Significant reliability improvements in reciprocating gas compressor packages at Arrow Energy
Prashant S. Parulekar A B , Richard Hudson A and Harrison Boyd AA Arrow Energy, 111 Eagle Street, Brisbane, Qld 4074, Australia.
B Corresponding author. Email: Prashant.Parulekar@arrowenergy.com.au
The APPEA Journal 58(1) 168-181 https://doi.org/10.1071/AJ17046
Submitted: 30 November 2017 Accepted: 1 February 2018 Published: 28 May 2018
Abstract
Arrow Energy operates a fleet of four-stage reciprocating compressors in the Surat Basin, boosting low-pressure coal-seam gas (at 60 kPag) to transmission pipeline pressure (in excess of 9000 kPag). Historically, the compressors and the gas engine drivers exhibited persistent problems associated with high vibrations, inadequate engine and process gas cooling, poor compressor valve reliability and premature engine component failures. Hot Queensland summer conditions further exacerbated these problems, which resulted in frequent unit trips during hot periods when gas and electricity prices demanded consistent gas production at nameplate capacity.
Since 2014, Arrow Energy has carried out systematic analytical studies to establish the compressor package component limitations and develop technical solutions to address these. Stub shaft-driven air coolers, compressor valves, gas engine heads and valves, compressor frame and crosshead mounting arrangements were some of the key components studied in detail. Utilising systematically designed field tests with laboratory calibrated test instruments, scale model laboratory tests, advanced computer simulations, data analytics and new technology trials, several key design modifications were implemented. The outcome of these design changes has enabled Arrow Energy to achieve a step-change in reliability for the better, with each reciprocating compression package (including gas engine driver) operating in excess of 98% reliability. The implemented changes were executed at minimal cost and resulted in significant reduction in maintenance costs. The increased reliability and consistent production during the peak summer hours easily justified the modifications made to the packages. This paper describes the technical work undertaken, changes implemented and their outcomes.
Prashant S. Parulekar has more than 25 years of international experience in the system design, construction and operation of large-scale energy projects and oil and gas facilities. He has a Master’s degree in Mechanical Engineering (M Phil) from The University of Queensland and a Bachelor’s degree from the University of Poona, India. Prashant is an adjunct faculty at The University of Queensland. He is a second-degree black belt in ITF-style Taekwon-do. |
Richard Hudson has more than 30 years’ experience working in major industrial and process-related industries within an operations and maintenance capacity. Along with his fitting and machining trade and numerous specialist trade-related extension competencies and qualifications, Richard has a Masters in Management from Macquarie Graduate School of Management (MGSM) and a Diploma of Engineering from Monash University. Richard is the Technical Authority (TA2) for Integrity and Assurance at Arrow Energy and heads up the Operations and Maintenance Support team for Arrow Energy’s existing brownfield operations. |
Harrison Boyd has more than 8 years’ experience working in the oil and gas industry in drilling and gas processing design, operations, and project engineering. Harry commenced his career as a Well Construction Engineer following the completion of B.A. Engineering (Chemical) (Hons) at RMIT University Melbourne. He has since followed the gas molecule chain from the reservoir to the well and through to gas processing. In his role as a Project Engineer for Operations, Harrison’s focus is on improving the availability and reliability of Arrow Energy’s existing brownfield assets. |
