don colley presentation o&gp
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Upstream Oil & Gas Plant Performance
Benchmarking, Auditing and Simulation
Don Colley, P.Eng.DGC Consulting Ltd.
Dr. Bill Svrcek, P.EngUniversity of Calgary
GPAC April 15, 2005
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DGC Consulting/UofC
Introduction This presentation will include:
Performance Benchmarking Energy and Environmental Audits Process Simulation
Tools for Energy Cost Optimization
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DGC Consulting/UofC
Performance Benchmarking Key Performance Indicators (KPIs)
Facility, process and equipment benchmarking Energy KPIs Environmental KPIs
UOG Applications Monitoring and Tracking Performance Screening and Assessing Facilities Continuous Improvement Target Setting
UOG Examples Sour Gas and Sweet Gas Conventional Oil and Heavy Oil
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DGC Consulting/UofC
KPI Structure
All based on production data: Numerator: Item of interest in units of
energy, mass or volume
Denominator: Total energy equivalent production Small and decreasing value is good Large and increasing value is bad
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DGC Consulting/UofC
Energy Equivalent Production
Denominator calculated as the sum of: Total gas production Total gas liquids production Total oil production Total sulphur production Total exported power Total exported heat energy
EEP expressed as GJ or BOE
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Items Benchmarked
Numerator can be: Energy consumption Carbon dioxide emissions Sulphur dioxide emissions Fresh water consumption Produced water disposal Sand production
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DGC Consulting/UofC
Operational Decoupling
Plant Total Energy Intensity (PTEI) = Plant Processing Energy Intensity, PPEI Compression or Pumping Intensity, C/PEI Plant Flare Energy Intensity, PFEI Plant Vent Energy Intensity, PVEI
Field Gathering Energy Intensity (FGEI)
Total Energy Intensity = PTEI + FGEI
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Monitoring & Tracking Performance
Performance Indicators with Targets can be set up to effectively monitor plant, process or equipment performance
Indicators can have low and high flags
DCS availability means operators can take immediate action to correct problems or schedule maintenance
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Facility Level Benchmarking(Applied to over 30 UOG facilities)
Sour Gas Processing Plants Sweet Gas Processing Plants Conventional Oil and Solution Gas Batteries Gathering Systems EOR Heavy Oil Projects
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DGC Consulting/UofC
Energy Intensity
0%
1%
2%
3%
4%
5%
6%
Jan-0
4Fe
b-04
Mar-0
4Ap
r-04
May-0
4Ju
n-04
Jul-0
4Au
g-04
Ave J
an-Au
g 04
Targe
tSe
p-04
Oct-0
4No
v-04
Ave S
ep-No
v 04
Inte
nsity
, GJ/
GJ
BTEI BPEI BFEI BVEI Bty/FldTEI BCompEI
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DGC Consulting/UofC
Gas Plant and Gathering Systems Energy Intensity
0%
2%
4%
6%
8%
10%
Jan-0
4Fe
b-04
Mar-0
4Ap
r-04
May-0
4Ju
n-04
Jul-0
4Au
g-04
Sep-0
4Oc
t-04
Nov-0
4De
c-04
Ave 2
004
Jan-0
5Fe
b-05
Ave J
an-Fe
b 05
Targ
et
Inte
nsity
, GJ/
GJ
GP TEI GP PEI GP FEI GS#1 TEI GS#2 TEI GP/GS TEI
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DGC Consulting/UofC
Process/Equipment KPIs
Gas Compressor or Oil/Water Pump EI = Energy Input / EEP
Amine System EI = Reboiler Energy Input / EEP
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Integrated Production Intensities
Wellhead to Point-of-Sale Intensity examples Sour Gas (field operations, plant processing and
field & sales compression)
Cold Heavy Oil (well operation, trucking and processing)
Thermal Heavy Oil (SAGD and conventional thermal production facility)
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DGC Consulting/UofC
60.4
30.2
90.9
5.0
192.0
6.60
40
80
120
160
200
Ener
gy In
tens
ity, G
J/E3
GJ
Sour Gas SR, Field+Processing Sour Gas SR, ProcessingHeavy Oil Cold, Field+Processing Heavy Oil Cold, ProcessingHeavy Oil Thermal, Field+Processing Heavy Oil Thermal, Processing
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DGC Consulting/UofC
Operational Auditing Purpose
Identify opportunities to reduce fuel gas and electricity costs and improve operational efficiency
Team Defining the objectives and scope of work defines
the team requirements
Results are opportunities to: Reduce energy consumption Optimized product yield Minimize emissions
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DGC Consulting/UofC
Typical Audit Schedule
As requiredFollow up support
1-4 hrsReport presentation or final debriefing
4-8 wksReport Preparation
1-4 hrsField debriefing
1-5 daysField work
2-4 wksData collection and field preparation
4-8 wksScheduling of field work
4-6 wksBudget development and approval
1-2 wksScope and expertise selection
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DGC Consulting/UofC
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DGC Consulting/UofC
Oil Battery Results
Cost: Option 1: Restaging pump estimated at $25,000Option 2: Install a VFD at $250,000.
Payout: Option 1: 3 monthsOption 2: 2 years
Annual Savings: $125,000/y250 kW @ $60/MWh and 350 d/y
New Conditions:78 m3/h @ 8,960 kPa with no throttle valve.
EE Opportunity:Restage the pump and remove the throttle valve to match actual flow volume conditions or install a VFD to control motor and pump speed.
Current conditions:Capacity: 125 m3/h @ 14,270 kPa design, 78 m3/h @ 16,540 kPa actual, throttled to 8,960 kPa discharge; 670 kW motor with 519 kW actual consumption.
