Gas Well Deliquification Workshop

Sheraton Hotel, Denver, Colorado

February 20 – 22, 2017

Optimizing Compressor
Operations – Part 2

Larry Harms
Production Optimization Consultant
 Parts 1 & 2???
• Part 1
– Why Common Metrics to Measure/Evaluate
Compressor Operations/Operators may not be
appropriate and what should be done instead
• Downtime, Horsepower Utilization, Maintenance
Costs
• Part 2
– Practical Tips for optimizing compression
operations improve metrics increase value

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 2

Denver, Colorado
 Assumptions for this presentation
• Focus on practical things based on actual
experiences common to most gas fields/
important to the average
operator/engineer/maintenance person

• You have some basic knowledge of this type

operation

• Mostly based on multi-stage compressors but

overlaps into wells and other areas
Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 3
Denver, Colorado
 Fact
• Unless our gas wells flow against gatherer’s
delivery pressure all of our revenue depends
on our compressors

• And even with flowing wells our revenue

depends on gatherer’s compressors

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 4

Denver, Colorado
 Conclusions for Compressor
Optimization
• Focus on the revenue side
(throughput)

• At the lowest cost possible (but don’t

worry as much about this and if you do,
focus on fuel gas consumption)

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 5

Denver, Colorado
 What are Metrics?

• Metrics are simplistic measurements used

to try to improve business performance.
They drive human behavior very efficiently
even though they usually aren’t directly
linked to the business’s principle goals
(provide the most value for shareholders
in a safe and ethical way) and may reduce
profits
Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 6
Denver, Colorado
What should we focus on?
• Knowing where value comes from

• Net Present Value Economics

– Or an agreed on valid proxy to NPV

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 7

Denver, Colorado
What should we focus on?
• Remove major Downtime causes that are
cheap/easy
– Temperature, Valves, Low/High Suction/ Engine
Overload (Details on these and more in Part 2)

• Fuel gas use per MCF vs. best possible, not

HP Utilization, to identify possible value
adding swaps (must measure fuel gas)
– Only needs to be reviewed on 6-12 month intervals
Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 8
Denver, Colorado
What should we focus on?
• Optimize wells in areas with excess
compression (especially before downsizing)

• Matching compression and wells to optimize

production
– Must train/grow personnel expertise in this area
– Regular 6-12 month review ( tie to well/ fuel gas review)

• Not letting compression load up wells

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 9
Denver, Colorado
What happens when field
pressures vary substantially
If field pressures go from 70 to 170 psig?

• Critical Rate increases by about 50%

– Flowing wells not protected by automation will
load up

• Plunger Lift cycles dramatically affected

• Fluid Levels change in pumping wells and

may gas lock or worse
Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 11
Denver, Colorado
Tips on Optimizing Field Pressure Swings
• Shut in wells when capacity lost (pressure
increases to point no more gas sold)

• Open up wells only when capacity is

available (Pressure less than Suction
Control valve set point)

• Have a plan and “tiers” of wells to

accomplish this
Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 12
Denver, Colorado
 Results of reducing pressure swings,
lowering pressure, optimizing

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 13

Denver, Colorado
 Results of reducing pressure swings,
lowering pressure, optimizing

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 14

Denver, Colorado
Tips on Optimizing Field Pressure Swings
• Install Most Flexible Compressors you can

• Rate, Suction and Discharge pressure along

with engine load will change

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 15

Denver, Colorado
 Basic Recip. Compressor
Operation

Very Simple Machines, rate not very flexible

Suction
Piston
Compressor Suction
Rod
Pcrank end

Phead end
Rod Load Cylinder

Discharge

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 16

Denver, Colorado
 Flexibility tools - Speed
• Easiest way to adjust capacity is to
change the compressor speed
• Range is narrow to meet emissions
requirements with nat. gas engine drivers
– Cat G3516 gas engine. Ratings: 492-1000 bkW (660-
1340 bhp) @ 1200-1400 rpm are NSPS site compliant
capable with customer-provided air-fuel ratio control
and aftertreatment. 43940.html
Source http://www.cat.com/en_US/products/new/power-systems/oil-and-gas/gas-
compression-engines/18443940.html

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 17

Denver, Colorado
 Flexibility tools - Speed
• Install Automatic RPM Controller that
works to maintain suction pressure

• When you need more capacity run gas

engines up to their max. speed (Cat 3516
max listed as 1400 RPM with a 5%
overspeed tolerance

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 18

Denver, Colorado
 Basic Recip. Compressor Operation
At the end of the stroke the “unswept” or
remaining volume is called “Clearance” and
we can vary this to increase flexibility
Suction
Piston
Compressor Suction
Rod
Pcrank end

Phead end
Rod Load Cylinder

Discharge

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 19

Denver, Colorado
 Basic Recip. Compressor Operation
Adding unswept volume via Spacers (under valves),
fixed volume or variable volume clearance pockets
(VVCP) increases flexibility/ability to optimize and
avoid constraints Suction
VVCP

Pcrank end

Phead end
Cylinder
Spacer
Discharge
Install VVCP’s on all +-5 MMCFD and over units
Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 20
Denver, Colorado
 Basic Recip. Compressor Operation

Suction Control
Valve
Compressor Skid
Discharge

Recycle Control
Valve
Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 21
Denver, Colorado
 Suction Control Valve
• Should normally be 100% open and only used in
“temporary conditions” (energy waster)

• Should eliminate all downtime due to driver

overload or high suction pressure

• Must be able to control even when there are

compressor shutdowns
– Impossible to do this effectively without shutting in
wells
Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 22
Denver, Colorado
 Suction Control Valve Tips
• Use highest flow capacity (Cv) valve
possible (that will maintain control)
– V-Ball’s or Butterflies at low pressures

• Use good PID controller

• Must tune with anticipated operating

conditions
Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 23
Denver, Colorado
 Recycle Control Valve
• Should normally be 100% closed and only used
in “temporary conditions” (energy waster)

• Should eliminate all downtime due to low

suction pressure

• Should be able to control at rates up to 100%

of unit capacity with fairly good shutoff

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 24

Denver, Colorado
 Recycle Control Valve Tips
• Use good PID controller, can get away with
lower quality than suction controller

• Use a robust valve because of high dP

– Check for leaks

• Must tune with anticipated operating

conditions
Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 25
Denver, Colorado
 Compressor Valves
• Usually the biggest maintenance item on
recips.

• Open and Close 1000+ times per minute

• Are not tolerant of liquids

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 26

Denver, Colorado
 Compressor Valve Tips
• Always consult manufacturer and/or valve
supplier to ensure you have right valves for
application (thanks Richard Childress @
Pegasus Optimization Managers)

• Cause of almost all valve problems is poor

separation causing liquid carryover

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 27

Denver, Colorado
 Separation Tips
• Always install a production separator in
centralized compressor applications

• Make sure separator/scrubbers are well

designed

• Maintain the production separator/scrubber

– Regularly clean out
– Internal diverters, mist pads, etc.
Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 28
Denver, Colorado
 If you follow the tips you will
• Reduce all major causes of downtime
– Low suction
– Engine Overload
– High Temperature (Valves)

• Reduce Fuel Gas Used

• Increase production

Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 29

Denver, Colorado
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Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 30

Denver, Colorado
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Feb. 20 - 22, 2017 2017 Gas Well Deliquification Workshop 31

Denver, Colorado