All posts by devteam

Detechtion Technologies to Speak at Produced Water Conference

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HOUSTON, TX (March 27, 2017) – Detechtion Technologies, the global leading Industrial IoT and Mobility solution provider in the oil and gas industry, will be speaking this week at the 8th Annual Cost-Effective Produced Water Management conference in Pittsburgh, Pennsylvania.

Britt Spencer, a Director in Detechtion’s Professional Services organization, was invited to speak on how oil & gas producers are using Mobility solutions to improve the effectiveness and cost efficiency of produced-water management in the Marcellus Shale. A case study will be offered to show how a Mobility solution was used to automate electronic water management run tickets.

Electronic water management run tickets are just the beginning. Water management in Detechtion’s Fieldlink™ Mobility product provides date, time and geo-stamping on all hauling activities to ensure complete accountability for arrival, departure, load and unload events. Source and destination information is captured as incurred including such things as vehicle check-in, custody signatures, and integrated phone functionality. In addition, the Fieldlink™ based, water-management solution also provides scheduling and dispatching, fully integrating with accounting and invoicing systems, to manage the process from start to finish. The solution also includes an automatic pricing module and streamlined invoice approval process between the producer and water hauler.

The new electronic process now generates approved invoices for payment in 2-3 days compared to the several weeks it used to take, resulting in more accurate, auditable data for the producer and more timely payment (and reduced DSO) for the water hauler.

“Water management is a great example of how Fieldlink™, the leading field automation & mobility platform for upstream oil & gas, can drive efficiencies in the oilfield,” advises Eric Neason, Senior Vice President of Products & Services at Detechtion. “But it’s just one of many applications our customers have successfully deployed to automate their production operations including site construction, pumper duties, chemical management, preventative maintenance, and health, safety & environment.”

Detechtion Extends the First IIoT Edge Device in Oil and Gas to Incorporate Optimization

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HOUSTON, TX (November 17, 2017) – Detechtion Technologies, the global leading Industrial IoT and Mobility solution provider in the oil and gas industry, today announced that it has successfully integrated its Enalysis™ software, which provides predictive analytics for compressors, with its Enbase™ Hub creating the first IIoT edge device to incorporate optimization.

Designed specifically for oil and gas, the Enbase™ Hub defines the new paradigm for managing field assets in remote, hazardous environments. Designed to go beyond simple monitoring, the Enbase™ Hub empowers users to monitor, protect, control, and optimize critical assets.

The initial release will be targeted at natural gas compressors. The Enbase™ Hub now has the capability to use the predictive models from Enalysis™ to calculate metrics such as high rod loads and low rod reversals so they may be included in the parameters monitored and used in safety shutdown systems for compressors, preventing catastrophic, costly equipment failures. Moreover, the KPIs calculated in Enalysis™ can also be used to update setpoints as part of a compression control strategy to ensure that a compressor is operating at its peak efficiency. All the direct measurements as well as analytics are available for display locally via the Enbase™ Hub Control Panel. They are also communicated back to the Enbase™ Dashboard for use across the organization.

“This achievement completes our vision of creating a single edge device that can monitor, protect, control and optimize a compressor.” said Virgil Haney, Chief Technology Officer of Detechtion, “We are working with our customers and existing and potential partners to leverage this IIoT platform for other applications in Oil and Gas.”

“Other solutions require customers to procure and integrate several pieces of hardware and software to achieve what we can now offer in our single edge device,” said Chris Smith, President and CEO of Detechtion, “This creates a more cost-effective solution in the short term and a much lower total cost of ownership over the lifetime of a fleet of compressors.”

Detechtion Delivers First Commercially Available Dual Communications Telemetry Device

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HOUSTON, TX (September 20, 2017) – Detechtion Technologies, the world leader in compression fleet optimization, today announced that it has delivered its first Enbase™ Hub with both satellite and cellular communications.

Designed specifically for oil and gas, the Enbase™ Hub defines the new paradigm for compression monitoring, protection, control, and optimization. The Enbase™ Hub mounts inside an existing compressor control panel and connects instantly to controllers, annunciators, pyrometers and sensors to provide all the information from these devices remotely through the Enbase™ Dashboard.

“Detechtion has taken advantage of the ubiquity and relative affordability of cellular networks in North America for connectivity to our edge devices.” said Virgil Haney, Chief Technology Officer of Detechtion. “This has created the opportunity for our customers to have visibility to a much denser set of data for decision making. There are, however, still areas where cell coverage is not adequate to ensure essential callouts are received immediately when an incident occurs.”

