Designing for Leak Free Operation

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1 This file was downloaded from 11 th LDAR Symposium May 18-19, 2011 New Orleans, LA Designing for Leak Free Operation The secret to reducing LDAR compliance costs! Standards Certification Education & Training Publishing Conferences & Exhibits David W. Reeves Senior Specialist for Bolting and Sealing Technology Chevron Refining

2 Overview This presentation contains the tools and information needed to significantly reduce your facilities fugitive emissions. 2

3 Overview LDAR: Leak Detection and Remediation Find it and fix it Program 3

4 Overview 1. DFFER: Design For Fugitive Emissions Reliability 2. LDAR: Leak Detection and Remediation 4

5 Overview If You re Dumb Enough to Buy it, Then Suppliers are Smart Enough to Sell it to YOU! 5

6 Outline A little Perspective Who am I? General background on Chevron s Sealing and Bolting Program Fugitive emissions bench mark data The 4 secret words to get to leak free Products that can help you get to leak free Resources you can use to reduce emissions 6

7 What is this? In 1969 we put man on the moon. Is there really a credible reason why we can t significantly reduce fugitive emissions? No! 7

8 David W. Reeves Chevron, 35 years Senior Specialist for Bolting and Sealing Technology Upstream, Downstream and Chemical 5 US Refineries Started researching bolted connections in 1994 Started working on valve packing in 1999 Started a targeted fugitive emissions reduction program in 2000 to bench mark what is possible 8

9 Leak Free Operation The expectation in Chevron is ZERO leaks: Zero Leaks regardless on of the number of startups and shutdowns Zero Leaks during plant upsets 9

10 Leak Free Operation Among a sampling of four refineries, over 30 process units started up leak free since BEFORE AFTER Among a sampling of four refineries, started up over nine major turnarounds leak free since Two refineries were completely shutdown and restarted leak free on 6 different occasions. 10

11 Equipment Covered 11

12 CC-COLLAR CE-ELBOW CSP-SCREWED PIPING CTC-TUBING COLLAR CTE-TUBING ELB CT-TEE CTT-TUBE FITTING TEE CTU-TUBING UNION CUB-UNION W SP BLIND CU-UNION F-FLANGE FO-ORIFICE PLATE FLG FSP-FLG SCREW PIPE GG-GAGE GLASS KC2-CENTRIFUGAL COMP KC-CENTRIFUGAL COMP KDHP-DOG HOUSE PLATE KR4-RECIP COMPRESSOR KR-RECIP COMPRESS KUV-UNLOADER VALVE KUV-UNLOADER VLV FLG KUV-UNLOADER VLV OTH PC2-CENTRIFUGAL PMP2 PC-CENTRIFUGAL PUMP RC-PRESS REL CLOSED RO-PRESS RELIEF OPEN TM-TRANSMITTER VC-CONTROL VALVE VC-CONTROL VLV FLG VC-CONTROL VLV OTH VG-GATE VALVE VG-GATE VLV FLG VG-GATE VLV OTH VL-BELLOWS VALVE VL-BELLOWS VLV FLG VN-NEEDLE VALVE VN-NEEDLE VLV FLG VN-NEEDLE VLV OTH VX-CHECK VALVE VX-CHECK VLV FLG All Flanges 0.12% 0.36% 1.23% 0.04% 0.40% 1.07% 0.63% 1.71% 0.28% 0.24% 1.11% 0.16% 0.16% 0.91% 0.16% 0.08% 0.12% 0.32% 0.12% 0.91% 0.36% 0.67% 0.40% 0.08% 1.63% 3.97% 3.89% 3.93% 3.97% 4.60% 4.01% 3.05% 2.10% 1.86% 0.44% 0.36% 0.16% Percentage of Total Leaks >100PPM 6.98% 15.43% 16.94% 32.01% In the Beginning 0.35 Percentage of Total Leaks By Component Type

