OIL INDUSTRY COMPRESSION EQUIPMENT

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ONSHORE VAPOR RECOVERY TECHNOLOGY
OFFSHORE VAPOR RECOVERY TECHNOLOGY
FIELD GAS GATHERING BOOSTER SYSTEM
CASINGHEAD PRESSURE REDUCTION TECHNOLOGY
PETROCHEMICAL PROCESSING
GAS PROCESSING
HY-BON DESIGNED CONTROLS

  Onshore Vapor Recovery Technology (back to top)

In 1952, Hy-Bon Engineering’s founder coined the term “vapor recovery unit” when he designed the first small compressor package specifically designed to capture natural gas emissions with high levels of hydrogen sulfide from oilfield stock tanks. Since that time, Hy-Bon has evolved into a global leader in this market, with more onshore vapor recovery installations than the next three competitors in this market combined. Hy-Bon units currently operate in over 20 countries, with a strong reputation for quality and reliability.

Unlike many companies that package a particular compressor type, and try to rationalize the compressor to the application, Hy-Bon takes a very different approach. As a packager of a wide range of compressor styles, we are able to focus solely on the gas stream in question, and design the most cost effective technical solution for compressing this gas stream to our customer’s requirements. In onshore vapor recovery, we typically recommend rotary vane, rotary screw or jet pump compressors. While we package many reciprocating compressors in other low pressure gas applications, they are not recommended for vapor recovery service due to their inability to handle extremely wet gas effectively.

Hy-Bon Engineering is able to assist you from the earliest design phase and development of specifications to the final commissioning and training of customer personnel. Dealing with extremely low pressure gas (shutdowns are often at .5 inches of water column – equivalent to 1/52 of one psi pressure) presents a unique set of challenges. Hy-Bon brings over 50 years experience to help our customers meet these challenges – as well as a cadre of successful projects handling gas streams with extremely high levels of H₂S, CO₂ and other corrosive elements.

Hy-Bon units range from small table top packages for minute gas streams to packages handling millions of cubic feet of gas per day. For small applications, Hy-Bon maintains an inventory of standard packages for reduced cost and quick customer turnaround.. For larger, more complex jobs, 3D modeling software is utilized so our customers can drop our package directly into their facility design software – dramatically reducing project lead times. We realize that the documentation on these jobs is often as important as the equipment; so special care is taken to insure all databooks are thorough and on time. Whatever the application, we would be honored to assist you in determining the best technical solution.

  Offshore Vapor Recovery Technology (back to top)

Hy-Bon Engineering is a global leader in the design and manufacture of custom vapor recovery units for the offshore market. Hy-Bon Engineering was a pioneer in providing vapor recovery for the offshore market, and continues a leadership role in this arena. Customers include Shell, Chevron Texaco, Kerr Magee, Hunt Petroleum, and Exxon Mobil, to name a few.

Detail project specifications, and tight weight and footprint limitations make each offshore project a unique challenge. Hy-Bon meets this challenge head on with the most experienced engineering team in this niche market in the industry. 3D modeling of the complete package is generally complete several weeks after receipt of order, and can be utilized by our customer to drop directly into their overall design. Exact interface points can be piped before the units even arrive on location, truncating project lead times. We also realize that the documentation is just as critical as the equipment, and detailed databooks are delivered in electronic and paper format to arrive with the equipment – not weeks afterwards!

For customers without detailed project specifications or specific design criteria, Hy-Bon can pull existing offshore designs form our library of projects in order to minimize design time and procurement cost. During the project, our customers receive detailed bi-weekly progress reports complete with digital pictures of the work in progress. After shipment, Hy-Bon’s trained service personnel can assist with startup and commissioning, as well as provide training courses for customer personnel.

  Field Gas Gathering Booster System (back to top)

Nearly every well operator in North America can attest to the fact that sales and distribution line pressures are going up constantly. Couple this with the fact that the flowing pressure of a well typically declines over its lifetime and it’s easy to see the need for compression on either individual wells or over a series of wells. If you can’t get the gas through the pipeline, you can’t get paid for it.

Field gas gathering is defined as collecting gas from a series of wells through a manifold system. Hy-Bon Engineering’s compressors are utilized to pull this gas through a manifold system and consolidate (normally at a higher pressure) into one homogenous gas stream. Booster compressors are utilized in applications where it is necessary to take gas from one pressure and “boost” it to a higher pressure. This boosting requirement may be due to a higher line pressure to be overcome or a downstream process that requires higher pressure or as the first stage of a multi-stage gas compression system. Based on the gas stream, pressure and volume; Hy-Bon packages reciprocating, rotary screw, rotary vane and liquid ring compressor systems for field gas gathering and boosting.

