Succes Story

Achieving Energy Recovery and Optimization for a Complex Gas Compression Facility

Optimizing Turbomachinery for $1.864 Million Savings per Year in Fuel Gas Consumption

A major oil and gas company in the Middle East operates a complex gas compression facility. Natural gas from multiple sources is compressed and supplied to major gas processing and Natural Gas Liquids (NGL) facilities. The facility includes medium-pressure (MP) booster compressors and high-pressure (HP) compression sections with parallel trains. CCC anti-surge controllers monitor compressor operation and a master pressure controller ensures gas delivery prioritization among end-users. 

CCC maintains a service agreement with this customer, conducting regular Preventive Maintenance (PM) visits to ensure equipment functionality and identify optimization opportunities. During recent visits, CCC observed manual settings for load sharing controllers and remote anti-surge/recycle valve openings, causing excessive gas recycle and power consumption. Investigation revealed that manual operation was likely due to poor speed controller behavior and unstable machine conditions. This inefficient operation led to wasted energy and unbalanced conditions. 

Undertaking our five-step turbomachinery performance and process optimization strategy, CCC experts identified and implemented improvements. Download the full case study to learn the specifics and how we saved this customer $1.864 million per year in fuel gas consumption alone.