Centrifugal Gas Compressors Energy Optimization Initiatives: A Way to Save Valuable Energy at Upstream Operation

Abstract

Abstract The objective of this paper is to showcase successful and innovative means and techniques to improve and enhance centrifugal gas compressors (CGCs) performance, using methods to minimize power consumption, with no need for capital investment. These techniques will assure, if effectively followed, considerable reduction of the consumed energy. CGCs are the most widely used equipment in the oil and gas industry to boost gas, mainly hydrocarbons, to satisfy process treatments and pipeline requirements. In addition, CGCs are one of the major energy consumers, and therefore present an exceptional opportunity for saving energy. Focusing on lowering inlet gas temperatures, considering suction throttling of discharge pressure instead of the traditional discharge throttling, will help to reduce energy consumption. In this paper, a detailed analysis of factors aggravate or lead to undesired CGCs performance will be discussed along with solutions to minimize adverse impact. For example, operating the gas compressors at relatively high inlet temperature will result in higher energy consumption. After performing need analysis, results prove that we would save 3-7% of running compressors consumed energy. In addition, during compressor design phase, it was found that most motor driven compressor system uses discharge throttling, which incurs high-energy consumption. Instead, it is recommended to consider suction throttling to control discharge pressure, as will be explained. This paper will focus on a detailed case study in one of the running CGCs in an upstream gas-oil separation plant (GOSP-A). This paper proves the effectiveness of the proposed techniques in reinstating the CGCs in GOSP-A, to ensure better performance and save energy. This innovative technique is based on extensive process data analysis — evaluating operating, design data, related performance curves, and reviewing international standards. It will be illustrated that this type of analysis and techniques is a valuable tool for saving energy, in most cases, at oil and gas industries