US009394770B2
`
`a2) United States Patent
`US 9,394,770 B2
`(10) Patent No.:
`
` Bootet al. (45) Date of Patent: Jul. 19, 2016
`
`
`(54) REMOTE POWER SOLUTION
`
`(56)
`
`References Cited
`
`(71) Applicant: GE Oil & Gas ESP, Inc., Oklahoma
`City, OK (US)
`Inventors: John Christopher Boot, Atlanta, GA
`(US); Thomas Giles Szudajski, Atlanta,
`GA (US); Benjamin Earl Ross
`;
`;
`Waukesha, WI (US)
`
`(72)
`
`(73) Assignee: GE Oil & Gas ESP, Inc., Oklahoma
`A
`City, OK (US)
`:
`:
`:
`:
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`US.C. 154(b) by 435 days.
`
`:
`(*) Notice:
`
`.
`(21) Appl. No.: 13/754,358
`(22)
`Filed:
`Jan. 30, 2013
`
`(65)
`
`Prior Publication Data
`
`US 2014/0209289 Al
`
`Jul. 31, 2014
`
`(51)
`
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`
`Int. Cl.
`HO2P 11/00
`HO2QH 7106
`H02P 9/00
`E21B 43/12
`HO2J 4/00
`E21B 41/00
`FO2D 29/06
`HO2P 9/04
`52) U.S.CL
`CPC oo. E21B 43/126 (2013.01); E21B 41/0085
`(2013.01); E21B 43/128 (2013.01); H02J 4/00
`(2013.01); YIOT 307/406 (2015.04)
`(58) Field of Classification Search
`USPC viececeseecnsteteteees 322/32, 36; 290/40 C, 40R
`See application file for complete search history.
`
`U.S. PATENT DOCUMENTS
`3,703,663 A * 11/1972 Wagner oe HO02H 7/062
`307/86
`3,911,286 A *
`10/1975 Uram oc GO6K 13/0825
`290/40 R
`6/1977 Ura wees FOID 17/24
`4,032,793 A *
`290/2
`4,118,635 A * 10/1978 Barrett cece FOLD 17/24
`290/40 R
`3/1980 Reed wii FOLK 23/105
`290/40 R
`4/1981 Berner wc F02D 29/06
`174/DIG. 15
`11/1983 Collins sceccccccccseese FOLD 17/145
`AL5/17
`5/1994 Hubler occ FO2D 31/006
`123/320
`6/1997 Rajamani ....... F02C 9/28
`60/39.27
`
`4,195,231 A *
`4,262,209 A *
`4,412,780 A *
`
`§311,063 A *
`5,636,507 A *
`
`(Continued)
`OTHER PUBLICATIONS
`
`.
`oo,
`.
`/
`International Search Report and Written Opinion issued in connec-
`tion with corresponding PCT Application No. PCT/US2014/011039
`on Nov.5, 2014.
`.
`.
`Primary Examiner — Pedro J Cuevas
`(74) Attorney, Agent, or Firm — Crowe & Dunleavy, PC.
`(57)
`ABSTRACT
`An independent powersystem provides electrical power to an
`electric submersible pumping system positionedin a well that
`produces petroleum products. The independent power system
`includes a generator and an engine connected to the generator.
`The engine is preferably provided with combustible gases
`from the
`petroleum products of the well. The independent
`P
`Pp:
`Pp
`power system further includes an integrated control system
`that is connectedto the electric submersible pumping system
`and the generator. The independent power system is config-
`ured to balance the loads created by the electric submersible
`pumping system with the output from the electrical generator.
`
`15 Claims, 3 Drawing Sheets
`
`
`
`432
`
`4
`
`
`
`Surface Facilities
`
`
`
`124
`
`126
`
`
`
`
`;
`112
`
`
`
`
`
`
`
`'
`02
`Engine|Generator||
`'
`4
`1e—|
`|
`125
`128
`Zz
`1
`110
`'
`'
`\
`\
`\
`ifr
`me
`
`
`
`if
`7
`
`
`r
`VFD
`XFMR
`
`
`
`Load
`eel
`l
`Banks |]|Switchboard|AVR|Filter ~
`
`
`
`
`136
`
`
`|-———]—106
`Integrated
`
`
`Controls
`I~422
`
`ure||Comm|Bet [| veo [*] xrMR
`
`
`
`
`Lf
`1
`120
`
`|
`J Ji]
`i
`138
`140
`128
`IiiI
`130
`
`
`
`
`__,
`
`
`ne |
`118-——_|
`
`
`
`16——|
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`1
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`CRUSOE-1012
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`CRUSOE-1012
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`1
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`

