Compressor Size Optimization

“They sized our compressors to be able to inject 600 mcfd for each well on the pad.”

In 2017, I was a production foreman and got moved to a new asset. This is what I was told when I questioned why there were Cat-3516s, Waukesha 7042s, and KTA-19s all over the field I inherited. That area of ~200 wells had a monthly compression LOE of over $700k. Over the next 3 years, we dove deep into optimizing the compression program. By the time the team moved on to the next area, our production, compression, I&E, and construction groups had collaborated on the effort to downsize 50% of the compressors, dual-purpose 30% of them (systematically inject and lower wellhead pressure - more on this amazing setup later), and cleaned up flow on the remainder. The result: significantly reduced fuel burn, increased production from the lower wellhead pressure, and monthly LOE reduced to $300k.

This is not bragging on my capability, as I could never do anything remotely this intense alone. This is showing what a well-structured organization can do when all the departments work together and have a general understanding of what each other focuses on.

Production determined the priorities and the potential for each pad-site and well. I&E installed automated control valves for injection and programmed software to control injection rates in each plunger phase. Construction designed and fabricated the piping and pressure control valves. Compression sized, located, and set the proper units.

How well do your departments work together for a finely optimized operation?