Company Reported Opportunities Technologies From Natural Gas STAR Partners EPA’s Natural Gas STAR...

Company Reported OpportunitiesCompany Reported OpportunitiesTechnologiesTechnologies

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

June 17, 2003June 17, 2003

Reducing Emissions, Increasing Efficiency, Maximizing Profits

Why Are Company Reported Opportunities Why Are Company Reported Opportunities Important?Important?

Simple vehicle for sharing successes and Simple vehicle for sharing successes and continuing program’s futurecontinuing program’s future BMP’sBMP’s: the consensus best practices: the consensus best practices PRO’sPRO’s: Partner Reported Opportunities: Partner Reported Opportunities Lessons LearnedLessons Learned: expansion on the most : expansion on the most

advantageous BMP’s and PRO’sadvantageous BMP’s and PRO’s All posted on the Gas STAR website: All posted on the Gas STAR website:

http://www.epa.gov/gasstarhttp://www.epa.gov/gasstar


Gathering & Processing Best Gathering & Processing Best Management PracticesManagement Practices

BMP 1: Replace Gas Pneumatics with BMP 1: Replace Gas Pneumatics with Instrument Air SystemsInstrument Air Systems

BMP 2: Install Flash Tank Separators onBMP 2: Install Flash Tank Separators on Glycol DehydratorsGlycol Dehydrators

BMP 3: Implement Directed Inspection & BMP 3: Implement Directed Inspection & Maintenance at Gas Plants and Booster Maintenance at Gas Plants and Booster StationsStations

BMP 4: Partner Reported Opportunities BMP 4: Partner Reported Opportunities (PRO’s)(PRO’s)


Gas STAR PRO Fact SheetsGas STAR PRO Fact Sheets

PRO Fact Sheets from Annual Reports PRO Fact Sheets from Annual Reports 1994-20021994-2002 54 posted PROs54 posted PROs 26 PRO’s applicable to Processing26 PRO’s applicable to Processing

16 focused on operating practices16 focused on operating practices 10 focused on technology10 focused on technology


Lessons LearnedLessons Learned

14 Lessons Learned posted14 Lessons Learned posted 8 applicable to Processing8 applicable to Processing

3 focused on operating practices3 focused on operating practices 5 focused on technology5 focused on technology

New Lessons Learned in developmentNew Lessons Learned in development Composite WrapComposite Wrap


Technology Focused Lessons LearnedTechnology Focused Lessons Learned

Convert Gas Pneumatic Controls to Convert Gas Pneumatic Controls to Instrument AirInstrument Air

Replacing Wet Seals with Dry Seals in Replacing Wet Seals with Dry Seals in Centrifugal CompressorsCentrifugal Compressors

Reduce Methane Emissions from Reduce Methane Emissions from Compressor Rod Packing SystemsCompressor Rod Packing Systems

Installation of Flash Tank SeparatorsInstallation of Flash Tank Separators Options for Reducing Methane Emissions Options for Reducing Methane Emissions

from Pneumatic Devices in the Natural Gas from Pneumatic Devices in the Natural Gas IndustryIndustry


Technology OpportunitiesTechnology Opportunities

Piping/PipelinesPiping/Pipelines Composite WrapComposite Wrap

SAVES… 5400Mcf/yrSAVES… 5400Mcf/yr PAYOUT… < 1yrPAYOUT… < 1yr

Compressors & EnginesCompressors & Engines Install Electric CompressorsInstall Electric Compressors

SAVES…6440Mcf/yrSAVES…6440Mcf/yr PAYOUT…> 10 yrs PAYOUT…> 10 yrs

Install Electric StartersInstall Electric Starters SAVES… 1350 Mcf/yrSAVES… 1350 Mcf/yr PAYOUT… 1-3 yearsPAYOUT… 1-3 years


More Technology OpportunitiesMore Technology Opportunities

DehydratorsDehydrators Reroute Glycol Skimmer GasReroute Glycol Skimmer Gas

SAVES… 7600Mcf/yrSAVES… 7600Mcf/yr PAYOUT… < 1 yr PAYOUT… < 1 yr

Reroute Glycol Dehydrator to Vapor RecoveryReroute Glycol Dehydrator to Vapor Recovery SAVES… 3300 Mcf/yrSAVES… 3300 Mcf/yr PAYOUT… < 1 yrPAYOUT… < 1 yr

Convert Gas Driven Pumps to AirConvert Gas Driven Pumps to Air SAVES… 2500Mcf/yrSAVES… 2500Mcf/yr PAYOUT… < 1 yrPAYOUT… < 1 yr


What is the Problem?What is the Problem?