The new dual communications Enbase™ Hub utilizes satellite communications for callouts like compressor shutdowns or other events that need immediate attention, while still using the cellular network to backhaul data to the Enbase™ Dashboard that is stored on local memory when cellular connections are available.

“Our mission is to create value by bringing connectivity and automation to remote and hostile environments”, said Haney, “and while we are still able to deliver that density of data at a price point that is not cost prohibitive utilizing the cellular network, essential callouts are not missed by relying on our satellite communications.”

Services Manager – Houston, TX

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Company Profile

Detechtion Technologies™ is the market leading Industrial IoT and mobile application provider enabling the digital oilfield. Through its Enalysis™, Enbase™ and Fieldlink™ product lines, Detechtion offers solutions for chemical injection, compression, and other production operations. These products and services span telematics, monitoring, control, predictive analytics, visualization and integration with other systems so that the vision of the digital oilfield will finally be achieved. Over 100 customers and thousands of users depend on Detechtion Technologies to monitor and manage over 10,000 assets worldwide.

Position Title

Services Manager

Reports To

VP, Services

Location

Houston, TX

Key Responsibilities

  • Develop thorough knowledge of customer organizations, needs and plans
  • Foster relationships with key contacts representing field, corporate and IT sponsors
  • Gather requirements, scope, and estimate / quote / propose new work with existing customers around mobile software platform
  • Work with customers to establish implementation plans and work effort involved for all levels of software implementation of mobile application and integration
  • Develop configuration specifications for screen and workflow design
  • Implementation of specifications to enhance existing workflows or create new workflows
  • Lead planning and implementation of individual customer projects
  • Project Manage customer projects, at times multiple projects simultaneously
  • Identify customer risks and issues and work in a timely fashion to provide proactive mitigation and remediation as necessary to ensure customer satisfaction
  • Work with Support as necessary to assist with customer related support items that require more in depth knowledge of customer.
  • Work with Product Management on road map of Fieldlink™ application by providing and championing specific customer feedback.
  • Ensure consistent, high quality implementations of Fieldlink™ application and related processes that meets customer needs and Detechtion best practices
  • Work with Detechtion Services team to ensure required resources are well understood
  • Work with Services to assist in account plans for existing customers and support sales efforts (including pilots) for new customers

Personal Characteristics

  • High energy, attention to detail, a strong work ethic and a determination to deliver results and add value
  • Strong experience, maturity and common sense
  • Positive attitude and a passion for customer service, including staying cool under pressure
  • Quick learner with ability to understand complex technical issues and facilitate focused corrective actions to make the customer successful
  • Ability to learn and work independently
  • Interested in customer, company and personal success
  • Flexible and able to adjust to rapidly changing circumstances and priorities
  • “Can do” attitude with a willingness to dive into details and be “hands on”; should be comfortable managing a project or evaluating a piece of code
  • Ability to lead a team towards shared goals & objectives, including leading by example
  • Strong sense of ownership and accountability, especially related to deadlines
  • Excellent personal presence and communication skills
  • Highly ethical with unquestionable integrity
  • Low ego and collaborative style

Qualifications

  • 3 + years working experience
  • Previous experience in technology or software professional services
  • Previous oil & gas industry experience
  • Previous project management / team leadership experience
  • Technical understanding of relational databases, noSQL databases, JavaScript a plus
  • Degree in Business, Engineering or Science
  • Excellent written and oral communication skills
  • Ability to travel 50% of the time (primarily in the US and Canada)
  • Possess US work authorization which does not require sponsorship by the employer for a visa

Compensation Package

  • Competitive base salary plus bonus plan eligibility.
  • Standard company benefits such as 401K, health insurance, etc.
Apply

Detechtion Technologies Establishes Preferred Service Provider Program with Alitek, Exile Automation and Techneaux Technology Services

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HOUSTON, TX (March 10, 2017) –  Detechtion Technologies, the world leading Industrial IoT and Mobility solution provider in the oil and gas industry, today announced the launch of its Preferred Service Provider Program, designed to ensure customers receive unparalleled service and allow Detechtion to scale its business as demand for its solutions rapidly grows. The company also announced it has added its first three service providers to this program: Alitek, Exile Automation and Techneaux Technology Services.

