Saving $900K in Fuel / Emissions per year through Plant Consolidation

In this case study, Detechtion Technologies carried out a detailed study into determining more economical alternatives of producing
the equivalent amount of gas without the need to open bypass. They were able to shut down one unit, and run the same amount of production, while redacting expenses on resources.

The Mission: 

Optimize the client’s gas plant by consolidating the operation of three compressors by shutting down one of the units in order to generate fuel savings and minimize operating expenses. 

Background: 

The client had been operating all of its compressors despite declining flow from the CSG field. In order to maintain adequate flow across all three units, the client had been decreasing speed on each unit and opening the bypass valve in order to maintain flow and safe operation. 

The Solution: 

Detechtion Technologies carried out a detailed study into determining more economical alternatives of producing the equivalent amount of gas without the need to open bypass. It was evaluated that the client did not need to operate all three units and could save fuel and operating costs on one whole unit. Through Detechtion’s proprietary software, a plant capacity curve was generated which represents the capacity at a range of suction pressures which the compressors can flow individually and collectively. The curve which visualizes the performance of the plant at its theoretical best, evaluated that the client could easily run only two compressor units at the suction pressures and flow rate that it was hitting with three units. 

The Impact:

the client implemented Detechtion Technologies’ 2 unit modification and the projected savings from de-activating one of the compressor units are listed. Not only did the client cut costs on a whole compressor unit but they also reduced CO2 emissions. The client immediately recognized impressive savings from shutting down one unit and within a year realized a cost savings of more than $900,000.