All of Hy-Bon’s field compressor packages can be configured to work with artificial lift systems such as plunger lifts. The automatic functionality of the units allow automatic restarts, even with natural gas engines.

Hy-Bon’s proven designs can be ordered either trailer or skid mounted for increased versatility. Our designs focus on safety and ease of operation and maintenance, with automated start / stop functions, easy to read gauges and indicator lights, integrated oil supply, and large scrubbers with automated liquid transfer systems. Hy-Bon offers both electric motor and engine drive models, with a variety of options available to fit your application.

  Casinghead Pressure Reduction Technology (back to top)

In the effort to wrench additional dollars from existing production, more and more producers are turning to the use of low horsepower compression to boost oil production from mature fields. Hy-Bon Engineering is a global leader in this technology, with hundreds of compressor packages currently operating in casinghead reduction applications successfully. Based on the gas stream, pressure and volume; Hy-Bon packages reciprocating, rotary screw, rotary vane and liquid ring compressor systems for reducing annulus pressure. In addition to building new units for our customers, Hy-Bon also maintains over 200 units in our rental fleet specifically targeted for this application.

The concept behind casinghead reduction is rather straightforward. Casinghead gas is relatively wet (.85 spec gravity / 16gpm), as it is basically flash gas from the formation. The weight of this column of wet gas sitting on the formation has an incremental effect on bottom hole pressure. This pressure is obviously dictated by oil specific gravity and the well depth. When wellhead pressure is added (ie flowline or 1st stage separator), this pressure on the formation is significantly impacted. The well pressures seen at the formation level are further complicated by fluctuating wellhead pressure from the pipeline. The concept is simple – relieving this pressure in the casinghead reduces the weight (pressure) on the formation, allowing oil or gas to more easily flow from the formation into the well bore. By reducing the pressure on the formation, the systems also dramatically reduce gas lock problems. Many cases exist of the technology of doubling or tripling production in mature fields. Each formation responds differently, but many mature basins have responded with phenomenal increases in production.

Hy-Bon’s proven designs can be ordered either trailer or skid mounted for increased versatility. Our designs focus on safety and ease of operation and maintenance, with automated start / stop functions, easy to read gauges and indicator lights, integrated oil supply, and large scrubbers with automated liquid transfer systems. Hy-Bon offers both electric motor and engine drive models, with a variety of options available to fit your application.

  Petrochemical Processing (back to top)

Unit at left was delivered to the Shengli Refinery in 1994 for a vapor recovery application, are capable of moving over 3 MMSCFD of gas at 200 psig utilizing LeROI rotary screw compressors. Vented and flared gas from multiple sources across the refinery was captured.

The 2002 China Installation is pictured at right.

Hy-Bon has over fifty years of experience specializing in the capture of low pressure gas. Many companies build a specific type of compressor package, but our expertise is working with our customer to clearly understand the gas stream and project requirements, and then designing a system based on the best technical solution. We package rotary vane, rotary screw, liquid ring, vapor jet or reciprocating compressor styles based on the application. Petrochemical applications often require the capture of very unique gas streams, with unique specifications, especially in regards to metallurgical considerations. Hy-Bon brings extensive experience in handling complex gas streams in the petrochemical market.

A 2002 installation in China was a large vapor recovery project for the Beijing Yanshan Petrochemical Company. The first unit was a G24 LeROI rotary screw compressor package moving approximately 1 MMSCFD of extremely acidic gas at 130 psi discharge pressure. The second unit was a G30 LeROI rotary screw package moving approximately 2 MMSCFD of the same type of gas at 130 psi discharge pressure. Both units are pulling gas off large accumulation tanks and capturing the previously vented gas stream for further processing and sale.

On a earlier project in 1994, Hy-Bon provided three large units to Shengli Refinery of Qi-Lu Petrochemical Corporation. The refinery was experiencing environmental and health issues due to a very large number of venting sources and low elevation flares. Hy-Bon was asked to design a system to capture these low pressure vapors from various sources and increase the pressure in order to transport the gas to some extremely large, high elevation flares a long distance from the plant. Hy-Bon provided two 300 horsepower TS24 LeROI rotary screw compressor packages which each moved 1.07 MMSCFD at 190 psi discharge pressure. The third package was a 200 horsepower G17 LeROI rotary screw package which moved 1.02MMSCFD at 130 psi discharge pressure.

