Devices, systems, and methods for drilling RIG power management

Abstract

A rig power management system may identify a power demand of a drilling rig. A rig power management system may when the power demand is greater than a threshold power setpoint, supplementing a rig power supply system with an energy storage system. A rig power management system may when the power demand is less than the threshold power setpoint, maintaining a power generation at an operating power setpoint to charge the energy storage system.

Description

DEVICES, SYSTEMS, AND METHODS FOR DRILLING RIG POWER MANAGEMENTCROSS-REFERENCE TO RELATED APPLICATION

[0001] The present document is based on and claims priority to US Provisional Patent Application No. 63 / 636,524, filed April 19, 2024, which is incorporated herein by reference in its entirety.BACKGROUND OF THE DISCLOSURE

[0002] Downhole drilling systems include multiple pieces of equipment. The equipment performs drilling activities, advancing a wellbore, reaming a wellbore, installing drill pipe, removing drill pipe, installing casing, grouting, pumping drilling fluid, performing administrative tasks, any other drilling activity, and combinations thereof. Electrical power may be supplied to the equipment in any manner. For example, a rig power supply system may include generators, grid power, battery power, and so forth. Electrical power may be a large expense and source of carbon emissions for a drilling system.SUMMARY

[0003] In some aspects, the techniques described herein relate to a method for rig power management. A power controller identifies a power demand of a drilling rig. When the power demand is greater than a threshold power setpoint, the power controller supplements a rig power supply system with an energy storage system. When the power demand is less than the threshold power setpoint, the power controller maintains a power generation at an operating power setpoint to charge the energy storage system.

[0004] In some aspects, the techniques described herein relate to a method for rig power management. A power controller monitors, over a monitoring period, a power supply from a rig power supply system and a state of charge of an energy storage system. The power controller identifies, over the monitoring period, a power supply pattern of the power supply. Based at least on part on the powersupply pattern and the state of charge, the power controller generates an operating power setpoint for the rig power supply system and the energy storage system. The operating power setpoint maintains the rig power supply system in a predetermined operating efficiency.

[0005] This summary is provided to introduce a selection of concepts that are further described in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. Additional features and aspects of embodiments of the disclosure will be set forth herein, and in part will be obvious from the description, or may be learned by the practice of such embodiments.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] In order to describe the manner in which the above-recited and other features of the disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings may be schematic or exaggerated representations of concepts, at least some of the drawings may be drawn to scale. Understanding that the drawings depict some example embodiments, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0007] FIG. 1 is a representation of a drilling system for drilling an earth formation, according to at least one embodiment of the present disclosure.

[0008] FIG. 2 is a schematic representation of a rig power management system, according to at least one embodiment of the present disclosure.

[0009] FIG. 3 is a representation of a rig power management system, according to at least one embodiment of the present disclosure.

[0010] FIG. 4-1 through FIG. 4-3 are power generation plots illustrating power generation over time, according to at least one embodiment of the present disclosure.

[0011] FIG. 5 is a flowchart of a method for drilling rig power management, according to at least one embodiment of the present disclosure.

[0012] FIG. 6 is a flowchart of a method for drilling rig power management, according to at least one embodiment of the present disclosure.

[0013] FIG. 7 is a representation of a computing system, according to at least one embodiment of the present disclosure.DETAILED DESCRIPTION

[0014] This disclosure generally relates to devices, systems, and methods for power management at a drilling rig. Drilling operations may utilize a variable amount of power. For example, during drilling operations, changes in drilling conditions, changing in drilling operations, and other changes of the drilling rig may cause the power demand to vary. A drilling rig may receive power from a rig power supply system. To supply the variable power, the rig power supply system may have a variable capacity. Changing the amount of power supplied by the rig power supply system may change the operational efficiency of the rig power supply system. Operating at a low efficiency may increase the operating costs of the drilling rig. For example, as discussed in further detail herein, the rig power supply system may include multiple generators (or power generation engines). The generators may have the highest operating efficiency at an efficiency utilization. Operating outside of the efficiency utilization may increase fuel consumption and / or increase wear and tear on the generators.

[0015] In accordance with at least one embodiment of the present disclosure, a rig power management system may monitor the power demand on the rig power supply system. The rig power management system may determine whether the power demand is greater than a threshold power setpoint. If the power demand is greater than the threshold power setpoint, then the rig power management systemmay supplement the power supply with power from an energy storage system. This may help to maintain the rig power supply system within the efficiency utilization. In this manner, the rig power management system may increase the amount of time the rig power management system stays within the efficiency utilization, thereby reducing the operating costs of the rig power supply system.

[0016] When the power demand is less than the threshold power setpoint, the rig power management system may charge the energy storage system. For example, the rig power management system may maintain the operation of the rig power supply within the efficiency utilization, using the power generation greater than the power demand to charge the energy storage system. This may maintain the operation of the rig power supply system within the efficiency utilization. In this manner, the rig power management system may increase the amount of time the rig power management system stays within the efficiency utilization, thereby reducing the operating costs of the rig power supply system.

[0017] FIG. 1 shows one example of a drilling system 100 for drilling an earth formation 101 to form a wellbore 102. The drilling system 100 includes a drill rig 103 used to turn a drilling tool assembly 104 which extends downward into the wellbore 102. The drilling tool assembly 104 may include a drill string 105, a bottomhole assembly (“BHA”) 106, and a bit 110, attached to the downhole end of drill string 105.

