In this paper, we propose to increase the efficiency of drilling rigs DR, through measurement, modeling, adjustment of DR operation, and incorporating an energy storage flywheel system FW resulting in significant reductions in fuel consumption and pollutant emissions. In this regard, we propose to: a) Develop a full system model of all power producing and consuming machinery and process components in the DR and utilize some system measurements and a neural net based identification approach to best fit the model to test data. b) Utilize the model in (a) to investigate alternative operation modes for the drilling rig to reduce fuel consumption and the resulting air pollutants. The model will also guide integration of an energy storage flywheel FW system into the drilling rig to replace a diesel generator DG in order to operate the remaining DG's at more efficient power levels and yet still handle peak power events with the energy stored in the FW. The model will also be employed to simulate charging of the flywheel from the braking energy as a result of inserting (tripping) the drillstring DS into the hole, and the subsequent use of this renewable energy for powering circulation such as pumps, drawworks, lights.
A challenge encountered with electric grid drilling EGD is that utilities levy significant surcharges on peak power demand. The flywheel system FW can charge at a constant low power rate from the grid over a long period of time and then discharge its stored energy at the intermittent, transient, high power levels required by the drilling rig. An example of this is that the power required to raise or lower the 250,000 lb drillstring DS by 90 ft. in 20 seconds is approximately 1.5 MW (2,000 hp), even neglecting electrical and mechanical losses. The FW reduces surcharge cost and EGD reduces NOX since power plants emit about 1/25 of the NOX produced by a diesel generator DG for the same amount of electrical energy (MW Hrs).