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Processor Best Management Practices Processor Best Management Practices and Opportunities and Opportunities
Lessons Learned from Natural Gas STARLessons Learned from Natural Gas STAR
Processors Technology Transfer WorkshopProcessors Technology Transfer Workshop
Gas Processors Association,Gas Processors Association,Devon Energy, Enogex, Devon Energy, Enogex,
Dynegy Midstream Services andDynegy Midstream Services andEPA’s Natural Gas STAR ProgramEPA’s Natural Gas STAR Program
April 22, 2005April 22, 2005
Page 2Reducing Emissions, Increasing Efficiency, Maximizing Profits
Processor Opportunities: AgendaProcessor Opportunities: Agenda
Industry EmissionsIndustry Emissions
Processing Best Management Practices (BMPs)Processing Best Management Practices (BMPs)
Selected Methane Saving OpportunitiesSelected Methane Saving Opportunities
Eliminate Unnecessary EquipmentEliminate Unnecessary Equipment
Composite WrapComposite Wrap
Leak Inspection & MaintenanceLeak Inspection & Maintenance
Discussion QuestionsDiscussion Questions
Page 3Reducing Emissions, Increasing Efficiency, Maximizing Profits
Natural Gas and Petroleum Industry Natural Gas and Petroleum Industry EmissionsEmissions
Processing plants responsible for 36 Bcf of methane Processing plants responsible for 36 Bcf of methane emissions annually, and gathering/ booster stations emissions annually, and gathering/ booster stations contribute >22 Bcfcontribute >22 Bcf
Transmission & Storage Transmission & Storage
98 Bcf 98 Bcf
Production/ Production/ Gathering/ Gathering/ Booster Booster
150 Bcf150 Bcf
Processing Processing 36 Bcf 36 Bcf
Distribution Distribution 73 Bcf73 Bcf
25 Bcf25 Bcf
10 Bcf10 Bcf
18 Bcf18 Bcf
1 Bcf1 BcfOil Downstream Oil Downstream
2 Bcf 2 Bcf
Inventory of U.S. Inventory of U.S. Greenhouse Gas Emissions Greenhouse Gas Emissions and Sinks 1990 - 2002and Sinks 1990 - 2002
EmissionsEmissions
ReductionsReductions
Page 4Reducing Emissions, Increasing Efficiency, Maximizing Profits
Best Management PracticesBest Management Practices
BMP 2: Install Flash Tank Separators in Glycol DehydratorsBMP 2: Install Flash Tank Separators in Glycol Dehydrators Glycol regeneration vents methaneGlycol regeneration vents methane
BMP 1: Convert Gas Pneumatic Controls to Instrument AirBMP 1: Convert Gas Pneumatic Controls to Instrument Air Gas pneumatic controls bleed methane to the atmosphereGas pneumatic controls bleed methane to the atmosphere
BMP 3: DI&M at Gas Processing BMP 3: DI&M at Gas Processing Plants and Booster StationsPlants and Booster Stations Equipment leaks cause Equipment leaks cause
methane emissions methane emissions
Page 5Reducing Emissions, Increasing Efficiency, Maximizing Profits
BMP4: Partner Reported Opportunities BMP4: Partner Reported Opportunities (PROs)(PROs)
PPartnerartner Identified and practiced Identified and practiced
by Gas STAR partners by Gas STAR partners - your peers- your peers
RReportedeported Submitted to EPA in partners’ Annual ReportsSubmitted to EPA in partners’ Annual Reports
OOpportunitiespportunities Peer-identified, cost-effectivePeer-identified, cost-effective practices and practices and
technologies to reduce methane emissionstechnologies to reduce methane emissions
Page 6Reducing Emissions, Increasing Efficiency, Maximizing Profits
Processor BMPsProcessor BMPs
Compressor Compressor RelatedRelated1%1%
BMP 1: BMP 1: PneumaticsPneumatics14%14%
Storage Storage RelatedRelated10%10%
Pipe Pipe Leak Leak RelatedRelated7%7%
Dehydrator Dehydrator RelatedRelated1%1%
OthersOthers37%37%
Eliminate Eliminate Unnecessary Unnecessary EquipmentEquipment30%30%
BMP 2: Flash BMP 2: Flash Tank SeparatorsTank Separators0%0%
BMP 3: DI&MBMP 3: DI&M< 1%< 1%
86% of the processing sector reductions 86% of the processing sector reductions came from PROscame from PROs
Page 7Reducing Emissions, Increasing Efficiency, Maximizing Profits
PRO Fact SheetsPRO Fact Sheets
Additional valuable informationAdditional valuable information Facilitate technology transferFacilitate technology transfer
One pageOne page
Easy to reviewEasy to review
29 PROs apply to Processing sector29 PROs apply to Processing sector 17 focused on operating practices17 focused on operating practices
12 focused on technologies12 focused on technologies
PRO Fact Sheets are derived from PRO Fact Sheets are derived from Annual Reports 1994-2003Annual Reports 1994-2003 Total 63 posted PRO Fact Sheets at epa.gov/gasstar/pro/index.htmTotal 63 posted PRO Fact Sheets at epa.gov/gasstar/pro/index.htm
Page 8Reducing Emissions, Increasing Efficiency, Maximizing Profits
