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Directed Inspection and Maintenance (DI&M). Lessons Learned from Natural Gas STAR Partners Producers Technology Transfer Workshop Devon Energy and EPA’s Natural Gas STAR Program Casper, Wyoming August 30, 2005. DI&M: Agenda. Methane Losses Methane Recovery Is Recovery Profitable? - PowerPoint PPT Presentation
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Directed Inspection and Maintenance Directed Inspection and Maintenance (DI&M)(DI&M)
Lessons Learned fromLessons Learned fromNatural Gas STAR PartnersNatural Gas STAR Partners
Producers Technology Transfer WorkshopProducers Technology Transfer Workshop
Devon Energy and Devon Energy and EPA’s Natural Gas STAR ProgramEPA’s Natural Gas STAR Program
Casper, WyomingCasper, WyomingAugust 30, 2005August 30, 2005
Slide 2Reducing Emissions, Increasing Efficiency, Maximizing Profits
DI&M: AgendaDI&M: Agenda
Methane LossesMethane Losses
Methane Recovery Methane Recovery
Is Recovery Profitable?Is Recovery Profitable?
Industry ExperienceIndustry Experience
Discussion QuestionsDiscussion Questions
Slide 3Reducing Emissions, Increasing Efficiency, Maximizing Profits
Natural Gas Industry EmissionsNatural Gas Industry Emissions
Production sector responsible for largest Production sector responsible for largest portion of emissionsportion of emissions
EmissionsEmissions
ReductionsReductions
Transmission Transmission
& Storage & Storage 101 Bcf 101 Bcf
Production Production 148 Bcf148 Bcf
Processing Processing 36 Bcf 36 Bcf
Distribution Distribution 68 Bcf68 Bcf
24 Bcf24 Bcf
7 Bcf7 Bcf
18 Bcf18 Bcf
1 Bcf1 BcfOil Downstream Oil Downstream 2 Bcf 2 Bcf
Inventory of US Greenhouse Gas Inventory of US Greenhouse Gas Emissions and Sinks 1990 - 2003Emissions and Sinks 1990 - 2003
Slide 4Reducing Emissions, Increasing Efficiency, Maximizing Profits
Oil and Gas Production Sector Oil and Gas Production Sector Methane EmissionsMethane Emissions
The production sector has several large The production sector has several large methane emission sources that can be targeted methane emission sources that can be targeted for reductionsfor reductions
Pneumatic Pneumatic DevicesDevices61 Bcf61 Bcf
Dehydrators Dehydrators and Pumpsand Pumps17 Bcf17 Bcf
Meters andMeters andPipeline LeaksPipeline Leaks10 Bcf10 Bcf
Gas Engine Gas Engine ExhaustExhaust12 Bcf12 Bcf
Well Venting Well Venting and Flaringand Flaring18 Bcf18 Bcf
Storage Tank Storage Tank VentingVenting9 Bcf9 Bcf
Other Other Sources Sources 21 Bcf21 Bcf
Inventory of US Greenhouse Inventory of US Greenhouse Gas Emissions and Sinks Gas Emissions and Sinks 1990 - 20031990 - 2003
Slide 5Reducing Emissions, Increasing Efficiency, Maximizing Profits
Control Valves4.0%
Open-Ended Lines11.1%
Other Flow Meters0.2%
Orifice Meters0.1%
Pressure Relief Valves3.5%
Valves26.0%
Blowdowns
0.8%
Connectors24.4%
Compressor Seals23.4%
Crankcase Vents4.2%
Pump Seals1.9%
Pressure Regulators0.4%
Source: Clearstone Engineering, 2002
Methane Losses Methane Losses by Equipment Typeby Equipment Type
Slide 6Reducing Emissions, Increasing Efficiency, Maximizing Profits
What is the Problem?What is the Problem?
Gas leaks are Gas leaks are invisibleinvisible, , unregulated unregulated andand gogo unnoticedunnoticed
Gas STAR Partners find that valves, Gas STAR Partners find that valves, connectors, compressor seals and open-connectors, compressor seals and open-ended lines (OELs) are major sourcesended lines (OELs) are major sources 27 Bcf of methane emitted per year by 27 Bcf of methane emitted per year by
reciprocating compressors seals and OELs, reciprocating compressors seals and OELs, each contributing equally to the emissionseach contributing equally to the emissions
Slide 7Reducing Emissions, Increasing Efficiency, Maximizing Profits
What are the Sources of Emissions?What are the Sources 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
Slide 8Reducing Emissions, Increasing Efficiency, Maximizing Profits
How Much Methane is Emitted?How Much Methane is Emitted?
Component Type% of Total Methane
Emissions% Leaks
Estimated Average Methane Emissions per
Leaking Component (Mcf/year)
Valves (Block & Control) 26.0% 7.4% 66Connectors 24.4% 1.2% 80Open-Ended Lines 11.1% 8.1% 186Pressure Relief Valves 3.5% 2.9% 844
Methane Emissions from Leaking Components
Source: Clearstone Engineering, 2002, Identification and Evaluation of Opportunities to Reduce Methane Losses at Four Gas Processing Plants. Report of results from field study of 4 gas processing plants in WY and TX to evaluate opportunities to economically reduce methane emissions.
Slide 9Reducing Emissions, Increasing Efficiency, Maximizing Profits
How Much Methane is Emitted?How Much Methane is Emitted?
