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Cleaner air Increased profits Easier predictive maintenance
®
EPAes(matesover50,0004-cylindercompressors(200,000cylinders)released65BcfofnaturalgasannuallytotheatmosphereaDributedtopackingleaks1
Packingleaksaresignificantcontributorsto
greenhousegases(GHG).
1U.S. EPA. Inventory of US Greenhouse Gas Emissions and Sinks 1990-2011 [April 13] 2$3.00 per mcf
EPAsurveyed178pipelinecompressors.Operatorsrunning100compressors(approximately400cylinders),onaverage,lose$259,200permonth.
LeakRate
(scfm)
LeakRate
(mcf/day)
LeakRate
(mcf/mo)
LeakRate
(mcf/yr)
Profit2/yr
percylinder
5 7.20 216 2,592 ($7,776)
12 17.28 518 6,216 ($18,648)
RealWorldData
ActualFieldMeasurementsofLeakingPacking9360403224484464993
MeasurementsweretakenwithaFoxThermalMeterModel10ALoca(on 1stQTR Packing Packing Loss$ 1stQTR Packing Packing Loss$ 2nd.QTR Packing Packing Loss$
Tes(ng LeakRate LeakRate Per/Day Tes(ng LeakRate LeakRate Per/Day Tes(ng LeakRate LeakRate Per/DayDate CFM CF/Day Date CFM CF/Day Date CFM CF/Day
2/23/2010 2.4 3456$13.82 2/6/2011 3.1 4464$17.86 4/6/2011 0.88 1267$5.072/23/2010 6.5 9360$37.44 2/6/2011 4.26 6134$24.54 4/6/2011 1.4 2016$8.062/23/2010 3.5 5040$20.16 2/6/2011 2.34 3369$13.48 4/6/2011 0.55 792$3.172/23/2010 2 2880$11.52 2/6/2011 1.76 2534$10.14 4/6/2011 0.31 446$1.792/23/2010 2.8 4032$16.13 4/4/2011 0.69 993$3.97 4/11/2011 0.685 986$3.952/23/2010 1.1 1584$6.34 4/4/2011 20.23 29131$116.52 4/11/2011 0.88 1267$5.072/23/2010 5 7200$28.80 4/4/2011 2.3 3312$13.25 4/11/2011 0.447 643$2.572/23/2010 2.9 4176$16.70 4/4/2011 0.35 504$2.02 4/11/2011 17.1 24624$98.502/23/2010 8.1 11664$46.66 5/17/2011 2.65 3816$15.262/23/2010 4.6 6624$26.50 5/17/2011 1 1440$5.762/23/2010 5.5 7920$31.68 5/17/2011 5.7 8208$32.832/23/2010 0 0$- 5/17/2011 2.9 4176$16.703/2/2010 0 0$- 5/21/2011 0 0$-3/2/2010 1.7 2448$9.79 5/21/2011 1.4 2016$8.063/2/2010 0 0$- 5/21/2011 0 0$-3/2/2010 1.6 2304$9.22 5/21/2011 1.15 1656$6.623/2/2010 1.3 1872$7.49 5/21/2011 2.5 3600$14.403/2/2010 4.8 6912$27.65 5/21/2011 2.6 3744$14.98
5/21/2011 2.3 3312$13.255/21/2011 2.8 4032$16.13
Leak-APributedLostRevenue
443cylinders,4.3mcf/day(avg)@$3/mcf
Day Month Year$575 $17,242 $207,0003Included in this study
TotalinvestmenttoinstallPLDs,ataverageprices,on200,000cylindersislessthanonequarterpercent(0.22%)ofannuallostmethanereleasedtotheatmosphere.
4U.S. EPA "Reducing Methane Emissions from Compressor Rod Packing Systems" (Oct 2006)
CO2equivalentpolluWon4
Howmuchcouldyousave?
methaneenergyloss
Determiningpackingleaks(pre-PLD):
• Handlingventlines,checkingoverheaWng• ShooWnglineswithinfraredorthermalimagecameras(staWcdatapoint)
• Runninglinestoskidcorners;observingoilblowingfromventline(s)
• Removinglinesandfeelinggasinpalmofhand
PackingLeakDetecWon
Currently,itisneithereasynorinexpensivetodeterminepackingcaseleak
rates.CompressorsoperateweeksormonthswithsubstanWalleaks.
