Optimising Compressor Re-wheel Design for Mature Assets
The challenge of re-wheeling is to optimise the new design and get it right first
time. MSE has carried out many re-designs and re-wheels of gas
compressors which are in successful operation. With this
experience, MSE has developed a range of software systems,
design tools and proven methodologies for developing a redesign
which is rigorously tested before its implementation.
The redesign is performed with the
CENTRIF program,
which identifies the new re-wheel configuration for optimum
performance. This new design is tested for off-design
performance to ensure it has the correct performance envelope to
accommodate the new reservoir conditions.
To ensure that the new re-design will operate in the production
facility we test the new compressor using the GASMAN model.
GASMAN is the
integrated model of the production system which includes the gas
compression system, the processing facility, the gas turbine
drive, the recycle system and the process control set points.
Re-design or Re-wheel?
The alternative to a complete compressor re-design and
replacement of equipment is "re-wheeling"; a re-wheeling
consists of changes to the compressor internals and can be
implemented in a few days, without requiring extended shut down.
Re-wheeling is a very expedient and cost effective option for
production optimisation of mature assets. The re-wheeling does
not require piping changes or removal of casings; it is limited
to the removal of the compressor internals and their replacement
with new optimised set of internals.
If the re-design of a production facility is like a major
"surgical operation", then re-wheeling can be viewed as "Key-hole surgery" which can be performed quickly; the production
facility regains the lost capacity and production gets restored.
Re-wheeling is a low cost, low risk and high reward operation.
The original compressor internals are retained as a backup to
further limit risks.
