Diagnosed cause of fire at Delaware gas compressor station: flash vessel overflow due to valve misalignment and low NPSHa. Delivered fix in 3 days—pump mods, control changes, and NGL reroute. Client accepted all recommendations.
Project Spotlight: Rapid Response to Compressor Station Fire: Resolving Flash Vessel Overflow
A major gas compressor station in Delaware experienced a critical condensate overflow that led to a fire and full facility shutdown. The incident stemmed from an overloaded flash vessel and vapor recovery unit (VRU), triggering urgent operational and safety concerns.
Our Response & Solution
CUE mobilized immediately, arriving on-site the next morning. Our team quickly diagnosed the root causes: a valve misalignment that directed compressor dumps into the flash vessel, and insufficient Net Positive Suction Head Available (NPSHa), leading to pump cavitation.
We performed detailed NPSH calculations and delivered actionable recommendations within three days:
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Lower the condensate pump by 2 feet
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Raise the vessel’s liquid level control point
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Increase pump backpressure to reduce NPSH required
To further improve system reliability, we proposed an alternate method for routing natural gas liquids (NGLs) directly into storage without depressurization, avoiding challenges in volatile liquid handling.
Outcome & Client Impact
Our recommendations were fully accepted and scheduled for implementation. The client also expressed interest in our proposed NGL capture method to ensure ongoing stability and performance.
Field Optimization Services Delivered:
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Emergency site visit and issue triage
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Collaborative review with client and engineering leads
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NPSH and mechanical evaluations
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Comprehensive recommendation package
Whether it’s troubleshooting operational setbacks or optimizing facility performance, CUE offers quick, practical solutions grounded in deep field experience.
Interested in quality engineering services for your upcoming oil and gas development? Contact us today to discuss how we can help ensure the success of your next project.