserted and off):  
                                               TABLE I                       Output   Csp1/   Csp2/   Csp3/   Csp4/   Csn1/   Csn2/   Csn3/   Csn4/       Voltage   Isp1   Isp2   Isp3   Isp4   Isn1   Isn2   Isn3   Isn4                   V1   0   0   0   0   1   1   0   1       V2   0   0   0   0   1   1   1   0       V3   1   0   0   0   1   0   0   0       V4   1   1   1   0   0   0   0   0       V5   1   1   0   1   0   0   0   0                  
 
         [0029]    Switching network  201  within circuit  200  operates as a converter (a regulated rectifier) while switching network  202  operates as an inverter. Switching networks  201  and  202  operate in exactly the same manner and provide similar waveforms. However, counterpart switching devices within networks  201  and  202  (i.e., switching device Csp 1  within network  201  and switching device Isp 1  within network  202 , etc.) need not—and in most cases generally will not—be switched at the same instant; instead, switching networks  201  and  202  may be operated independently, but in concert, to produce the stepped sinusoidal output voltage V ac     —     out  for one power phase (A, B or C). Thus, switching network  201  operates at the frequency of the input voltage V ac     —     in  with one set of switching angles θ 1     —     c  and θ 2     —     c  and switching network  202  operates at the frequency of the output voltage V ac     —     out  with a different set of switching angles θ 1     —     i  and θ 2     —     i.    
         [0030]    As reflected in TABLE I, taken in conjunction with FIGS. 2 and 3, switching devices Csp 1 /Isp 1  and Csn 1 /Isn 1  within each network  201  and  202 , together with diodes D 1  and D 2 , connect the conductors carrying the input voltage V ac     —     in  and the output voltage V ac     —     out  to node V3 during the following portions of each (respective) cycle: from the start of the cycle to the point corresponding to switching angle θ 1     —     c /θ 1     —     i ; between the points corresponding to π−θ 1     —     c /θ 1     —     i  and π+θ 1     —     c /θ 1     —     i ; and from the point corresponding to 2π−θ 1     —     c /θ 1     —     i  to the end of the respective cycle.  
         [0031]    Switching devices Csp 1 /Isp 1 , Csp 2 /Isp 2  and Csp 3 /Isp 3  within each network  201  and  202  connect the conductors carrying the input voltage V ac     —     in  and the output voltage V ac     —     out  to node V4 during the portions of each respective cycle from θ 1     —     c /θ 1     —     i  to θ 2     —     c /θ 2     —     i  and π−θ 2     —     c /θ 2     —     i  to π−θ 1     —     c /θ 1     —     i . Switching devices Csp 1 /Isp 1 , Csp 2 /Isp 2  and Csp 4 /Isp 4  within each network  201  and  202  connect the conductors carrying the input voltage V ac     —     in  and the output voltage V ac     —     out  to node V4 during the portion of each cycle from θ 2     —     c /θ 2     —     i  to π−θ 2     —     c /θ 2     —     i .  
         [0032]    Switching devices Csn 1 /Isn 1 , Csn 2 /Isn 2  and Csn 3 /Isn 3  within each network  201  and  202  connect the conductors carrying the input voltage V ac     —     in  and the output voltage V ac     —     out  to node V2 during the portions of each cycle from π+θ 1     —     c /θ 1     —     i  to π+θ 2     —     c /θ 2     —     i  and 2π−θ 2     —     c /θ 2     —     i  to 2π−θ 1     —     c/θ   1     —     i . Switching devices Csn 1 /Isn 1 , Csn 2 /Isn 2  and Csn 4 /Isn 4  within each network  201  and  202  connect the conductors carrying the input voltage V ac     —     in  and the output voltage V ac     —     out  to node V1 during the portion of each cycle from π+θ 2     —     c /θ 2     —     i  to 2π−θ 2     —     c /θ 2     —     i .  
         [0033]    The number of voltage levels employed, together with the number of switching angles employed, may be greater than the five voltage levels V1-V5 (e.g., seven, nine, etc.) total and two switching angles (e.g., three, four, etc.) per switching network illustrated in the exemplary embodiment, and/or the voltage levels selected need not be uniformly spaced (i.e., varying in integer unit increments) as shown.  
         [0034]    Circuit  200  has a low part count since discrete clamping diodes are not required for each voltage level and/or multiple, series-connected, discrete diodes of a given rating as needed to handle the appropriate voltage. In addition, the output voltage V ac     —     out  exhibits relatively low harmonics, such that expensive and complex sine wave filters are not required. In addition, the system of the present invention may be scaled to medium voltage (1,500 to 15,000 volts) power transmission without the requirement for a step-up transformer.  
         [0035]    Control of circuit  200  may optionally be optimized for load balancing and minimization of harmonics by appropriate selection of switching angles θ 1     —     c /θ 1     —     i  and θ 2     —     c /θ 2     —     i . For the purposes of such optimization, a modulation index MI may be defined as a ratio of the maximum desired output voltage magnitude (set based on the target operating speed) for a switching network  201  or  202  to the maximum output voltage obtainable from that switching network—that is, the desired magnitude of voltage level V1/V5 to the maximum obtainable voltage level V1/V5 for switching network or converter  201 , and the desired magnitude of the output voltage V ac     —     out  to the maximum obtainable output voltage for switching network or inverter  202 .  