[0018] The drill string 105 may include several joints of drill pipe 108 connected end-to-end through tool joints 109. The drill string 105 transmits drilling fluid through a central bore and transmits rotational power from the drill rig 103 to the BHA 106. In some embodiments, the drill string 105 may further include additional components such as subs, pup joints, etc. The drill pipe 108 provides a hydraulic passage through which drilling fluid is pumped from the surface. The drilling fluid discharges through selected-size nozzles, jets, or other orifices in the bit 110 for the purposes of cooling the bit 110 and cutting structures thereon, and for lifting cuttings out of the wellbore 102 as it is being drilled.

[0019] The elements of the drilling system 100 may be powered by a rig power supply system 112. The rig power supply system 112 may include one or more prime movers 113 and an energy storage system 114 In some embodiments, one or more elements of the rig power supply system 112 are located on-site. For example, the rig power supply system 112 may be built and maintained at a location proximate to the drilling system 100, including on land owned or leased by the owner of the drilling system 100, within sight of the drilling system 100, or within an on-site distance of the drilling system 100. The on-site distance may be any distance, including 5 m, 10 m, 25 m, 50 m, 100 m, 250 m, 500 m, 1 ,000 m, 1 ,500 m, any other distance, and combinations thereof. In some embodiments, on-site power is power that is generated exclusively for the drilling system 100. In some embodiments, on-site power is power that is generated for the drilling system 100 and other drilling and / or hydrocarbon-processing systems located near the drilling system 100.

[0020] The prime movers 113 may be any type of power source. For example, the prime movers 113 may include one or more on-site generators. A generator may be a combustion engine powered by a combustion fuel diesel, gasoline, natural gas (including a mixture of one or more of methane, ethane, propane, butane, pentane, and hexane), any other hydrocarbon, hydrogen, any other combustion fuel, and combinations thereof. In some examples, the prime movers 113 may include an on-site renewable power source, such as solar, wind power, hydropower, geothermal power, tidal power generators, any other renewable power source, and combinations thereof. In some examples, the prime movers 113 may include grid power. Grid power may be power that may be generated remotely from the drilling system 100. Grid power may be power that is generated for a plurality of different locations, uses, or customers.

[0021] In some embodiments, the prime movers 113 include a combination of power supplies. For example, the prime movers 113 may include a combination of two or more of a combustion generator, renewable power, and grid power. This may increase the diversity of power supply to the drilling system 100, therebyallowing the drilling system 100 to continue operations if a failure of one of the prime movers 113 occurs.

[0022] The energy storage system 11 may store energy for use by the drilling system 100. The energy storage system 114 may be chargeable. For example, energy may be added to the energy storage system 114. When energy is added to the energy storage system 114, at least a portion of the input energy may be stored as potential energy. The energy storage system 114 may discharge the potential energy to convert it to electricity. The energy storage system 114 may store energy in any manner. For example, the energy storage system 114 may include one or more chemical batteries or battery banks. In some examples, the energy storage system 114 may include water energy storage, such as a water tank or pond located at an elevated location. To store energy, water is pumped to the elevated pond. To generate energy, water may be released from the elevated pond to a lower pond to drive a turbine. In some examples, the energy storage system 114 may include any other energy storage system. In some embodiments, the energy storage system 114 is located on-site.

[0023] As discussed herein, during operation of the drilling system 100, the powered elements of the drilling system 100 may draw power from the rig power supply system 112 with a power demand. The power demand may be the total amount of power drawn from the rig power supply system 112 by all of the components of the drilling system 100. The power demand may fluctuate. For example, changes in the operating status of the various components of the drilling system 100 may increase or decrease their respective power draw. The rig power supply system 112 provides variable power to the drilling system 100 based on the variable demand.

[0024] The prime movers 113 have a utilization efficiency, which may be the efficiency of operation at which the prime movers 113 have the lowest operating cost. The utilization efficiency may be based on any metric. For example, the utilization efficiency may be based on a pre-determined operating efficiency. The pre-determined operating efficiency may be based on electricity supply cost (e.g.,fuel cost, grid power cost), carbon dioxide emissions, electricity availability (e.g., solar / wind power availability), equipment maintenance (e.g., equipment wear and tear), any other efficiency metric, and combinations thereof. The pre-determined operating efficiency may be identified to reduce the total operating costs. For example, when the prime movers 113 operate at the utilization efficiency (and the pre-determined operating efficiency, the operating costs of the drilling system 100 may be decreased and / or the operating efficiency of the drilling system 100 may be increased.

[0025] The energy storage system 114 may provide supplemental or auxiliary power to the prime movers 113 to provide power to the drilling system 100. In some situations, the energy storage system 114 may provide power to supplement power demand peaks. For example, when the power demand of the drilling system 100 peaks (e.g., temporarily increases), the energy storage system 114 may provide power to the rig power supply system 112 to cover the increase in the power demand. As discussed herein, the prime movers 113 may be capable of charging the energy storage system 114. When the power generation at the utilization efficiency is greater than the power demand, the prime movers 113 may charge the energy storage system 114.

[0026] The energy storage system 114 has a state of charge (SOC), which may be a representation of the amount of available and / or accessible energy in the energy storage system 114. In some embodiments, the SOC is a percentage of the total available energy in the energy storage system 114. In some embodiments, the SOC is a representation of the total amount of energy available in the energy storage system 114 (e.g., the available energy in ampere-hours (Ahr), watt-hours (Wh), kilowatt-hours (kWh), megawatt-hours (MWh), gigawatt- hours (GWh), and so forth). In some embodiments, when the SOC of the energy storage system 114 is below a charging threshold, the rig power supply system 112 causes the prime movers 113 to charge the energy storage system 114. The charging threshold may be a representation of the minimum level of charge to maintain in the energy storage system 114. In some embodiments, when the SOCof the energy storage system 114 is within a charging range, the rig power supply system 112 may cause the prime movers 113 to charge the energy storage system 114 if the power generation at the utilization efficiency is greater than the power demand. This may help to maintain the prime movers 113 at or near to the utilization efficiency.

