Drilling Rig Power Bus Management for Mud Pump Readiness
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Solution Overview
Problem
Drilling rig power systems face inefficiencies due to underutilized internal combustion engine (ICE) systems in mud pumps, leading to increased fuel consumption, emissions, and maintenance needs, while fully electric rigs suffer from electrical power distribution losses.
Innovation Solution
A rig mud pump drive system incorporating an ICE connected to a mechanical drive train with electric generators/motors, controlled by a power management system that optimizes ICE operation within its efficient range and maintains readiness through electric power assistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ICE system operates continuously to maintain readiness, then the mud pump drive remains in a state of readiness, but fuel consumption and emissions increase
Solution Approach 1:
The ICE system operates periodically rather than continuously - it runs during peak power requirements and cyclical loads, then shuts down during lower demand periods. The power management system monitors power requirements and activates the ICE only when needed, maintaining readiness through controlled periodic operation rather than continuous running.
Solution Approach 2:
The patent replaces continuous mechanical operation of the ICE with an electrical power management system that uses generators and energy storage devices. This substitution allows the system to maintain readiness through electrical power availability without requiring the ICE to run continuously, reducing fuel consumption while maintaining operational capability.
2Power
If the ICE system operates at peak power to meet maximum requirements, then power availability is sufficient, but the system is underutilized most of the time operating below peak power
Solution Approach 1:
The power management system dynamically adjusts ICE operation based on real-time power requirements. Rather than operating at fixed peak power settings, the system modulates ICE output to match actual demand, operating at optimal efficiency points when possible and only reaching peak power when truly needed. This dynamic adjustment eliminates the waste of operating below peak power while maintaining sufficient power availability.
Solution Approach 2:
The system changes operational parameters by using multiple power sources (ICE, generators, energy storage) in different combinations based on power requirements. This allows the ICE to operate at efficient parameter ranges rather than being constrained to peak power settings, improving energy efficiency while maintaining the ability to meet maximum power demands when required.
3Power
If the ICE system is oversized for peak power requirements, then peak power availability is ensured, but the system operates substantially below peak power most of the time
Solution Approach 1:
The power system is segmented into multiple independent power sources - the ICE, generator sets, and energy storage devices - rather than relying on a single oversized ICE. This segmentation allows each component to operate at its optimal capacity, with the ICE sized appropriately for efficient operation rather than being oversized for peak demands that are met by other segmented components.
Solution Approach 2:
The power management system provides multi-functionality by using different power sources for different operational scenarios. The ICE handles base load and efficient operation, generators provide peak power augmentation, and energy storage handles transient demands. This universal approach ensures peak power availability without requiring the ICE to be oversized, improving operational efficiency across all operating conditions.
4Reliability
If the ICE system operates continuously, then after-treatment systems function properly, but maintenance load and heat requirements increase
Solution Approach 1:
The ICE operates periodically with scheduled intervals that allow after-treatment systems to complete their regeneration cycles during operation. The power management system monitors after-treatment system status and coordinates ICE operation to provide necessary heat and load for proper functioning, then allows shutdown periods that reduce maintenance requirements compared to continuous operation.
Data Source
AI summary
A power system and method for the adaptive power control of a drilling rig. While operating the internal combustion engine in its efficient operating range, unrequired mechanical power is converted to electrical power for storage, or use via the electrical bus on the rig. When the internal combustion engine is not required to provide mechanical or electrical power it is deactivated, and then reactivated—electrical storage on the system in the meantime providing electrical power to the bus as required. The power supply and management system could be retroactively fitted to an existing drilling rig by the incorporation of a generator and electrical storage device thereon. The system and method of the present invention allow for the optimized use of combustion-based power on a drilling rig while minimizing environmental emissions from the idle running of the at least one internal combustion engine.