Houston-based Alitek offers a variety of services to help clients identify, plan, implement, deploy, and support solutions that improve business processes, increase efficiency and reduce risk through better management of information. To date, Alitek has focused on projects implementing Detechtion’s Fieldlink™ mobility solution.  “We have a strong track record partnering with commercial software providers to deliver their solutions in a way that enables customers to use their technology, information, and employees more effectively and efficiently, which is why Detechtion’s offerings are such a great fit for us,” said Tod Knight, Alitek Partner and CTO.

Exile Automation, based in Calgary, Alberta, manages, designs, and maintains a variety of high-quality process control, measurement and automation projects. Exile has capabilities to install Enbase automation products as well as complete compressor control panel retro-fits.  Dean Blahut, Managing Partner with Exile Automation said, “we have worked with Detechtion Technologies for years helping clients get compressor data into Enalysis™ and are excited for the opportunity to help bring the new Enbase™ products to the Canadian market.”

The team at Techneaux, with offices in Lafayette, Houston, and Denver, helps customers design, implement, and maintain solutions to solve their process control and monitoring needs. Techneaux is primarily focused on projects deploying Enbase™ Hubs, the edge devices serving as the backbone of Detechtion’s Industrial IoT platform.  Shannon Landry, who leads the Industrial Controls team at Techneaux Technology Services, said, “we are excited to be part of the new Preferred Service Provider Program with Detechtion, to help customers implement the Enbase™ product line to gain better transparency and control of their oilfield assets.”

“We selected Alitek, Exile and Techneaux for our Detechtion Preferred Service Provider Program based on our past history working with these companies, their strong technical capabilities, and our shared commitment and passion for customer success,” said Eric Neason, Senior Vice President of Products & Services at Detechtion Technologies. “While we will retain and grow our own dedicated field and implementation services teams, partnering with these three companies allows us to scale as demand for our offerings continues to grow.”

Quality Assurance Manager – Houston, TX

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Company Profile

Detechtion Technologies™ is the market leading Industrial IoT and mobile application provider enabling the digital oilfield. Through its Enalysis™, Enbase™ and Fieldlink™ product lines, Detechtion offers solutions for chemical injection, compression, and other production operations. These products and services span telematics, monitoring, control, predictive analytics, visualization and integration with other systems so that the vision of the digital oilfield will finally be achieved. Over 100 customers and thousands of users depend on Detechtion Technologies to monitor and manage over 10,000 assets worldwide.

Position Title

Quality Assurance Manager

Reports To

Senior Vice President, Software Development

Location

Houston, TX

Key Responsibilities

  • Design a comprehensive testing approach and plan for our software products.
  • Work with the development teams to execute the testing plan.
  • Work with the software teams to design and deliver a continuous integration testing environment.
  • Design stress / load tests.
  • Troubleshoot and diagnose unexpected software behaviors reported by customers.
  • Effectively communicate error conditions to software development team and how they differ from expected functionality.
  • Manage the workflow of the QA process within an agile development method.
  • Report QA activities and key performance indicators to management.

Personal Characteristics

  • Ability to patiently and scientifically analyze problems and determine their root causes.
  • High energy, attention to detail, a strong work ethic and a determination to deliver results and add value.
  • Quick learner with ability to understand complex technical issues and facilitate focused corrective actions to make the customer successful.
  • Interested in customer, company and personal success.
  • Flexible and able to adjust to rapidly changing circumstances and priorities.
  • Strong sense of ownership and accountability, especially related to deadlines.
  • Low ego and collaborative style.
  • Excellent written and oral communication skills.

Qualifications

  • 5+ years working experience.
  • Experience creating and running software testing programs in an agile environment.
  • Technical ability to run automated tests and work with test environments.
  • Experience with html5, javascript and web applications.
  • Understanding of automated testing and test frameworks.
  • B.S. in Engineering or Science.

Compensation Package

  • Competitive base salary plus bonus plan eligibility.
  • Standard company benefits such as 401K, health insurance, etc.
Apply

Sales Distribution Representative – Houston, TX

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Company Profile

Detechtion Technologies™ is the market leading Industrial IoT and mobile application provider enabling the digital oilfield. Through its Enalysis™, Enbase™ and Fieldlink™ product lines, Detechtion offers solutions for chemical injection, compression, and other production operations. These products and services span telematics, monitoring, control, predictive analytics, visualization and integration with other systems so that the vision of the digital oilfield will finally be achieved. Over 100 customers and thousands of users depend on Detechtion Technologies to monitor and manage over 10,000 assets worldwide.