  Gas Processing (back to top)

Many applications require treatment, or processing, of methane gas in order in order to utilize the gas for its intended use. Hy-Bon’s field proven compression packages have been placed in these types of services for many years. Our compressors are often utilized to feed gas to any of several different treatment facilities, namely nitrogen strippers, carbon dioxide strippers or reinjection wells and microbial treatment equipment for landfill gas to name a few.
Hy-Bon Engineering works closely with the manufacturer of the treatment facility to develop the proper mix of discharge pressures, temperatures, oil content, etc. to deliver the gas to the treatment facility at the prime operating conditions for these facilities. At Hy-Bon, we don’t subscribe to the theory that any off the shelf compression package can fit any application. That’s why we insist on working closely with you and with the manufacturers of the treatment equipment. This ensures that your needs are met every step of the way.

  Hy-Bon Designed Controls (back to top)

By and large, a compressor package is only as good as its control system. Hy-Bon Engineering designs and builds the majority of our control systems. We utilize industry-standard components such as Allen-Bradley, General Electric, Siemens or Modicon programmable logic controllers and interface devices. For all electric-driven packages, Hy-Bon prepares the logic for the operation of the equipment, programs the PLC and builds the control panel to house the equipment. On the majority of our engine-driven compressor packages we utilize engine/compressor controllers from F.W. Murphy.
Hy-Bon’s control systems range from the simplest relay logic panels with lights to indicate unit status to systems that incorporate operator interfaces that can be accessed at the panel or controlled remotely via a data highway system. Automation is the key for most customers. Packages must be capable of running unattended for days or months at a time.
The low pressures we typically deal with present a unique challenge to the successful operation of this equipment. Minute fluctuations in suction pressures and temperatures can have a profound effect upon how the system operates. We are experts in dealing with these variations in operational characteristics.

LANDFILL COMPRESSION

Methane Gas Booster

Every landfill operator in the U.S. is now faced with addressing the issue of the gas produced by the landfill (LFG) during the decomposition of organic matter residing in the landfill. The U.S. Environmental Protection Agency has determined that this gas must be collected and may no longer be vented to the atmosphere.

Landfill gas is typically composed of 55% methane and 45% carbon dioxide. It is wet in nature and therefore quite corrosive. Most landfills give this gas up rather reluctantly, with pressures of 1-2” W.C. being quite common. The majority of landfills in North America have already been required to install a gathering system to collect the LFG rather than allowing it to vent to the atmosphere. Typically this collection system consists of wells bored into the closed sections of the landfill to relieve the LFG pressure and to flow this gas to a manifolded system. Hy-Bon’s compressor systems collect this gas from the manifold and compress it to be used for any of several beneficial uses.

Landfill gas may be utilized in its “raw” form to power natural gas burning engine-driven generator packages. These systems create electricity from the LFG to be used to supplement onsite electrical needs or sold into the power grid. Other landfill gas systems are in place in which the operator actually cleans up the LFG, through membrane systems, chemical systems or pressure-swing absorption systems, to pipeline grade quality.

Dependent upon the beneficial use for the LFG, Hy-Bon designs and builds compression systems to handle the operator’s needs. These systems can range from low pressure, single-stage units to medium pressure two- or three-stage systems. Hy-Bon equipment can be designed to handle a variety of gas streams, as well as the most sophisticated customer specifications.

REPAIR PART SALES

Hy-Bon Engineering’s staff of Materials experts handles your parts needs 24 hours a day 7 days a week. Our vast experience with compressor parts and components, coupled with experience managing the materials function across multiple locations, allows us to provide fast professional results at an extremely competitive price. Hy-Bon is constantly working to provide our customers with the parts they need when they need them. We do this by maintaining an ever increasing parts inventory and staff, and focusing on you the customer.

Hy-Bon Engineering currently maintains one of the largest inventories of compressor parts, repair kits and exchange (rebuilt) compressors. We stock and ship fast to you, electrical components, pneumatic sensors and valves, temperature sensors, mechanical seals, bearings, hubs and couplings, belts, sheaves, gauges, controls, and many others.