Summary of Natural Gas Losses from the Top Ten Leakers1.
Plant No.
Gas Losses From Top 10
Leakers (Mcfd)
Gas Losses From All Equipment
Leakers (Mcfd)
Contribution By Top 10 Leakers
(%)
Contribution By Total Leakers
(%) 1 43.8 122.5 35.7 1.78
2 133.4 206.5 64.6 2.32 3 224.1 352.5 63.6 1.66
4 76.5 211.3 36.2 1.75 Combined 477.8 892.84 53.5 1.85
1Excluding leakage into flare system
Slide 10Reducing Emissions, Increasing Efficiency, Maximizing Profits
Methane RecoveryMethane Recovery
Fugitive losses can be dramatically reduced Fugitive losses can be dramatically reduced by implementing a DI&M programby implementing a DI&M program
Voluntary program to identify and fix leaks Voluntary program to identify and fix leaks that are cost effective to repair that are cost effective to repair
Survey cost will pay out in the first yearSurvey cost will pay out in the first year
Provides valuable data on leakers with Provides valuable data on leakers with information of where to lookinformation of where to look
Slide 11Reducing Emissions, Increasing Efficiency, Maximizing Profits
What is DI&M ?What is DI&M ?
Direct Inspection and MaintenanceDirect Inspection and Maintenance Cost-effective practice by definitionCost-effective practice by definition Find and fix significant leaksFind and fix significant leaks Choice of leak detection technologiesChoice of leak detection technologies Strictly tailored to company’s needs Strictly tailored to company’s needs
DI&M is NOT the regulated volatile organic DI&M is NOT the regulated volatile organic compound (VOC) leak detection and repair compound (VOC) leak detection and repair program (LDAR) program (LDAR)
Slide 12Reducing Emissions, Increasing Efficiency, Maximizing Profits
How Do You Implement DI&M?How Do You Implement DI&M?
SCREEN and MEASURE leaks
ESTIMATE repair cost, fix to a payback criteria
DEVELOP a plan for future DI&M
RECORD savings/REPORT to Gas STAR
CONDUCT baseline survey
FIX on the spot leaks
Slide 13Reducing Emissions, Increasing Efficiency, Maximizing Profits
How Do You Implement DI&M?How Do You Implement DI&M?
Screening - finding leaksScreening - finding leaks Soap bubble screeningSoap bubble screening Electronic screening Electronic screening
(sniffer)(sniffer) Toxic Vapor Analyzer Toxic Vapor Analyzer
(TVA)(TVA) Organic Vapor Analyzer Organic Vapor Analyzer
(OVA)(OVA) Ultrasound Leak Ultrasound Leak
Detection Detection Acoustic Leak DetectionAcoustic Leak Detection Optical Leak ImagingOptical Leak Imaging
Acoustic Leak DetectionAcoustic Leak Detection
Toxic Vapor AnalyzerToxic Vapor Analyzer
Slide 14Reducing Emissions, Increasing Efficiency, Maximizing Profits
How Do You Implement DI&M?How Do You Implement DI&M?
Evaluate the leaks detected - measure Evaluate the leaks detected - measure resultsresults
Leak Measurement Using a High Volume SamplerLeak Measurement Using a High Volume Sampler High Volume SamplerHigh Volume Sampler
Toxic Vapor Analyzer Toxic Vapor Analyzer (correlation factors)(correlation factors)
RotametersRotameters
Slide 15Reducing 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
Slide 16Reducing Emissions, Increasing Efficiency, Maximizing Profits
Is Recovery Profitable?Is Recovery Profitable?
Slide 17Reducing Emissions, Increasing Efficiency, Maximizing Profits
DI&M - Lessons LearnedDI&M - Lessons Learned
A successful, cost-effective DI&M program A successful, cost-effective DI&M program requires measurement of the leaksrequires measurement of the leaks
A high volume sampler is an effective tool for A high volume sampler is an effective tool for quantifying leaks and identifying cost-quantifying leaks and identifying cost-effective repairseffective repairs
Open-ended lines, compressor seals, Open-ended lines, compressor seals, blowdown, engine-starter and pressure relief blowdown, engine-starter and pressure relief valves represent <3% of components but valves represent <3% of components but >60% of methane emissions>60% of methane emissions
The business of leak detection is about to The business of leak detection is about to change dramatically with new technologychange dramatically with new technology
Slide 18Reducing Emissions, Increasing Efficiency, Maximizing Profits
DI&M - Partner ExperienceDI&M - Partner Experience
Partner A: Leaking cylinder head was tightened, Partner A: Leaking cylinder head was tightened, which reduced the methane emissions from almost which reduced the methane emissions from almost 64,000 Mcf/yr to 3,300 Mcf/yr64,000 Mcf/yr to 3,300 Mcf/yr Repair required 9 man-hours of laborRepair required 9 man-hours of labor Gas savings were approximately 60,700 Mcf/yrGas savings were approximately 60,700 Mcf/yr Value of gas saved was $182,100/year at $3/McfValue of gas saved was $182,100/year at $3/Mcf
Partner B: One-inch pressure relief valve emitted Partner B: One-inch pressure relief valve emitted almost 36,774 Mcf/yralmost 36,774 Mcf/yr Required five man-hours of labor and $125 of materialsRequired five man-hours of labor and $125 of materials Value of the gas saved was $110,300 at $3/McfValue of the gas saved was $110,300 at $3/Mcf