Imprecisemethodstodetermine&measure
leakinggasvolume.
• Iflinestubedtoventsorflares,impossibletodeterminelostgasvolume
PackingLeakDetectorsdetermine:• Over-lubrica(on• Improperpackingmaterial• Incorrectpackinginstalla(on• Pistonrodhardness/smoothness
PLDsmateriallyimproveoperators’abilitytoeffec(velymanagepacking• Enhancepredic(vemaintenance• Enhancebudge(ng• ReduceLeaseOperatorExpenditure(LOE)
• Firstreal-Wmeassessmenttool• EstablishesZER0-leakbaselines• Assesseshealth&effecWvenessofcompressorpacking,packingglandhealth
PackingLeakDetectors®
Piston Piston Rod
PackingCasePackingRings
Ventcup
VentLine
CompressorCylinder
PLD
toventcontrolandVaporRecovery
System
Leakindicator
Aspackingringswear,gasmigratesalongpistonrodstopackingcaseventcups.GasflowsthroughventlinestoconnectedPackingLeakDetectors(PLDs).Asleakingpressureachievesspecifiedthresholds,PLDsprovidemechanicalvisualleakindica(onsandsendelectronicsignalsviatransmiDerstoPLDMonitorPanels(whenproperlyconfigured)SystemsemployingPLDMonitorPaneloffercapabilitytoremotelyaccesstemperatureandpressuredataviaModbusRTURS232orRS485SerialCOMM.Datacanbetailoredtomeetrequirements.
PackingLeakDetecWon:Future
M-SquaredPackingLeakDetectorsaresimpleandinexpensivedevicestubedtopackingvents.Pre-determined,industry-appropriateorgeneralleakratethresholds,suchas1-2.5scfm,canbecalibrated.
TransmiPer-equippedPLDs
Configura(onsequippedforPLDMonitorPanelsofferremotelyaccessibletemperatureandpressuredata.• ViaModbusRTURS232orRS485• Datacanbetailoredtomeetrequirements
MechanicalPinPLDs
Asleakratesexceedthresholds,visualindicatorpinsextend.Pinsarecalibratedtoindicategasleakrate/volume.
• PLDMonitoringPanel• ModbusRTUviaRS485/RS232• Analoginputs• Adaptstoexis(ngpanelorstand-aloneNEMAenclosure
• 12or24VDC• Class1Division2-rated• SDcardslot• PLDPanelProgram
SamplePLDMonitorScreenShots
ConfiguraWons
PLDwithzero-emissionsblock
PLD316stainlesssteel3 PLDanodizedaluminumwithpressureport3
3PLDsanodizedaluminumor316stainlesswithpressureportavailable.
4PLDsanodizedaluminumor316stainlesswithpressureandtemperatureportsavailable.
PLDanodizedaluminumwithpressure&temperatureports4
PLDBenefits
• Real-Wme,ZERO-leakbaselinesforneworre-builtpacking• Engineeredfordifferentgasesandvaryingrates• CanbeusedonmulWpleservicecompressors• PLDoutletscanbere-directedforlow-pressuregasapplicaWonspendingpackingservicingorreplacement
• 24X7localpackingmonitoring• ConfiguraWonsequippedforPLDMonitorPanelsofferremotelyaccessibletemperatureand/orpressuredata
• CommunicaWonviaModbusRTURS485/RS232• Datacanbetailoredtomeetrequirements
Summary
First,dynamicpackingglandhealthtool.
Determines• ZERO-leakbaselines• Packingleaks&rates• Packingfailure• Appropriatenessofpackingmaterial• Installa(onirregulariWes• Excessivepistonrodsmoothness/hardness• Over-lubricaWon• Local&remotemonitoringconfigurable
BeyondPLDs
M-SquaredPLDsarepartofamodularapproachtoloweringmethaneemissions.
Oncedetected,gasleakscanberedirectedandcaptured.
• Redirectedemissionscanbedirectedtoflares,vents,or,atpre-determinedvolumethresholds,senttoholdingvessels
• Recapturedgasescanbere-compressedbyM-Squaredvaporrecoveryunits(VRUs)forsales
M-SquaredProducts&Services,Inc.
Packing Leak Detector Questions?
Contact:JonathanMann,M-SquaredProducts&Services001+337.280.8977mobile001+337.935.6578officejmann@m-squaredinc.com
www.m-squaredinc.com
CharlesMann,[email protected]