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

Abstract

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.

1 . A method for correcting a power factor of a motor comprising a plurality of phases, the method comprising the steps of:
 determining a total power;   calculating a total reactive power;   determining a total present power factor from the total power;   determining a desired power factor based on the total present power factor; and,   calculating a capacitance for each phase of the plurality of phases from the total reactive power, the total power, and the desired power factor.   
     
     
         2 . The method of  claim 1 , wherein the step of calculating the total reactive power further comprises the steps of:
 measuring an instantaneous voltage;   measuring an instantaneous current; and,   shifting the instantaneous voltage to generate a shifted instantaneous voltage.   
     
     
         3 . The method of  claim 2 , further comprising the step of calculating an average reactive power from the instantaneous current and the shifted instantaneous voltage. 
     
     
         4 . The method of  claim 2 , wherein the step of determining a total power further comprises the step of calculating an average active power from the instantaneous voltage and the instantaneous current. 
     
     
         5 . The method of  claim 1 , wherein the step of determining a total present power factor further comprises the steps of:
 determining an apparent power from the total power and the total reactive power; and,   calculating the total present power factor from the total power and the apparent power.   
     
     
         6 . The method of  claim 1 , further comprising the step of adding the capacitance to each phase of the plurality of phases. 
     
     
         7 . A method for allocating energy consumption for a set of wells comprising the steps of:
 receiving an electricity reading;   receiving a set of energy data;   calculating a total energy generated from the set of energy data;   calculating a total net energy from the set of energy data;   calculating an energy correction difference from the electricity reading and the total net energy;   calculating a percentage of the total energy generated for each well of the set of wells; and,   calculating a correct net energy consumption from the percentage for each well of the set of wells.   
     
     
         8 . The method of  claim 7 , further comprising the steps of:
 measuring an energy consumption for each well of the set of wells based on a period of time; and,   measuring an energy generated for each well of the set of wells based on the period of time.   
     
     
         9 . The method of  claim 8 , further comprising the step of receiving a stroke period of the set of wells as the period of time. 
     
     
         10 . The method of  claim 7 , further comprising the steps of:
 calculating a total energy consumption from the set of energy data; and,   calculating a net energy for each well of the set of wells from the set of energy data.   
     
     
         11 . A system for monitoring a rod pump motor further comprising a plurality of phases, the system comprising:
 an energy monitoring device connected to the rod pump motor, programmed to carry out the steps of:
 measuring a set of motor data; 
 determining an energy generation amount from the set of motor data; 
 determining an energy consumption amount from the set of motor data; 
 comparing the energy generation amount to a first threshold; 
 generating a first set of pulses if the energy generation amount exceeds the first threshold; 
 comparing the energy consumption amount to a second threshold; and, 
 generating a second set of pulses if the energy consumption amount exceeds the second threshold. 
   
     
     
         12 . The system of  claim 11 , wherein the energy monitoring device is further programmed to carry out the steps of:
 determining the energy generation amount for each of the plurality of phases to generate a set of energy generation amounts;   determining the energy consumption amount for each of the plurality of phases to generate a set of energy consumption amounts;   comparing each of the set of energy generation amounts to the first threshold;   generating the first set of pulses if any of the set of energy generation amounts exceeds the first threshold;   comparing each of the set of energy consumption amounts to the second threshold; and,   generating the second set of pulses if any of the energy consumption amounts exceeds the second threshold.   
     
     
         13 . The system of  claim 11 , wherein the energy monitoring device is further programmed to carry out the steps of:
 determining a full load amp rating;   determining a stroke period;   measuring a current on each phase of the plurality of phases during the stroke period;   calculating an RMS current for each phase of the motor during the stroke period to generate a set of RMS currents;   comparing each of the set RMS currents to the full load amp rating; and,   generating an alert if any of the set of RMS currents exceeds the full load amp rating.   
     
     
         14 . The system of  claim 11 , wherein the energy monitoring device is further programmed to carry out the step of determining an energy demand for a predetermined period from the set of motor data. 
     
     
         15 . The system of  claim 14 , wherein the energy demand is a peak demand. 
     
     
         16 . The system of  claim 14 , wherein the energy demand is a continuous demand. 
     
     
         17 . A system for allocating energy for a set of wells comprising:
 a network;   a set of energy monitoring devices connected to the network and to the set of wells;   a network server connected to the network and programmed to carry out the steps of:
 receiving an electricity reading; 
 receiving a set of energy data; 
 calculating a total energy generated from the set of energy data; 
 calculating a total net energy from the set of energy data; 
 calculating an energy correction difference from the electricity reading and the total net energy; 
 calculating a percentage of the total energy generated for each of the set of wells; and, 
 calculating a correct net energy consumption from the percentage for each of the set of wells. 
   
     
     
         18 . The system of  claim 17 , wherein the set of energy monitoring devices is programmed to carry out the steps of:
 measuring an energy consumption for each of the set of wells based on a time period; and,   measuring an energy generated each of the set of wells based on the time period.   
     
     
         19 . The system of  claim 18 , wherein the time period is a stroke period. 
     
     
         20 . The system of  claim 17 , wherein the network server is further programmed to carry out the step of:
 calculating a total energy consumption from the set of energy data; and,   calculating a net energy for each of the set of wells from the set of energy data.   
     
     
         21 . A method for monitoring a rod pump motor further comprising a plurality of phases, the method comprising the steps of:
 measuring a set of motor data;   determining an energy generation amount from the set of motor data;   determining an energy consumption amount from the set of motor data;   comparing the energy generation amount to a first threshold;   generating a first set of pulses if the energy generation amount exceeds the first threshold;   comparing the energy consumption amount to a second threshold; and,   generating a second set of pulses if the energy consumption amount exceeds the second threshold.   
     
     
         22 . The method of  claim 21 , further comprising the steps of:
 determining the energy generation amount for each of the plurality of phases to generate a set of energy generation amounts;   determining the energy consumption amount for each of the plurality of phases to generate a set of energy consumption amounts;   comparing each of the set of energy generation amounts to the first threshold;   generating the first set of pulses if any of the set of energy generation amounts exceeds the first threshold;   comparing each of the set of energy consumption amounts to the second threshold; and,   generating the second set of pulses if any of the energy consumption amounts exceeds the second threshold.   
     
     
         23 . The method of  claim 21 , further comprising the steps of:
 determining a full load amp rating;   determining a stroke period;   measuring a current on each phase of the plurality of phases during the stroke period;   calculating an RMS current for each phase of the motor during the stroke period to generate a set of RMS currents;   comparing each of the set RMS currents to the full load amp rating; and,   generating an alert if any of the set of RMS currents exceeds the full load amp rating.   
     
     
         24 . The method of  claim 21 , further comprising the step of determining an energy demand for a predetermined period from the set of motor data. 
     
     
         25 . The method of  claim 24 , wherein the step of determining an energy demand for a predetermined period from the set of motor data further comprises the step of determining a peak demand for the predetermined period. 
     
     
         26 . The method of  claim 24 , wherein the step of determining an energy demand for a predetermined period from the set of motor data further comprises the step of determining a continuous demand for the predetermined period.