Compressed air in the oil and gas industry
Reliable performance for extreme conditions
Compressed air plays a central role in numerous safety-critical and process-relevant applications in the oil and gas industry. It is used, for example, as control and instrument air for the reliable actuation of valves and regulation systems, to power pneumatic tools and actuators, and as an energy source for conveying and lifting equipment. Compressed air also provides the basis for nitrogen generation in membrane and PPE systems, which is essential for inerting and protection processes. Safety-critical systems such as emergency shutdowns, fire-extinguishing systems and braking mechanisms also rely on a constant and dependable supply of compressed air.
Compressors face particularly rigorous demands in the oil and gas industry: they must operate reliably in both extreme environmental conditions and safety-critical areas. Operational safety and availability are paramount, since unplanned downtime can lead not only to significant costs but also to considerable risks.
KAESER compressors are built to meet these demanding conditions. Their meticulous design ensures reliable operation even at high ambient temperatures: air-cooled, fluid-injected rotary screw compressors operate reliably up to 60 °C, while air-cooled, oil-free rotary screw compressors deliver dependable performance up to 55 °C. This temperature resilience makes them particularly well suited to desert regions and Middle Eastern climates, where they deliver outstanding availability and efficiency even under extreme conditions. The result is durable, safe compressed air solutions that ensure maximum operational reliability, even in extreme heat.
Applications
Compressed air applications in the oil and gas industry
KAESER provides reliable and energy-efficient compressed air solutions for a wide range of applications: from control and instrument air to nitrogen generation and the dependable supply of compressed air in demanding environments.
Our services and solutions
KAESER provides individually tailored compressed air systems precisely matched to the rigorous safety and performance requirements of the oil and gas industry. Featuring exceptionally durable design, the compressors ensure maximum reliability and outstanding energy efficiency – even under extreme ambient conditions.
A key advantage is the low discharge temperature of air-cooled compressors — just 6 K above ambient — which greatly enhances the stability and efficiency of the entire system. Thanks to state-of-the-art technology, energy consumption and operating costs are reduced while meeting even the most rigorous safety and quality standards. The result: maximum availability, long service life and outstanding efficiency.
High-performance compressed air solutions engineered to meet international standards
Another decisive factor in the oil and gas industry is the reliability and compliance of the compressors in use. Fluid-injected rotary screw compressors are subject to API 619, 5th edition, which defines clear requirements for design, safety, performance and documentation, thereby ensuring reliable operation under extreme ambient and process conditions. Oil-free rotary screw compressors are manufactured in accordance with ISO 10440-2, likewise ensuring the highest standards of safety, performance and service life.
KAESER compressors meet both standards and are therefore ideally suited to the stringent safety and performance requirements of the oil and gas industry. With state-of-the-art compression technology, energy-efficient air treatment and durable components, they deliver consistently clean, dependable compressed air – even in the most demanding operating conditions.
Efficiency, maintenance and remote monitoring
Energy efficiency is also crucial: in many facilities, the compressed air supply is one of the largest energy consumers. Systems engineered for low energy demand significantly reduce operating costs and simultaneously aid environmental protection.
A well-planned maintenance concept, easy access to all key components and the option of remote monitoring all support smooth, safe operation. This enables maintenance work to be scheduled efficiently and helps maximise both compressed air availability and compressor service life.
KAESER compressors combine these advantages to optimum effect: energy-efficient technology, durable construction and intelligent monitoring solutions ensure that your compressed air supply remains consistently reliable, economical and powerful – even under the demanding conditions of the oil and gas industry.
Interesting facts
FAQs, facts and useful insights about the oil and gas industry
In the oil and gas industry, different types of compressors are used depending on the specific requirements:
- Fluid-injected rotary screw compressors: These are the preferred choice for the continuous supply of instrument and control air, for process air generation and for nitrogen production systems. Their durable design ensures reliable operation even under extreme operating conditions.
- Oil-free rotary screw compressors: They deliver exceptionally clean compressed air and are ideal for sensitive applications that demand maximum purity, such as measurement and control technology or safety-critical processes.
- Portable compressors: These are used wherever a flexible compressed air supply is required, for example on construction sites in pipeline engineering, for drilling operations or for temporary offshore applications.
KAESER provides tailored solutions for each of these applications, designed to meet the rigorous requirements of the oil and gas industry – delivering reliability, durability and outstanding energy efficiency.
Compressed air systems in the oil and gas industry must meet exceptionally high requirements for safety, reliability and performance. To ensure this, the compressors used are manufactured in accordance with internationally recognised standards.
Fluid-injected rotary screw compressors – API 619, 5th edition:
API 619 is a globally recognised standard for rotary compressors used in the oil and gas industry. It defines comprehensive requirements regarding design, materials, safety measures and performance. Its purpose is to ensure reliable operation under extreme process conditions, such as those found in refineries, petrochemical plants or offshore platforms. Compliance with API 619 ensures that compressors are particularly robust, resistant to high pressures and temperatures, and safe in continuous operation.
Oil-free rotary screw compressors – ISO 10440-2:
ISO 10440-2 specifies the requirements for packaged, oil-free rotary screw compressors used in the oil, gas and petrochemical industries. The standard covers design, safety, performance and documentation. It guarantees that compressors operate reliably, efficiently and with long service life even in challenging environments such as desert regions.
In addition, all compressors are individually configured to customer-specific requirements, for example in terms of performance, air quality or special operating conditions.
The result: Compressed air systems that comply with international standards and which deliver maximum operational safety, availability and efficiency – even under the extreme conditions of the oil and gas industry.
Remote monitoring opens up entirely new opportunities for the oil and gas industry to operate systems more efficiently, safely and economically. Instead of responding only when faults occur, companies can now continuously monitor the status of their compressors through intelligent sensor technology. Pressure, temperature, vibration and flow are recorded around the clock, making any deviation immediately visible. This means: Potential issues are detected before they occur - preventing costly downtime and avoiding safety-critical situations.
With predictive maintenance, maintenance shifts from being a cost factor to a genuine competitive advantage. Maintenance intervals can be planned accurately, unplanned outages are eliminated, and spare parts can be sourced in good time and according to actual need. The result: lower operating costs and significantly higher system availability.
Efficiency is also noticeably improved: Detailed performance data make it possible to optimise compressor operation. Energy consumption and emissions are reduced, while overall plant efficiency increases – benefitting both the business and environmental sustainability. Remote monitoring also enhances workplace safety, since fewer personnel need to be deployed in potentially hazardous areas. Another major advantage is the automatic documentation of all operating data, ensuring seamless and straightforward compliance with environmental and safety regulations.
KAESER’s SIGMA AIR MANAGER 4.0 compressed air management system connects all relevant components, records data in real time and dynamically optimises processes. This provides complete transparency and elevates energy efficiency, operational safety and cost-effectiveness to a whole new level.