Position Title

Sales Distribution Representative

Reports To

SVP Sales and Marketing

Location

Houston, TX

Key Responsibilities

  • Quoting
    • Receive requests from customers for quotes
    • Prepare and send quote
    • Product, Kit or System quotes can include
  • Receive orders (PO) from customers
    • Confirm pricing
    • Confirm correct and complete parts
    • Confirm timing including anticipated delivery date vs. customer need by date
  • Order Management
    • In-house orders
    • 3rd party
    • Track all order status
    • Confirm shipment with customer and provide tracking number
    • Keep customer notified of any changes to ship date or ability to meet need-by date based on status of inventory and incoming parts

Personal Characteristics

  • High energy, attention to detail, a strong work ethic and a determination to deliver results and add value
  • Strong experience, maturity and common sense
  • Positive attitude and a passion for customer service, including staying cool under pressure
  • Interested in customer, company and personal success
  • Flexible and able to adjust to rapidly changing circumstances and priorities
  • “Can do” attitude with a willingness to dive into details and be “hands on” when needed
  • Strong sense of ownership and accountability, especially related to deadlines

Qualifications

  • 3-5+ years working experience preferred
  • Previous experience in hardware or technology order fulfillment
  • Excellent written and oral communication skills
  • B.S. or B.A. degree preferred

Compensation Package

  • Competitive base salary plus bonus plan eligibility.
  • Standard company benefits such as 401K, health insurance, etc.
Apply

Services Director – Houston, TX

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Company Profile

Detechtion Technologies™ is the market leading Industrial IoT and mobile application provider enabling the digital oilfield. Through its Enalysis™, Enbase™ and Fieldlink™ product lines, Detechtion offers solutions for chemical injection, compression, and other production operations. These products and services span telematics, monitoring, control, predictive analytics, visualization and integration with other systems so that the vision of the digital oilfield will finally be achieved. Over 100 customers and thousands of users depend on Detechtion Technologies to monitor and manage over 10,000 assets worldwide.

Position Title

Services Director

Reports To

SVP Products & Services

Location

Houston, TX

Key Responsibilities

  • Develop thorough knowledge of customer organizations, needs and plans
  • Foster relationships with key contacts representing field, corporate and IT sponsors
  • Gather requirements, scope, and estimate / quote / propose new work with existing customers
  • Work with customers to schedule work including hardware, Detechtion field services, and 3rd party partner field services as well as coordinate as needed with Detechtion Engineering Services, Support and R&D teams
  • Balance resource and hardware needs against capacity / availability
  • Provide oversight, management and proactive status communication to ongoing customer implementations and deployments of the Enbase™ product line
  • Work with customers (both service companies and their end user customers) to understand and meet their integration needs
  • Identify customer risks and issues and work in a timely fashion to provide proactive mitigation and remediation as necessary to ensure customer satisfaction
  • Ensure consistent, high quality installations of Enbase™ hardware that meets customer needs and Detechtion best practices
  • Ensure consistent, high quality implementations of Enbase™ software that meets customer needs and Detechtion best practices
  • Work with Detechtion executive team to ensure required resources are well understood
  • Work with Finance to establish hardware forecasts and appropriate inventory levels
  • Work with Sales to execute account plans for existing customers and support sales efforts (including pilots) for new customers

Personal Characteristics

  • High energy, attention to detail, a strong work ethic and a determination to deliver results and add value
  • Strong experience, maturity and common sense
  • Positive attitude and a passion for customer service, including staying cool under pressure
  • Quick learner with ability to understand complex technical issues and facilitate focused corrective actions to make the customer successful
  • Interested in customer, company and personal success
  • Flexible and able to adjust to rapidly changing circumstances and priorities
  • “Can do” attitude with a willingness to dive into details and be “hands on” when needed
  • Ability to lead a team towards shared goals & objectives, including leading by example
  • Strong sense of ownership and accountability, especially related to deadlines
  • Excellent personal presence and communication skills
  • Highly ethical with unquestionable integrity
  • Low ego and collaborative style

Qualifications

  • 5-7+ years working experience
  • Previous experience in technology or software professional services
  • Previous oil & gas industry experience
  • Previous project management / team leadership experience
  • S. in Engineering or Science
  • Excellent written and oral communication skills
  • Ability to travel 30% of the time (primarily in the US and Canada)

