Wellsite Power Control for Variable Generator Load Efficiency
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Solution Overview
Problem
Combustion engine electrical generator units in well construction systems operate at low efficiency during varying power demand, leading to high gas and particulate emissions, especially during low and unoptimized load conditions.
Innovation Solution
Implement a control system with a processor and computer program code to manage electrical power output levels based on demand, incorporating an electrical energy storage unit and hydrogen gas source to optimize generator efficiency and reduce emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If generator units operate to match electrical power demand during low power demand stages, then electrical power supply is maintained, but generator efficiency decreases and emissions increase
Solution Approach 1:
The system dynamically adjusts generator operation based on power demand stages. During low power demand, the controller reduces generator load or shuts down generators, allowing them to operate efficiently at optimal load points rather than continuously at variable loads. This dynamic adjustment resolves the contradiction by maintaining power supply through coordinated operation while preserving generator efficiency.
Solution Approach 2:
The system changes operational parameters by dividing well construction operations into multiple power demand stages and adjusting generator output accordingly. The controller modifies generator operating parameters (load, speed, fuel injection) based on the current stage, enabling generators to operate at efficient parameter points while still meeting varying power demands.
2Power
If additional generator units are turned on during high power demand stages, then electrical power supply is increased, but generator warm-up time is reduced and efficiency decreases
Solution Approach 1:
The system performs preliminary warming up of generator units before they are needed for high power demand stages. The controller prepares standby generators by bringing them to operational temperature and optimal operating conditions in advance, so when high power demand arises, they can immediately contribute at efficient operating points without the efficiency penalty of cold starts.
Solution Approach 2:
The system maintains continuous useful action by keeping generator units in a prepared state during intermediate power demand stages. Rather than complete shutdown followed by cold start, generators remain in a warm standby mode that preserves thermal energy, enabling rapid transition to high power output while maintaining efficiency.
3Adaptability or versatility
If generator units operate at variable loads to match power demand, then electrical power is supplied flexibly, but emissions increase
Solution Approach 1:
The system segments well construction operations into distinct power demand stages (e.g., low power stage, intermediate stage, high power stage). By dividing the continuous operation into discrete stages with characteristic power requirements, the controller can select optimal generator configurations for each stage, avoiding the emissions penalty of variable load operation and achieving both adaptability and emission reduction.
Solution Approach 2:
The system uses multiple generator units that can be selectively activated based on power demand stages. Rather than operating a single generator at inefficient variable loads, the system can bring additional generators online in discrete steps, allowing each generator to operate at more efficient load points and reducing overall emissions while maintaining flexibility.
Data Source
AI summary
An example well construction system includes well construction equipment, a power supply system, and a control system. The well construction equipment performs well construction operations. The power supply system outputs electrical power to the well construction equipment. The power supply system includes an electrical generator unit and a control system including a processor and a memory storing a computer program code. The computer program code causes the control system to control an electrical power output level of the power supply system during the well construction operations. The computer program code also causes the control system to control operation of the well construction equipment during the well construction operations based on the electrical power output level during the well construction operations and an electrical power demand level of the well construction equipment during the well construction operations.