Upgrading Four Centrifugal Compressors

Designing efficient, reliable, and low emissions process machinery for a sustainable world
Rev. September 2023 1

Upgrading four centrifugal compressors to recover additional tens of millions of barrels of Oil
(Increase oil field recovery, profitability and operational life)
Anecdote: With time, on many offshore platforms, the gas to oil ratio increases. We were also facing a similar situation. Four
compressors, on two platforms, were upgraded to massively increase the volumetric flow of each compressor by sixty (60%)
percent. It allowed greater total recovery of oil from this field to the tune of an additional XX million (confidential) barrels of oil and
increased the field economic life by ~ eight years. The total cost of upgrading the four compressors and associated equipment was
estimated to be less than US$33 million. With the average oil price of $50 per barrel, the upgrade was estimated to generate over
time an additional revenue in excess of US$1.5 billion, and the payback period of less than three months. J
Consider recovering additional millions of barrels of oil from your old oil fields with sensible compressor upgrades. With right
techno-commercial advice, such upgrades can be easily justified and implemented.
Figures: New vs old performance conditions - courtesy MAN ES / Hydrocarbon Processing, Aug 2017
Key features of the compressor upgrade: A large volumetric flowrate increase of 60% of was achieved. Each compressor upgrade
was carried out in major, but separate, turnarounds of 30 days duration. Some of the key technical decisions taken to upgrade the
facility and package engineering were:
www.gl-mach.com , E: [email protected] , T: +61 456 980 655

Global Machinery Consultants Pty. Ltd., A.C.N No. 094 649 699, A.B.N. 20 094 649 699. Perth, Melbourne, Australia
© This document is the property of Global Machinery Consultants Pty Ltd., Australia.
Designing efficient, reliable, and low emissions process machinery for a sustainable world
Rev. September 2023 2

a. Casing / piping: The existing compressor casing, and suction and discharge piping were re-used. This minimised any re-design
and the field work. The gas inlet and exit velocities from compressor flanges were still less than 30 m/sec. The gas velocities
in the suction and the discharge piping were also less than allowable values.
b. Impellers: To handle the larger gas volumes, wider impellers and stator channels were required. The compressor rotating
speed was increased by 1000 rpm, and the new required head was developed using six (6) impellers instead of the existing
seven (7). This allowed the new bundle to fit in the existing radial split compressor casing.
c. The gearbox transmission ratio was changed from 7.1 to 7.82 to increase the compressor speed by 1000 rpm. Two new
gearboxes were purchased.
d. Rotor dynamics study was carried out including the compressor lateral analysis and the train torsional analysis.
e. Dry gas seals were found to be suitable for the new conditions, however, new dry gas seals were purchased for each
compressor body to reduce the offshore turnaround time and any potential risk from the old seals.
f. New drive motors of larger power rating (5360 kW) were purchased. The existing electrical cables were reused. The existing
platform power was found to be suitable to handle the new higher start torque conditions.
g. The existing couplings were not suitable for the new operating conditions. New high speed and low speed couplings were
purchased.
h. Even though the total weight of the skid was increased by 4000 kgs, the existing package base plate was found to be suitable
for the new duty. The centre of gravity shift was found to be acceptable.
i. Lube oil requirement of the new compressor and motor were higher but the existing lube oil system including its controls
were found to be suitable for the new duty.
j. Compressor surge control philosophy was unchanged though the anti-surge control valves were changed to a larger size.
k. A field performance test was conducted to verify and incorporate the new surge control point in the compressor control logic.
I and my colleague (Mr. A.K.) used the experience to publish a detailed technical paper on this exercise. The technical paper and
can be found at the following link.
https://www.gl-mach.com/wp-content/uploads/2020/08/HP0717-Upgrade_Process_Compressor_to_enhance_production.pdf
The opportunity: There are hundreds of oil fields where suitable compressor upgrades can significantly increase the production
and extend the economic life of the field by improving the total recovery of oil. It could (should) also reduce the gas flaring. The
reduction in the carbon dioxide emissions would help any company meet its commitment to reducing greenhouse gas emissions.
Before the 1980s, typically @25% of the oil in place was recovered from the oil fields. With the advent of gas lift, water injection,
gas re-injection and higher gas handling capabilities, the total oil recovery has gradually increased to 70% of the field oil reserves.
New technologies could help recover as much as 85% of the oil from the oil fields.
Consider compressor upgrades. It is potentially one of the easiest wins available at many sites while minimising the environmental
foot print.
Consulting with plant design specialists could help develop the business case for enhanced profitability and improved ESG
credentials!
Email us - [email protected]
www.gl-mach.com , E: [email protected] , T: +61 456 980 655

Global Machinery Consultants Pty. Ltd., A.C.N No. 094 649 699, A.B.N. 20 094 649 699. Perth, Melbourne, Australia
© This document is the property of Global Machinery Consultants Pty Ltd., Australia.

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Designing efficient, reliable, and low emissions process machinery for a sustainable world

Rev. September 2023 1

www.gl-mach.com , E: [email protected] , T: +61 456 980 655

Rev. September 2023 2

www.gl-mach.com , E: [email protected] , T: +61 456 980 655

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