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John Crane Gas Seal TechnologyCuts Costs, Emissions and Downtime

CUSTOMER NEED

• The company’s publicized commitment to the environment and meeting potential emission regulations were priorities.

• The upgrade needed to lower operating costs with short-term payback.

• Downtime from oil seal maintenance and replacements hurt production.

• Oil seal methane leaks cut deep into profits.

BACKGROUND

Industry: Natural gas processing

Site: Single compressor operation, process gas owned by equipment operator

Location: United States

End Product: Natural gas 85% methane

Equipment Utilization: 355 days a year

H Y P O T H E T I C A L C A S E S T U D Y : N A T U R A L G A S I N D U S T R Y S E R V I C E O F F E R I N G : T U R N K E Y U P G R A D E S E R V I C E F O R C E N T R I F U G A L

C O M P R E S S O R S H A F T S E A L S

HIGHLIGHTS

• Customer compared the three viable options to reduce methane emissions using John Crane’s Lifecycle Cost Calculator (LCC). (See lifecycle cost graph)

• Results from LCC showed gas processor could immediately beginsaving millions of dollars by upgrading from shaft oil seal to time-tested gas seal technology.

• These calculated savings are the result of reduced methane emissions, downtime and maintenance costs.

• Company confident of full compliance with potential environmental regulations regarding compressor emissions.

5 MONTHSScenario 1

Scenario 2

Scenario 4

Gas seal upgradepayback

11 MONTHSGas seal upgrade

ROI

7 MONTHSGas seal upgradepayback

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PROJECTED LCC ECONOMIC RESULTS

Calculated over 15 years, the total lifecycle cost of…

• Capturing the uncontrolled, vented methane and routing to a flare device is projected to be $20M.

• Capturing the uncontrolled, vented methane and routing for another purpose is projected to be $13M.

• Upgrading the oil seal to a gas seal is only $2M.

• Annual operating costs drop to just $73,000 compared to $1.4M with oil seals, representing more than $1.3M in savings.

• Product loss due to leakage estimated to drop to $31,000 — a $470,000 cost reduction from oil seals.

• Maintenance and downtime annual expenses are estimated to reduce to $30,000 — down $792,000 compared to oil seal.

• Methane leaked into atmosphere nearly eliminated, preparing the way for compliance with potential environmental and greenhouse gas legislation.

H Y P O T H E T I C A L C A S E S T U D Y : N A T U R A L G A S I N D U S T R Y

NATURAL GAS PROCESSING

• Assumes 1 compressor running approximately 100% utilization with the equipment operator owning the natural gas flowing through the compressor

• Centrifugal compressor with 2 seals running on a 5.52 shaft at 9,440 rpm and 470 psi

• Assumes methane content of 85% with a natural gas value of $2.86 per thousand cubic ft

• Assumes oil seal mean time between repair of 12 months

• Lost production due to oil seal maintenance estimated to be 200 hours per year

TECHNICAL SOLUTION

• Turnkey Upgrade Service for Centrifugal Compressor Shaft Seals, including as standard:

- Equipment audit and emissions baseline measurement

- Oil seal and system removal and disposal

- Custom gas seal solution (including rotor dynamics optimization and compressor modification if required)

- Installation and commissioning of narrow section gas seal, separation seals and gas seal system

- Emissions reduction monitoring

• Optional services include:

- Coupling change

- Bearing service

- Thermoplastic inter-stage labyrinth upgrade

$1.3 MILLION REDUCTION

ANNUAL OPERATING COSTS

- Replacement filters

- Dry gas seal management

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Oil Seal Routed to Atmosphere

Oil Seal Routed to Flare

Oil Seal Routed to Capture/Use

Time (Years)

LIFECYCLE COST VERSUS TIME

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Gas Seal

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15

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35

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