Rod Pump Motor Power Factor Correction and Energy Allocation

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Solution Overview

Problem

Existing rod pumping systems for oil and gas wells face inefficiencies in energy usage and power factor management, leading to increased energy costs and inaccurate energy allocation across multiple wells, due to the cyclic loading and elasticity of the systems, which results in periods of overload, negative load, and low power factors.

Innovation Solution

A system and method for controlling a motor of a rod pumping system by measuring current and voltage on a per-stroke basis, predicting RPM, correcting power factors, and allocating energy consumption using an energy monitoring device and network server, which calculates and adjusts the power factor and allocates energy generation and consumption accurately across multiple wells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional rod pumping systems operate with cyclic loading and elasticity, then the system can handle variable production demands, but power factor deteriorates and energy efficiency decreases

Engineering Contradiction:

Improvevariable production demand handlingVSAvoidenergy efficiency

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The system applies periodic control actions synchronized with the rod pumping cycle. The controller measures instantaneous power, voltage, and current at multiple points during each stroke cycle and applies corrective actions periodically to maintain power factor within desired ranges while adapting to variable production demands

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system dynamically changes operating parameters including power factor setpoints, voltage levels, and current thresholds based on real-time measurements. The controller adjusts these parameters periodically throughout the stroke cycle to optimize energy efficiency while maintaining adaptability to varying production requirements

Inventive Principle:

Principle #35Parameter changes

2Use of energy by moving object

If motor operates during heavily loaded steady state, then motor efficiency is maximized, but rod pumping system cannot accommodate elastic loading variations

Engineering Contradiction:

Improvemotor efficiencyVSAvoidloading variation accommodation

Core Design Contradiction:

Use of energy by moving objectVSAdaptability or versatility

Solution Approach 1:

The system transitions from static motor operation to dynamic control that adapts to elastic loading variations. The controller continuously measures instantaneous power and adjusts motor operation throughout the stroke cycle, enabling the motor to efficiently handle both steady-state and variable loading conditions by changing its operating characteristics in real-time

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements feedback control by measuring instantaneous power, voltage, and current during motor operation. The controller uses this feedback to adjust motor operation dynamically, maintaining high efficiency while accommodating elastic loading variations through continuous measurement and adjustment throughout the stroke cycle

Inventive Principle:

Principle #23Feedback

3Loss of energy

If energy consumption is measured at electricity meter, then total energy usage is recorded, but accurate allocation to individual wells cannot be determined

Engineering Contradiction:

Improvetotal energy recordingVSAvoidenergy allocation accuracy

Core Design Contradiction:

Loss of energyVSMeasurement precision

Solution Approach 1:

The system segments the energy measurement function by deploying individual energy monitoring devices at each well location in addition to the central electricity meter. Each device measures instantaneous power, voltage, and current specific to its well, enabling accurate allocation of energy consumption to individual wells while maintaining total energy recording capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system adds a spatial dimension to energy measurement by distributing monitoring devices across multiple well locations. This transforms the single-point measurement at the electricity meter into a multi-dimensional measurement network that captures both total energy usage and individual well consumption patterns simultaneously

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Ease of operation

If power factor is not corrected, then system operation is simple, but demand charges and grid losses increase

Engineering Contradiction:

Improvesystem operation simplicityVSAvoiddemand charges

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The system implements self-service power factor correction by automatically measuring instantaneous power and calculating required correction without external intervention. The controller autonomously determines when and how much power factor correction is needed based on real-time measurements, eliminating the need for manual adjustment while reducing demand charges and grid losses

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS9279838B2System, method and apparatus for computing, monitoring, measuring, optimizing and allocating power and energy for a rod pumping system

Publication Date: 2016.03.08 BREX LLC

AI summary

A system and methods are provided for controlling a motor of a rod pumping system using previous RPMs of the motor and predicting an RPM of the motor; correcting a power factor of a motor of a rod pumping system; allocating energy consumption and allocating energy generation for a set of wells connected to an electricity meter using an amount of energy generated by each well; and generating an alert if a set of data is beyond a threshold for the set of data.