[0027] The BHA 106 may include the bit 110 or other components. An example BHA 106 may include additional or other components (e.g., coupled between to the drill string 105 and the bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement-while-drilling (“MWD”) tools, loggingwhile-drilling (“LWD”) tools, downhole motors, underreamers, section mills, hydraulic disconnects, jars, vibration or dampening tools, other components, or combinations of the foregoing. The BHA 106 may further include a rotary steerable system (RSS). The RSS may include directional drilling tools that change a direction of the bit 110, and thereby the trajectory of the wellbore. At least a portion of the RSS may maintain a geostationary position relative to an absolute reference frame, such as gravity, magnetic north, and / or true north. Using measurements obtained with the geostationary position, the RSS may locate the bit 110, change the course of the bit 110, and direct the directional drilling tools on a projected trajectory.

[0028] In general, the drilling system 100 may include other drilling components and accessories, such as special valves (e.g., kelly cocks, blowout preventers, and safety valves). Additional components included in the drilling system 100 may be considered a part of the drilling tool assembly 104, the drill string 105, or a part of the BHA 106 depending on their locations in the drilling system 100.

[0029] The bit 110 in the BHA 106 may be any type of bit suitable for degrading downhole materials. For instance, the bit 110 may be a drill bit suitable for drilling the earth formation 101 . Example types of drill bits used for drilling earth formations are fixed-cutter or drag bits. In other embodiments, the bit 110 may be a mill used for removing metal, composite, elastomer, other materials downhole, or combinations thereof. For instance, the bit 110 may be used with a whipstock tomill into casing 107 lining the wellbore 102. The bit 110 may also be a junk mill used to mill away tools, plugs, cement, other materials within the wellbore 102, or combinations thereof. Swarf or other cuttings formed by use of a mill may be lifted to surface, or may be allowed to fall downhole.

[0030] FIG. 2 is a schematic representation of a rig power management system 216, according to at least one embodiment of the present disclosure. The rig power management system 216 may include a power controller 218. As used herein, the power controller 218 may include any type of controller unit, such as a programmable logic controller (PLC), a personal computer (PC), an industrial PC, a digital control system (DCS), any other controller, and combinations thereof. The power controller 218 may manage the allocation of power of one or more prime movers 213 and an energy storage system 214 based on a rig power demand 220. The power controller 218 may control power at the prime movers 213 by instructing the prime movers 213 to start or stop one or more of the prime movers 213. For example, the power controller 218 may monitor the power demand 220 and, if the power demand 220 is greater than the power generation of the prime movers 213 and the energy storage system 214, then the power controller 218 may instruct the prime movers 213 to start an additional generator or connect an additional power source. In some examples, if the power demand 220 is less than the power generation of the prime movers 213, then the power controller 218 may instruct the prime movers 213 to turn off one of the generators or disconnect one of the power sources. In this manner, operating the prime movers 213 may include operating the prime movers 213 at less than an entirety of the total number of generators. As discussed in further detail herein, the starting and stopping of the prime movers 213 may be based on a timer 230 setpoint.

[0031] The rig power management system 216 may include a rig power control system 222. The rig power control system 222 may control the operation of the prime movers 213. For example, the rig power control system 222 may regulate the rotational rate (e.g., in rotations per minute, RPM) of the generators of the prime movers 213, the frequency of the generators of the prime movers 213, thevoltage of the generators of the prime movers 213, control the load balance between the generators of the prime movers 213, and so forth. In some embodiments, the rig power control system 222 is independent from the power controller 218. For example, the power controller 218 may control which of the generators are activated, and the rig power control system 222 may control the operation of the activated generators. In some embodiments, the rig power control system 222 is a third-party controller. For example, the rig power control system 222 may be provided by the manufacturer of the prime movers 213. Maintaining the power controller 218 separate from the rig power control system 222 may facilitate a reduction in the processing load on the power controller 218. This may improve the responsiveness of the power controller 218 to changes in the power demand 220. In this manner, the power controller 218 may operate in real-time or near real-time to respond to sudden changes in the power demand 220.

[0032] The power controller 218 may include various managers, monitoring devices (e.g. communication modules, input / output modules, power monitoring devices, etc.), or other controllers (e.g. PLCs, remote PLC couplers, PC, industrial PCs, Energy Storage System 214 etc.) that monitor and provide input to determine which of the prime movers 213 to connect and / or turn on. For example, the power controller 218 may include an SOC manager 224. The SOC manager 224 may be in communication with the energy storage system 214 and monitor the SOC of the energy storage system 214. The SOC manager 224 may monitor any aspect of the SOC, including the SOC as a percentage of the total charge, the SOC as an amount of stored energy, the rate of change of the SOC (e.g., the rate of discharge, the rate of charging), the SOC of different portions of the energy storage system 214 (e.g., different batteries or battery banks within the energy storage system 214), any other aspect of the SOC of the energy storage system 214, and combinations thereof. The power controller 218 may utilize the SOC to manage the operation of the prime movers 213. For example, if the power demand 220 is less than the utilization efficiency of the number of currently operating generators and the SOC of the energy storage system 214 is less than a charging threshold,then the power controller 218 may connect the prime movers 213 to the energy storage system 214 to cause the prime movers 213 to charge the energy storage system 214. This may maintain the power demand 220 within the efficiency utilization while increasing the SOC of the energy storage system 214. In some examples, the power demand 220 may increase above the efficiency utilization and the energy storage system 214 may be above the charging threshold. In this situation, the energy storage system 214 may supplement the power generation of the prime movers 213 with the energy storage system 214. This may allow the prime movers 213 to stay within the efficiency utilization for longer without adding an additional generator (which would cause all of the prime movers 213 to operate outside of the efficiency utilization).

