ESP Power Supply With Battery Assist for Peak Load Efficiency
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Solution Overview
Problem
Existing systems for powering electric submersible pumps (ESPs) in remote oil production wells are inefficient, leading to increased emissions, maintenance costs, and reduced ESP lifespan due to the need for large diesel generators that run at lower loads.
Innovation Solution
A High Efficiency Power System that includes a smaller diesel generator and a battery system, where the battery supplies extra power during startup and higher load requirements, and the generator recharges the battery and supplies power during normal operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large diesel generator is used to supply power during ESP startup and high load conditions, then the system can meet peak power demands, but the generator must run at lower loads during normal operation leading to inefficiency, increased emissions, and higher maintenance costs
Solution Approach 1:
The power supply system is segmented into two independent sources: a large diesel generator for peak power demands and a smaller battery system for normal operation. This segmentation allows each component to operate in its optimal range - the generator handles startup and high load conditions while the battery handles steady-state operation, eliminating the inefficiency of running a large generator at partial load.
Solution Approach 2:
The system dynamically switches between power sources based on real-time power demands. The controller monitors load conditions and automatically transitions between generator-only mode, battery-assist mode, and battery-only mode, ensuring the generator operates only when necessary at high efficiency points while the battery handles variable normal operations.
2Reliability
If a large diesel generator is sized to meet peak startup power demands, then sufficient power is available for ESP startup, but the generator runs continuously at lower loads causing increased emissions and maintenance requirements
Solution Approach 1:
The power supply function is segmented between the generator (for reliable peak power) and the battery (for clean normal operation). This segmentation maintains power supply reliability during startup and high-demand conditions while eliminating emissions during continuous normal operation by using the battery as the primary source.
Solution Approach 2:
The generator operates periodically rather than continuously - only during ESP startup, high load conditions, or when battery charge needs replenishment. This periodic operation dramatically reduces total emissions and maintenance requirements while maintaining reliability when needed most.
3Adaptability or versatility
If a large diesel generator is used to supply variable power demands, then the system can respond to flow condition fluctuations, but the generator must be kept running constantly leading to poor power quality performance
Solution Approach 1:
The system dynamically responds to power quality issues by automatically switching between power sources. When the generator exhibits poor power quality, the controller detects the degradation and transitions to battery power or adjusts the generator-battery power split, maintaining reliable power supply while isolating the system from generator-induced power quality problems.
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
This system reduces emissions and maintenance costs, extends ESP lifespan by 50%, and achieves annual fuel savings of approximately $700,000, while also improving power quality and reducing harmonic vibrations.
Implementation Method 1
a battery system, where the battery supplies extra power during startup and higher load requirements
Implementation Method 2
the generator recharges the battery and supplies power during normal operations
Data Source
AI summary
A system for supplying power to an electric submersible pump is provided. The system includes a variable frequency drive connected to a motor. The motor is mechanically connected to the electric submersible pump. A generator and a battery are connected to the variable frequency drive. The battery is appropriately sized so that it can power the variable frequency drive during startup operations of the electric submersible pump and during generator maintenance periods. The system includes a means for detecting when power from the generator is insufficient to meet the load demand of the electric submersible pump. When that occurs, the battery sends power to the variable frequency drive to meet the load demand of the electric submersible pump. The system also includes a means for charging the battery using the generator when the battery has dropped below a threshold level.