Surveillance of gas facility mechanical equipment is a vital part of Exxon's current operation. Proper utilization of this equipment presents a significant opportunity in cost control, presents a significant opportunity in cost control, optimizing revenue and minimizing investment requirements. If reciprocating compressors and centrifugal compressors are not operated properly and adequately maintained, oil production, gas production and gas plant liquids will be curtailed production and gas plant liquids will be curtailed accordingly. Availability of horsepower when needed is an obvious requirement for maximizing revenue from production of oil, gas and gas plant products.
This paper describes a mechanical equipment surveillance program that has been developed in the East Texas Division of Exxon Co., U.S.A. Production Department. The statistics that are Production Department. The statistics that are quoted refer only to this division, and although similar programs are in effect in other divisions within Exxon's Production Department, only the specific program as developed by the East Texas Division is described.
The existing machinery maintenance program was begun in 1968 with the establishment of an engineering surveillance group at the division level. By 1978, surveillance personnel had also been added to the engineering groups in the four district offices. There is a total of 463,000 BHP in 390 units in gas compression and generator service spread over one 75,000 square mile area of this division.
The machinery maintenance system can be divided into four basic functions:
Predictive/Preventive Maintenance
Performance monitoring
Technical input
Development of on-site maintenance capability
These four facets of the system are discussed below, followed by a summary of the benefits that have been accrued from the system to date.
Exxon has utilized predictive maintenance techniques since 1968 when the first Beta Engine/ Compressor Analyzer (E/CA) was purchased. The Beta analyzer was developed by the Southwest Research Institute of San Antonio, Texas to analyze reciprocating engines and compressors in operation. The analyzer became a reality in January, 1965 when Beta Corp. of Dallas, Texas began marketing it.
The Beta E/CA is comprised of three main units which are:
The motion transducer
The indicator unit
The auxiliary unit
Other basic components used with the Beta E/CA are the synchronizing light, pressure transducers, oscilloscope camera and ignition and vibration pickups. pickups.
