Directed Inspection & Maintenance At Compressor and Gate Stations

Directed Inspection & Maintenance Directed Inspection & Maintenance At Compressor and Gate StationsAt Compressor and Gate Stations

Lessons LearnedLessons Learned

from Natural Gas STARfrom Natural Gas STAR

NiSource and NiSource and

EPA’s Natural Gas STAR ProgramEPA’s Natural Gas STAR ProgramJune 3, 2003June 3, 2003

Page 2Reducing 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

STAR partners find that valves, connectors, STAR partners find that valves, connectors, compressors and open-ended lines (OEL) are compressors and open-ended lines (OEL) are major sourcesmajor sources 50.7 Bcf/yr of methane are emitted by compressors 50.7 Bcf/yr of methane are emitted by compressors

and facility componentsand facility components 1% of the leakers contribute 90% of the emissions1% of the leakers contribute 90% of the emissions

Fugitive emissions depend on operating Fugitive emissions depend on operating practices, equipment age and maintenancepractices, equipment age and maintenance


Distribution of Natural Gas Losses Distribution of Natural Gas Losses by Source Categoryby Source Category

Combustion EquipmentCombustion Equipment9.9%9.9%

Amine VentsAmine Vents0.5%0.5%

Flare SystemsFlare Systems24.4%24.4%

Non-leaking ComponentsNon-leaking Components0.1%0.1%

NRU VentsNRU Vents0.3%0.3%

Storage TanksStorage Tanks11.8%11.8%

Leaking ComponentsLeaking Components

53.1%53.1%

Source: Clearstone Engineering, 2002Source: Clearstone Engineering, 2002


Natural Gas Losses from Natural Gas Losses from Equipment Leaks by Type of ComponentEquipment Leaks by Type of Component

Control ValvesControl Valves4.0%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%

Compressor SealsCompressor Seals23.4%23.4%

Crankcase VentsCrankcase Vents4.2%4.2%

Pump SealsPump Seals1.9%1.9%

Pressure RegulatorsPressure Regulators0.4%0.4%

Source: Clearstone Engineering, 2002Source: Clearstone Engineering, 2002


How Much Methane is Emitted?How Much Methane is Emitted?

Study covered 13 Study covered 13 StationsStations Average: 7 recipsAverage: 7 recips Average: 2 turbinesAverage: 2 turbines Inlet: 500-700 psiInlet: 500-700 psi Outlet: 700-1,000 psiOutlet: 700-1,000 psi 34,400 components 34,400 components

testedtested Average: 2,707 Average: 2,707

components per components per stationstation

FindingsFindings 5% leakers or 135 5% leakers or 135

componentscomponents 385-200,000 Mcf/yr 385-200,000 Mcf/yr

total leakage ratestotal leakage rates Average: 41,000 Average: 41,000

Mcf/yrMcf/yr

Source: 1999 EPA/GRI/PRCI StudySource: 1999 EPA/GRI/PRCI Study


How Can These Losses Be Reduced?How Can These Losses Be Reduced?

Implementing a Directed Inspection and Implementing a Directed Inspection and Maintenance ProgramMaintenance Program Voluntary program to identify and fix leaks that Voluntary program to identify and fix leaks that

are cost effective to repairare cost effective to repair Outside of mandatory LDAR programOutside of mandatory LDAR program Survey cost will pay out in the first yearSurvey cost will pay out in the first year Provides valuable data on leakersProvides valuable data on leakers

AND of course, implementing other AND of course, implementing other BMP’s BMP’s and and PRO’sPRO’s!!


How Do You Implement a DI&M How Do You Implement a DI&M Program?Program?

SCREEN and MEASURE leaks SCREEN and MEASURE leaks

Estimate repair cost, fix to PAYBACK criteriaEstimate repair cost, fix to PAYBACK criteria

Develop a PLAN for future DI&MDevelop a PLAN for future DI&M

Record savings/REPORT to Gas STARRecord savings/REPORT to Gas STAR

CONDUCT Baseline surveyCONDUCT Baseline survey

FIX leaks on the spotFIX leaks on the spot


How Do You Implement a DI&M How Do You Implement a DI&M Program?Program?

