Nalco Water’s Inlet Integrity Program helps Texas gas processing plant avoid compressor failures, saving over $300,000 per year

about 3 hours ago

Fouling can significantly impact the efficiency of gas processing operations, particularly within the inlet separator. Without a proactive program, operators must plan for frequent maintenance, which is costly and time-consuming. Nalco Water recently launched its Inlet Integrity Program to help gas processors proactively manage performance. The solution combines innovative products with localized service and reporting to help companies identify and address challenges before they cause significant impact.

Nalco Water recently employed the program at a gas processing facility near Midland, Texas, where low-pressure compressors were failing at an average rate of one per day. The facility suffered from high fouling rates due to contaminants such as iron sulfide, salts, and other general foulants in the gas stream, leading to daily shutdowns for maintenance. The frequent cleanings resulted in significant costs, substantial personnel time and flaring due to backed-up gas.

“With the right balance of chemical innovation and technical expertise, Nalco Water can deploy proactive solutions that help operators maintain reliable, efficient performance,” said Lottie Elwood, senior vice president and general manager, Global Chemical at Nalco Water. “By approaching this facility’s challenges in holistic manner, we were able to determine the problem quickly and pinpoint a solution to address it.”

As a first step, Nalco Water focused on identifying the problem. The facility processes 275 million standard cubic feet (MMSCF) of gas per day. It routes about 75 MMSCF of this gas through seven compressors immediately downstream from the plant’s inlet separator. Fouling in the compressors’ valves was identified as the source of the failures. To identify the composition of the fouling deposits, samples were sent to the Nalco Water Analytical Lab and shown to primarily consist of salt.

Nalco Water recommended a patented antifoulant from its Inlet Integrity Program to address the problem. This antifoulant helps remove solids and dissolved salts from the gas stream in the inlet separator, enabling them to be blown down with water. Nalco Water deployed the solution in front of the inlet separator using an atomizer to ensure proper distribution into the gas stream.

Samples of the blowdown water were taken and analyzed for salt content. The blowdown samples showed a large salt increase in the water — almost 250% from pretrial samples. This data was a leading indicator that the product was removing the foulant in the inlet separator, preventing it from traveling to the compressors. This data, along with additional analytical reports, were automatically sent to the ECOLAB3D™ digital intelligence platform in order to help the plant review and understand trends.

With the Inlet Integrity Program solution in place, no compressors went down due to fouling or hot valves for the duration of a 10-week trial. The plant went from daily compressor maintenance to two and a half months without incident, enabling operators to focus their time on improving other parts of the plant.

The absence of compressor maintenance also saved significant costs related to labor and replacement parts and led to other benefits such as reduced gas flaring. In total, the Inlet Integrity Program delivered a value of over $300,000 and helped save 1,255 metric tons of CO₂.

“The success at this facility reinforces the effectiveness of the Inlet Integrity Program in addressing chronic processing challenges,” Elwood said. “The company was simultaneously able to save time and money, as well as reduce greenhouse gas emissions by leveraging the power of chemistry, data and domain expertise.”