13 CC-COLLAR CE-ELBOW CSP-SCREWED PIPING CTC-TUBING COLLAR CTE-TUBING ELB CT-TEE CTT-TUBE FITTING TEE CTU-TUBING UNION CUB-UNION W SP BLIND CU-UNION F-FLANGE FO-ORIFICE PLATE FLG FSP-FLG SCREW PIPE GG-GAGE GLASS KC2-CENTRIFUGAL COMP KC-CENTRIFUGAL COMP KDHP-DOG HOUSE PLATE KR4-RECIP COMPRESSOR KR-RECIP COMPRESS KUV-UNLOADER VALVE KUV-UNLOADER VLV FLG KUV-UNLOADER VLV OTH PC2-CENTRIFUGAL PMP2 PC-CENTRIFUGAL PUMP RC-PRESS REL CLOSED RO-PRESS RELIEF OPEN TM-TRANSMITTER VC-CONTROL VALVE VC-CONTROL VLV FLG VC-CONTROL VLV OTH VG-GATE VALVE VG-GATE VLV FLG VG-GATE VLV OTH VL-BELLOWS VALVE VL-BELLOWS VLV FLG VN-NEEDLE VALVE VN-NEEDLE VLV FLG VN-NEEDLE VLV OTH VX-CHECK VALVE VX-CHECK VLV FLG All Flanges 0.12% 0.36% 1.23% 0.04% 0.40% 1.07% 0.63% 1.71% 0.28% 0.24% 1.11% 0.16% 0.16% 0.91% 0.16% 0.08% 0.12% 0.32% 0.12% 0.91% 0.36% 0.67% 0.40% 0.08% 1.63% 3.97% 3.89% 3.93% 3.97% 4.60% 4.01% 3.05% 2.10% 1.86% 0.44% 0.36% 0.16% Percentage of Total Leaks >100PPM 6.98% 15.43% 16.94% 32.01% In the Beginning 0.35 Percentage of Total Leaks By Component Type

14 PPM Leakage on Methane Gas AND Temperature in Degrees F PPM Leakage on Methane Gas AND Temperature in Degrees F The 4 Secret Words: Below shows fugitive emissions testing on 2 valves. Which one would you buy? Valve #4, OEM Packing in 4 Inch Gate Valve Valve #2, Packing A + B in 4 Inch Gate Valve Test Ended after 3rd excursion over 500PPM. Static Avg. (PPM) Temperature (F) Static Max (PPM) Temperature (F) Packing Completed 5,000 Without Exceeding 500PPM. Cycle Number Cycle Number

15 The 4 Secret Words: Jerry Maguire Show Me The Money! Show Me The Data!!! (Must be comparative.) In God We Trust! Everyone Else, Bring The Data!

16 Bench Mark Fugitive Emissions Data Big Thanks To Buzz Harris and Joe Wilwerding SAGE Environmental Consulting, L.P. "Friendly Service, No Surprises! For the following data 16

17 Bench Mark Fugitive Emissions 17

18 Bench Mark Fugitive Emissions 18

19 Bench Mark Fugitive Emissions 19

20 Bench Mark Fugitive Emissions 20

21 Bench Mark Fugitive Emissions 21

22 Bench Mark Fugitive Emissions 22

23 Bench Mark Fugitive Emissions Top 10% with the lowest leak rates. A leak rate higher than 3.5% is the Level of Shame 23

24 Bench Mark Fugitive Emissions 24

25 Bench Mark Fugitive Emissions 25

26 Is it Luck? Not quite! 1999 changed from Slade to CW-2000 Packing 1999 required all SW gaskets to have inner rings 2000 updated valve packing standard to require use of CW study to rank fugitive emission sources 2003 wrote the Chevron valve test procedure and started testing valve packing from different manufacturers 2003 started using graphite covered corrugated metal gaskets in pipe flanges 2003 AQMD Rule 1173 drops limit from 1,000 to 500 PPM 2004 invented first packing combo to ace Chevron test 2005 presented valve packing test results at the Valve World Conference 2005 first published the valve packing document 2007 AQMD audit of Chevron facility 2007 started using Kam (KAG) pipe flange gaskets 26