Summary of Screening and Measurement Techniques

Instrument/

Technique Effectiveness

Approximate

Capital Cost

Soap Solution

$

Electronic Gas Detectors

$$

Acoustic Detection/ Ultrasound Detection

$$$

TVA (FID)

$$$

Bagging

$$$

High Volume Sampler

$$$

Rotameter

$$

Source: EPA’s Lessons Learned Study


Cost-Effective Repair ExamplesCost-Effective Repair Examples

Repair the Cost Effective Components

Component Value of

Lost gas1 ($)

Estimated Repair cost

($)

Payback (Months)

Plug Valve: Valve Body 12,641 200 0.2

Union: Fuel Gas Line 12,155 100 0.1

Threaded Connection 10,446 10 0.0

Distance Piece: Rod Packing 7,649 2,000 3.1

Open-Ended Line 6,959 60 0.1

Compressor Seals 5,783 2,000 4.2

Gate Valve 4,729 60 0.2

Source: Hydrocarbon Processing, May 2002 1Based on $3/Mcf gas price


DI&M – Transmission Partner ExperienceDI&M – Transmission Partner Experience Partner A: 15 Stations surveyed annually Partner A: 15 Stations surveyed annually

Survey and repairs averaged $350/station Survey and repairs averaged $350/station Methane savings averaged 11,067 Mcf/stationMethane savings averaged 11,067 Mcf/station

Partner B: 2 Stations surveyed quarterly Partner B: 2 Stations surveyed quarterly Survey costs $200/station Survey costs $200/station 24 leaks detected & repaired; 23 repaired at 24 leaks detected & repaired; 23 repaired at

average $50 eachaverage $50 each

Total Gas Savings $ 498,030Total Gas Savings $ 498,030

Total DI&M Cost Total DI&M Cost $ (5,250)$ (5,250)

SAVINGS $ 492,780SAVINGS $ 492,780

Total Gas Savings $ 51,240Total Gas Savings $ 51,240

Total DI&M Cost Total DI&M Cost $ (2,750)$ (2,750)

SAVINGS $ 48,490SAVINGS $ 48,490


DI&M – Distribution Partner ExperienceDI&M – Distribution Partner Experience Partner C: 86 Stations surveyedPartner C: 86 Stations surveyed

Repairs made to 66 of 105 leaks foundRepairs made to 66 of 105 leaks found Gas savings totaled 1,519 Mcf, with net savings Gas savings totaled 1,519 Mcf, with net savings

averaging $50 per facility surveyedaveraging $50 per facility surveyed

Partner D: surveyed 306 facilitiesPartner D: surveyed 306 facilities Repaired 824 leaks, four described as “large”Repaired 824 leaks, four described as “large” Gas savings totaled 117,800 Mcf, 143 Mcf per leakGas savings totaled 117,800 Mcf, 143 Mcf per leak

Total Gas Savings $ 6,557 Total Gas Savings $ 6,557

Survey Costs $ (1,700)Survey Costs $ (1,700)

Repair Costs Repair Costs $ ( 753)$ ( 753)

Savings $ 4,104Savings $ 4,104

Total Gas Savings $ 353,430 Total Gas Savings $ 353,430

Total DI&M Costs Total DI&M Costs $ (16,500)$ (16,500)

Net Savings $ 336,930Net Savings $ 336,930


Related Studies and PRO Fact SheetsRelated Studies and PRO Fact Sheets

Lessons Learned StudiesLessons Learned Studies DI&M at Compressor StationsDI&M at Compressor Stations DI&M at Gate Stations and Surface FacilitiesDI&M at Gate Stations and Surface Facilities DI&M at Gas Processing Plants and Booster DI&M at Gas Processing Plants and Booster

StationsStations PRO Fact SheetsPRO Fact Sheets

DI&M at Remote FacilitiesDI&M at Remote Facilities


Discussion QuestionsDiscussion Questions

To what extent are you implementing this To what extent are you implementing this practice?practice?

Do you have other best practice Do you have other best practice opportunities to improve on this practice?opportunities to improve on this practice?

How could these Lessons Learned studies How could these Lessons Learned studies be improved upon or altered for use in be improved upon or altered for use in your operation(s)?your operation(s)?

What are the barriers (technological, What are the barriers (technological, economic, lack of information, regulatory, economic, lack of information, regulatory, etc.) that are preventing you from etc.) that are preventing you from implementing this practice?implementing this practice?

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Directed Inspection & Maintenance At Compressor and Gate Stations