From 84% to 91.5% Utilization: Optimizing Fleet Efficiency for Higher Throughput

In natural gas gathering applications, minimizing suction pressure across compressor fleets is essential for maintaining high production levels, particularly in fluctuating and declining fields. Many operators face challenges in achieving optimal suction pressures and compressor utilization across their entire fleet, often comprising hundreds of units with varying capacities and requirements.

THE CHALLENGE

One of Australia's leading natural gas producers (The Producer), sought to enhance fleet-wide compressor performance to maximize gas recovery, extend field life, and boost utilization across over 100 compressors. Faced with declining fields and inconsistent compressor performance, The Producer needed a robust, data-driven solution to identify opportunities for efficiency and optimize each unit for evolving field conditions.

THE SOLUTION

By implementing optimization and failure prevention solutions by Detechtion, The Producer gained access to advanced tools including Digital Twin analytics for identifying performance issues or opportunities, modelling capabilities for what-if analysis, and fleet wide reporting to identify the most impactful opportunities within a compressor fleet. These tools enabled a holistic view of the compressor fleet and allowed The Producer to:

• Optimize Suction Pressure: Using compressor performance curves and analytics, The Producer continuously monitored and adjusted the compressor configurations for maximum well deliverability.
• Increase Running Speed and Reduce Downtime: Simulation tools and Start-up packages, which are detailed recommendations on setpoint and shutdown point config, allowed The Producer to fine-tune individual compressor settings, leading to an increase in throughput and overall fleet performance.
• Leverage Comprehensive Fleet Data: With comprehensive Fleet Management Reports, The Producer prioritized high-impact changes and maintenance across the fleet, reducing potential production losses and enhancing decision-making.

RESULTS

Over a four-year period, The Producer experienced a 7.5% improvement in fleet utilization, contributing to increased production and reduced downtime. Key performance indicators included:

• Increased Compressor Utilization: By deploying Enalysis tools, utilization across the fleet improved, helping The Producer to maximize gas production despite field decline. (7.5% Increase to Utilization)
• Increase Production through Reduction in Suction Pressure: Adjustments to individual compressor configurations and pressure settings led to a reduction in suction pressure, which helped increase gas deliverability. (The Producer attributed that compressor fleet optimization alone contributed to 5-10MMscd of increased production)
• Enhanced Maintenance and Optimization: With regular fleet health checks and diagnostics, The Producer was able to identify and mitigate potential issues proactively, resulting in fewer interruptions and extended compressor lifespans. (Reduction to Unscheduled Downtime)

CONCLUSION

By leveraging Enalysis to deliver its optimization and failure prevention solutions, The Producer successfully enhanced compressor fleet management, boosting utilization, and enabling sustainable production in challenging field conditions. This case study underscores the value of data-driven fleet optimization for natural gas producers aiming to maximize recovery and extend field life.