Situation:Oil battery with excess pump capacity for disposal of produced water. With no speed control on pump, throughput is controlled with a throttle valve.
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Sour Gas Production Results
Cost:Option 1: NilOption 2: Nil.
Payout: Option 1: 0 monthsOption 2: 0 years
Note: Fuel gas saved become gas sales.
Annual Savings:Option 1: 3800 kW @ $5.25/GJ and 350 d/y for $600,000/yOption 2: 5200 kW @ $5.25/GJ and 350 d/y for $825,000/y
New Conditions:Option 1: 45 m3/h @ 46 wt%.Option 2: 35 m3/h @ 40 wt%.
EE Opportunity:Stepwise reductions in both amine re-circulation rate and amine strength until target operating conditions are achieved.
Current conditions:Amine flow at 72 m3/h @ 46 wt% requiring 5570 kW of reboiler duty. Heat medium heater @70% efficiency consumes fuel gas at $2,200,000/y.
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Payout: Option 1: 0 monthsOption 2: 0 years
New Conditions:Heaters: 10-15% EA.Gas Engine: 2.4-9.5% EA.
Cost: Nil
Note: Fuel gas saved become gas sales.
Annual Savings: $49,000/y@ $5.25/GJ and 350 d/y
EE Opportunity:Heater: Operating at 24% excess air.TEG Reboiler: Operating at 140 EAIncinerator: Operating at 115% EAGas Engine: Operating at 30% EA
Current conditions:Gas plant with reboilers, heaters, incinerators and gas engines operating with excess air levels of up to 150%.
Sour Gas Production Results
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DGC Consulting/UofC
Potential Savings vs Plant Energy Cost (CETAC Project)
0%
5%
10%
15%
20%
25%
30%
35%
40%
$0 $5,000,000 $10,000,000 $15,000,000 $20,000,000 $25,000,000 $30,000,000
Annual Fuel Gas and Electric Pow er Energy Cost (16 plants)
Pote
ntia
l Sav
ings
FG & EE Cost Savings GHG Emission ReductionsGHG Emission Reductions FG & EE Cost Savings
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Simulation Tool
Objective Performance targets Process modeling and optimization Case studies Results and discussion Conclusions
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Objective is to optimize operations based on specific criteria Energy Product Yield Environmental
And set performance targets for the: Facility Process Equipment
Process Modeling & Optimization
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For gas plants we must consider:
Specific Configurations
Individual Processing Units
Granularity
Process Modeling & Optimization
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Gas Plant Without Recycle
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Gas Plant Without Recycle
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Gas Plant With Recycle
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Gas Plant With Recycle
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TEG Dehydration Unit
Tower
Glycol_Gas_Contactor
Saturated_Raw_Gas
V1
Hx1
Tower
Teg_Regenerator
Sep1
Lean_TEGM1
TEG_Make_Up
P1
Hx2
S
Saturated_Gas_Higher_Heating_Value
S
Flash_Tank_Gas_Higher_Heating_Value
S
Still_Vent_Higher_Heating_Value
Sales Gas
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DGC Consulting/UofC
Residual Water and BTEX Emissions as a Function of Glycol Rate
0
1
2
3
4
5
6
7
8
9
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5Glycol Rate (gpm)
Res
idua
l Moi
stur
e (lb
H2O
/MM
SCF)
0
5
10
15
20
25
30
35
40
45
BTE
X Em
issi
on (l
b/hr
)
Residual Mositure(lbH2O/MMSCF)BTEX Emission (lb/hr)
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DGC Consulting/UofC
Energy Input to Reboiler and PEI as a Function of Glycol Rate
0
50
100
150
200
250
300
350
400
450
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5Glycol Rate (gpm)
Ener
gy In
put t
o R
eboi
ler (
'000
' BTU
/h)
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
PEI (
%)
Energy Input to Reboiler ('000' BTU/h)PEI (%)
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DGC Consulting/UofC
Benefits
Eco-efficiency indicators can be imbedded into simulators as tools to optimize performance
Key indicator targets related to energy intensity are established
Process modeling provides a means to examine existing plant configurations and examine other options for energy optimization
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DGC Consulting/UofC
Benefits Plant age, feed and product yield along with
technology can be taken into account when performing comparisons, setting targets or benchmarking performance
Management can select facility level KPIs to monitor performance against corporate goals
Operators can be provided with effective guidance
Simulation tools can be effectively used with audits to improve operational efficiency
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DGC Consulting/UofC
Presentation Summary
In this presentation we have examined tools for: Improving Operational Efficiency.
They include: Performance Benchmarking using KPIs Energy and Environmental Audits Process Simulation
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DGC Consulting/UofC
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Discussion
AcknowledgementComponents of this presentation were developed as part of a CETAC-West
Integrated Audit and Benchmarking Program
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DGC Consulting/UofC
References Upstream Oil & Gas Plant Benchmarking, D.G. Colley, CSChE
2004. Eco-efficiency Benchmarking and Modeling to Optimize Natural
Gas Plant Operational Efficiency, D.G. Colley, W.Y. Svrcek and B.R. Young, CSChE 2004.
Eco-efficiency Benchmarking and Modeling to Optimize Natural Gas Plant Operational Efficiency, D.G. Colley, W.Y. Svrcek and B.R. Young, HP, January 2005.
Energy and Emission Optimization of the Glycol Dehydrator Process, D.G. Colley, W.Y. Svrcek and H Adam, 1992 GRI Glycol Dehydrator Air Emission Conference.
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