         [0036]    The converter (switching network  201 ) within circuit  200  should provide approximately the same output voltage magnitude as the power source, and therefore the modulation index of the converter (MI_c) will generally fall within a narrow range—for instance, from 0.8 to 1.0, depending on the power source voltage—but need not necessarily be so limited. However, the inverter (switching network  202 ) within circuit  200  needs to provide variable voltage, with a modulation index MI_i varying from 0.1 to 1.0 depending on the desired motor speed. Both the converter and the inverter have two switching angles: θ 1     —     c  and θ 2     —     c  for the converter and θ 1     —     i  and θ 2     —     i  for the inverter.  
         [0037]    The switching angles to balance voltages and minimize harmonic content of the input and output voltages may be initially calculated and optimized by intensive off-line calculation and simulation. Further simulation of operation under load conditions may then be performed to balance the voltage by controlling the power factor on input for correction, to obtain the optimal switching angles for one voltage-balanced operation point. By repeating this procedure, optimal switching angles for all needed operation points (different modulation index values) may be obtained.  
         [0038]    For the system depicted in FIGS. 1-3 and described above, with a modulation index of the converter MI_c=0.9, the optimal initial switching angles (in degrees) for various selected values of the modulation index of the inverter (MI_i) are given below in TABLE II:  
                               TABLE II                       MI_I   θ 1 c     θ 2 c     θ 1 i     θ 2 i                     1.0000   0.4510   0.4510   0.0000   0.0000       0.9750   0.3948   0.5014   0.0000   0.3176       0.9500   0.3259   0.5498   0.0000   0.4510       0.9250   0.2330   0.5970   0.0000   0.5548       0.9000   0.1550   0.6233   0.1550   0.6233       0.8750   0.1053   0.6342   0.2582   0.6711       0.8500   0.0899   0.6367   0.3463   0.7085       0.8250   0.1035   0.6345   0.4232   0.7403       0.8000   0.1201   0.6314   0.4897   0.7706       0.7750   0.1295   0.6294   0.5474   0.8009       0.7500   0.1320   0.6289   0.5987   0.8313       0.7250   0.1308   0.6291   0.6457   0.8615       0.7000   0.1285   0.6296   0.6898   0.8910       0.6750   0.1273   0.6299   0.7319   0.9197       0.6500   0.1281   0.6297   0.7723   0.9475       0.6250   0.1309   0.6291   0.8114   0.9746       0.6000   0.1350   0.6282   0.8492   1.0011       0.5750   0.1395   0.6271   0.8858   1.0271       0.5500   0.1439   0.6261   0.9213   1.0527       0.5250   0.1474   0.6252   0.9557   1.0781       0.5000   0.1499   0.6246   0.9892   1.1033       0.4750   0.1513   0.6242   1.0219   1.1282       0.4500   0.1518   0.6241   1.0538   1.1530       0.4250   0.1515   0.6241   1.0851   1.1775       0.4000   0.1509   0.6243   1.1159   1.2019       0.3750   0.1503   0.6245   1.1462   1.2260       0.3500   0.1498   0.6246   1.1761   1.2499       0.3250   0.1495   0.6247   1.2057   1.2735       0.3000   0.1497   0.6246   1.2349   1.2970       0.2750   0.1501   0.6245   1.2639   1.3203       0.2500   0.1509   0.6243   1.2926   1.3435       0.2250   0.1517   0.6241   1.3211   1.3665       0.2000   0.1526   0.6239   1.3493   1.3894       0.1750   0.1533   0.6237   1.3774   1.4123       0.1500   0.1540   0.6235   1.4053   1.4351       0.1250   0.1544   0.6234   1.4331   1.4578       0.1000   0.1547   0.6233   1.4608   1.4805       0.0750   0.1549   0.6233   1.4884   1.5031       0.0500   0.1549   0.6233   1.5159   1.5257       0.0250   0.1550   0.6233   1.5433   1.5482       0.0000   0.1549   0.6233   1.5708   1.5708                  
 
         [0039]    Optimal initial switching angles under the same conditions are also plotted in FIG. 4.  
         [0040]    [0040]FIG. 5 is a diagram of a control system for converter/inverter switching networks according to one embodiment of the present invention. Based on source reactive current calculations, a phase a between the power source voltage V ac     —     in  and the voltage received by converter  201  (i.e., the phase difference across inductor  203  in the example shown) is determined and employed by direct current (DC) voltage regulation portion of controller  500  to regulate the DC voltage across the capacitors C 1 -C 4 . Modulation index MI_c and modulation index MI_i are employed, by the switching pattern table and control logic within controller  500 , to compute (or select from a table such as that in TABLE II) switching angles for converter  201  and inverter  202 , with corrections. Modulation index MI_c is employed by controller  500  to control the power factor on the power source, while modulation index MI_i is employed to control the output voltage.  
         [0041]    It is important to note that while the present invention has been described in the context of a fully functional system, those skilled in the art will appreciate that at least portions of the mechanism of the present invention are capable of being distributed in the form of a machine usable medium containing instructions in a variety of forms, and that the present invention applies equally regardless of the particular type of signal bearing medium utilized to actually carry out the distribution. Examples of machine usable mediums include: nonvolatile, hard-coded type mediums such as read only memories (ROMs) or erasable, electrically programmable read only memories (EEPROMs), recordable type mediums such as floppy disks, hard disk drives and compact disc read only memories (CD-ROMs) or digital versatile discs (DVDs), and transmission type mediums such as digital and analog communication links.  
         [0042]    Although the present invention has been described in detail, those skilled in the art will understand that various changes, substitutions, variations, enhancements, nuances, gradations, lesser forms, alterations, revisions, improvements and knock-offs of the invention disclosed herein may be made without departing from the spirit and scope of the invention in its broadest form.