`

`US 9,394,770 B2
`
`Page 2
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
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`8,823,208 B2*
`
`8,829,698 B2*
`
`9/2014 Bekiarov oo... HO02P 9/48
`307/10.1
`9/2014 Koeneman ............ FO1P 3/00
`290/1A
`9/2003 Burstall ....0..... B60K 6/105
`;
`322/4
`7/2004 Pinkerton,III ....... HO02J 7/1446
`322/32
`
`2003/0178972 Al*
`
`2004/0124813 Al*
`
`2005/0166594 Al*
`
`2008/0077336 Al*
`
`2008/0122408 Al*
`
`2009/0206599 A1l*
`
`3/1998 Thomson oo... H02J 3/38
`290/40 B
`3/1998 Thompson... H02] 3/38
`290/2
`9/2004 Armstronget al.
`2004/0188360 Al
`5/1998 Thomson oo. HO02J 3/38
`5,754,033 A *
`307/57 2004/0256109 Al=12/2004 Johnson
`
`5,973,481 A * 10/1999 Thompson ..........0 H02J 3/38
`2005/0122084 Al*
`6/2005 Pinkerton,III ....... HO02J 7/1446
`290/2
`322/32
`6,304,056 BL* 10/2001 Gale vce HO02J 7/0029
`8/2005 Jayabalan .............. B60K 6/485
`320/104
`60/698
`7/2002 Gale voce FO2N 11/04
`2007/0227470 Al* 10/2007 Cole woe HO02K 11/048
`123/179.28
`123/3
`6/2003 Gale voces HO02J 7/1446
`3/2008 Fernandes............ GOIR 15/142
`123/339.14
`.
`702/57
`1/2005 Pinkerton,III ....... H02J 7/1446
`5/2008 Keiter 0... F02D 29/06
`290/52
`;
`322/28
`4/2005 Burstall 0... B60K 6/105
`8/2008 Grimeset al.
`2008/0203734 Al
`74/573.1
`11/2008 Zubrin et al.
`2008/0283247 Al
`4/2006 Jayabalan ou... B60K 6/485
`2008/0309095 Al* 12/2008 Keiter wo... cece F02D 29/06
`60/716
`290/40 R
`4/2006 Pinkerton,III ....... HO02J 7/1446
`8/2009 Yamamura.............. F02B 63/04
`290/52
`290/2
`9/2006 Schien wees C10B 53/00
`210/188
`7,633,173 B2* 12/2009 Keiter 0. F02D 29/06
`290/40 A
`5/2010 Tami cece HO2J 1/14
`290/40 C
`5/2012 Yamamura............. F02B 63/04
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`7/2012 Koeneman «cu FO1P 3/00
`2900/1 A
`
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`
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`
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`
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`
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`
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`
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`
`1/2013 Elizondo
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`307/65
`3/2013 Anderson ........... B60G 13/14
`318/375
`7/2013 Koeneman ............. FO1P 3/00
`290/1 A
`9/2014 Cole we H02K 1/2786
`123/179.28
`
`2013/0119948 Al*
`
`2014/0208751 Al*
`
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`;
`307/39
`5/2013 Bekiarov we HO2P 9/48
`322/24
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`60/647
`2014/0365022 A1* 12/2014 Ghosh we G06Q 50/06
`700/291
`2014/0365024 Al* 12/2014 Ghosh ue G06Q 50/06
`700/291
`2015/0357952 AL* 12/2015 Taylor wwe HO02P 9/04
`290/40 C
`2015/0377164 A1* 12/2015 Kanno we FO2D 29/02
`290/40 R
`1/2016 Dustman ............... GO6F 1/3287
`710/315
`
`2016/0018878 Al*
`
`* cited by examiner
`
`2
`
`