27 This is the end of PART 1 of a series. Open the next file to continue the presentation. 27

28 11 th LDAR Symposium May 18-19, 2011 New Orleans, LA Designing for Leak Free Operation The secret to reducing LDAR compliance costs! Standards Certification Education & Training Publishing Conferences & Exhibits David W. Reeves Senior Specialist for Bolting and Sealing Technology Chevron Refining

29 Overview This is PART 2 of a series of files. Together they include all of the slides presented by David Reeves at the 2011 ISA LDAR Symposium. 2

30 The Golden Rules 1. Most equipment manufacturers do not understand performance differences in sealing material performance! 2. It is extremely rare that only one sealing material will work in any given application. 3. The assumption is that over time equipment will leak. If the right material is installed the right way, this is generally NOT TRUE! 3

31 Bench Mark Fugitive Emissions Or to put it another way, the chance of having a valve packing leak in this facility >500 PPM in 2010 was 1.4 per 1,000, or 433 out of 311,874 inspection! 4

32 All Valves Trend Data 5

33 Gate Valve Leak Trend Data 6

34 Gate Valve Leak Trend Data 7

35 All Valves Trend Data 8

36 How Much Pollution is that? If Facility 1 has 433 valves that leak an average 10,795 PPM (433 out of 311,874 inspection,.139% leak rate), they would put 9.79 tons of pollution into the air. Using EPA Mobile6.2 criteria of: 8.8 kilograms (19.4 lb s) of CO2/gallon, 22.1 MPG for the average car, 12,000 miles per year driven, Metric Formula the average car would put 5.54 tons of pollution in the air. So it is all about 1-3/4 average cars on the road per year!! 9

37 How Much Pollution is that? If Facility 1 has 433 valves that leak an average 10,795 PPM (433 out of 311,874 inspection,.139% leak rate), they would put 9.79 tons of pollution into the air. Or one inspector Using driving EPA Mobile miles to criteria of: 8.8 kilograms the refinery ( days lb s) a of CO2/gallon, 22.1 week MPG for for 11 the months. average car, 12,000 miles per year driven, Metric Formula the average car would put 5.54 tons of pollution in the air. So it is all about 1-3/4 average cars on the road per year!! 10

38 How Much Cost is that? Given a 250,000 BPD facility, sniffs every source once a quarter, 25 air inspectors (200 inspections per 50/hr would cost $2,383,000 to complete over 1,300,000 inspections per year. Reducing the number of inspections, and thus the number of inspectors could more than offset the emissions from these leaking valves. Just a thought. 11

39 Bench Mark Fugitive Emissions 12

40 Bench Mark Fugitive Emissions 13

41 Does Chevron have the technology to reach World Class fugitive emissions performance? Probably! Why? Chevron has done the most research, which means we in touch with a number of labs We are in touch with almost all manufacturers in the world To improve or compete with these numbers, a facility would have to have an integrated emissions reduction program, including research, facility data, written standards, emissions based material selection and control over what gets purchased and how it gets installed. 14

42 Facility 2 Fugitive Emissions 15

43 Bellow Seal Leak Trend Data 16

44 Bellow Seal Leak Trend Data This curve is pretty typical across all valve classes 17

45 All Valves Trend Data 18

46 Bellows versus All Other Valves Includes Ball, Control, Gate, Needle and Check Valves 10 to 1 difference 3 to 1 difference 19

47 Why Testing is Imperative You can t tell performance differences without direct comparative testing Every time you buy a valve, gasket or packing, you are voting with your companies dollars as to the quality of that product, and you will get what you pay for! The dirty little secret is, if the product fails to perform, you own the problem and the cost to correct it, not the manufacturer! 20

48 This is the end of PART 2 of a series. Open the next file to continue the presentation. 21

49 11 th LDAR Symposium May 18-19, 2011 New Orleans, LA Designing for Leak Free Operation The secret to reducing LDAR compliance costs! Standards Certification Education & Training Publishing Conferences & Exhibits David W. Reeves Senior Specialist for Bolting and Sealing Technology Chevron Refining