Dehydrators present an excellent place to Dehydrators present an excellent place to reduce emissionsreduce emissions HowHow much methane is emitted?much methane is emitted?

A 20 MMcf/day dehydrator with a vent A 20 MMcf/day dehydrator with a vent condenser, no flash tank separator and a condenser, no flash tank separator and a circulation rate of 5 gpm may produce 7,600 circulation rate of 5 gpm may produce 7,600 Mcf/yr of lossesMcf/yr of losses

How can these losses be reduced?How can these losses be reduced? Install a flash tank separatorInstall a flash tank separator Pipe vent gases to vapor recovery Pipe vent gases to vapor recovery Adjust circulation ratesAdjust circulation rates



TanksTanks Install Pressurized Storage for condensateInstall Pressurized Storage for condensate

SAVES… 7,000 Mcf/yrSAVES… 7,000 Mcf/yr PAYOUT… 1-3 yearsPAYOUT… 1-3 years



Pneumatics & ControlsPneumatics & Controls Convert Pneumatics to Mechanical ControlsConvert Pneumatics to Mechanical Controls

SAVES…500 Mcf/yrSAVES…500 Mcf/yr PAYOUT… < 1 yrPAYOUT… < 1 yr

Replace Burst Plates with secondary RV’sReplace Burst Plates with secondary RV’s SAVES…500 Mcf/yrSAVES…500 Mcf/yr PAYOUT… < 1 yrPAYOUT… < 1 yr



ValvesValves Use YALEUse YALE®® closures for ESD Testing closures for ESD Testing

SAVES… 1,800 Mcf/yrSAVES… 1,800 Mcf/yr PAYOUT… 1-3 yearsPAYOUT… 1-3 years

Use Ultrasound to locate leaksUse Ultrasound to locate leaks SAVES… 2,000 Mcf/yrSAVES… 2,000 Mcf/yr PAYOUT… < 1 yrPAYOUT… < 1 yr


What is the Problem?What is the Problem?

Mandated Emergency Shutdown (ESD) Mandated Emergency Shutdown (ESD) Testing Testing

How much methane is emitted?How much methane is emitted? An 8” ESD valve with a 3’ stack @ 500 psi vents An 8” ESD valve with a 3’ stack @ 500 psi vents

400 Mcf/min400 Mcf/min How can these losses be reduced?How can these losses be reduced?

Use of YALEUse of YALE®® closure device reduces loss to 40 closure device reduces loss to 40 scf for 8” ESD valvescf for 8” ESD valve

A YALEA YALE®® closure device is a screwed-on pipe cap closure device is a screwed-on pipe cap with a built-in bleed valvewith a built-in bleed valve


PPartner Experienceartner Experience

Emergency Shutdown (ESD) TestingEmergency Shutdown (ESD) Testing 1,800 Mcf/yr savings based on a station with eight 1,800 Mcf/yr savings based on a station with eight

compressors and ten 8” ESD valvescompressors and ten 8” ESD valves Payout is 1-3 years Payout is 1-3 years YALEYALE®® Closure Devices cost around $800-1,600 Closure Devices cost around $800-1,600

for 8” to 12” sizesfor 8” to 12” sizes YALEYALE®® Closure Devices require vent stack with Closure Devices require vent stack with

threaded end connectionthreaded end connection


Discussion QuestionsDiscussion Questions

To what extent are you implementing these To what extent are you implementing these technologies?technologies?

Do you have other opportunities to suggest?Do you have other opportunities to suggest? How could these opportunities be improved How could these opportunities be improved

upon or altered for use in your operation?upon or altered for use in your operation? 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 these practices?implementing these practices?

Company Reported Opportunities Technologies From Natural Gas STAR Partners EPA’s Natural Gas STAR...

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