[0033] The power controller 218 may further receive power consumption information from a rig kW manager 226. The rig kW manager 226 may receive information related to the power demand 220 from any location. For example, the rig kW manager 226 may receive power demand information by monitoring the outgoing power from the prime movers 213. In some examples, the rig kW manager 226 may receive power demand information from the rig power control system 222. In some examples, the rig kW manager 226 may receive power demand information from the prime movers 213. In some examples, the rig kW manager 226 may include multiple power monitors that may monitor the power draw from individual components that generate the power demand 220. In some examples, the rig kW manager 226 may be connected to a rig management system to identify which pieces of equipment are operating and their respective applied load. The power controller 218 may receive the power draw from the rig kW manager 226 to determine the power demand 220 on the drilling system. As discussed herein, the power controller 218 may use the power demand 220 to make decisions regarding the number of prime movers 213 operating and the operation of the energy storage system 214 with respect to the prime movers 213 (e.g., supplementing power to the prime movers 213, receiving charge from the prime movers 213).

[0034] The power controller 218 may further include a power limit manager 228. The power limit manager 228 may monitor the power limit of the prime movers 213. The power limit may be the maximum amount of power that the prime movers 213 can output before failure and / or damage to the prime movers 213. As discussed herein, the power demand 220 may fluctuate, at times in an unpredictable manner. The power limit manager 228 may work with or permit without interfering with the rig power control system 222 to maintain sufficient capacity in the power generation of the prime movers 213 to provide power during a power fluctuation. In some embodiments, the power limit manager 228 may help to determine the efficiency utilization of the prime movers 213. The power limit manager 228 may be in communication with the rig power control system 222 to manage operation of the prime movers 213.

[0035] The power controller 218 may adjust / change / update a timer 230 to manage the prime movers 213. The power controller 218 may monitor the power status and / or identify a power supply pattern of the rig power management system 216 over time. The power controller 218 may monitor the power status and / or identify the power supply pattern of the rig power management system 216 over a monitoring period. In some embodiments, the monitoring period may be in a range having an upper value, a lower value, or upper and lower values including any of 1 sec, 1 min., 2 min, 5 min., 10 min., 15 min., 20 min., 25 min., 30 min., 35 min., 40 min., 45 min., 50 min., 55 min., 1 hour, 1.5 hours, 2 hours, 3 hours, 4 hours, 6 hours, 9 hours, 12 hours, 18 hours, 1 day, 2 days, 3 days, 1 week, 1 month, 1 year or any value therebetween. For example, the monitoring period may be greater than 1 sec. In another example, the monitoring period may be less than 1 year. In yet other examples, the monitoring period may be any value in a range between 1 sec. and 1 year. In some embodiments, it may be critical that the monitoring period is between 15 min. and 45 min. to use the past performance of the rig power management system 216 to manage the power system of the rig power management system 216.

[0036] The power controller 218 may monitor any aspect of the power status of the rig power management system 216 over time to identify the power supply pattern the adjust the timer 230 to respond (start / stop prime movers 213) in accordance to drilling condition. For example, the power controller 213 may monitor the power demand 220 over time. The power controller 218 may receive the power demand 220 over time from the rig kW manager 226. The power controller 218 may identify any type of power supply pattern, including the average power demand 220, increases in the power demand 220, decreases in the power demand 220, fluctuation patterns in the power demand 220, any other trends in the power demand 220, and combinations thereof. The power controller 218 may receive the analysis of the power demand 220, including the power supply pattern, and determine how to place the prime movers 213 within the efficiency utilization and / or determine how to extend the amount of time the prime movers 213 are maintained within the efficiency utilization by adjusting the timer 230. For example, the power controller 218 may determine that, based on the power supply pattern, the prime movers 213 may be maintained within the efficiency utilization for an additional period of time by supplementing power generation with the energy storage system 214. In some examples, the power controller 218 may determine that, based on the existing patterns identified by the power controller 218, the prime movers 213 may be maintained within the efficiency utilization for an additional period of time by charging the energy storage system 214. As discussed herein, this may help to increase the operating efficiency of the rig power management system 216, thereby decreasing operating costs.

[0037] FIG. 3 is a representation of a rig power management system 316, according to at least one embodiment of the present disclosure. Each of the components of the rig power management system 316 can include software, hardware, or both. For example, the components can include one or more instructions stored on a computer-readable storage medium and executable by processors of one or more computing devices, such as a client device or server device. When executed by the one or more processors, the computer-executableinstructions of the rig power management system 316 can cause the computing device(s) to perform the methods described herein. Alternatively, the components can include hardware, such as a special-purpose processing device to perform a certain function or group of functions. Alternatively, the components of the rig power management system 316 can include a combination of computerexecutable instructions and hardware.

[0038] Furthermore, the components of the rig power management system 316 may, for example, be implemented as one or more operating systems, as one or more stand-alone applications, as one or more modules of an application, as one or more plug-ins, as one or more library functions or functions that may be called by other applications, and / or as a cloud-computing model. Thus, the components may be implemented as a stand-alone application, such as a desktop or mobile application. Furthermore, the components may be implemented as one or more web-based applications hosted on a remote server. The components may also be implemented in a suite of mobile device applications or “apps.”

