Systems and methods for controlling power output to a load by multiple gensets based on load operation modes

• US 10,491,004 B2
• Filed: 10/19/2016
• Issued: 11/26/2019
• Est. Priority Date: 10/19/2016
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Gerdes, Josenia, Janardhan, Vijay, Schroeder, Edward, Nofsinger, Stephen
• Primary Examiner(s): Tan, Richard
• Application Number:
  US15/297,843
• Publication Number:
  US 20180109110A1
• Time in Patent Office: 1,133 Days
• Field of Search: 307 8, 307 16, 307 43, 307 52, 307 53, 307 57, 307 76, 307 84, 307153
• CPC Class Codes: F02B 63/04 for electric generators
• CPC Class Codes: H02J 2300/10 The dispersed energy generation being of fossil origin, e.g. diesel generators
• CPC Class Codes: H02J 3/381 Dispersed generators
• CPC Class Codes: H02J 3/466 Scheduling the operation of the generators, e.g. connecting or disconnecting generators to meet a given demand
• CPC Class Codes: H02K 7/1815 structurally associated with reciprocating piston engines general aspects of generating sets, e.g. housing, F02B63/04

Abstract

A control system for a plurality of generator sets (gensets) includes a plurality of controllers and a data link. Each of the plurality of controllers is operatively associated with at least one of the plurality of gensets. The plurality of controllers is configured to control power output of each of the plurality of gensets, based on a plurality of operating modes. Each of the plurality of operating modes is configured for a power consumption scenario associated with the load. The datalink connects each of the plurality of controllers to at least one other controller of the plurality of controllers. The plurality of controllers is further configured to select a current operating mode, from the plurality of operating modes, for the plurality of gensets and control power output of at least one of the plurality of gensets based on the current operating mode.

Claims

1. A control system for a plurality of generator sets (gensets), the plurality of gensets configured to provide power to a load, the system comprising:

a plurality of controllers, each of the plurality of controllers operatively associated with at least one of the plurality of gensets and each of the plurality of gensets being operatively associated with at least one of the plurality of controllers, the plurality of controllers being configured to control power output to the load of each of the plurality of gensets based on a plurality of operating modes for the load, wherein each of the plurality of operating modes for the load are configured for a power consumption scenario associated with the load; and

a datalink connecting each of the plurality of controllers to at least one other controller of the plurality of controllers,

wherein the plurality of controllers are configured to;

select a current operating mode for the load, from the plurality of operating modes, wherein selecting the current operating mode for the load is based at least in part on a current operating state of the load;

determine which gensets of the plurality of gensets are available for outputting power to the load;

select at least one genset of the available gensets to be active or redundant based on the power consumption scenario for the current operating mode for the load; and

control power output of at least one of the active or redundant gensets based on the power consumption scenario for the current operating mode for the load.

2. The control system of claim 1, wherein the plurality of controllers includes a plurality of genset controllers, each of the plurality of genset controllers corresponding to one of the plurality of gensets and being operatively associated with said corresponding one of the plurality of gensets, and wherein each of the plurality of genset controllers communicate amongst themselves to determine optimal genset control operations based on the current operating mode.

3. The control system of claim 2, wherein a first genset controller, of the plurality of genset controllers, is configured to instruct a first genset, of the plurality of gensets, to power on and communicate with at least one other genset controller, of the plurality of genset controllers, to determine the current operating mode for the load, of the plurality of operating modes, based upon which the first controller will control a power output of the first genset.

4. The control system of claim 1, wherein the plurality of controllers includes a master controller and a plurality of genset controllers, each of the plurality of genset controllers corresponding to one of the plurality of gensets and being operatively associated with said corresponding one of the plurality of gensets, and wherein the master controller is configured to:

determine optimal genset control operations based on the current operating mode for the load, and

communicate the optimal genset control operations to each of the plurality of genset controllers, and

wherein each of the plurality of genset controllers is configured to control power output of its respective genset of the plurality of gensets based on the optimal genset control operations.

5. The control system of claim 1, further comprising an input device configured to generate load information associated with the load and provide the load information to the plurality of controllers, wherein the plurality of controllers are further configured to receive the load information;

and wherein selecting the current operating mode for the load, from the plurality of operating modes, by the plurality of controllers, for the plurality of gensets is based on the load information.