Sample of Processing PROsSample of Processing PROs Begin DI&M at Remote FacilitiesBegin DI&M at Remote Facilities Convert Engine Starting to NitrogenConvert Engine Starting to Nitrogen Convert Pneumatics To Mechanical ControlsConvert Pneumatics To Mechanical Controls Eliminate Unnecessary Equipment and/or SystemsEliminate Unnecessary Equipment and/or Systems Install Electric StartersInstall Electric Starters Pipe Glycol Dehydrator to VRUPipe Glycol Dehydrator to VRU Recycle Line Recovers Gas During Condensate LoadingRecycle Line Recovers Gas During Condensate Loading Replace Ignition –Reduce False StartsReplace Ignition –Reduce False Starts Use Inert Gases & Pigs to Perform Pipeline PurgesUse Inert Gases & Pigs to Perform Pipeline Purges Use of Composite Wrap RepairUse of Composite Wrap Repair
Overview of PROsOverview of PROs
Page 9Reducing Emissions, Increasing Efficiency, Maximizing Profits
Operating Practice PROsOperating Practice PROs
Eliminate unnecessary equipment and/or systemsEliminate unnecessary equipment and/or systems
Rerouting of glycol skimmer gasRerouting of glycol skimmer gas
Pipe glycol dehydrator to vapor recovery unitPipe glycol dehydrator to vapor recovery unit
Inspect and repair compressor station blowdown Inspect and repair compressor station blowdown valvesvalves
Begin DI&M at remote facilitiesBegin DI&M at remote facilities
Page 10Reducing Emissions, Increasing Efficiency, Maximizing Profits
Eliminate Unnecessary Equipment Eliminate Unnecessary Equipment and/or Systemsand/or Systems
What is the problem?What is the problem? As operating parameters change over As operating parameters change over
time, partners have found that certain time, partners have found that certain pieces of equipment initially crucial to pieces of equipment initially crucial to operations have become superfluous operations have become superfluous
Partner solutionPartner solution Take unnecessary equipment out of Take unnecessary equipment out of
serviceservice
Methane savingsMethane savings Based on removal of 10 separators and 3 Based on removal of 10 separators and 3
glycol dehydratorsglycol dehydrators
ApplicabilityApplicability Applies to all facilities that are operating Applies to all facilities that are operating
well below design levelswell below design levels
Methane SavingsMethane Savings
5 to 130,000 Mcf/yr5 to 130,000 Mcf/yr
Project Project EconomicsEconomics
Project Project CostCost
< $1,000< $1,000
Annual Annual O&M O&M CostsCosts
< $100< $100
PaybackPayback < 1 yr< 1 yr
Page 11Reducing Emissions, Increasing Efficiency, Maximizing Profits
ExxonMobil ExxonMobil Replaced a 930 horsepower (Hp) compressor Replaced a 930 horsepower (Hp) compressor
with 465 Hp at its Fresh Water Bayou facility in with 465 Hp at its Fresh Water Bayou facility in southern Vermilion Parish, Louisianasouthern Vermilion Parish, Louisiana Total project cost = $30,000Total project cost = $30,000 Emissions reductions = 1,556 Mcf/yrEmissions reductions = 1,556 Mcf/yr Value Savings: $3/Mcf x 1556 Mcf = $4,668/yrValue Savings: $3/Mcf x 1556 Mcf = $4,668/yr
Took two satellite tanks out of service and Took two satellite tanks out of service and began pumping directly to the tank batterybegan pumping directly to the tank battery Total project cost = $120,000Total project cost = $120,000 Emissions reductions = 15,735 Mcf/yrEmissions reductions = 15,735 Mcf/yr Value Savings: $3/Mcf x 15,735 Mcf = $47,205/yrValue Savings: $3/Mcf x 15,735 Mcf = $47,205/yr
Eliminate Unnecessary Equipment Eliminate Unnecessary Equipment and/or Systemsand/or Systems
Page 12Reducing Emissions, Increasing Efficiency, Maximizing Profits
Technology PROsTechnology PROs
Use of composite wrap repairUse of composite wrap repair
Install pressurized storage of condensateInstall pressurized storage of condensate
Use ultrasound to identify leaksUse ultrasound to identify leaks
Recycle line recovers gas during condensate Recycle line recovers gas during condensate loadingloading
Convert gas-driven chemical pumps to Convert gas-driven chemical pumps to instrument airinstrument air
Page 13Reducing Emissions, Increasing Efficiency, Maximizing Profits
Use of Composite Wrap RepairUse of Composite Wrap Repair
What is the problem?What is the problem? Pipeline is shutdown and vented to cut Pipeline is shutdown and vented to cut
and weld pipe segment in damaged areasand weld pipe segment in damaged areas
Partner solutionPartner solution Use composite wrap, which consists of a Use composite wrap, which consists of a
filler material, a thin composite wrap and filler material, a thin composite wrap and a special adhesivea special adhesive