50 Overview This is PART 3 of a series of files. Together they include all of the slides presented by David Reeves at the 2011 ISA LDAR Symposium. 2

51 Chevron Packing Test Off the Shelf Valve Test Media: Methane gas Test Pressure: 600 psig (41 Bar) Test Temperature: 500 degrees F at the stuffing box (260C) Thermal Cycles: 10 cycles, 70F to 500F and back to 70F every 500 cycles No. of Cycles: 5,000 fully open to fully close, or until 500ppmv is reached the third time, Hot Torqued after first 30 cycles Test Valve: ANSI Class 300, API 600, NPS 4, Carbon Steel Gate Valve Leak Detection Method: EPA Method 21 Minimum number of Tests: Two for each valve manufacturer 3

52 Fugitive Emissions Testing Matt Wasielewski, Yarmouth Research

53 Fugitive Emissions Testing

54 Packing Test Results 6

55 Packing Test Results Test results and product references included in this presentation are intended for comparative purposes only and do not constitute an endorsement by Chevron. End users should conduct their own material selection based on their specific operating requirements. 7

56 PPM Leakage on Methane Gas AND Temperature in Degrees F PPM Leakage on Methane Gas AND Temperature in Degrees F PPM Leakage on Methane Gas AND Temperature in Degrees F PPM Leakage on Methane Gas AND Temperature in Degrees F Same Valve, 4 Packings Valve #2, OEM Packing in 4 Inch Gate Valve Valve #2, Packing A in 4 Inch Gate Valve Test Ended after 3rd excursion over 500PPM. Static Avg. (PPM) Temperature (F) Test Ended after 3rd excursion over 500PPM. Static Max (PPM) Temperature (F) Cycle Number Cycle Number Valve #2, Packing B-2 in 4 Inch Gate Valve Valve #2, Packing A + B in 4 Inch Gate Valve PPMv before "hot torque" Packing Completed 5,000 Static Max (PPM) Temperature (F) Static Max (PPM) Temperature (F) Packing Completed 5,000 Without Exceeding 500PPM. Cycle Number Cycle Number

57 PPM Leakage on Methane Gas AND Temperature in Degrees F OEM Packing Test Results Valve #4, OEM Packing in 4 Inch Gate Valve Test Ended after 3rd excursion over 500PPM. Static Avg. (PPM) Temperature (F) Temperature Changes PPM Leakage Rate Cycle Number 9

58 PPM Leakage on Methane Gas AND Temperature in Degrees F OEM Packing Test Results Valve #1, OEM Packing in 4 Inch Gate Valve Only Valve to Complete 5,000 Cycles without leaking greater than 500 PPM for the 3rd time (only 1 excursion noted). Static Avg. (PPM) Temperature (F) Kitz Valve, Nippon Pillar Packing Cycle Number 10

59 Packing Test Results 11

60 Packing Test Results 12

61 Packing Test Results 13

62 Packing Test Results 14

63 Packing Options Garlock 212ULE Teadit 010-ELE Teadit

64 Packing the box 16

65 This is the end of PART 3 of a series. Open the next file to continue the presentation. 17

66 11 th LDAR Symposium May 18-19, 2011 New Orleans, LA Designing for Leak Free Operation The secret to reducing LDAR compliance costs! Standards Certification Education & Training Publishing Conferences & Exhibits David W. Reeves Senior Specialist for Bolting and Sealing Technology Chevron Refining

67 Overview This is PART 4 of a series of files. Together they include all of the slides presented by David Reeves at the 2011 ISA LDAR Symposium. 2

68 Let s talk about Pipe Flanges 3

69 Let s talk about Pipe Flanges What does SW Stand for? Serial Weepers? 4

70 Let s talk about Pipe Flanges 5

71 Spiral Wound Gaskets Remember this number (12,500 psi) and note the number of SW stresses that are below the line!! 6

72 Data from José Carlos C. Veiga, Teadit Thickness (mm) Leakage (ppm) Spiral Wound Gaskets 6.00 LOW DENSITY - NORMAL GUIDE RING Travel Leakage (ppm) Gasket Seating Stress (psi) 7