[0039] The rig power management system 316 may manage the power distribution of a rig power supply 312. The rig power supply 312 may include any power source that provides power to a drilling rig. The rig power supply 312 may include any power source. For example, the rig power supply 312 may include one or more combustion generators 332, grid power 334, renewable power sources 336, an energy storage system 314, any other power source, and combinations thereof. A rig power supply manager 337 may manage the operation of the individual elements of the rig power supply 312. For example, the rig power supply manager 337 may manage the operation of the generators 332, including managing load, frequency, RPM, any other aspect of the generators, and combinations thereof. In some examples, the rig power supply manager 337 may manage the operation of any other element of the rig power supply 312, including managing local voltage transformation and distribution of grid power 334 and / or renewable power sources 336.

[0040] The rig power management system 316 may monitor a rig power demand 320. The rig power demand 320 may originate from any source or equipment on the drilling rig. A non-exhaustive list of examples of drilling equipment may include a draw works 338, drilling fluid pumps 340, auxiliary equipment 342, any other drilling equipment, and combinations thereof.

[0041] In some embodiments, a rig power supply manager 337 manages the operations of individual rig equipment. For example, the rig power supply manager 337 may adjust the operation of one or more individual rig components to adjust the power demand. In some examples, the rig power supply manager 337 may reduce the speed of the drawworks. In some examples, the rig power supply manager 337 may reduce the volume of mud pumped downhole by slowing down the pumps.

[0042] The rig power management system 316 may further include a power controller 318. The power controller 318 may manage which of the elements of the rig power supply 312 are connected to and provide power to supply the rig power demand 320. For example, the power controller 318 may include a power supply switch 344. The power supply switch 344 may be connected to the rig power supply 312 may switch a connection of the rig power supply 312 to connect or disconnect an element of the rig power supply 312 to supply the rig power demand 320.

[0043] In some embodiments, the power supply switch 344 connects different elements of the rig power supply 312 to the rig power demand 320. For example, the power supply switch 344 may connect one or more of the generators 332, the grid power 334, the renewable power sources 336, the energy storage system 314, any other power source, and combinations thereof. As a specific, non-limiting example, the power supply switch 344 may connect the generators 332 and the grid power 334 to provide the power to supply the rig power demand 320. As a specific, non-limiting example, the power supply switch 344 may connect the generators 332 and the renewable power sources 336. As a specific, non-limiting example, the power supply switch 344 may connect the generators 332 and the energy storage system 314. As a specific, non-limiting example, the power supplyswitch 344 may connect the grid power 334 and the renewable power sources 336. As a specific, non-limiting example, the power supply switch 344 may connect the grid power 334 and the energy storage system 314. As a specific, non-limiting example, the power supply switch 344 may connect the renewable power sources 336 and the energy storage system 314. As a specific, non-limiting example, the power supply switch 344 may connect the generators 332, the grid power 334, and the renewable power sources 336. As a specific, non-limiting example, the power supply switch 344 may connect the generators 332, the grid power 334, and the energy storage system 314. As a specific, non-limiting example, the power supply switch 344 may connect the generators 332, the renewable power sources 336, and the energy storage system 314. As a specific, non-limiting example, the power supply switch 344 may connect the grid power 334, the renewable power sources 336, and the energy storage system 314. As a specific, non-limiting example, the power supply switch 344 may connect the generators 332, the grid power 334, the renewable power sources 336, and the energy storage system 314.

[0044] In some embodiments, the power supply switch 344 may connect different components of the same type of rig power supply 312. For example, the generators 332 may include multiple different generators 332. As the rig power demand 320 increases, the power supply switch 344 may connect additional generators 332 to provide power for the rig power demand 320. As the rig power demand 320 decreases, the power supply switch 344 may disconnect one or more of the generators 332 to increase the operating efficiency of the individual generators 332.

[0045] Each component of the rig power supply 312 may have an efficiency utilization. The efficiency utilization may be the utilization at which the particular component operates efficiently. For example, the generators 332 may have an efficiency utilization that may result in an efficient electrical power generation, as calculated by volume of fuel per unit at the electrical power generate value (e.g., kW per gallon / liter). The grid power 334 may have different price points for operation at different times of day (e.g., high price for power in the afternoon, lowprice for power in the evening). The renewable power sources 336 may have an efficiency based on the availability of the power (e.g., periods of high sunlight for solar power, periods of high wind for wind power). The energy storage system 314 may have a particular SOC or SOC range at which the charge / discharge rate is increased and / or at which the charge / discharge sequence may reduce the degradation of the battery.

[0046] In accordance with at least one embodiment of the present disclosure, the power controller 318 may control which elements of the rig power supply 312 are connected to the rig power demand 320 to the rig power supply 312 in the efficiency utilization. To identify which elements of the rig power supply 312 to connect and / or disconnect, the power controller 318 may utilize one or more analysis managers. For example, the power controller 318 may utilize an SOC manager to monitor the SOC of the energy storage system 314. If the SOC of the energy storage system 314 is below a charging threshold, the power supply switch 344 may cause the other elements of the rig power supply 312 to charge the energy storage system 314. If the energy storage system 314 is above the charging threshold, the power controller 318 may cause the energy storage system 314 to provide power to satisfy the rig power demand 320.

[0047] The power controller 318 may further include a rig kW manager 326. The rig kW manager 326 may monitor the power draw on the rig power demand 320 to determine how much power the rig power supply 312 is to supply. In some embodiments, the rig kW manager 326 may communicate with the rig power supply manager 337 to determine the power draw by the rig power demand 320.

[0048] The power controller 318 may further include a power limit manager 328 that may analyze the power limit for the various elements of the rig power supply 312 and maintain a buffer to prevent the power limit from being exceeded by variations in the rig power demand 320.