Compensation Package

  • Competitive base salary plus bonus plan eligibility.
  • Standard company benefits such as 401K, health insurance, etc.
Apply

Compressor Engineer – Houston, TX

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Company Profile

Detechtion Technologies provides compressor optimization and fleet management solutions to natural gas producers through our principal product Enalysis™. Each year, Detechtion’s clients are provided with a significant return on their investment using Enalysis™ through the successful diagnosis of compressor inefficiencies, reductions in fuel gas consumption, increases in natural gas production, and the prevention of catastrophic failures. Detechtion is led by a vibrant, highly motivated management team focused on providing best-in-class service to our existing clients and aggressively adding new customers. Detechtion has offices in Houston, Calgary, and Brisbane. Visit www.detechtion.wpengine.com for more information.

Candidate Profile

The successful applicant will play an essential role within the Operations Group working alongside a young, energetic team. We are looking for a candidate who demonstrates the following characteristics:

  • Self-motivated
  • Strong analytical skills
  • Excellent interpersonal skills
  • Detail oriented
  • High willingness to learn

Responsibilities

Become technically competent in the responsibilities of the Operations Group:

  • Natural Gas Reciprocating and Rotary Compressor theory
  • EnalysisTM diagnostic system
  • Compression simulation software
  • Running compressor diagnostics
  • Identifying optimization opportunities
  • Onsite evaluation of compression assets
  • Working on technology enhancement projects

Requirements

The successful applicant will have a Bachelor degree in Mechanical or Petroleum Engineering, and field experience in the Oil and Gas Industry will be an asset.

Contact Information

Kari Scotton: [email protected].

Please write “Compressor Engineer Position” on the subject line and attach your resume and cover letter to apply.
No phone calls please.

Compressor Insights from Detechtion – September 2016

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Thought of the Day


Aligning Business Objectives When Natural Gas Producers Lease Compression Assets

The line between operational and maintenance responsibility is often blurred when managing a fleet of compression assets. Additional complexity is introduced when some of the assets are owned and some are leased. In this quarter’s blog, we will look at the different philosophies and metrics for operating and maintaining a fleet of leased compression assets.

When a natural gas production company leases compression assets to service their gathering network, they generally agree to service level agreements around availability and mechanical availability with the compression leasing company.

Availability is generally defined as:

Total Available Runtime Hours – Total Downtime Hours
Total Available Runtime Hours

Total downtime hours include both scheduled downtime for preventative maintenance and compressor overhauls as well as unscheduled downtime for any reason not associated with scheduled downtime.

Mechanical availability is generally defined as:

Total Available Runtime Hours – Downtime Hours Due to Mechanical Issues
Total Available Runtime Hours

The natural gas producer and the compression leasing company agree to terms and service levels around these two metrics and then move to operations. However, these two metrics do not take into account the level of efficiency or utilization that each compressor has delivered for each hour of runtime. Consequently, a leasing company may meet their contractual guarantees of availability and mechanical availability, while opportunities around process losses and inefficiencies caused by the mechanical conditions inside each compressor and cylinder go unrealized as that responsibility remains with the entity responsible for operations. It is in these instances that Detechtion can help bridge the gap between maintenance and operational philosophies. Using Enalysis™, we can help leasing companies meet their service level agreements around availability and mechanical availability and highlight utilization opportunities that can be acted upon and realized by operations.

When a natural gas producer deploys Enalysis™ on those leased assets, operational opportunities that either increase throughput or save on power consumption are quickly identified. These opportunities are sent to the compression leasing company and natural gas producer. Depending on who is responsible for operations dictates how those opportunities are realized.

In a best practice we have observed, there are joint monthly meetings with the leasing company, operating company and Detechtion to ensure that business objectives are aligned. At these monthly meetings, opportunities for increased gas throughput (along with recommended operating changes like pocket adjustments, speed changes, etc.), power savings, and any inefficiencies identified through Enalysis™ are jointly reviewed and prioritized. Whether implemented by the leasing company or by the operator, the benefits are significant. We have found that utilization opportunities average about 1.5% of daily throughput and power savings average about 6% annually.

By deploying Enalysis™ on leased compression assets, natural gas producers can then feel confident that they are getting the most out of their compression investment and the leasing company can drive towards that peak efficiency with the confidence that they are not exposing their compression assets to extreme conditions as they move towards increased availability and mechanical availability through predictive maintenance analytics.