73 Data from José Carlos C. Veiga, Teadit Spiral Wound Gaskets 8

74 Data from José Carlos C. Veiga, Teadit Spiral Wound Gaskets 9

75 Data from José Carlos C. Veiga, Teadit Spiral Wound Gaskets 10

76 Data from José Carlos C. Veiga, Teadit Thickness (mm) Leakage (ppm) Spiral Wound Gaskets 6.00 LOW DENSITY - SCRATCHED GUIDE RING 250 Travel 2 Leakage (ppm) Gasket Seating Stress (psi) 11

77 Data from José Carlos C. Veiga, Teadit Thickness (mm) Leakage (ppm) Spiral Wound Gaskets 6.00 HIGH DENSITY - NORMAL GUIDE RING 100 Series2 Leakage (ppm) Gasket Seating Stress (psi) 12

78 Data from José Carlos C. Veiga, Teadit Thickness (mm) Leakage (ppm) Spiral Wound Gaskets 6 HIGH DENSITY - SCRATCHED GUIDE RING 100 Travel Leakage (ppm) Gasket Seating Stress (psi) 13

79 Data from José Carlos C. Veiga, Teadit Thickness (mm) Leakage (ppm) KAG Pipe Flange Gasket 6 5 Strain KAG Leakage (ppm) Gasket Seating Stress (psi) 14

80 Pipe Flange Gaskets KAG (Kamprofile) Spiral Wound 15

81 Pipe Flange Field Data 16

82 Pipe Flange Field Data 17

83 Let s talk about Pipe Flanges 18

84 Inner Rings Approximately 60% of SW gaskets sold in the US are sold without an inner ring. European operations report SWG w/o inner rings at 25%, and 75% with inner rings. US trends have shown a 300% increase in 2010 to 1 St Q 2011 shifting to SWG with inner rings. 19

85 Inner Rings From: Doug VanTassell Sent: Thursday, May 12, :42 PM To: Reeves, David W. (dree) As for (the) comments on 60% of their sales is without inner rings I don't know how they sleep at night. Only 5% of our sales are without inner rings and we inform the sites that these gaskets do not meet current industry standards and introduce foreign material in to their Systems. 20

86 Inner Rings From: Doug VanTassell suppliers should be actively educating and informing their customers and selling gaskets that meet current standards. Since most gaskets are sold by distributors and most of them don't know much about their product it is a tough situation. We have much more involvement with the end user like Advanced has with you. The Flexs and Lamons of the world have to educate the end user and the end user needs to revise their spec to be current. So really the responsibility falls to the end user to write tight specs. 21

87 Let s talk about Pipe Flanges 22

88 Pipe Flange Gaskets 23

89 Pipe Flange Gaskets 24

90 Pipe Flange Gaskets If it doesn t have an inner ring, it doesn t get installed (in Chevron), all sizes, all classes! 25

91 Graphite Oxidation Test Results 26

92 SW Crush Test Results 27

93 Flange Loading 28

94 Flange Loading 29

95 Flange Loading 30

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59

Methods 100,000 90,000 Stud Loads Set by PSC During 1/01 #4CU S/D on Edwards Bypass Valves Stud Load Target 130,000 120,000 E-1585A Channel to Shell, Clad Gaskets, Air Impact

20,000 40,000 10,000 30,000 0 F-1100A, Pass 1 F-1100A, Pass 2 F-1100A, Pass 3 F-1100A, Pass 4 F-1100B, Pass 4 F-1100B, Pass 5 F-1100B, Pass 6 F-1100B, Pass 7 F-1100B, Pass 8

10,000 0 Stud Number 60,000 E-1585B Floating Head Final Torque, Clad Gaskets, New Studs, No Washer 60,000 E-1585B Channel to Shell Final Tensioning, New B7 Studs Average Bolt

