Synchronized Engine-Generator Load Control for Dynamic Peak Demand
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Solution Overview
Problem
Existing power management systems for drilling rigs and similar operations face inefficiencies due to oversized engines to handle peak demands, leading to high emissions and poor fuel efficiency, as they struggle to maintain steady-state power output and equal load sharing among generators.
Innovation Solution
A power management system with synchronized, constant-speed engine/generators and a controller that adjusts their load between 0% and 100% of their nameplate rating, using circuit breakers to connect or disconnect generators based on demand, combined with energy storage systems to optimize fuel efficiency and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If oversized engine/generators are used to meet peak power requirements, then the system can handle intermittent high loads, but fuel efficiency deteriorates and emissions increase
Solution Approach 1:
The system dynamically adjusts the operating load of each engine/generator based on real-time power demands, allowing units to operate at optimal efficiency points rather than static oversized capacity. The controller continuously monitors load requirements and redistributes power allocation to maintain engines in efficient operating ranges.
Solution Approach 2:
The system changes operational parameters by adjusting the load percentage of individual engine/generators based on demand. Instead of running fixed oversized engines, the system varies the operating parameters (load level) to match actual power requirements, enabling efficient operation during both peak and base load conditions.
2Power
If multiple engine/generators operate in parallel to meet variable loads, then power capacity is sufficient, but load sharing becomes unequal and efficiency is reduced
Solution Approach 1:
The controller implements continuous feedback monitoring of each engine/generator's load and performance characteristics. Based on this feedback, the system dynamically adjusts the load distribution to achieve equal and efficient sharing among all operating units, preventing any single unit from operating inefficiently.
Solution Approach 2:
The system dynamically reallocates load among engine/generators based on real-time conditions. When demand changes, the controller adjusts which units operate and at what load levels, ensuring that operating units always share the load equally and efficiently rather than using fixed static allocation.
3Adaptability or versatility
If engine/generators are frequently started and stopped to match demand, then power capacity matches load requirements, but engine life is reduced due to rapid starts
Solution Approach 1:
The system performs preliminary actions by keeping engine/generators running at reduced load rather than shutting them down completely. This preliminary state allows for rapid response to increased demand without requiring cold starts, thereby extending engine life while maintaining adaptability to load changes.
Solution Approach 2:
Instead of binary on/off operation, the system uses dynamic load modulation to adapt to changing demands. Engines operate continuously with variable load levels, dynamically adjusting output to match demand while avoiding the wear associated with frequent startup cycles.
4Reliability
If excess engine/generators are kept online for redundancy and peak demand, then system reliability is improved, but fuel consumption increases during intermittent demands
Solution Approach 1:
The system applies partial action by keeping only the necessary number of engine/generators online based on real-time demand assessment. Rather than running all available units for redundancy, the controller determines the minimum number of units needed to meet current and anticipated demand, reducing fuel consumption while maintaining adequate reliability.
Solution Approach 2:
The system changes the operational status parameter of engine/generators dynamically. Instead of fixed online/offline states, the controller adjusts which units are operational based on demand patterns, allowing the system to maintain reliability when needed while minimizing fuel consumption during lower demand periods.
Data Source
AI summary
A power management system in which multiple engine/generators each has an output line adapted to supply AC power to a load. An AC bus is connected to an output of each of the multiple engine/generators. A controller is electrically connected to regulate power supplied to the AC bus. The multiple engine/generators are synchronous at full speed. The load of each of the multiple engine/generators can be rapidly varied between 0% and 100%. The controller is adapted to activate or deactivate at least one of the multiple engine/generators relative to the load. Through this novel control, the operation of the multiple engine/generators is more efficient so as to reduce fuel use and emissions output while more effectively meeting the load demand of the application.