Methane savingsMethane savings Based on repair frequencies between 2 - Based on repair frequencies between 2 -
65 times per year65 times per year
ApplicabilityApplicability Suitable for non-leaking defects on Suitable for non-leaking defects on
straight sections with up to 80% wall loss straight sections with up to 80% wall loss and no internal corrosionand no internal corrosion
Methane SavingsMethane Savings
5,400 Mcf/yr5,400 Mcf/yr
Project Project EconomicsEconomics
Project Project CostCost
> $10,000> $10,000
Annual Annual O&M O&M CostsCosts
< $100< $100
PaybackPayback ImmediateImmediate
Page 14Reducing Emissions, Increasing Efficiency, Maximizing Profits
Use of Composite Wrap RepairUse of Composite Wrap Repair
Repairing non-leaking pipeline damage with Repairing non-leaking pipeline damage with composite wrap sleeves, such as Clock Springcomposite wrap sleeves, such as Clock Spring®® Eliminates venting emissions Eliminates venting emissions InexpensiveInexpensive Can repair while operatingCan repair while operating
Non-leaking pipeline defects Non-leaking pipeline defects CorrosionCorrosion DentsDents GougesGouges Source: Clock Spring® Company L. P.
Page 15Reducing Emissions, Increasing Efficiency, Maximizing Profits
New PROsNew PROs
Broad dissemination of PROs is key to Broad dissemination of PROs is key to program success and effective peer-based program success and effective peer-based technology transfertechnology transfer
Zero Emission DehydratorsZero Emission Dehydrators
Recover Gas from Pipeline Pigging OperationsRecover Gas from Pipeline Pigging Operations
Nitrogen Rejection Unit OptimizationNitrogen Rejection Unit Optimization
Page 16Reducing Emissions, Increasing Efficiency, Maximizing Profits
DI&M at Gas Processing Plants and DI&M at Gas Processing Plants and Booster StationsBooster Stations
Gas leaks are Gas leaks are invisibleinvisible, , unregulated unregulated andand gogo unnoticedunnoticed
Gas STAR Partners find that valves, connectors, Gas STAR Partners find that valves, connectors, compressor seals and open-ended lines (OELs) compressor seals and open-ended lines (OELs) are major sourcesare major sources 24 Bcf of methane lost from processing plant fugitive 24 Bcf of methane lost from processing plant fugitive
emissions each yearemissions each year
Fugitive methane emissions depend on operating Fugitive methane emissions depend on operating practices, equipment age and maintenancepractices, equipment age and maintenance
Page 17Reducing Emissions, Increasing Efficiency, Maximizing Profits
Sources of EmissionsSources of Emissions
PCPC PCPC
CompressorCompressor
FCFC
DCDC LCLC TCTC
VCVC
FTSFTS
FCFC LCLC
LCLCCon
tact
or
Con
tact
or
Energy Energy Exchange Exchange
PumpPump
DehydratorDehydrator
ReboilerReboiler
PressureReliefValve
DrainValve
Compressor Seal
Pneumatic Controller
Page 18Reducing Emissions, Increasing Efficiency, Maximizing Profits
Distribution of Losses by CategoryDistribution of Losses by Category
Source: Clearstone Engineering, 2002Source: Clearstone Engineering, 2002
Combustion EquipmentCombustion Equipment 9.9% 9.9%
Amine VentsAmine Vents 0.5% 0.5%
Vents and FlaresVents and Flares24.4%24.4%
Non-leaking ComponentsNon-leaking Components 0.1% 0.1%
NRU VentsNRU Vents0.3%0.3%
Storage TanksStorage Tanks 11.8% 11.8%
Leaking ComponentsLeaking Components53.1%53.1%
Page 19Reducing Emissions, Increasing Efficiency, Maximizing Profits
Distribution of Leaks by ComponentDistribution of Leaks by Component
Control ValvesControl Valves
4.2%4.2%
4.0%4.0%
Open-Ended LinesOpen-Ended Lines11.1%11.1%
Other Flow MetersOther Flow Meters0.2%0.2%
Orifice MetersOrifice Meters0.1%0.1%
Pressure Relief ValvesPressure Relief Valves3.5%3.5%
ValvesValves26.0%26.0%
BlowdownsBlowdowns0.8%0.8%
ConnectorsConnectors24.4%24.4%
CompressorCompressor SealsSeals23.4%23.4%
Crankcase VentsCrankcase Vents
Pump SealsPump Seals1.9%1.9%
Pressure RegulatorsPressure Regulators0.4%0.4%
Source: Clearstone Engineering, 2002Source: Clearstone Engineering, 2002
Page 20Reducing Emissions, Increasing Efficiency, Maximizing Profits
Partner ExperiencePartner Experience
Success #1Success #1 A leaking cylinder head was tightened, which A leaking cylinder head was tightened, which
reduced methane emissions from almost 64,000 reduced methane emissions from almost 64,000 Mcf/yr to 3,300 Mcf/yr. The repair required 9 man-Mcf/yr to 3,300 Mcf/yr. The repair required 9 man-hours of labor, and the annualized gas savings hours of labor, and the annualized gas savings were approximately 60,700 Mscf/yr. The estimated were approximately 60,700 Mscf/yr. The estimated value of the gas saved was $182,100/yr.value of the gas saved was $182,100/yr.