WASTE WATER COMPRESSION

One of the by-products of anaerobic digestion in a sewage treatment plant is produced vapor from the digester tank. This relatively low BTU gas (typically 900-1000 BTU/cu. ft.) is comprised primarily of 55% methane and 45% carbon dioxide. Sewage digestion takes place in an aqueous environment, therefore, the gas is saturated with water when it comes off the system. Hy-Bon was instrumental in the development of a specialized compressor package for the capture and compression of these highly corrosive vapors.

Since that time, Hy-Bon has provided integrated packages for wastewater treatment facilities across the United States and across the globe. Hy-Bon is a leader in wastewater gas recovery, and can offer standard packages or custom designed units to highly detailed customer specifications. With over 50 years experience in handling low pressure gas streams, Hy-Bon’s engineers can draw on experience from multiple industries to address the most challenging gas streams.

These packages typically incorporate the use of a rotary vane compressor to take these vapors from a pressure of 2-3” W.C. to 40 psig or less discharge pressure. These compressed vapors are sent to one of three systems where they are utilized for a beneficial purpose. One system involves natural gas burning generator sets to generate electricity to be used by the sewage treatment plant. The second system consists of a low-BTU fuel gas boiler system to generate steam for the plant for heating purposes or to feed steam-powered turbines. The third beneficial use for the gas is to send it back to the bottom of the digester tank to be used to churn the sludge that collects on the bottom of the tanks.

Digester gas units must be constructed to combat the destructive effects of a saturated, high CO₂ content gas stream. Hy-Bon’s units are equipped with stainless steel piping and valve trims to handle the corrosive nature of the gas. In addition, the units must be able to address the issue of removing the water vapor from the gas stream. We utilize a suction filtration system and a discharge liquid knockout system to handle the water content within the stream. Despite sophisticated controls, all Hy-Bon units are designed for ease of maintenance, and years of trouble free service.

OTHER BIOGAS APPLICATIONS

In an effort to combat the rising costs of vehicle fuel, many agencies and companies are now looking at Compressed Natural Gas (CNG) as an alternative fuel source. CNG is used in the mass transportation industry (buses, fleet vehicles and taxis) with more and more vehicles being converted to natural gas usage every day.

CNG fuel utilization requires pressures in excess of 3000 psig. Vehicles must be outfitted with specially constructed high pressure tanks to carry the pressurized fuel to be burned in the vehicle’s engine. Hy-Bon was an early pioneer in the development of CNG fueling stations, having placed the first four CNG fueling stations within the state of Texas. Hy-Bon also placed vehicular fueling station compressors into the City of Las Vegas’s municipal bus line site.

Hy-Bon’s expertise is building the compressor skid and enclosure. However, we also work with the customer to develop complete turnkey installations, from the compressor through the storage system, all the way to the dispensing system. Our proven designs have worked extremely well in systems installed throughout the western U.S., from California to Texas. Various sizes and configurations are available, from oil-lubricated to oil-free cylinder design.

NEW AND EXCHANGE COMPRESSORS

   

Hy-Bon Engineering maintains one of the largest inventories in our industry of compressor parts, repair kits and exchange (rebuilt) compressors in the low horsepower (<1,200hp) arena.

MACHINE SHOP COMPRESSOR REPAIR

Hy-Bon Engineering’s factory trained technicians provide detailed repair services to customer owned compressor units and compressor skid packages. All repaired compressors receive a full 90 day warranty. Specializing in compressor systems under 1,200 horsepower, Hy-Bon has developed extensive expertise in the repair and refurbishment on this size range of compressor. With over $1.5 million of inventory in repair parts and components, Hy-Bon can add extremely quick turnaround times to an outstanding quality repair.

Machining is completed in-house to factory specifications in order to control quality and minimize turnaround times.

Rotary Vane: Hy-Bon, A-C Ro-Flo, Fuller, DeMag
Rotary Screw: LeRoi
Reciprocating: Quincy, Gardner Denver, Corken, Gemini
Liquid Ring: Travaini Pump

Hy-Bon offers full repair services for customer-owned compressors – and a unique compressor exchange program which allows the customer to substantially reduce their compressor downtime and maintain production volumes.  The customer orders an exchange compressor that will be shipped to them immediately by whatever means the customer wants.  The customer then sends their compressor back to Hy-Bon.  The compressor is evaluated and if repairable, a credit is issued that will offset the cost of the exchange compressor.  The customer is not waiting days or weeks for their compressor to be repaired.  Minimum downtime + maximum production + outstanding quality = a great combination!