Convert Gas Pneumatic Convert Gas Pneumatic Controls to Instrument Air Controls to Instrument Air Lessons Learned Lessons Learned from Natural Gas STAR Partners from Natural Gas STAR Partners EPA’s Natural Gas STAR Program, EPA’s Natural Gas STAR Program, Pioneer Natural Resources USA, Inc., and Pioneer Natural Resources USA, Inc., and The Gas Processors Association The Gas Processors Association June 17, 2003 June 17, 2003
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Convert Gas Pneumatic Controls to Instrument Air Lessons Learned from Natural Gas STAR Partners EPA’s Natural Gas STAR Program, Pioneer Natural Resources.
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Convert Gas Pneumatic Controls to Convert Gas Pneumatic Controls to Instrument AirInstrument Air
Lessons LearnedLessons Learned
from Natural Gas STAR Partnersfrom Natural Gas STAR Partners
EPA’s Natural Gas STAR Program,EPA’s Natural Gas STAR Program,
Pioneer Natural Resources USA, Inc., andPioneer Natural Resources USA, Inc., and
The Gas Processors AssociationThe Gas Processors Association
Sources of Methane LossesSources of Methane Losses
As part of normal operations, pneumatic As part of normal operations, pneumatic devices release natural gas into the devices release natural gas into the atmosphereatmosphere
High-bleed devices bleed in excess of 6 scf High-bleed devices bleed in excess of 6 scf per hourper hour Equates to >50 Mcf/ yearEquates to >50 Mcf/ year Typical high-bleed pneumatic devices bleed an Typical high-bleed pneumatic devices bleed an
Magnitude of Methane LossesMagnitude of Methane Losses
Major source of methane losses from the Major source of methane losses from the natural gas industrynatural gas industry
Pneumatic devices are used throughout the Pneumatic devices are used throughout the natural gas industrynatural gas industry Over 13,000 in the processing sectorOver 13,000 in the processing sector Estimated methane loss of 16 Bcf/year = $48 Estimated methane loss of 16 Bcf/year = $48
Determine the Gas Value SavedDetermine the Gas Value Saved Value of Gas = (IAValue of Gas = (IAu u + UA+ UAuu) * M * P/1000) * M * P/1000
IAIAuu= Instrument Air Use: e.g. 35 control loops= Instrument Air Use: e.g. 35 control loops UAUAuu= Utility Air Use: e.g. assume 10 cfm utility gas= Utility Air Use: e.g. assume 10 cfm utility gas M = Minutes in a year (525,600)M = Minutes in a year (525,600) P = Price of Gas: assume $3.00/Mcf P = Price of Gas: assume $3.00/Mcf
Value of Gas = (35*1Value of Gas = (35*1 + 10) * 525,600 * 3.00 / 1,000+ 10) * 525,600 * 3.00 / 1,000 Value of Gas Saved = $ 71,000/yearValue of Gas Saved = $ 71,000/year
1 1 Electrical Power at 7.5 cents/ kWh.Electrical Power at 7.5 cents/ kWh.22 Maintenance costs include $1,200 compressor service and $2,000 air drier membrane replacement Maintenance costs include $1,200 compressor service and $2,000 air drier membrane replacement33 Compressor overhaul cost of $3,000, inflated at 10% per year Compressor overhaul cost of $3,000, inflated at 10% per year44 Value of gas = $3.00/Mcf Value of gas = $3.00/Mcf55 Net Present Value (NPV) based on 10% discount rate for 5 years Net Present Value (NPV) based on 10% discount rate for 5 years
Year 0 Year 1 Year 2 Year 3 Year 4 Year 5
Installation Cost ($) (45,750)
O&M Cost ($) 0 (13,140)1
(3,200)2
(13,140)
(3,200)
(13,140)
(3,200)
(13,140)
(3,200)
(13,140)
(3,200)
Overhaul Cost ($) 0 0 0 0 0 (4,800) 3
Total Cost ($) (45,750) (16,340) (16,340) (16,340) (16,340) (21,140)
Gas Savings ($) 0 71,000 4 71,000 71,000 71,000 71,000
Installed compressed air system to drive Installed compressed air system to drive pneumatic devices in 10 South Louisiana pneumatic devices in 10 South Louisiana facilitiesfacilities
Project Cost = $40,000Project Cost = $40,000 Emissions Reductions = 23,000 Mcf/yearEmissions Reductions = 23,000 Mcf/year Savings = $69,000 / year Savings = $69,000 / year Payback Period ~ 7 months Payback Period ~ 7 months
Instrument air system has potential to Instrument air system has potential to increase revenue and cut methane emissionsincrease revenue and cut methane emissions
It may extend the life of system equipmentIt may extend the life of system equipment Installing low-bleed devices in conjunction Installing low-bleed devices in conjunction
with switch to instrument air is economicalwith switch to instrument air is economical Existing infrastructure can be usedExisting infrastructure can be used Rotary air compressors lubricated with oil Rotary air compressors lubricated with oil
must be filtered ahead of membrane dryermust be filtered ahead of membrane dryer
Liquid nitrogen systemLiquid nitrogen system Expensive and potential safety hazardExpensive and potential safety hazard
Mechanical controls and instrumentation Mechanical controls and instrumentation systemsystem No power source neededNo power source needed Limited application, frequent calibration requiredLimited application, frequent calibration required
Electric and electro-pneumatic devicesElectric and electro-pneumatic devices
To what extent are you implementing this To what extent are you implementing this BMP?BMP?
How can this Lessons Learned study be How can this Lessons Learned study be improved upon or altered for use in your improved upon or altered for use in your operation(s)?operation(s)?
What are the barriers (technological, What are the barriers (technological, economic, lack of information, etc.) that are economic, lack of information, etc.) that are preventing you from implementing this preventing you from implementing this technology?technology?