mgsc ibdp: optimization of surface facilities...inspection and maintenance 5 service valves, piston...

TRIMERIC CORPORATION

Presented at Midwest Carbon Sequestration Science Conference on 9/18/12

Presented by:

Ray McKaskle, P.E. Trimeric Corporation

MGSC IBDP: Optimization of Surface Facilities


Presentation Overview

p  Equipment Design, Installation, and Operation

p  Equipment Performance p  Lessons Learned p System Improvements p Relationships Between Surface and

Downhole Conditions p Summary p Acknowledgements

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Design Basis and Permit Conditions Summary

Note – Values above are for normal operating conditions, startup, testing, and shutdown conditions may vary

Parameter Units Design

Requirement UIC Permit

Requirement

Injection Rate tonne / day 250 - 1,000 < 1,200 Injection Rate MMscfd 4.8 - 19.0 Flow Control % of set point + / - 10 Surface Pressure psig 1,057 - 2,000 < 1,950 Surface Temp. deg F 88 - 120 60 - 150 CO2 Purity % mol. > 99 Oxygen Content ppm < 100 Water Content lb / MMscf < 30 Water Content ppm < 633

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Block Flow Diagram

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Overall Process Flow Diagram

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CO2 Source: Fermenter Wet Scrubber Discharge

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Blower and Compressor Buildings

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Blower System

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Reciprocating Compressors

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Interstage Coolers

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Dehydration System - Contactor

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Dehydration System – Regeneration Skid

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Final Cooler

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Multistage Centrifugal Pump

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Injection Well

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Actual Injection Rate vs. Date

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0

100

200

300

400

500

600

700

800

900

1000

1100

1200

11/3/11 12/3/11 1/2/12 2/1/12 3/2/12 4/1/12 5/1/12 5/31/12 6/30/12 7/30/12 8/29/12 9/28/12

Daily In

jection Ra

te (ton

ne/day)


Causes for Unscheduled Downtime

Item

Reduced Rate Days

Down Days Comment

Blower Motor 2 13 Motor Wiring (Warranty Issue) (8 days) Oil Leak Led to Bearing Failure (7 days)

Cylinder Lube Oil Systems 14

Replaced Pumps with New Design and Corrected Wiring Issues Jul. 2012

Motor Soft Starter 8 Initial Construction Wiring Issues Operating Limits 5 Press., Temp. and Level Limits

Equipment Related Totals 29 13

Data from 11/8/11 – 9/10/12

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Causes for Scheduled Downtime

Item

Reduced Rate Days

Down Days Comment

Scheduled Preventive Maintenance 2 6 Compressor Hardware Inspection and Maintenance 5

Service Valves, Piston Rods, Seals, etc.

Equipment Related Totals 7 6

Data from 11/8/11 – 9/10/12

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Downtime Due to External Factors

Item

Reduced Rate Days

Down Days Comment

Well / Instrument Testing 14 4

Includes Step Rate and Shut In Tests, Well Logging, Instrument Calibrations

Utility / Source Outage 5 1

Includes CO2 Supply, Power, Cooling Water Outages or Shortages

External Factor Totals 19 5

Data from 11/8/11 – 9/10/12

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Oxygen Content During Injection

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0

10

20

30

40

50

60

70

80

90

100

11/3/11 12/3/11 1/2/12 2/1/12 3/2/12 4/1/12 5/1/12 5/31/12 6/30/12 7/30/12

O2 co

ncen

tration, ppm

v


Water Content During Injection

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0

5

10

15

20

25

30

11/3/11 12/3/11 1/2/12 2/1/12 3/2/12 4/1/12 5/1/12 5/31/12 6/30/12 7/30/12

H2O con

centratio

n, lb

H2O

/ M

Mscf

Moisture analyzer was out of service due to upstream regulator failure


Performance Metrics

Performance Metric Status

Inject 333,333 tonne / year Injection to date equates to 312,806 tonne /

year, which is 94% of goal Water content

(typical 7 lb/MMscf, spec. 30 lb/MMscf)

Average 5 lb/ MMscf Max 10 lb / MMscf

1-sigma Standard Deviation 1 lb / MMscf Oxygen Content (typical 7 ppmv, spec. 100 ppmv)

Average 7 ppmv Max 93 ppmv

1-sigma Standard Deviation 7 ppmv

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Lessons Learned

p  Temperature control for cooling water supply may be required to keep control cooling water return temperatures at acceptable levels in cold weather

p  Pipeline insulation was needed due to concerns with downhole pressure variations induced by ambient temperature and weather variations

p  Even after insulating pipeline, variations in surface injection temperature due to cooling water temperature variations caused undesirable variations in downhole pressure

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System Improvements and Optimization (1 of 2)

p  Blower recycle valve is now used in addition to blower vent valve in response to high blower discharge pressure

p  Interstage cooling temperature set points lowered to reduce power consumption and cooling water return temperatures

p  Low pressure shutdowns on reciprocating compressors replaced with differential pressure shutdowns to reduce nuisance trips

p  New type of cylinder lubrication pumps installed and wiring issues corrected. Further improvements are in progress.

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System Improvements and Optimization (2 of 2)

p  Tuning dehydration reboiler fuel gas valve and reducing reboiler temperature set point have reduced fuel consumption

p  Pipeline insulation added to stabilize injection temperature in order to reduce downhole pressure variations previously caused by changes in ambient temperature and weather

p  Raised temperature set point for CO2 leaving final cooler to a value that can be sustained even when cooling water supply temperatures are high

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Possible Future Improvements and Optimization

p  Temperature control for cooling water supply may be required to keep control cooling water return temperatures at acceptable levels in cold weather

p  Heat exchangers may need to be taken out of service for cleaning in 2013

p  Multistage pump may be used to sustain desired injection rates in future years if cooling water supply temperatures are high, if heat exchanger performance degrades, or if resistance from formation increases

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Surface vs. Downhole Before Insulation

0

20

40

60

80

100

120

3000

3050

3100

3150

3200

3250

3300

3350

3400

3450

3500

1/11/12 12:00 1/12/12 0:00 1/12/12 12:00 1/13/12 0:00 1/13/12 12:00 1/14/12 0:00

Tempe

rature, d

eg F

Pressure, p

sig

Downhole Press Surface Injection Temp CWS TempAmbient Temp Final Cooler Temp

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Surface vs. Downhole After Insulation

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65

70

75

80

85

90

95

100

105

3100

3150

3200

3250

3300

3350

3400

3450

3500

7/2/12 0:00 7/2/12 12:00 7/3/12 0:00 7/3/12 12:00 7/4/12 0:00

Tempe

rature, d

eg F

Pressure, p

sig

Downhole Press Surface InjectionTemp CWS TempAmbient Temp Final Cooler Temp


Summary

p  The compression and dehydration system performs in accordance with process design requirements

p Blower motor failures and cylinder lubrication system issues were the leading causes of unscheduled downtime

p Control of surface injection temperature has proven to be important to reduce downhole injection pressure variations

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Acknowledgements

p  Department of Energy – Darin Damiani and John Litynski

p  Illinois State Geological Survey – Rob Finley and Scott Frailey

p  ADM – Kevin Burris and Tom Stone

p  Schlumberger Carbon Services – Scott Marsteller and Jim Kirksey

p  Enerflex – Bill Strahan

p  Trimeric – Kevin Fisher, Rosalind Jones, Joe Lundeen, and Brad Piggott

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mgsc ibdp: optimization of surface facilities...inspection and maintenance 5 service valves, piston...

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