Wellsite Powertrain Segmentation for Peak Load Management
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Solution Overview
Problem
Current wellbore pumping operations for oil and gas wells face inefficiencies due to the need for oversized diesel engines to meet peak hydraulic horsepower demands, resulting in high capital expenditure, increased emissions, and manpower requirements, as well as difficulties in maintaining equipment in harsh environments.
Innovation Solution
A powertrain system that includes a power source sized for average power demand and an energy storage unit to supplement peak demands, with a power management system to direct energy efficiently between the source and storage, eliminating the need for oversized equipment and reducing emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If oversized diesel engines are used to meet peak hydraulic horsepower demands, then peak power demand is satisfied, but capital expenditure and equipment weight increase
Solution Approach 1:
The power system is segmented into two independent components: a base diesel engine providing continuous average power, and a separate energy storage system (battery bank with DC-DC converter) providing peak power supplements. This segmentation allows each component to be optimally sized for its specific function, eliminating the need for an oversized engine that must handle both average and peak demands.
Solution Approach 2:
The patent merges the diesel engine powertrain with an electric energy storage system into a hybrid power architecture. The diesel engine and battery bank work in parallel, with the battery handling transient peak demands and the engine providing steady-state power, creating a combined system that leverages the strengths of both power sources.
2Power
If oversized diesel engines are used to meet peak hydraulic horsepower demands, then peak power demand is satisfied, but fuel consumption and emissions increase
Solution Approach 1:
The power system is segmented into two independent parts: a base diesel engine providing continuous average power, and a separate energy storage system (battery bank with DC-DC converter) providing peak power supplements. This segmentation allows the engine to operate at optimal efficiency points during average load conditions, while the battery handles transient peak demands that would otherwise require the engine to run at inefficient high-power levels.
Solution Approach 2:
The energy storage system operates in periodic cycles, charging during low-demand periods when the engine runs at efficient operating points, and discharging during peak-demand periods. This periodic charge-discharge pattern allows the engine to maintain steady, efficient operation while the battery provides supplemental power during transient peaks.
3Power
If oversized diesel engines are used to meet peak hydraulic horsepower demands, then peak power demand is satisfied, but manpower requirements and maintenance complexity increase
Solution Approach 1:
The patent replaces the traditional mechanical power transmission system (engine directly coupled to pump through gearbox) with an electrically-based hybrid system. The diesel engine drives a generator that produces electricity, which is then managed by a control system that directs power to electric motors coupled to the pumps. This substitution of mechanical direct-drive with an electrical powertrain simplifies the mechanical linkage while adding intelligent power management capabilities.
Solution Approach 2:
The control system acts as an intermediary between the diesel engine, energy storage system, and pumps. It manages power flow, determines when to charge or discharge the battery, and coordinates the operation of all components, replacing the need for complex mechanical linkages and reducing overall system complexity.
4Power
If traditional mechanical drive systems with gearboxes are used, then power transmission is achieved, but maintenance difficulty in harsh environments increases
Solution Approach 1:
The patent replaces the traditional mechanical power transmission system (engine directly coupled to pump through gearbox) with an electrically-based hybrid system. The diesel engine drives a generator that produces electricity, which is then managed by a control system that directs power to electric motors coupled to the pumps. This substitution of mechanical direct-drive with an electrical powertrain eliminates the need for complex mechanical linkages and reduces maintenance requirements in harsh wellsite environments.
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 solution allows for efficient operation at average power levels, reducing fuel consumption and emissions, and simplifying setup and maintenance, while ensuring peak power demands are met without the need for large, heavy equipment.
Implementation Method 1
A powertrain system that includes a power source sized for average power demand and an energy storage unit to supplement peak demands
Implementation Method 2
with a power management system to direct energy efficiently between the source and storage
Data Source
AI summary
A powertrain for powering wellsite pumping operations includes a power source for producing energy, a power bank, electric motors coupled to pumps, and a power management system. The power source can be a prime mover coupled to a generator, the prime mover sized for supply up to the average power demand of the pumping operation, and the power bank is sized to supply up to at least the difference between the peak and average power demand of the pumping operation, thereby providing a load levelling means to satisfy peak demand of the operation. The power management system manages the direction of current flow, state of charge of the power bank, and power source operation to provide least fuel consumption while meeting the power demand of the pumping operation.