`

`U.S. Patent
`
`Jul. 19, 2016
`
`Sheet 1 of 3
`
`US 9,394,770 B2
`
`104
`
`102
`
`112
`
`Fuel Source
`
`GenSet
`
`108
`
`
`
`Engine
`
`Gen
`
`Integrated
`Controls
`trol
`
`FIG. 1
`
`3
`
`

`

`U.S. Patent
`
`Jul. 19, 2016
`
`Sheet 2 of 3
`
`US 9,394,770 B2
`
`114
`
`Engine
`
`Generator
`
`||—1
`
`32
`
`|
`
`102°
`
`.
`
`1.~
`
`110
`
`Load
`Banks
`
`Integrated
`Controls
`
`124
`
`138
`
`140
`
`130
`
`126
`
`128
`
`134
`{—_» VFD . XFMR
`
`
`
`
`
`
`
`
`Surface Facilities
`
`
`
`
`
`
`FIG. 2
`
`118
`
`”
`
`4
`
`

`

`
`
`Switchboard
`
`Filter
`
`Integrated
`
`Surface Facilities
`
`U.S. Patent
`
`Jul. 19, 2016
`
`Sheet 3 of 3
`
`US 9,394,770 B2
`
`
`
`Controls
`
`5
`
`

`

`US 9,394,770 B2
`
`1
`REMOTE POWER SOLUTION
`
`FIELD OF THE INVENTION
`
`This invention relates generally to the field of electrical
`generation systems, and moreparticularly, but not by way of
`limitation, to electrical generation systems adapted for pro-
`viding powerto electric submersible pumping systems and
`associated auxiliary systems installed in locations without
`access to an established powergrid.
`
`10
`
`BACKGROUND
`
`2
`the electrical loads, predicting a change in the demandof the
`electrical loads with an integrated control system; and adjust-
`ing the output of an electrical generator with the integrated
`control system to accommodate the demandofthe electrical
`loads.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a diagrammatic depiction of a remote power
`supply system constructed in accordance with a presently
`preferred embodiment.
`FIG.2 is a diagrammatic depiction of a preferred embodi-
`ment of a remote powersupply system connectedto a pair of
`electric submersible pumping systems.
`FIG.3 is a diagrammatic depiction ofanalternate preferred
`embodiment of a remote power supply system connected toa
`pair ofelectric submersible pumping systems.
`
`20
`
`DETAILED DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`Submersible pumping systemsare often deployed in wells
`to recover petroleum fluids from subterranean reservoirs.
`Typically, a submersible pumping system includes a number
`of components, including an electric motor coupled to one or
`more high performance pump assemblies. Production tubing
`is connected to the pump assemblies to deliver the petroleum
`fluids from the subterranean reservoirto a storage facility on
`the surface.
`
`The motoris typically an oil-filled, high capacity electric
`motor that can vary in length from a few feet to nearly one
`hundredfeet, and may be rated up to hundredsofhorsepower.
`Prior art motors often include a fixed stator assemblythat
`surrounds a rotor assembly. The rotor assembly rotates within
`the stator assembly in response to the sequential application
`of electric current through different portions of the stator
`assembly. ‘lhe motor transfers power to the pump assembly
`through a commonshaft keyedto the rotor. For certain appli-
`cations, intermediate gearboxes can be used to increase the
`torque provided by the motorto the pump assembly.
`Poweris typically provided to the motor from a variable
`frequency drive (or variable speed drive) through an output
`(step up) transformer. The variable frequency drive is pro-
`vided powerfrom a local electrical power grid. The electric
`submersible pumping system typically includes a long power
`cable that extends from the surface facilities to the electrical
`
`motor positioned downhole.
`Petroleum reservesare often located in isolated,rural loca-
`tions. In certain areas, access to an established powergrid is
`impossible or cost-prohibitive. There is, therefore, a need for
`a system that can reliably and efficiently provide electrical
`powerto electric submersible pumps without access to an
`established powergrid. It is to this and other deficiencies in