If you are a natural gas producer who leases compression assets or the leasing company that provides them and want to make sure that utilization of those assets is being measured and acted upon, please reach out to us at Detechtion so we can quantify what opportunities exist in a leased compression fleet.


Representative Win


Increased Throughput – Maximizing Power Usage

Proposed

Optimize the client’s compressor station to maximize production and increase overall utilization.

Background

A compressor station composed of two identical reciprocating compressors was commissioned in a high activity field aimed to accommodate high flow rates and variable conditions. Cylinder actions were setup as single-acting to accommodate the variable conditions resulting in high uptime, and swinging gas flow rates. The subsequent year, activity in the field slowed and the rates/pressures steadied. With the steadied pressures and slowly declining gas rates, the two compressors became ideal candidates for optimization as identified through Enalysis™’ Cash Flow at Risk and Incremental Production calculations.

In an on-going effort to improve on and meet production targets, the gas producer opted to pursue the potential for increased production through compressor optimization.

Optimization Methodology

For a reciprocating compressor to be fully optimized for maximum throughput, either or both of the cylinder capacity utilization and the horsepower utilization should be 100%. Through the use of individual compressor performance curves, such as the one below, and a Detechtion Technologies’ Start-up Package of high and low pressure set points, detailed in this edition’s Tech-Tip, compressor units can be evaluated for opportunities to:

  • Increase running speed
  • Adjust cylinder action
  • Reduce added cylinder clearance
  • Optimize suction pressure
  • Decrease recycle set point

Thus resulting in increased utilization and maximum throughput.

Outcome

After a detailed review of the current compressor station operating parameters through Detechtion Technologies’ Enalysis™ system, a new configuration with new high and low pressure set points were presented to the gas producer. With the new configuration, the compressors were capable of flowing more gas at much lower suction pressures than the current plant inlet pressure.

The new pressure set points were programmed into each panel to protect the compressors, the stage 1 cylinders were changed to double acting from single acting, the pockets were adjusted to 1.75” and the suction set-point decreased by 23 psig to pull harder on the field and increase production.

The changes resulted in approximately 4.6 mmscfd of additional throughput for the station as the field production was stimulated by the lower suction pressure. For the time frame that was closely observed, the units sustained an average production increase of 4.6 mmscfd over the following 30 days, equating to an immediate $414,000 in revenue increase for the time frame observed, assuming $3.00/mscf that, when annualized, resulted in $5,037,000 in increased revenue!

Compressor Configurations Power Usage Suction Pressure Discharge Pressure Station Throughput
Before SAHE0”,SAHE0”//DA0”//DA0” 74% 75psig 750psig 11.0mmscfd
After DA1.75”,DA1.75”//DA0”//DA0” 96% 52psig 750psig 15.6mmscfd
Change +22% -23psig 0psig +4.6mmscfd


Tech Tip


The Optimization Life-Cycle

Compressor optimization is an ongoing process aiming to maximize production revenues while minimizing operating costs, all the while holding safety paramount. The engineering approach and delivery to achieve compressor optimization will vary on a case-by-case basis, while the workflow process often remains the same:

  1. Identify Opportunity
  2. Define Optimization Objectives
  3. Create Solution – Start-up Package
  4. Track Results

The steps above highlight the basic framework needed to assess an optimization opportunity. Often times, there are restrictions set by existing business processes, upstream/downstream conditions, parallel/series compression, or facility limits which must also considered but are not detailed in this article. It is important to consider the impact of any process change, in order to anticipate the expected benefit and risk as part of any management of change (MOC) process. With proper planning and execution, compressor optimization often results in a high value return for low cost efforts!

    1. Identify Opportunity

Finding an opportunity is the first step in optimizing a compressor. Whether you are regularly assessing Enalysis™ reports or closely monitoring its operation, here are some questions you can ask yourself to see if an opportunity presents itself:

      1. Is your compressor not meeting the defined objectives it was set out to do?
      2. Is your compressor bypassing or pinching back the suction control valve often?
      3. Is your compressor frequently hitting alarm set points?
      4. Does your Enalysis™ report frequently indicate CFRs or other flags?

If the answer to any of these questions is yes, then you might have an opportunity to improve production or reduce your operating costs!