6. The control system of claim 5, wherein the input device includes a load sense determiner operatively associated with a transmission network that is associated with the plurality of gensets, and wherein the load sense determiner is configured to determine the load information by sensing power characteristics at the load via the transmission network.

7. The control system of claim 5, wherein the input device includes a digital input, wherein the digital input is configured to provide the load information to the plurality of controllers, based on input from a user.

8. The control system of claim 7, wherein the load information provided by the digital input is mode selection information indicative of an operator selected operating mode for the load, and wherein selecting the current operating mode for the load, from the plurality of operating modes, by the plurality of controllers for the plurality of gensets is based at least in part on the mode selection information.

9. The control system of claim 8, wherein the current operating mode for the load selected by the plurality of controllers is the operator selected operating mode, and wherein the plurality of controllers are configured to override the operator selected operating mode for the load and select a different operating mode for the load based on an internal logic.

10. The system of claim 1, wherein selecting the current operating mode for the load, from the plurality of operating modes, by the plurality of controllers for the plurality of gensets is based at least in part on a schedule associated with the load.

11. A power system for providing electrical power to an external load, the power system comprising:

a plurality of gensets configured to generate electrical power for the external load;

a transmission network configured to provide the electrical power generated by the plurality of gensets to the external load;

a plurality of controllers, wherein each of the plurality of controllers is operatively associated with at least one of the plurality of gensets, and wherein each of the plurality of gensets is operatively associated with at least one of the plurality of controllers, wherein each of the plurality of controllers is configured to control power output to the external load of each of the plurality of gensets based on a plurality of operating modes for the external load, and wherein each of the plurality of operating modes for the external load is configured for a power consumption scenario associated with the external load;

a datalink connecting each of the plurality of controllers to at least one other controller of the plurality of controllers,

wherein the plurality of controllers are configured to;

select a current operating mode for the external load from the plurality of operating modes for the external load for one or more active gensets of the plurality of gensets, wherein the current operating mode for the external load for each of the active gensets is at least partially based on a determination of available gensets; and

control power output of at least one of the available gensets based on the power consumption scenario for the current operating mode for the external load.

12. The power system of claim 11, wherein at least one of the plurality of gensets includes:

a prime mover configured to mechanically rotate; and

a generator coupled to the prime mover and configured to generate electrical power in response to mechanical rotation of the prime mover.

13. The power system of claim 11, wherein the external load is associated with an oil rig and each of the plurality of operating modes for the external load are configured for a power consumption scenario associated with the oil rig.

14. The power system of claim 13, wherein one of the plurality of operating modes for the external load is a standby mode, the standby mode being associated with a standby power consumption scenario in which lower powered gensets of the plurality of gensets are used.

15. The power system of claim 13, wherein one of the plurality of operating modes for the external load is a drilling mode, the drilling mode being associated with a drilling power consumption scenario in which one or more genset redundancies are used.

16. The power system of claim 13, wherein one of the plurality of operating modes for the external load is a tripping mode, the tripping mode being associated with a tripping power consumption scenario in which a plurality of genset redundancies are used.

17. The power system of claim 13, wherein one of the plurality of operating modes for the external load is a back reaming mode, the back reaming mode associated with a back reaming power consumption scenario in which active gensets and redundancies are used to prevent product loss.

18. The power system of claim 11, further comprising an input device configured to generate load information associated with the load and provide the load information to the plurality of controllers,

wherein the plurality of controllers are further configured to receive the load information, and

wherein selecting the current operating mode for the external load, from the plurality of operating modes, by the plurality of controllers, for the plurality of gensets is based on the load information.

19. A method for controlling power output to a load by a plurality of gensets, the method comprising:

providing a plurality of operating modes, wherein each of the plurality of operating modes is configured for a power consumption scenario associated with the load;

selecting a current operating mode, from the plurality of operating modes, for the plurality of gensets;

communicating, amongst a plurality of controllers, to determine optimal genset control operations based on the current operating mode, wherein each of the plurality of controllers is operatively associated with at least one of the plurality of gensets;

controlling a power output of at least one of the plurality of gensets based on the current operating mode and the optimal genset control operations; and

displaying the power output of the at least one of the plurality of gensets on a user interface, wherein displaying the power output includes displaying the current operating mode and whether each genset is online, offline, redundant, or unavailable.

20. The method of claim 19, further comprising a step of receiving load information associated with the load, and

wherein selecting the current operating mode, from the plurality of operating modes, for the plurality of gensets, is based on the load information.