Structured Energy Trending and Performance Assessment for Combustion Engine (SETPACE©) - An Innovative Approach to Decarbonize Combustion Emissions from Upstream Operations

Abstract This paper introduces a state-of-the-art tool known as SETPACE© (Structured Energy Trending and Performance Assessment for Combustion Engine) which has the capability to validate authenticity of fuel gas flow meter reading, improving fuel gas accounting; quantify fuel efficiency (thermal efficiency) degradation by comparing theoretical vs actual fuel consumption for individual machines based on current operating parameters; quantify fuel gas reduction from various improvement opportunities and generate near-to-real fuel gas forecast. PETRONAS Upstream Energy Efficiency (EE) journey, which began in 2021, aims to reduce energy consumption without affecting production, thereby increasing gas sales and decreasing Greenhouse Gas (GHG) emissions. By 2023, SETPACE© had been widely implemented across all domestic assets in Malaysia. More than 90% of fuel gas (energy) within these assets is consumed for gas compression and power generation. The assessment of over 170 turbomachines across more than 80 oil and gas facilities has revealed that approximately 18% fuel gas reduction from year 2023 conventional forecast is discovered through accounting and forecasting improvement. Baseline results show gas turbines’ fuel efficiency estimate ranging from 4% to 32%. Fuel inefficiency in machinery typically stems from two (2) main factors: performance degradation and low operating loads. Machines with significant deviations in fuel efficiency often consume more fuel than necessary due to deteriorated performance. Addressing this through performance restoration, typically as part of routine planned maintenance, can reduce fuel gas consumption. This approach is particularly viable if the cost is offset by fuel gas savings, with an estimated maximum reduction of 11% from the actual fuel gas reported in 2023. Gas Turbine Generators (GTGs), designed for redundancy and to manage upstream uncertainties, may operate at low loads, leading to inefficient fuel use. While this operational philosophy ensures reliability, it results in higher fuel consumption. Optimizing GTG train operations is estimated to achieve an additional 5% reduction in fuel gas consumption. Furthermore, energy demand optimization and partial electrification is estimated to contribute an additional 11% reduction in fuel gas usage. Decarbonizing combustion through Energy Efficiency (EE) measures is anticipated to reduce GHG emissions by approximately 0.8 to 1.4 million tons of CO2 equivalent per year and recover energy, resulting in an estimated annual savings of USD 20 to 35 million.