Success #2Success #2 A one-inch pressure relief valve emitted almost A one-inch pressure relief valve emitted almost
36,774 Mcf/yr. Five man-hours of labor and $125 of 36,774 Mcf/yr. Five man-hours of labor and $125 of materials eliminated the leak. The annualized value materials eliminated the leak. The annualized value of the gas saved was more than $110,300.of the gas saved was more than $110,300.
Gas values based on $3/McfGas values based on $3/Mcf
Page 21Reducing Emissions, Increasing Efficiency, Maximizing Profits
Partner Experience Cont.Partner Experience Cont.
Success #3Success #3 A blowdown valve leaked almost 14,500 Mcf/yr. A blowdown valve leaked almost 14,500 Mcf/yr.
Rather than replace the expensive valve, the Rather than replace the expensive valve, the Partner spent just $720 on labor and materials Partner spent just $720 on labor and materials to reduce the emissions to approximately 100 to reduce the emissions to approximately 100 Mscf/yr. The gas saved was approximately Mscf/yr. The gas saved was approximately 14,400 Mcf/yr, worth $43,200.14,400 Mcf/yr, worth $43,200.
Success #4Success #4 A tube fitting leaked 4,121 Mcf/yr. A very quick A tube fitting leaked 4,121 Mcf/yr. A very quick
repair requiring only five minutes reduced the repair requiring only five minutes reduced the leak rate to 10 Mcf/yr. The annualized value of leak rate to 10 Mcf/yr. The annualized value of the gas saved was approximately $12,300.the gas saved was approximately $12,300.
Page 22Reducing Emissions, Increasing Efficiency, Maximizing Profits
DI&M by Leak ImagingDI&M by Leak Imaging
Real-time visual image of gas leaksReal-time visual image of gas leaks Quicker identification & repair of leaksQuicker identification & repair of leaks Screen hundreds of components an hourScreen hundreds of components an hour Screen inaccessible areas simply by viewing themScreen inaccessible areas simply by viewing them Aerial surveillance of flow linesAerial surveillance of flow lines
Page 23Reducing Emissions, Increasing Efficiency, Maximizing Profits
Infrared Gas Imaging TechnologyInfrared Gas Imaging Technology
Active and passive IR technologiesActive and passive IR technologies
Shoulder- and/or tripod- mountedShoulder- and/or tripod- mounted
Hand-held prototype 2005Hand-held prototype 2005
Aerial surveillance applicationsAerial surveillance applications
Require battery or power cordRequire battery or power cord
Most very large leaks (> 3cf/hr) clearly seenMost very large leaks (> 3cf/hr) clearly seen
Page 24Reducing Emissions, Increasing Efficiency, Maximizing Profits
Infrared Gas ImagingInfrared Gas Imaging
Video recording of fugitive leak found by infrared Video recording of fugitive leak found by infrared cameracamera
Page 25Reducing Emissions, Increasing Efficiency, Maximizing Profits
Discussion QuestionsDiscussion Questions
To what extent are you implementing any of To what extent are you implementing any of these PROs?these PROs?
What are the barriers (technological, economic, What are the barriers (technological, economic, lack of information, regulatory, etc.) that are lack of information, regulatory, etc.) that are preventing you from implementing any of these preventing you from implementing any of these technologies?technologies?
How often do you perform DI&M at your How often do you perform DI&M at your processing facility?processing facility?