Remote power system

• US 4,831,277 A
• Filed: 08/11/1987
• Issued: 05/16/1989
• Est. Priority Date: 08/11/1987
• Status: Expired due to Fees

• Current Assignee: Nicholas S. Christopher
• Original Assignee: Nicholas S. Christopher
• Inventors: Christopher, Nicholas S.
• Primary Examiner(s): Shoop, Jr., William M.
• Assistant Examiner(s): Duncanson, Jr., W. E.
• Application Number:
  US07/084,102
• Time in Patent Office: 644 Days
• Field of Search: 290/1 R, 290/1 A, 290/1 B, 290/2, 290/40, 123/3
• US Class Current: 290/1.00A
• CPC Class Codes: F02B 63/04 for electric generators

Abstract

A power system specifically adapted to provide DC power for powering a DC load at a remote site under severe environmental conditions, such as is found at remote gas pipeline locations. The power system includes a slow speed heat engine adapted to be powered by fuel, preferably taken directly from the gas pipeline, the supply of which is controlled by means of a pressure regulator. The engine is adapted to be directly coupled to an oversized, slow speed three-phase alternator so as to produce AC power, which is subsequently rectified to DC power output for powering a load in the range of 500 to 5,000 watts. The engine is particularly adapted to be started with a hand crank or a portable starter, and is provided with ceramic main bearings, an oversized lubrication system, redundant independent ignition systems and a highly superior cooling system. The cooling system includes a variable speed fan, the operation and speed of which is adapted to be automatically controlled in response to a sensed engine temperature for purposes of maintaining the engine temperature at a particular level. A rotary magnetic encoder system is provided for sensing the engine speed and for controlling the pressure regulator in response to the sensed speed to achieve optimum engine speed. Redundant safety shutdown systems are adapted to shut down the engine upon the occurrence of certain critical events. The remote power system is characterized by long life, minimal maintenance requirements and a mean time between failure equal to or in excess of 20,000 hours.

Claims

1. A remote power system comprising a slow speed engine, a slow speed alternator adapted to be directly coupled to said engine for producing AC power, a rectifier for converting said AC power to a DC power output, said DC output being adapted to power a load, said engine being adapted to be powered by a fuel, a pressure regulator controlling the supply of said fuel to said engine, redundant independent ignition systems provided for said engine, a cooling system provided for said engine, said cooling system including a heat exchanger, a fan, a fan motor for operating said fan and welded stainless steel cooling pipes for connecting said engine to said heat exchanger, means for sensing the temperature of said engine, the operation of said fan being controlled automatically to maintain said engine at an optimum predetermined temperature in response to said sensed temperature, a lubricating system provided for said engine, said lubricating system including an oversized lubricating oil sump, oil filter, fuel filter, and air filter, a rotary magnetic encoder system for sensing the speed of said engine and for controlling operation of said pressure regulator in response to said sensed speed to maintain engine speed, and redundant safety shutdown systems for shutting down said engine by cutting off said supply of said fuel when the oil pressure for said power system is lower than desired, when said sensed engine temperature is higher than desired or when said sensed speed of said engine is higher than desired, each of said shutdown means being required to be activated in order to shut down said engine.

2. The remote power system recited in claim 1 wherein said engine is a 10 HP, 600 RPM, horizontal cylinder, large displacement engine.

3. The remote power system recited in claim 1 wherein said fuel for powering said engine is a low BTU gas such as natural gas, wellhead gas, methane, butane, propane and the like.

4. The remote power system recited in claim 1 wherein said fuel for powering said engine is obtained directly from a gas pipeline.

5. The remote power system recited in claim 1 wherein said alternator is a 6 KW, 1200 RPM, three-phase brushless alternator, said alternator being adapted to be operated at 600 RPM.

6. The remote power system recited in claim 1 wherein said engine is provided with ceramic main bearings.

7. The remote power system recited in claim 1 wherein an air to fuel ratio for said engine is adapted to be preset, such that said engine does not possess a governor.

8. The remote power system recited in claim 1 wherein said engine is adapted to be started by means of a hand crank or a portable starter means, such that said engine does not possess a starting system.

9. The remote power system recited in claim 1 wherein said rectifier is a 24 Volt DC, three-phase bridge rectifier.

10. The remote power system recited in claim 1 wherein said ignition systems include dual platinum multi-electrode spark plugs.

