Intelligent Controls Drive Down Land Rig Operations Costs | Cat | Caterpillar

Intelligent Controls Drive Down Land Rig Operations Costs

Smart engine management offers drillers more control to lower fuel and maintenance costs

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Land rigs require high power availability to support today’s demanding drilling operations. However, constantly fluctuating between the extremes of too much or too little power required from a genset can increase fuel and maintenance costs. Addressing such challenges requires a solution that allows drilling companies to maintain critical power levels without compromising performance.

Advanced digital tools enable drillers to reduce engine runtime and fuel consumption, which are essential considerations when evaluating approaches to improve operational efficiency.

Smart EMS, EMCP 4.4 on engine

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A digital control system that can program and automate runtime in a manner that maintains the appropriate amount of power output when demand surges or drops can be valuable in the pursuit of such improvements. Smart solutions, such as digital engine management technologies, allow drillers to maximize performance and efficiency.

Field-Proven to Reduce Fuel Consumption and Maintenance

Developed for electric and hybrid land rigs, the Cat^® Smart Engine Management System (EMS) seamlessly manages the number of engines needed to meet performance requirements. It automates engine management with programmable targets to minimize the number of engines simultaneously running at higher loads. Autonomous tools turn engines on when rig power demand is high and off when demand is low to reduce energy consumption.

With more than 25,000 hours of field validation[i], Smart EMS is field-proven to monitor rig demand and engine load continuously to eliminate manual intervention. This reduces unnecessary usage, which also reduces fuel consumption and costs. Decreased runtime also reduces equipment wear, promoting longer field life and a lower total cost of ownership as maintenance and repair frequency is effectively decreased.

Empower Crews to Focus on the Highest-Value Task

The Cat EMCP 4.4 Master Control Panel is a critical component of Smart EMS that monitors and controls up to eight engine generators in parallel, with or without a single utility source. It offers drillers important advantages in the oilfield, including:

Reliable asset protection for the complete genset for enhanced performance and extended service life.
Faster troubleshooting with full-text fault codes in 16 languages to minimize nonproductive time.
Ease of use through a human machine interface (HMI) that enables new and seasoned crew members to access engine controls, diagnostics and operating information from an intuitive touchscreen.
Data-driven performance through telematics that leverage rig data to optimize power and performance, whether using VisionLink^® or another data management system.
Greater diesel displacement, as Dynamic Gas Blending (DGB) engines can effectively operate at higher loads.

With the EMCP 4.4, crews can focus more time on improving drilling performance rather than maintenance activities.

Digitalization Delivers Efficiency Gains

Automated control of a drilling operation helps drillers optimize engine runtime, effectively reducing fuel consumption and operating costs. Applying smart digital controls across all stages of a project — drilling, backreaming, tripping and standby — eliminates manual adjustments to realize the efficiency impact of real-time modifications. As drilling companies seek innovative ways to leverage existing assets, the EMCP 4.4-powered Smart EMS helps extend equipment longevity to achieve lower costs and greater operational efficiency.

^{1 Cat® Smart EMS. https://www.cat.com/en_US/by-industry/oil-and-gas/land-drilling-production/smart-ems.html}

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