Dual Fuel Engine Generator Power Switching for Drilling Rig Load Transients
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Solution Overview
Problem
Drilling rigs face inefficiencies and high emissions due to the limitations of dual fuel engine/generators in responding to dynamic power demands, leading to reduced productivity and increased fuel consumption, especially during intermittent load requirements like tripping operations.
Innovation Solution
An energy storage system is integrated with dual fuel engine/generators, allowing for power switching between the engine/generator and storage based on load requirements, using a silicon-controlled rectifier and phase microcontroller to optimize power delivery and reduce reliance on resistive load banks, enabling efficient energy recovery and reduced fuel consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If dual fuel engine/generators are used to supply power to drilling rig loads, then fuel consumption and emissions are reduced compared to diesel engines, but the system cannot respond quickly enough to dynamic power demands during intermittent load requirements
Solution Approach 1:
The energy storage system is pre-charged during periods of low power demand and naturally responds immediately when power demand increases, eliminating the need for the dual fuel engine to ramp up quickly. The system performs the power delivery action in advance by storing energy, which then becomes available instantly when needed.
Solution Approach 2:
The energy storage system acts as an intermediary between the dual fuel engine/generator and the drilling rig loads. It buffers the mismatch between the slow-response engine and the dynamic load requirements, allowing the engine to operate at steady state while the storage system handles transient power demands.
2Reliability
If oversized power systems are used to meet peak power requirements during tripping operations, then power availability is ensured, but system complexity and fuel consumption increase
Solution Approach 1:
The power supply system is segmented into two distinct components: the dual fuel engine/generator for base load power and the energy storage system for peak power supplementation. This segmentation allows each component to be optimized for its specific function rather than requiring one oversized engine to handle all conditions.
Solution Approach 2:
The system dynamically switches between power sources based on real-time power demand conditions. The controller monitors load requirements and automatically adjusts the contribution from the engine versus the energy storage system, optimizing performance and fuel consumption across varying operating conditions.
3Reliability
If auxiliary diesel gensets are used to ensure power supply during peak demands, then power reliability is maintained, but emissions and fuel consumption increase
Solution Approach 1:
The system changes the operational parameters of the dual fuel engine by using the energy storage system to absorb transient load variations. This allows the engine to operate at steady-state conditions with optimized fuel-air mixture and combustion parameters, maximizing the benefits of dual fuel operation while minimizing emissions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enhances the reliability and responsiveness of dual fuel engine/generators to match diesel engine performance, reducing natural gas fuel consumption, emissions, and eliminating the need for auxiliary diesel gensets, while providing a stable power supply during fuel interruptions.
Implementation Method 1
A rectifying means is connected to an output line of the engine/generator. The rectifying means serves to convert the AC power to DC power.
Implementation Method 2
an energy storage system, switchably connected to the load, having a capacity to store power
Data Source
AI summary
A system for providing power to a load of a drilling rig has a dual fuel engine/generator and an energy storage system. The load is switchably connected to one or both of the dual fuel engine/generator and the energy storage system. The dual fuel engine/generator and the energy storage system have a capacity suitable for supplying requisite power to the load. A rectifier is connected to an output line of the engine/generator so as to convert the AC power to DC power. The energy storage system is a battery. The dual fuel engine/generator can be either a dedicated duel fuel system or a fumigation system.