[0049] As discussed herein, the power controller 318, which includes a timer 330, that may analyze trends in the power supply and / or the power draw of the rigpower demand 320. As discussed herein, the power controller 318 may analyze the trends and utilize the timer 330 to determine the rate at which one, or plurality, of the elements of the rig power supply 312 to connect to supply power to the rig power demand 320.

[0050] FIG. 4-1 is a representation of a first power generation plot 446-1 having time 448 on the x-axis (e.g., horizontal axis) and power 450 on the y-axis (e.g., vertical axis). The first power generation plot 446-1 includes a power demand line 452. The power demand line 452 may represent the total power demand of the drilling system. Over a first period 454-1 , power, to meet the power demand of the power demand line 452 may be supplied by a first generator 432-1 and a second generator 432-2. While operating in the first period 454-1 , the first generator 432- 1 and the second generator 432-2 may be operating at or near the utilization efficiency while meeting the power demand.

[0051] In a second period 454-2, power demand, represented by the power demand line 452, may increase. The first generator 432-1 and the second generator 432-2, combined, may not be able to supply the increased power demand. Conventionally, to meet the increased power demand, a third generator may be turned on or connected. But turning on a third generator may cause the first generator 432-1 and the second generator 432-2 to operate at less than the utilization efficiency.

[0052] In accordance with at least one embodiment of the present disclosure, a power controller may identify that an energy storage system 414 may supplement the power supply from the first generator 432-1 and the second generator 432-2 to meet the increased power demand. The power controller may identify that the energy storage system 414 may be sufficient to meet the increased power demand for a period of time. This may increase the amount of time at which the first generator 432-1 and the second generator 432-2 may operate at the utilization efficiency.

[0053] In a third period 454-3, the power demand may further increase. The energy storage system 414 may be insufficient to supplement the power supply for the increased power demand. This may cause power controller to turn on a third generator 432-3. The load between the three generators (collectively 432) may be managed by a rig power supply manager and / or power controller, which may balance the load across the generators 432. This may reduce the individual load per generator, which may cause the generators 432 to operate out of the utilization efficiency.

[0054] In some embodiments, in the third period 454-3, the generators 432 may charge the energy storage system 414. For example, the power controller may increase the total power demand to charge the energy storage system 414. This may help to recover at least a portion of the SOC expended in the second period 454-2.

[0055] FIG. 4-2 is a representation of a second power generation plot 446-2 having time 448 on the x-axis (e.g., horizontal axis) and power 450 on the y-axis (e.g., vertical axis). The second power generation plot 446-2 includes a power demand line 452. The power demand line 452 may represent the total power demand of the drilling system. Over a first period 454-1 , power, to meet the power demand of the power demand line 452 may be supplied by a first generator 432-1 and a second generator 432-2. While operating in the first period 454-1 , the first generator 432-1 and the second generator 432-2 may be operating at or near the utilization efficiency while meeting the power demand.

[0056] In a second period 454-2, the power demand may be increased. A power controller may determine that, at the increased power demand, the energy storage system 414 may at least partially supplement power supply to meet the increased power demand. The power controller may further determine that the utilization of the first generator 432-1 and the second generator 432-2 may be increased to meet the increased power demand. The power controller may determine that while the increased utilization may result in a negligible increase, or net zero increase, in efficiency, the negligible / net zero increase in efficiency may be offset by theamount of time the rig power supply system may operate with two generators 432. This may result in a maintained higher overall efficiency of the rig power supply system.

[0057] FIG. 4-3 is a representation of a third power generation plot 446-3 having time 448 on the x-axis (e.g., horizontal axis) and power 450 on the y-axis (e.g., vertical axis). The third power generation plot 446-3 includes a power demand line 452. The power demand line 452 may represent the total power demand of the drilling system. Over a first period 454-1 , power, to meet the power demand of the power demand line 452 may be supplied by a first generator 432-1 and a second generator 432-2. While operating in the first period 454-1 , the first generator 432- 1 and the second generator 432-2 may be operating at or near the utilization efficiency while meeting the power demand.

[0058] In a second period 454-2, the power controller may determine to charge the energy storage system 414. In some embodiments, the power controller may increase the power generation of the second generator 432-2 and the first generator 432-1 to charge the energy storage system 414. In some embodiments, the power demand may decrease, and the power controller may maintain the power generation of the generators 432 to charge the energy storage system 414. In this manner, the power controller may utilize charging of the energy storage system 414 to extend the amount of time in which the generators 432 operate at the utilization efficiency.

[0059] FIG. 5 and FIG. 6, the corresponding text, and the examples provide a number of different methods, systems, devices, and computer-readable media of the rig power management system 216. In addition to the foregoing, one or more embodiments can also be described in terms of flowcharts comprising acts for accomplishing a particular result, as shown in FIG. 5 and FIG. 6. FIG. 5 and FIG. 6 may be performed with more or fewer acts. Further, the acts may be performed in differing orders. Additionally, the acts described herein may be repeated or performed in parallel with one another or parallel with different instances of the same or similar acts.

[0060] As mentioned, FIG. 5 illustrates a flowchart of a series of acts or a method 556 for rig power management of a downhole drilling rig, according to at least one embodiment of the present disclosure. While FIG. 5 illustrates acts according to one embodiment, alternative embodiments may omit, add to, reorder, and / or modify any of the acts shown in FIG. 5. The acts of FIG. 5 can be performed as part of a method. Alternatively, a computer-readable medium can comprise instructions that, when executed by one or more processors, cause a computing device to perform the acts of FIG. 5. In some embodiments, a system can perform the acts of FIG. 5.