96 Stud Load in PSI Stud Load in PSI Stud Load in PSI Stud Load in PSI Stud Loading Methods 100,000 90,000 Stud Loads Set by PSC During 1/01 #4CU S/D on Edwards Bypass Valves Stud Load Target 130, ,000 E-1585A Channel to Shell, Clad Gaskets, Air Impact Gun, Used Coarse Thread Bolts Average Bolt Stress 72,000 Targeted Bolt Stress 52,500 80, ,000 70, ,000 60,000 90,000 50,000 40,000 30,000 80,000 70,000 60,000 50,000 20,000 40,000 10,000 30,000 0 F-1100A, Pass 1 F-1100A, Pass 2 F-1100A, Pass 3 F-1100A, Pass 4 F-1100B, Pass 4 F-1100B, Pass 5 F-1100B, Pass 6 F-1100B, Pass 7 F-1100B, Pass 8 F-1160, Pass 1 F-1160, Pass 3 F-1160, Pass 4 F-1160, Pass 5 F-1160, Pass 6 F-1160, Pass 7 F-1160, Pass 8 Control Valve F-1100B, Pass 2 Control Valve F-1100B, Pass 4 20,000 10,000 0 Stud Number 60,000 E-1585B Floating Head Final Torque, Clad Gaskets, New Studs, No Washer 60,000 E-1585B Channel to Shell Final Tensioning, New B7 Studs Average Bolt Stress 29,500 Targeted Bolt Stress 33,500 Average Bolt Stress 47,300 Targeted Bolt Stress 45,000 50,000 50,000 40,000 40,000 30,000 30,000 20,000 20,000 10,000 10, Stud Number Stud Number ETGI

97 Flange Loading 32

98 Flange Loading 33

99 This is the end of PART 4 of a series. Open the next file to continue the presentation. 34

100 11 th LDAR Symposium May 18-19, 2011 New Orleans, LA Designing for Leak Free Operation The secret to reducing LDAR compliance costs! Standards Certification Education & Training Publishing Conferences & Exhibits David W. Reeves Senior Specialist for Bolting and Sealing Technology Chevron Refining

101 Overview This is PART 5 of a series of files. Together they include all of the slides presented by David Reeves at the 2011 ISA LDAR Symposium. 2

102 What it takes to implement change Your own motivation What your boss and management is willing to support Your ability to influence your own company

103 What Organization will cause the most trouble? Purchasing How do you handle them? Written standards with stated, agreed to objectives! Remember this: If your not approaching the target, you won t be picking up flack!

104 If you are effective Emissions Career / Value to your company:

105 Overview I said I would give you the tools and information needed to significantly reduce your facilities fugitive emissions. 6

106 Advanced Sealing Thumb Drives Word Documents: Pipe flange assembly specification template Valve Packing specification and Installation template Approved gasket materials and services template 7

107 Advanced Sealing Thumb Drives Spreadsheets: 24 and Less Pipe Flange Stud Loads, Gasket Stresses and Torque Values spreadsheet 24 and Over Large Flange Stud Loads, Gasket Stresses and Torque Values spreadsheet 8

108 Advanced Sealing Thumb Drives PowerPoint Documents: LDAR Presentation Advanced Sealing Co. Overview UOP Alky One Presentation 9

109 Advanced Sealing Thumb Drives PDF Documents: Teadit 2235 Yarmouth Test Results Advanced Sealing CGG Brochure Advanced Sealing KAG Brochure Advanced Sealing Alky One Brochure Advanced Sealing Kamprofile Pipe Flange Brochure 10

110 What About Next Year? YOU! 11

111 Acknowledgements Sage Environmental Services Teadit Kitz Valve Nippon Pillar Advanced Sealing 12

112 Questions? David W. Reeves 510-CTN

SETTING THE STANDARDS TO BE LEAK FREE

Emissions Reduction Technology Forum 12 th LDAR Symposium May 15-17, 2011 New Orleans, LA SETTING THE STANDARDS TO BE LEAK FREE GASKETS AND PACKINGS DESIGNED FOR A LEAK FREE OPERATION Standards Certification