11. The remote power system recited in claim 1 wherein said fan is a variable speed fan and said fan motor is a permanent magnet DC fan motor, said operation of said fan being controlled to maintain said engine at a precise 240°

F. temperature.

12. The remote power system recited in claim 1 further comprising a heavy duty oil field skid base.

13. The remote power system recited in claim 12 wherein said lubricating oil sump is a stainless steel tank built into said base.

14. A remote power system comprising a 600 RPM slow speed heat engine, a 1200 RPM three-phase alternator adapted to be directly coupled to said engine to operate at 600 RPM for producing AC power, a bridge rectifier for converting said AC power to a DC power output, said DC output being adapted to power a load, said engine being adapted to be powered by a fuel, a modulating type proportional gas fuel pressure regulator for controlling the supply of said fuel to said engine, a three-phase alternator, redundant independent ignition systems provided for said engine said ignition systems including dual platinum spark plugs and dual solid state ignition subsystems, ceramic main bearings provided for said engine, a cooling system provided for said engine, said cooling system including a heat exchanger, a variable speed fan, a permanent magnet DC fan motor for operating said fan and argon-welded stainless steel cooling pipes for connecting said engine to said heat exchanger, electronic means for sensing the temperature of said engine, means for automatically controlling the operation and speed of said fan in response to said sensed temperature to maintain said engine temperature at about 240°

F., a lubricating system provided for said engine, said lubricating system including an oversized lubricating oil sump, a forty-gallon oil filter, an air cleaner that is oversized by a factor of approximately twenty and an oversized fuel filter, a rotary magnetic encoder system for sensing the speed of said engine and for controlling operation of said pressure regulator in response to said sensed speed to maintain engine speed, and redundant safety shutdown systems for shutting down said engine by cutting off said supply of said fuel when the oil pressure for said power system is lower than desired, when said sensed engine temperature is higher than desired or when said sensed speed of said engine is higher than desired, each of said shutdown means being required to be activated in order to shut down said engine.

15. The remote power system recited in claim 14 wherein said bearings are made from Syalon.

16. The remote power system recited in claim 14 wherein an air to fuel ratio for said engine is adapted to be preset, such that said engine does not possess a governor.

17. The remote power system recited n claim 14 wherein said engine is adapted to be started by means of a hand crank or a portable starter means, such that said engine does not possess a starting system.

18. The remote power system recited in claim 14 further comprising a heavy duty oil field skid base.

19. A power system for utilization at a remote gas pipeline comprising a 600 RPM slow speed heat engine, a 1200 RPM three-phase alternator adapted to be directly coupled to said engine to operate at 600 RPM for producing AC power, a three-phase bridge rectifier for converting said AC power to a DC power output, said D output being adapted to power a 24 volt DC load in the range of 500 to 5,000 watts, said engine being adapted to be powered directly by gas from said gas pipeline, said engine being adapted to be started by means of a hand crank or by means of a portable starter whereby said engine does not include a starting system, said engine having a preset air to fuel ratio whereby said engine does not require a governor, a pressure regulator for controlling the supply of said gas to said engine, redundant independent ignition systems provided for said engine, ceramic main bearings for said engine, a cooling system provided for said engine, said cooling system including a heat exchanger, a variable speed fan, a motor for operating said fan and welded stainless steel cooling pipes for connecting said engine to said heat exchanger, said cooling system utilizing a thermo syphon vapor phase type closed cycle cooling process whereby a water pump is not provided, electronic means for sensing the temperature of said engine, means for automatically controlling the operation and speed of said fan in response to said sensed temperature to maintain said engine temperature at about 240°

F., a lubricating system provided for said engine, said lubricating system including an oversized lubricating oil sump, oil filter, air cleaner and fuel filter, a rotary magnetic encoder system for sensing the speed of said engine and for controlling operation of said pressure regulator in response to said sensed speed to maintain engine speed, redundant safety shutdown systems for shutting down said engine by cutting off said supply of said fuel when the oil pressure for said power system is lower than desired, when said sensed engine temperature is higher than desired or when said sensed speed of said engine is higher than desired, each of said shutdown means being required to be activated in order to shut down said engine, and an oil field skid base provided for said power system, said remote power system being characterized by a Mean Time Between Failure at least equal to 20,000 hours.

20. The remote power system recited in claim 19 wherein said sump is a stainless steel tank built into said skid.