[0061] A power controller may identify a power demand of a downhole drilling system at 558. The power controller may identify when the power demand is greater than a threshold power setpoint. The threshold power setpoint may be based on the utilization efficiency of a rig power supply system. For example, the threshold power setpoint may be based on the highest efficiency of utilization of the rig power supply system. In some embodiments, when the rig power supply system is operating at the threshold power setpoint, the rig power supply system may be operating at an operating power setpoint. In some embodiments, the operating power setpoint is the setpoint at which the rig power supply system is operating at any given time. In some embodiments, the operating power setpoint is the setpoint at which the rig power system operates at the utilization efficiency. In some embodiments, the operating power setpoint includes a power generation range. For example, the operating power setpoint may include a power generation range related to the utilization efficiency. The power generation range may be power generation within 25-100% or any value therebetween.

[0062] When the power demand is greater than the threshold power setpoint, the power controller may supplement the rig power supply system with an energy storage system at 560. For example, the power controller may connect the energy storage system to the power supply. This may allow the generators or other elements of the rig power supply system to continue to operate at the utilization efficiency for a longer period of time.

[0063] When the power demand is less than the threshold power setpoint, the power controller may maintain the power generation at the operating power setpoint to charge the energy storage system at 562. Maintaining the power generation at the operating power setpoint to may help to increase the operating efficiency of the rig power supply system while charging the energy storage system for later use.

[0064] In some embodiments, the power controller may adjust the threshold power setpoint and / or the operating power setpoint. For example, as discussed herein, the power controller may increase the threshold power setpoint and / or the operating power setpoint to extend the amount of time the rig power supply system operates in at or near the utilization efficiency while supplementing the power supply with the energy storage system. In some examples, the power controller may decrease the threshold power setpoint and / or the operating power setpoint while charging the energy storage system.

[0065] As mentioned, FIG. 6 illustrates a flowchart of a series of acts or a method 664 for rig power management of a downhole drilling rig, according to at least one embodiment of the present disclosure. While FIG. 6 illustrates acts according to one embodiment, alternative embodiments may omit, add to, reorder, and / or modify any of the acts shown in FIG. 6. The acts of FIG. 6 can be performed as part of a method. Alternatively, a computer-readable medium can comprise instructions that, when executed by one or more processors, cause a computing device to perform the acts of FIG. 6. In some embodiments, a system can perform the acts of FIG. 6.

[0066] A power controller may monitor, over a monitoring period, a power supply from a rig power supply system and a state of charge of an energy storage system at 666. The power controller may identify, over the monitoring period, a power supply pattern of the power supply at 668. As discussed herein, the power supply pattern may be any power supply pattern, including instantaneous power demand or supply, average power supply and demand, power demand or supplyincrease, power demand or supply decrease, power demand or supply variation, any other power demand or supply pattern, and combinations thereof.

[0067] Based at least in part on the power supply pattern and the state of charge, the power controller may generate an operating power setpoint for the rig power supply system and the energy storage system at 670. The operating power setpoint may be the setpoint at which the generators or other power generating element of the rig power supply system generate electricity to power the drilling rig system. The operating power setpoint may maintain the rig power supply system in a pre-determined operating efficiency. In some embodiments, the predetermined operating efficiency may be the same as or similar to the utilization efficiency discussed herein. In some embodiments, operating at the operating power setpoint may include supplementing the rig power supply system with the energy storage system. In some embodiments, the operating at the operating power setpoint may include charging the energy storage system. In some embodiments, based on the operating power setpoint, the power controller may power or depower at least a portion of the rig power supply system. In some embodiments, as discussed herein, generating the operating power setpoint may include changing the utilization of the rig power supply system.

[0068] FIG. 7 illustrates certain components that may be included within a computer system 700. One or more computer systems 700 may be used to implement the various devices, components, and systems described herein.

[0069] The computer system 700 includes a processor 701 . The processor 701 may be a general-purpose single or multi-chip microprocessor (e.g., an Advanced RISC (Reduced Instruction Set Computer) Machine (ARM)), a special purpose microprocessor (e.g., a digital signal processor (DSP)), a microcontroller, a programmable gate array, etc. The processor 701 may be referred to as a central processing unit (CPU). Although just a single processor 701 is shown in the computer system 700 of FIG. 7, in an alternative configuration, a combination of processors (e.g., an ARM and DSP) could be used.

[0070] The computer system 700 also includes memory 703 in electronic communication with the processor 701. The memory 703 may be any electronic component capable of storing electronic information. For example, the memory 703 may be embodied as random access memory (RAM), read-only memory (ROM), magnetic disk storage media, optical storage media, flash memory devices in RAM, on-board memory included with the processor, erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM) memory, registers, and so forth, including combinations thereof.

[0071] Instructions 705 and data 707 may be stored in the memory 703. The instructions 705 may be executable by the processor 701 to implement some or all of the functionality disclosed herein. Executing the instructions 705 may involve the use of the data 707 that is stored in the memory 703. Any of the various examples of modules and components described herein may be implemented, partially or wholly, as instructions 705 stored in memory 703 and executed by the processor 701 . Any of the various examples of data described herein may be among the data 707 that is stored in memory 703 and used during execution of the instructions 705 by the processor 701 .

[0072] A computer system 700 may also include one or more communication interfaces 709 for communicating with other electronic devices. The communication interface(s) 709 may be based on wired communication technology, wireless communication technology, or both. Some examples of communication interfaces 709 include a Universal Serial Bus (USB), an Ethernet adapter, a wireless adapter that operates in accordance with an Institute of Electrical and Electronics Engineers (IEEE) 802.11 wireless communication protocol, a Bluetooth® wireless communication adapter, and an infrared (IR) communication port.

