Hoerbiger Wellhead Compression at OMV PETROM Bucharest, April 2015 Rudolf Navratil – Vasile Stănculescu
Hoerbiger WHC at OMV-PETROM 2 2
Joining Forces OMV-PETROM Biggest company in Romania and biggest oil & gas company in South Eastern Europe Hoerbiger Compression Technology World market leader for compressor components and biggest provider of services around reciprocating compressors
April 2015
Principles of Wellhead Compression
Hoerbiger WHC at OMV-PETROM 3
GAS IN
GAS OUT
LIQUID OUT
April 2015
Hoerbiger WHC at OMV-PETROM 4 4
Wellhead Compression Applications or “Giving new life to your mature oil & gas fields”
• Surface pressure reduction • Increased gas volume • Liquid loading
Natural Gas Production
• Replacing/rerating centralized (old) compressor stations • Bringing additional compression capacity into mature fields • Distributing compression throughout the gas field according
to needs Gas Gathering
• Casing pressure reduction for enhanced oil production • Compression of flare gas
Compression of Associated Gas
April 2015
Hoerbiger & SERTCO in Area East Reynosa
Mexico City
MEXICO
BRAZIL
Sao Paulo
Caracas VENEZUELA
Bogota
COLOMBIA
Santa Cruz
ECUADOR
Lima
PERU
BOLIVIA
Talara
Quito
Neuquen
Santiago
Comodoro Rivadavia
ARGENTINA
URUGUAY
Buenos Aires
Montevideo
PARAGUAY CHILE
35
32 Pacific Rubiales
ENAP
PDVSA (Sales)
Petrobras
9 Interoil, Sabia (offshore)
Paka Sur, Ecopetrol
Petrobras, Vintage
32
6
318
YPF Contract
PAE, Pluspetrol, YPF, Sinopec
Petrobras, Pesa
Apache, Total, Roch, Petrobras, Capex, Tecpetrol, Petrolifera
Tecpetrol
391 HOERBIGER de México
HOERBIGER do Brazil
HOERBIGER Andean Region HOERBIGER de Venezuela HOERBIGER de Colombia HOERBIGER de Ecuador HOERBIGER de Peru HOERBIGER de Bolivia
HOERBIGER Southern Cone Region HOERBIGER de Argentina HOERBIGER de Chile
45 18
7
187 61
3
12 9
2
6
Friday, April 24, 2015 WHC: Latin America 5
Hoerbiger & SERTCO in Area East
Rosneft Sakhalin (RU)
1
Rentals Sold units
Rosneft Nizhnevartovsk (RU)
12
KazNefteGazProm (KZ) Petrom (RO)
7 Romgaz (RO)
4
NIS (SRB)
13
Hoerbiger WHC at OMV-PETROM
4
Total: 44 units Russia: associated gas (containerized units) Kazakhstan: associated gas and gas gathering Romania: gas gathering Serbia: associated gas and gas gathering
Service Centre Romania
Service Centre Moscow
6
1 1
Rosneft Stavropol (RU)
Lukoil Perm (RU)
1 Gazpromneft Noybrsk (RU)
April 2015
Unit Type 350 HP
Hoerbiger WHC at OMV-PETROM 7
• Standard type in Eastern Europe • Suction pressure: 0 to 6,8 barg • Discharge pressure: up to 25 barg • Volume: up to 67.000 Sm3/day • 8,8 L gas engine drive; 130 HP • Fuel consumption: up to 680 Sm3/day • Liquid handling: up to 15 m3/day • Skid or trailer mounted
April 2015
Unit Type 98 “Junior”
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• Suction pressure: 0 to 3,9 barg • Discharge pressure: up to 17,5 barg • Volume: up to 16.800 Sm3/day • 4,3 L gas engine drive; 50 HP • Fuel consumption: up to 240 Sm3/day • Liquid handling: up to 4,8 m3/day • Skid or trailer mounted
TRIAL UNITS:
2 units available for customer trials Temporary CE certified Trials would be free of costs for
customers Units will be operated by Hoerbiger
engineers For arrangements please get in touch with
Mr. Csaba Jozsa-Csiki
April 2015
CE Certification CE certification for all Countries within European Union:
ATEX and coordination with TÜV: AgA TECH Austria (ATmosphère EXplosive) All electrical equipment; surface temperatures PED (Pressure Equipment Directive): TÜV Austria All pressure vessels and pipes larger than and incl. 2” and all safety devices HAZOP analysis (HAZardous OPerations)
Environmental requirements: acc. to local laws (sound and exhaust gas emissions)
Holder of certification: HOEZA as supplier
Hoerbiger WHC at OMV-PETROM 9 April 2015
History of Hoerbiger WHC project ► Background of Hoerbiger Wellhead compressor project
► In 2012 a service contract was concluded ► In 2014 was extended until 2016
► 13 Hoerbiger Wellhead compressors were bought for: ► Replace 10 GK Bulbuceni Compressors Station
► Compressing approx. 2,600 boe/day ► Safety operation of compression process
► Availability of new compressors was under 95 %, due to: ► Technical defects ► High fluctuation of fluid rate and water cut, dirty gas
► Proposals solutions: ► Re-design different components of compressors ► Instillation of separation units and tested new unit “PALL ”filter
Technical characteristics of Hoerbiger Wellhead compressor:
Suction pressure: 6 barg Discharge pressure: 25 barg Gas rate: 395 boe/day
10 Hoerbiger WHC at OMV-PETROM April 2015
Current status of WHC project
► No. of Wellhead compressors in function: 11 units ► 2 units in stand by
► Availability of Wellhead compressors, over 95 % ► The unit filter was tested
► Solved the problems due to dirty gas ► Additional Gas compression: 54,300 boe/year ► Saving Gas consumption: 6,540 boe/year ► OPEX saving: 0.5 Mn Euro/year ► Payback time: 2,9 years
Hoerbiger WHC at OMV-PETROM 11 April 2015
Special Challenge – Solids in the Gas Main reason for unit availabilities < 95 %: premature wear of parts (control valves, valves, piping, compressors, gas starters, etc.) and clogged filters. Solution: additional filter elements downstream of the units 1st trial: Pall Highflow® filters with 10 and 20 µm for liquids to analyze type, size and quantity of solids - 10 µm: 8 days with 35.000 Sm3/day; solids 8,2 mg/Sm3 - 20 µm: 12 days with 40.000 Sm3/day; solids 11,5 mg/Sm3
12 Hoerbiger WHC at OMV-PETROM April 2015
Special Challenge – Solids in the Gas
13
Test results: Mainly formation minerals (SiO2); no indication for corrosion products Average solids content: 10 mg/Sm3 gas Recommendation: type E604Y400 filters; rating for gas of 99,995 % for
particles > 0,3 µm
Hoerbiger WHC at OMV-PETROM
2nd trial: with recommended filter type E604Y400 to check efficiency (life time per filter up to Δp of 1,5 bar) Results: life times of up to 374 hours achieved
April 2015
Availability of Hoerbiger WHC Units 4 business models available: Sales of units: including start-up, training and specified spare parts Service of (sold) units: including spare parts and consumables, if
requested also capital goods; minimum availability f.e. 95 %, max. response time (depending on location)
Rental of units: “all inclusive”; min. rental period 2 years Operation of units: performance contracts; min. period 2 years
14 Hoerbiger WHC at OMV-PETROM April 2015
Thank you!
Hoerbiger WHC at OMV-PETROM 15 April 2015