`the priorart that the present inventionis directed.
`
`40
`
`45
`
`SUMMARYOF THE INVENTION
`
`In preferred embodiments, the present invention includes
`an independent power system configured to provideelectrical
`powerto an electric submersible pumping system positioned
`in a well that produces petroleum products. The independent
`powersystem includes a generator and a driver connected to
`the generator. The driver is preferably an enginethat is pro-
`vided with combustible gases from the petroleum products of
`the well. The independent power system further includes an
`integrated control system that is connected to the electric
`submersible pumping system and the generator. The indepen-
`dent power system is configured to balance the loads created
`by the electric submersible pumping system with the output
`from the electrical generator.
`In another aspect, preferred embodiments include a pro-
`cess for providing electrical power from a generator to one or
`moreelectrical loads that are not connected to an established
`power grid. The process includes the steps of generating
`electrical power with a generator, monitoring the demand of
`
`In accordance with a preferred embodimentofthe present
`invention, FIG. 1 provides a general diagrammatic depiction
`of an independent power system 100. The independent power
`system 100 preferably includesat least one genset 102, a fuel
`source 104, an integrated control system 106 and one or more
`loads 108. The independent powersystem optionally includes
`a load bank 110.
`
`The genset 102 includes a driver 112 coupled to a generator
`114. As generally knownin the art and in accordance with
`presently preferred embodiments, the driver 112 is an engine
`that converts chemical energy in the fuel from the fuel source
`104 into mechanical energy. The generator 114 then converts
`the mechanical energy from the engine 112 into electrical
`energy. The loads 108 are general references for devices or
`systems that consumeelectrical power during a selected
`operation, such as, for example, electric motors, computers,
`motor controllers, lighting, heating and otherelectrical equip-
`ment. The loads 108 mayspecifically include surface pumps,
`water processing equipment, battery pumps, waste treatment
`equipment, lighting and transfer pumps.
`The integrated control system 106 includes automated con-
`trol devices that are configured to control the operation ofthe
`loads 108, monitorthe operation ofthe loads 108, monitor the
`operation ofthe genset 102 and adjust the output ofthe genset
`102. Ina broad sense, the preferred embodimentofthe inde-
`pendent power supply 100 depicted in FIG. 1 provides an
`automated method for detecting the operation of the loads
`108, identifying a power requirementfor each load 108, and
`manipulating the operation of the engine 112 and generator
`114 to satisfy the power requirementfor each load 108. In this
`way, the integrated control system 106 balances the power
`output from the genset 102 with the power demand from the
`one or more loads 108.
`Unlike conventional installations in which loads are con-
`nected to a larger powergrid, the small numberof loads 108
`within the independent power system 100 cause the power
`demandto berelatively volatile. For example, if one of the
`loads 108 consumesa significant portion of the total output
`from the genset 102, and the load 108 is suddenly turnedoff,
`the demandfrom the genset 102 mustbe rapidly reduced. The
`integrated control system 106 is configured to quickly detect
`or evenpredict the change in power demandso thatthe output
`ofthe genset 102 can be immediately balanced.
`Demand from the loads 108 can be predicted by the inte-
`grated control system 106 based on scheduled operational
`changes, historic patterns of operation or from variation in
`
`6
`
`