[0073] A computer system 700 may also include one or more input devices 711 and one or more output devices 713. Some examples of input devices 711 include a keyboard, mouse, microphone, remote control device, button, joystick, trackball,touchpad, and lightpen. Some examples of output devices 713 include a speaker and a printer. One specific type of output device that is typically included in a computer system 700 is a display device 715. Display devices 715 used with embodiments disclosed herein may utilize any suitable image projection technology, such as liquid crystal display (LCD), light-emitting diode (LED), gas plasma, electroluminescence, or the like. A display controller 717 may also be provided, for converting data 707 stored in the memory 703 into text, graphics, and / or moving images (as appropriate) shown on the display device 715.

[0074] The various components of the computer system 700 may be coupled together by one or more buses, which may include a power bus, a control signal bus, a status signal bus, a data bus, etc. For the sake of clarity, the various buses are illustrated in FIG. 7 as a bus system 719.

[0075] The embodiments of the rig power management system have been primarily described with reference to wellbore drilling operations; the rig power management system described herein may be used in applications other than the drilling of a wellbore. In other embodiments, rig power management system according to the present disclosure may be used outside a wellbore or other downhole environment used for the exploration or production of natural resources. For instance, rig power management system of the present disclosure may be used in a borehole used for placement of utility lines. Accordingly, the terms “wellbore,” “borehole” and the like should not be interpreted to limit tools, systems, assemblies, or methods of the present disclosure to any particular industry, field, or environment.

[0076] One or more specific embodiments of the present disclosure are described herein. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, not all features of an actual embodiment may be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous embodiment-specific decisions will be made to achieve the developers’ specificgoals, such as compliance with system -related and business-related constraints, which may vary from one embodiment to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0077] Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. For example, any element described in relation to an embodiment herein may be combinable with any element of any other embodiment described herein. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within 5%, within 1 %, within 0.1 %, or within 0.01 % of a stated value.

[0078] A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function” clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Eachaddition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims.

[0079] The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that is within standard manufacturing or process tolerances, or which still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1 % of, within less than 0.1 % of, and within less than 0.01 % of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to “up” and “down” or “above” or “below” are merely descriptive of the relative position or movement of the related elements.

[0080] The present disclosure may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments are to be considered as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. Changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

CLAIMSWhat is claimed is:1 . A method for rig power management, the method comprising: identifying a power demand of a drilling rig; when the power demand is greater than a threshold power setpoint, supplementing a rig power supply system with an energy storage system; and when the power demand is less than the threshold power setpoint, maintaining a power generation at an operating power setpoint to charge the energy storage system.

2. The method of claim 1 , wherein supplementing the rig power supply system includes supplementing the rig power supply system to maintain the operating power setpoint.

3. The method of claim 2, wherein the operating power setpoint is at a utilization efficiency for the rig power supply system.

4. The method of claim 1 , wherein the operating power setpoint is less than the threshold power setpoint.

5. The method of claim 1 , wherein the operating power setpoint is less than a power limit of the rig power supply system.

6. The method of claim 1 , wherein supplementing the rig power supply system includes supplementing the rig power supply system until a state of charge of the energy storage system is less than a charging threshold.

7. The method of claim 1 , wherein identifying the power demand includes identifying the power demand over a monitoring period.

8. The method of claim 1 , wherein identifying the power demand includes identifying the power demand at the rig power supply system.

9. The method of claim 1 , wherein the rig power supply system includes a plurality of generators, and wherein the threshold power setpoint includes operation of less than an entirety of the plurality of generators.

10. The method of claim 9, further comprising managing the plurality of generators to maintain each of the plurality of generators at a predetermined operating efficiency.

11. The method of claim 1 , further comprising adjusting the operating power setpoint based at least in part on the power demand and a state of charge of the energy storage system.

12. A method for rig power management, the method comprising: monitoring, over a monitoring period, a power supply from a rig power supply system and a state of charge of an energy storage system; identifying, over the monitoring period, a power supply pattern of the power supply; and based at least on part on the power supply pattern and the state of charge, generating an operating power setpoint for the rig power supply system and the energy storage system, the operating power setpoint maintaining the rig power supply system in a pre-determined operating efficiency.

13. The method of claim 12, wherein the operating power setpoint includes supplementing the rig power supply system with the energy storage system.

14. The method of claim 12, wherein the operating power setpoint includes charging the energy storage system with the rig power supply system.

15. The method of claim 12, further comprising, based on the operating power setpoint, powering or depowering at least a portion of the rig power supply system.

16. The method of claim 12, wherein identifying the power supply pattern includes identifying that the rig power supply system is operating at autilization, and wherein generating the operating power setpoint includes changing the utilization of the rig power supply system.

17. The method of claim 16, wherein changing the utilization includes increasing the utilization of the rig power supply system to prevent starting up a generator of the rig power supply system.

18. A rig power management system, comprising: a plurality of generators; an energy storage system; and a power controller including a processor and memory, the memory including instructions that cause the processor to: identify a power demand of a drilling rig; when the power demand is greater than a threshold power setpoint, supplement a power generation of the plurality of generators with the energy storage system; and when the power demand is less than the threshold power setpoint, maintaining the power generation of the plurality of generators at an operating power setpoint to charge the energy storage system.

19. The rig power management system of claim 18, wherein supplementing the power generation of the plurality of generators includes supplementing the power generation of the plurality of generators to maintain the operating power setpoint.

20. The rig power management system of claim 19, wherein the operating power setpoint is at a utilization efficiency for the plurality of generators.

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