    1. Define Optimization Objectives

Defining the ideal outcome beforehand can determine the success of the opportunity early on. Accommodating additional production, allowing for increased line pressure, or improving on the current operation are all common scenarios that can typically be defined with some accuracy. By considering a range of operating conditions, we can setup a compressor more capable of handling a multitude of conditions.

When given a range of potential operating conditions, Detechtion will often focus on accommodating a wider array of conditions, instead of running at a fixed point. The reason being is that compressors are often subjected to variable conditions, and any time a compressor pinches back gas with the suction control valve or recycles to regulate pressures, efficiency is lost.

    1. Create Solution – Start-up Package

Using Detechtion’s Curves, Online Simulator, or reaching out to your Engineering Account Manager will enable you to find the optimal solution for your compressor. Assuming we have a 3-stage compressor, and are setting up the compressor to handle the 8 to 10 mmscfd at a discharge pressure range of 700 to 1100psig, Enalysis™' Simulator determined the ideal configuration to be DA2”, DA2"//DA0"//DA0" with the limiting factor being 99% HP Utilization. Upon finding the ideal configuration, we need to verify the compressor can handle the other operating conditions, and make sure we are going to be satisfied with the outcome.

Variable Min Average Max
Configuration DA2",DA2"//DA0"//DA0"
Discharge Range (psig) 700 1000 1100
Flow Range (mmscfd) 8 9 10
Suction Pressure (psig) 58 67 77
HP Utilization (%) 77% 91% 99%

Running two more simulations as seen in the above chart proves that we can operate in our desired minimum to maximum range. The next step is to determine the full operating range for our compressor with the creation of a start-up package.

Detechtion produces start-up packages for our clients which is a document that details the configuration, control points, and shutdown set points required for the compressor to run optimally. The start-up package considers the full range of pressures that the compressor could operate in and limits the conditions so that it will not exceed any potentially catastrophic conditions. For example; Rod Loads, net rod loads, reversals, and low volumetric efficiencies, are factors not visibly evident but could have catastrophic results if not considered.

The process for creating a start-up package may differ depending on your equipment, maintenance practices and/or operating philosophies. The process that Detechtion typically follows is detailed as follows and is based on 4 operating points:

Limiting Factors/Objectives High Shutdowns High Suction Control
Keep Driver Utilization <105% <99%
Keep Rod Loads <95% <90%
Keep Reversals <65% <70%
Corresponding Load Step 1 2
Limiting Factors/Objectives Low Suction Bypass High Suction Control
Keep Discharge Temperatures < Max Allowable < Max Allowable
Keep Volumetric Efficiencies >20% >16%
Keep HP Utilization >30% >25%
Keep Rod Loads <90% <95%
Corresponding Load Step 4 6

Using these 4 operating points as our limiting factors, the following start-up package was created and represents the full operating range along with the control points and shutdowns for our chosen configuration. This documentation and knowledge can now be handed off to the personnel responsible for completing the MOC review and making the adjustments:

Although the objective only required the asset to move between 8-10mmscfd at a 700-1100 psig discharge pressure, the above start-up package indicates that if needed, the compressor can handle flow between 5-10 mmscfd, between a range of 35-77 psig suction pressure while protecting the units if these wider ranges are exceeded. The wider operating band will keep the unit out of recycle ultimately improving the unit’s overall efficiency.

    1. Track Results

After the changes have been made and the compressor is optimized, it is important to ensure that the results were as expected. Detechtion has numerous approaches to assessing the benefits of a configuration change which involves assessing changing trends, verbal feedback, or looking over a time period. Assuming the data is available, comparing the 30 days before and after the optimization provides an excellent resource for assessing the overall outcome of the change and whether or not the opportunity was acted on effectively or if further opportunities exist for optimization.

Key Performance Indicator 30 Day Before 30 Day After Change Comment
Average Production (mmscf) 9 9.2 0.2 $12,000/month Production Gain (@2.00/mscf)
Average Suction Pressure (psig) 70 66 -4
Average Discharge Pressure (psig) 1000 1000 0
Average HP Utilization (%) 85 92 7 $1,020/month increase to fuel cost (@2.00/mscf)
Average Fuel Usage (mscf) 212 229 17
Downtime (hrs) 18 6 -12 $xx,xxx/month saved in personnel callouts

If you are happy with the results, it is time to give those involved a pat on the back for creating positive results, continue monitoring the asset, and look for the next opportunity!