`

`US 9,394,770 B2
`
`4
`112 is a reciprocating engine capable of operating solely on
`methane,ethane or other gases scavenged from the well 118.
`Suitable engines are offered by General Electric Company
`under the Waukesha brand. Notably, scavenging methane and
`ethane to power the engine 112 presents an environmentally
`responsible process for disposing of these gases. In the past,
`such gases have often been vented or flared at the well 118.
`Throughuse of emissionscatalysts within the engine 112,the
`exhaust gases generated by combustion within the engine 112
`present a significant environmental benefit over the disposal
`of unspent gases at the well 118. The performance ofthe
`emissions catalysts can be optimized by maintaining the
`engine 112 withinits preferred operating parameters through
`use of the integrated control system 106 and the load banks
`110.
`
`In this way, the embodiment of the independent power
`system 100 depicted in FIG. 2 is capable of operating without
`connection to an existing power grid or to an externally-
`supplied fuel source. The ability to operate the independent
`power system 100 without reliance on the delivery of liquid
`fuels represents a significant benefit over the prior art.
`Althoughreciprocating enginesare presently preferred, in an
`alternate embodiment, the engine 112 is a turbine engine.
`Suitable turbine engines are available from General Electric
`Company and can be configured to operate on a variety of
`fuels.
`
`20
`
`40
`
`45
`
`3
`operational characteristics. For example, if the load 108 is an
`electrical pump, the power demandfor the electrical pump
`can be predicted based on the flowrate of the discharge from
`the pump. As the flowrate increases or decreases, the inte-
`grated control system 106 can be configured to predict an
`upcoming change in demandforthe electric motor and adjust
`the output of the genset 102 accordingly.
`In case of a sudden or unpredictable drop-off in power
`usage by the loads 108, the load bank 110 is activated to
`take-up the excess powerandstop the engine 112 from racing.
`The load bank 110 can also be activated to maintain a mini-
`mum load to keep the engine 112 withinits preferred operat-
`ing parameters (for instance not running at too low a speed
`and hence too low a temperature). Inversely, if the demand of
`the loads 108 increases so the sum of the demand is higher
`than the normal output of the genset 102, the integrated con-
`trol system 106 can be configured to overdrive for a period of
`timeto satisfy the demand. Should an overdrive event occur,
`the integrated control system 106 can be configured to send a
`warning that the independent powersystem 100 is experienc-
`ing a generation shortfall.
`Turning to FIG. 2, shown therein is a diagrammatic repre-
`sentation of a preferred embodiment of the independent
`powersystem 100 used to provide powerto electric submers-
`ible pumping systems 116 deployed in wells 118. Although
`the application of the independent powersystem 100 is not so
`limited, it will be appreciated the that independent power
`system 100 will find particular utility in providing power to
`electric submersible pumping systems disposed in wells
`drilled in remote locations for the production of petroleum
`products.
`Aswill be understood by those skilledin theart, the electric
`submersible pumping system 116 typically includes a cen-
`trifugal pump that is driven by one or moreelectrical motors.
`Electricity is provided to the electrical motors through a
`powercable that extends from the surface to the motordis-
`posed within the well 118. When energized,the electric sub-
`mersible pumping system 116 pushes pumpedfluids out of
`the well 118 to surface facilities 120. The surface facilities
`120 mayinclude, for example, phase separators, storage bat-
`teries and gathering lines used to separate, store and transfer
