Generator Load Bank Control for Fluctuating Drill Rig Loads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Drilling rigs face power fluctuations due to intermittent usage of electrical equipment, leading to inefficient generator operation and potential blackouts from rapid load changes, as generators are most efficient within a specific power output range and struggle to quickly respond to varying loads.
Innovation Solution
A power system that includes a generator with a minimum efficient load rating, a load bank to provide a passive load, and a controller to engage the load bank, calculating and managing the load bank power demand to maintain a constant generator load, thereby stabilizing power output and reducing fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the generator operates with highly fluctuating loads from intermittent equipment usage, then the drilling rig can operate with flexible equipment scheduling, but the generator efficiency deteriorates and power spikes occur that cause automatic shutdowns
Solution Approach 1:
The patent introduces a load bank as an intermediary component between the generator and the drilling rig equipment. The load bank absorbs excess power during low-demand periods and provides supplemental power during high-demand periods, mediating the fluctuations and preventing direct impact on generator operation stability.
Solution Approach 2:
The system dynamically changes the load parameters by engaging and disengaging the load bank based on real-time power demand conditions. The controller monitors generator output and equipment demand, adjusting the load bank engagement to maintain generator operation within efficient and stable parameters.
2Speed
If the generator responds rapidly to load changes, then the power supply can match fluctuating equipment demand, but the generator operates outside its efficient power output range and efficiency deteriorates
Solution Approach 1:
The load bank is pre-positioned and ready to engage immediately when needed. During low-demand periods, the load bank absorbs excess power in advance, allowing the generator to maintain steady operation without needing to rapidly adjust output when equipment demand suddenly increases.
Solution Approach 2:
The system maintains continuous useful action by keeping the generator operating continuously within its efficient range. The load bank ensures the generator always has a baseline load to maintain efficiency, while the controller manages power distribution to ensure continuous supply matches equipment needs.
3Use of energy by moving object
If the generator operates at minimum efficient load rating, then energy efficiency is improved, but the system cannot handle rapid increases in power demand from equipment
Solution Approach 1:
The patent merges the generator power source with the load bank to create a hybrid power system. The load bank is electrically connected in parallel with the generator, combining their power outputs to meet equipment demand while allowing the generator to operate efficiently at its minimum rating.
Solution Approach 2:
The system dynamically adjusts power distribution between the generator and load bank based on real-time conditions. The controller monitors equipment demand and automatically adjusts the load bank engagement level, creating a dynamic power supply system that adapts to changing conditions while maintaining generator efficiency.
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 ensures generators operate efficiently by maintaining a constant load, minimizing power fluctuations, and preventing blackouts by engaging the load bank to absorb or dissipate excess power, thus maintaining stable power supply to the drilling rig.
Implementation Method 1
a load bank to provide a passive load and a controller to engage the load bank... engaging the load bank to absorb or dissipate excess power
Data Source
AI summary
A power system for an electrical system with highly fluctuating loads is powered by one or more power sources that are slow to react to load changes. The power sources are connected to electrical equipment used on the drill rig which provide active load to the generate. One or more load banks may be positioned to provide passive load to the generators to maintain generally constant generator load, while allowing for instant access to power as active load increases. Generators may be run at 100% capacity, a maximum efficient capacity, or at a high enough level to allow for a sufficiently rapid increase in power output. At least one parameter of a drilling operation may be utilized to anticipate load demand changes.