E-Products enable industrial machines to gain flexibility and productivity

Transcription

1 E-Products enable industrial machines to gain flexibility and productivity Leonardo Uriona, Co-Founder EKU Power Drives Publication, duplication or disclosure to third parties - even in the form of excepts - are strictly forbidden unless expressly approved by EKU Power Drives GmbH, which furthermore reserves all rights particularly in regard of the use, processing or reproduction of content to any intellectual property claims.

2 Vision EKU power drives provides power management automation optimizing assets resources 2

3 Power installations for well stimulation Tractors P = 5.6 MW Pumps P = 25.2 MW CAPEX: 18.4 Mio USD Engine OPEX: 4.8 Mio USD/a Backside P = 2.4 MW Main control room P = 0.5 MW ~34 MW of installed power, controlled manually! Horsepower is the biggest cost driver on the well site 3

4 High pressure pump with diesel engine 4

5 Pump power train efficiency Engine Power [%] Load Profile Load Factor 24 % Optimization Area Operating Time [%] Increase equipment effectiveness to increase the return on net operating assets During pump operation average request is 58 % of installed power More than 50 % of the operating time is idle, producing nothing but costs 5

6 ESC : Engine Standby Controller Fast Charge Active Lubrication Active Heating Electric Starter Li-Ion Battery ESC = Energy management system 6

7 ESC TM system architecture Charging system with optimization algorithms 24V Li-Ion battery with integrated power distribution Integrated control system with conditioning monitoring Electric starters Bypass pumps Redundant electric or diesel fueled heating system Automated Start / Stop Enable new state called READY Keep the power train in READY state for more than 135 min Reduce up to 95 % of idle time Reduce tractors on site (approx. 5.4 MW installed power) 7

8 Fleet roll out Tractors P = 5.6 MW Pumps P = 25.2 MW CAPEX: 18.4 Mio USD Engine OPEX: 3.8 Mio USD/a Backside P = 2.4 MW Main control room P = 0.5 MW OPEX reduction of approx. 1 Mio USD/a for analyzed fleet Removing tractors additionally reduces CAPEX and OPEX 8

9 Pump power train efficiency Engine Power [%] Load Profile Load Factor 24 % ESC Optimization Area Operating Time [%] ESC eliminates idle and increases load factor up to 48 % ESC increases equipment effectiveness and flexibility 9

10 Increased process flexibility with READY and SOPHIA READY enables control over engine operating hour distribution Transition to streamlined condition based maintenance 10

11 Pump power train efficiency Engine Power [%] Mild Hybrid Load Profile Load Factor 24 % ESC Optimization Area Operating Time [%] 11

12 Mild-Hybrid roll out Tractors P = 5.6 MW Pumps P = 25.2 MW CAPEX: 18.4 Mio USD Engine OPEX: 4.8 Mio USD/a Backside P = 2.4 MW Main control room P = 0.5 MW Reduces approx 8.5 MW of installed Power Increases engine load factor up to 85 % 12

13 Adaptive distributed mini grid Transfer plant Transfer plant Transfer plant [1] Load 1 Load 2 Load 3 Load N Cooperative control system Logic communication structure HV - DC energy transfer network Distributed energy sources and batteries Reduced single point of failure DDS communication protocol (OMG) 13

14 What s next? 14

15 Anyone who has never made a mistake has never tried anything new. Albert Einstein [1] A. N. V. D. A. L. F. Bidram, Cooperative Synchronization in Distributed Microgrid Control, Arlington, TX: Springer, Publication, duplication or disclosure to third parties - even in the form of excepts - are strictly forbidden unless expressly approved by the Management of EKU Power Drives GmbH. EKU Power Drives GmbH furthermore reserves all rights particularly in regard of the use, processing or reproduction of content to any intellectual property claims. 15