`the pumpedpetroleum products from the well 118. Although
`twoelectric submersible pumping system 116 are depicted in
`FIG.2, it will be appreciated that fewer or greater numbers of
`electric submersible pumping systems 116 may be connected
`Ina particularly preferred embodiment, the central control
`to a single independent power system 100. It will also be
`module 122 includes a switchboard 132, an automatic voltage
`appreciated that, although the present disclosure includes the
`
`prescribed use of the electric submersible pumping systems regulator 134 andafilter 136. The switchboard 132 is used to
`116, preferred embodiments of the independent power sys-
`direct power supplied by the genset toward a designated load,
`tem 100 will include use in connection with surface-mounted
`such asthe electric submersible pumping systems 116 or the
`load banks 110. The automatic voltage regulator 134 andfilter
`136 are used to condition the power supplied by the genset
`102 and to removeor diminish the voltage waveform distor-
`tions and harmonics within the independent power system
`100. The filter 136 preferably includes a separate control
`system that provides data about harmonics detected in the
`independent power system 100. The filter 136 is preferably
`programmedto automatically self-activate to reduce or elimi-
`nate harmonics detected in the independent power system
`100. The data from thefilter 136 can also be provided to the
`integrated control system 106 so that other adjustments
`within the independent power system 100 can be made to
`alleviate the harmonics.
`
`Continuing with FIG.2, the independent power system 100
`includes a central control module 122, load banks 110, a
`high-resistance ground 124, one or more variable frequency
`drives 126 (two are shown) and one or more step-up trans-
`formers 128 (two are shown). Each of these componentsis
`preferably positioned ona commonplatform or skid 130. The
`use of a skid 130 allows the independent power system 100 to
`be easily transported to remote locations without the use of
`cranes and reduces rig-up time. In a particularly preferred
`embodiment, the skid 130 is configured to be rolled on and off
`a conventional lowboytrailer.
`The central control module 122 includes the integrated
`control system 106 and other components used to control,
`condition and direct power supplied by the genset 102. The
`central control module 122 is preferably configured as an
`enclosure that protects the internal components in an envi-
`ronmentally controlled structure. Heating, cooling and ven-
`tilation equipment (not shown) is all powered by the genset
`102.
`
`electrical pumping systems.
`The electric submersible pumping system 116 further
`includesa series of sensors that output signals representative
`ofvarious operational characteristics, including, for example,
`flowrate, temperature, pressure, vibration and unintended
`leakage withinthe electric submersible pumping system 116.
`The operation and monitoring of downholeelectric submers-
`ible pumping systemsis more fully described in U.S. Pat. No.
`8,347,953 issued Jan. 8, 2013, entitled “Inline Monitoring
`Package for Electrical submersible Pump,’the disclosure of
`whichis herein incorporated by reference.
`In the embodiment depicted in FIG. 2, the independent
`power system 100 includes the genset 102, which in turn
`includes a driver coupled to a generator 114. The driver is
`preferably an engine 112 that is connected to the surface
`facilities 120 and drawsa fuel source from the surface facili-
`
`ties 120. In a particularly preferred embodiment, the engine
`
`The central control module 122 provides the conditioned
`powerto the variable frequency drives 126. The variable
`frequency drives 126 are used to adjust the frequency of the
`alternating current, which in turn adjusts the operational
`
`7
`
`

