Electric power costs, which are often a major component of operating costs, do not necessarily require complex or expensive solutions to realize significant savings. This article focuses on one such solution that has application in several different oil- or gas-patch applications. Beyond just addressing reduced power consumption, the solution also provides transient surge protection and can reduce lost production due to equipment downtime, equipment replacement as well as repairs and associated labor hour reductions.

Although band-pass filters are not a new concept, Stems Electronics, LLC (STEMS), a four-year old company based out of Plainview, Texas, now offers a product that will provide line filter conditioning, enhanced power factor correction and top of the line surge and lightning protection, all in one device. Although a relatively new product, there are numerous U.S. applications serviced by a national sales organization. Products are also being sold in Canada, Mexico, Puerto Rico and Europe. Within the U.S., STEMS units are being applied by producers in different applications (artificial lift, injection pumps, compressors, etc.). Having realized positive results, several operators now purchase units on a regular basis.

Figure 1 illustrates why operators would do so. When applied in a 150-hp injection system in Wyoming, the units realized an 18% savings in daily electric cost. This system required eight STEMS units, costing approximately $28,000. With the demonstrated savings, considering purchased power only, this translates to a payout period of only 16 months. Long-term, there are other equipment/reliability savings that will be realized.

are watt-related charges and can be eliminated through power factor correction. When compared to the regular cost of power factor correction, load bank capacitors have a much longer payout than STEMS equipment. STEMS units are also very effective in reducing power factor penalties and demand charges. Keep this in mind! Whenever energy is expended, one pays for it whether it does useful work or is wasted as heat.

Before choosing a unit, one must first test the condition of the motor to determine which size unit is necessary to achieve satisfactory results. Going a step beyond that, STEMS doesn't "permanently" install units until initial performance demonstrates expected improvements. STEMS provides a three-year pro-rated warranty, a $2,000,000 product liability insurance policy (this means should a downstream protected motor be fried by lightning, the loss will be covered) and a 12-month money back guarantee that electrical consumption will be reduced by 5%. In actuality, savings average 10-12% with an average payout of 6-18 months (with all installations proving fewer than 24 months). Payouts are longer for smaller loads (less than 20 hp). STEMS offers a lease program to those who qualify and meet the criteria.