Gas STAR Technologies and Gas STAR Technologies and Practices Practices for DI&M and Compressor Seals for DI&M and Compressor Seals ( ( Opportunities for Cost Effective Methane Opportunities for Cost Effective Methane Sensors) Sensors) EPA’s Natural Gas STAR Program, EPA’s Natural Gas STAR Program, El Paso Corporation, and El Paso Corporation, and Southern Gas Association Southern Gas Association October 27, 2003 October 27, 2003
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EPA’s Natural Gas STAR Program, El Paso Corporation, and Southern Gas Association
Gas STAR Technologies and Practices for DI&M and Compressor Seals ( Opportunities for Cost Effective Methane Sensors). EPA’s Natural Gas STAR Program, El Paso Corporation, and Southern Gas Association October 27, 2003. Agenda. Equipment leaks What is the problem? Where are the leaks? - PowerPoint PPT Presentation
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Gas STAR Technologies and PracticesGas STAR Technologies and Practicesfor DI&M and Compressor Sealsfor DI&M and Compressor Seals
((Opportunities for Cost Effective Methane Sensors)Opportunities for Cost Effective Methane Sensors)
EPA’s Natural Gas STAR Program,EPA’s Natural Gas STAR Program,
El Paso Corporation, andEl Paso Corporation, and
Southern Gas AssociationSouthern Gas AssociationOctober 27, 2003October 27, 2003
What is the problem?What is the problem? Where are the leaks?Where are the leaks? What Gas STAR Partners are doing.What Gas STAR Partners are doing. A low-cost sensor option.A low-cost sensor option.
Compressor sealsCompressor seals What is the problem?What is the problem? Where are the leaks?Where are the leaks? What Gas STAR Partners are doing.What Gas STAR Partners are doing. A low-cost sensor option.A low-cost sensor option.
STAR partners find that valves, STAR partners find that valves, connectors, compressors and open-connectors, compressors and open-ended lines (OEL) are major leak sourcesended lines (OEL) are major leak sources 50.7 Bcf/yr of methane are emitted by 50.7 Bcf/yr of methane are emitted by
compressors and facility componentscompressors and facility components 1% of the leakers contribute 90% of the 1% of the leakers contribute 90% of the
emissionsemissions Fugitive emissions depend on operating Fugitive emissions depend on operating
practices, equipment age and practices, equipment age and maintenancemaintenance
Equipment leaksEquipment leaksWhat is the Problem?What is the Problem?
Open ended lines (OEL) Open ended lines (OEL) account for 11%account for 11% Block valvesBlock valves Blowdown vents, motor Blowdown vents, motor
starters, vent and drain starters, vent and drain connectionsconnections
Through-valve leakage is Through-valve leakage is the primary sourcethe primary source Often from vent stacksOften from vent stacks Valve seat wears or fouls, Valve seat wears or fouls,
requiring either more requiring either more pressure, cleaning or pressure, cleaning or replacementreplacement
Objective: Automated detection of LARGE leaks Objective: Automated detection of LARGE leaks that are cost-effective to repairthat are cost-effective to repair
Potential application:Potential application:
Equipment alerts operator to cost-effective leakEquipment alerts operator to cost-effective leak
Business as usual site visitBusiness as usual site visit
Operator directs repairs on the spotOperator directs repairs on the spot
Compressor sealsCompressor sealsWhat is the problem?What is the problem?
Compressor seals account for 23.4% of emissionsCompressor seals account for 23.4% of emissions 11.9 Bcf/yr of methane are emitted by compressors11.9 Bcf/yr of methane are emitted by compressors Over 8,500 compressors in gas transmission sectorOver 8,500 compressors in gas transmission sector
Where are the leaks?Where are the leaks? Reciprocating compressor rod packingReciprocating compressor rod packing
Fourth largest gas industry emissions at 16 Bcf/yrFourth largest gas industry emissions at 16 Bcf/yr Leakage typically occurs from:Leakage typically occurs from:
Nose gasketNose gasket Between cupsBetween cups Ring movementRing movement Down shaftDown shaft
All packings leakAll packings leak ~60 scfh new~60 scfh new >900 scfh worn>900 scfh worn
Where are the leaks?Where are the leaks? Centrifugal compressor dry sealsCentrifugal compressor dry seals
Most new compressors are supplied with dry sealsMost new compressors are supplied with dry seals Leakage typically occurs from:Leakage typically occurs from:
Labyrinth seal into static barrierLabyrinth seal into static barrier Seal vent Seal vent
after tandem after tandem sealseal
Little leakage Little leakage from seal facefrom seal face
Seal vents emitSeal vents emit 0.5-3 scfm0.5-3 scfm Spinning
What Gas STAR Partners are doing.What Gas STAR Partners are doing.
Leakage is reduced through routine Leakage is reduced through routine monitoring and seal maintenancemonitoring and seal maintenance Conventional rod packing rings require Conventional rod packing rings require
replacement every 3 to 5 yearsreplacement every 3 to 5 years An economic leak rate is determined An economic leak rate is determined
based on costs and gas savingsbased on costs and gas savings Replace rings when it is economicalReplace rings when it is economical
Saves gas and moneySaves gas and money Extends the life of the piston rodExtends the life of the piston rod Reduces methane emissionsReduces methane emissions
Opportunities for Inexpensive Leak SensorsOpportunities for Inexpensive Leak Sensors
Application: Compressor seal and seal oil ventsApplication: Compressor seal and seal oil vents
Objective: Automated detection of LARGE leaks Objective: Automated detection of LARGE leaks that are cost-effective to repairthat are cost-effective to repair
Potential application:Potential application:
Equipment alerts operator to cost-effective leakEquipment alerts operator to cost-effective leak
Business as usual site visitBusiness as usual site visit
How accurate would sensors need to be How accurate would sensors need to be in quantifying methane emissions?in quantifying methane emissions?
Would methane emissions sensor Would methane emissions sensor outputs need to be transmitted to a outputs need to be transmitted to a SCADA center?SCADA center?
To what degree are candidate sites for To what degree are candidate sites for low cost fugitive sensors non-electrified?low cost fugitive sensors non-electrified?
What are other applications for What are other applications for inexpensive methane emissions inexpensive methane emissions sensors?sensors?