`

`US 9,394,770 B2
`
`5
`speed of the motorof the electric submersible pumping sys-
`tem 116. The step-up transformers 128 are used to increase
`the voltage of the electricity leaving the variable frequency
`drives 126 to account for voltage drop experienced during
`transmission to the electric submersible pumping system 116.
`Alternatively, the genset 102 can be configured to produce a
`higher voltage (such as 4160V instead of 480V). If the genset
`102 is configured to produce a sufficiently high voltage, it
`may be possible to omit the step-up transformers from the
`independent powersystem 100.
`In an alternate preferred embodiment, the independent
`power system 100 is connected to two or more variable fre-
`quency drives 126 such that harmonics and wave distortion
`are cancelled through destructive interference. To achieve
`cancellation of harmonics and wave distortions,
`two
`matched-sets of variable frequency drives 126 are connected
`to the genset 102 and operated 180 degrees out of phase. Any
`resulting harmonics and wavedistortions created by the non-
`linear loads from the matched-sets of variable frequency
`drives 126 are cancelled or significantly offset. Thus, when
`connected to multiple variable frequency drives 126, it is
`preferred that the variable frequency drives 126 be configured
`and operated as symmetrical, non-linear loads that coopera-
`tively cancel harmonics and wavedistortions. The use of a
`harmonics-cancelling configuration may obviate the need for
`the filter 136 within the central control module 122.
`
`10
`
`15
`
`20
`
`25
`
`6
`frequencythat is dependent on the speed at which the engine
`112 is operated. To increase the speed ofthe electric submers-
`ible pumping systems 116, the speed of the engine 112 is
`increased, whichin turn increasesthe frequencyofthe current
`supplied by the alternator 142. The use of a variable fre-
`quencyalternator 142that is directly connectedto theelectric
`submersible pumping system 116 eliminates the need for
`expensive variable frequency drives 126. Furthermore,
`because the power supplied by the genset 102 is directly
`responsiveto the demandofthe electric submersible pumping
`systems 116, the load banks 110 can be removed from the
`independent power system 100. The genset 102 will not pro-
`duce excess capacity because it
`is operated strictly in
`response to demandsofthe electric submersible pumping
`systems 116.
`Under both embodiments depicted in FIGS. 2 and 3, the
`integrated control system 106 is preferably programmed to
`ensure that devices within the independent power system 100
`and the electric submersible pumping systems 116 arestarted
`in an optimalorder. The integrated control system 106 waits
`until one device in the start-up chain is operating correctly
`before starting the next device. The integrated control system
`106 also ensures that pumps are started in sequence without
`putting too high a start-up load on the independent power
`system 100 and to minimize harmonics and reactive power
`issues. Customer-specific inputs can also be included within
`the integrated control system 106. For example, the integrated
`The integrated control system 106 receives inputs repre-
`control system 106 can be programmedto activate electric
`sentative ofthe operational characteristics ofthe electric sub-
`
`mersible pumping systems 116. The integrated control sys- submersible pumping systems 116 onapriority basis to
`30
`tem 106 also receives inputs from the genset 102 and other
`ensure that certain higher priority pumps are operational
`components within the independent power system 100. In
`before lower priority pumpsare brought online.
`response to these inputs, the integrated control system 106 is
`It is to be understood that even though numerouscharac-
`configured to balance the power produced by the genset 102
`teristics and advantages of various embodiments of the
`with the demandsofthe electric submersible pumping sys-
`present invention have beenset forth in the foregoing descrip-
`tems 116 and other loads within the independent powersys-
`tion, together with details of the structure and functions of
`various embodiments ofthe invention,this disclosureisillus-
`tem 100. As the output from the genset 102 is adjusted to
`satisfy the demandsofthe submersible pumping systems 116,
`trative only, and changes may be madein detail, especially in
`the integrated control system 106 also manipulates other
`matters of structure and arrangementof parts within the prin-
`components within the independent power system 100 to
`ciples of the present invention to the full extent indicated by
`increase the powerfactor of the independent power system
`the broad general meaning ofthe terms in which the appended
`100 and to optimize the performanceof the electric submers-
`claims are expressed.It will be appreciated by those skilled in
`ible pumping systems 116. As noted above, in certain circum-
`the art that the teachings of the present invention can be
`stances it will be desirable for the integrated control system
`applied to other systems without departing from the scope
`106 to activate the load banks 110. The load banks 110 can be
`and spirit of the present invention.
`used to buffer changes in the overall demand on the genset
`102.
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`Ina particularly preferred embodiment, the central control
`module 122 further includes a data communication system
`138 and a back-up power supply 140. The data communica-
`tion system 138 is configured to relay information about the
`operation of the independent power system 100 andtheelec-
`tric submersible pumping systems 116 to a remote monitor-
`ing location. The data communication system 138 may
`include satellite, radio, cellular, or other communications
`hardware. In the event the genset 102 fails to deliver powerto
`the central control module 122,the back-up power supply 140
`allows the data communication system 138 to continue to
`send information to the remote monitoring facility for a
`period oftime. This allows the independent power system 100
`to self-report service needs even without power from the
`genset 102.
`Turning now to FIG. 3, shown therein is an alternate pre-
`ferred embodimentof the independent power system 100. In
`the alternate embodiment depicted in FIG. 3, the variable
`frequency drives 126 have been removed and replaced with a
`variable frequency alternator 142. The variable frequency
`alternator 142 is configured to provide current at an output
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`Whatis claimed is:
`1. A process for providing electrical power from a genera-
`tor to one or moreelectrical loads that are not connected to an
`established powergrid, the process comprising thestepsof:
`generating electrical power with a generator;
`monitoring the demandofthe electrical loads;
`adjusting the output of an electrical generator with the
`integrated control system to accommodate the demand
`of the electrical loads, and
`predicting a change in the demand ofthe electrical loads
`with an integrated control system.
`2. The process of claim 1, wherein the one or moreelectri-
`cal loads are selected from the group consisting of submers-
`ible pumps, surface pumps, water processing equipment, bat-
`tery pumps, waste treatment equipment, lighting, drilling
`equipment, auxiliary electrical equipment and transfer
`pumps.
`3. The process of claim 2, wherein the one or moreelectri-
`cal loads is an electric submersible pumping system, and
`wherein the step of monitoring the demandofthe electrical
`loads comprises monitoring in real-time the operational char-
`acteristics of the electric submersible pumping system.
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`

`US 9,394,770 B2
`
`7
`4. The process of claim 3, further comprising the step of:
`using a variable frequency drive to adjust the operational
`speed ofthe electric submersible pumping system.
`5. The process of claim 3, further comprising the step of:
`using a variable frequency alternator to adjust the opera-
`tional speed of the electric submersible pumping sys-
`tem.
`
`6. The process of claim 1, further comprisingthesteps of:
`detecting a decrease in the demand of the one or more
`electrical loads; and
`activating a load bank to draw powerfrom the generator.
`7. The process of claim 1, wherein the one or moreelectri-
`cal loads is two electric pumping systems, and wherein the
`step of monitoring the demand ofthe electrical loads com-
`prises monitoring in real-time the operational characteristics
`of the two electric pumping systems.
`8. The process of claim 7, further comprising thesteps of:
`providing a pair of matched variable frequency drives,
`wherein each ofthe pair of matched variable frequency
`drives is connected to a separate one of the twoelectric
`pumping systems; and
`operating the pair of matched variable frequency drives to
`cancel harmonics generated by the non-linear loads pro-
`duced by each of the variable frequency drives.
`9. An independent power system comprising:
`a generator that produces an electrical power output;
`a driver connected to the generator;
`an electrical load that places an electrical demand on the
`generator; and
`an integrated control system connected to the electrical
`load and the generator; wherein the integrated control
`system is configured to predict a change in the demand
`of the electrical load and automatically balance the out-
`put from the generator with the demandoftheelectrical
`load.
`
`10. The independent power system of claim 9, wherein the
`electrical load is selected from the group consisting of sub-
`mersible pumping systems, surface pumping systems, water
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`8
`processing equipment, battery pumps, waste treatment equip-
`ment, lighting, drilling equipment, auxiliary electrical equip-
`ment and transfer pumps.
`11. The independent power system of claim 10, wherein
`the electrical
`load is an electrical pumping system, and
`wherein the independent power system further comprises:
`a variable frequency drive in electrical communication
`with the generator andthe electrical pumping system;
`and
`
`wherein the operational speed of the electrical pumping
`system is adjusted by controlling the variable frequency
`drive.
`
`12. The independent power system of claim 10, wherein
`the generator comprises a variable frequency alternator and
`wherein the variable frequency alternator is configured to
`provide current at a selected frequencyto the electrical pump-
`ing system.
`13. The independent power system of claim 9 further com-
`prising:
`a data communication system configured to relay informa-
`tion about the operational characteristics ofthe indepen-
`dent power system andthe electrical loads; and
`a back-up power supply connected to the data communi-
`cation system.
`14. The independent power system of claim 9, wherein the
`driver is an enginethat is selected form the group consisting
`of reciprocating engines and turbine engines.
`15. The independent power system of claim 9, further
`comprising:
`a load bank; and
`wherein the integrated control system can activate the load
`bank to draw power from the generator to balance the
`output ofthe generator with the sum ofthe demand from
`the load bank and the demandfrom theelectrical load.
`*
`*
`*
`*
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