Detecteren, analyseren van gaslekken ter reductie van de emissies bij industriële activiteiten

Transcription

1 Detecteren, analyseren van gaslekken ter reductie van de emissies bij industriële activiteiten THE SNIFFERS Hans Hooyberghs CEO VSL, 11 Themadag Gasanalyse

2 having a rich corporate history 2001: Set up of The Sniffers NV and hiring of first full time employee 2002: First versions of software packages 2005: First large project in Middle East 2006: Partnering up with Creafund and Thierry Vandeghinste to accelerate growth 2007: Significant reinforcement of the sales and marketing functions 2009: Set-up of agent contracts and network in the Middle East 2010: Move to new offices in Balen : Mr. Van Baelen starts with the training of dogs to detect emissions, while working at Borealis 2001: Rudy and Michel Van Baelen start working full time in the company : Expansion of the range of services to multinationals in the targeted oil and gas and chemical industry, as well as regional expansion : Expand I program, strengthening the organisation and accelerating growth geographically (in the Middle East and Europe) : Expand II Building upon its existing strong market position, the company aims to expand its geographical reach to further penetrate existing markets and expand its portfolio of services 1

3 offering both emission monitoring and pipeline services 2 divisions 75% 25% Emission monitoring / Energy saving services Emissions enter the atmosphere through leaking pipes and equipment such as valves, flanges, pump seals, connections etc. The services are performed on above ground pipes, for the following target industries: oil & gas (on- and offshore), chemicals, gas transport and pharmaceutical production Activities consist of measuring all possible leak sources, processing the data via a proprietary software tool, reporting the leaks and advising with loss reduction programs Full range of services, including Leak Detection And Repair (LDAR), IR Quick Scan, flare loss monitoring, steam loss monitoring and tank loss monitoring Pipeline services (underground) Activity scope includes services provided on underground pipelines, typically for oil & gas companies, chemical companies as well as for pipeline network companies Services comprise pipeline integrity inspections, coating and protection surveys, leak detection and other pipeline services In contrast with emission monitoring activities, these services are mainly delivered in Belgium and The Netherlands, largely due to proximity requirements 2 Full inventory of all equipment, combined with quality check of P&ID s 4 Quality check analysis in software, generation of repair orders, writing of report 2 Measurement of coating and leak detection, taking photographs 4 Data analysis, running of analyses templates, generation of reports Preparation Source inventory Measuring Reporting Preparation Measuring Data capturing Reporting 1 Planning, gathering company/unit information and structure, mapping streams on P&ID s 3 Full measurement of all equipment sources, first repair round and data input in database 1 Planning, project scope determination, pre survey 3 Download of the measurements, download of track and trace data 2

4 TS has a broad range of emission monitoring services LDAR IR Camera monitoring Flare loss monitoring Tank emission monitoring Steam loss monitoring Inspections Picture Picture Picture Picture Picture Picture Leak Detection and Repair Detection of leaks and measurement of emissions by measuring equipment at each stage of the process such as valves, flanges, pump seals, pressure relief valves, etc. Loss calculation in SFEMP software Use of PID/FID measurement equipment Detects virtually all leaks (irrespective of size) Detection of large emission leaks by using an Infra Red camera to inspect at process line equipment The only equipment available to measure non accessible facilities or storage tanks Typical applications include time-efficient quick scanning (screening for large gas leaks) Loss calculation in SFEMP software Detection of internal leaks on valves, etc. to reduce the leaking of product to the Flare, where the product is burned Usage of specific ultrasonic equipment Loss calculation in FLAME software Detection of emission leaks on large tanks Usage of specific leak measurement equipment and infra-red cameras Measurement and analysis is performed on fixed roof tanks as well as internal and external floating roof tanks Emission profiles are achieved by continuous measurements Detection of steam leaks on steam traps, including analysis and pressure profile Usage of specific ultrasonic equipment or heat sensitive cameras Includes a technical plot plan creation, benchmarks and technical repair plan Including financial payback calculation Thermography Compressed air loss monitoring thickness measurements Helicalrobotics inspections for corrosion and cracks 3

5 What are fugitive emissions and what is LDAR? Fugitive emissions are atmospheric emissions coming from process line equipment, such as valves, flanges, pump seals, open ended lines, compressor- and agitator seals, pressure relief valves, Even when an equipment only suffers a little emission, all leaks in a complete process plant can together cause a huge emission. An LDAR (Leak Detection And Repair) program is a project or a program to measure, to control and to reduce fugitive emissions. 4

6 Main purpose of LDAR program Getting knowledge/confirmation of the Estimated Fugitive Emissions of all the units. Reduction of Fugitive Emissions: - Direct, by source measurements in the unit followed by a first-repairattempt. - Indirect, by improving the inspection- and maintenance program (e.g. follow-up measurements, planned reparation during shut-down) 5

7 Why? 1) Environment Less emissions (cleaner world) Health of employees less emissions Take care of stake holders Better waste treatment 6

8 Why? 2) Safety Less emissions Reduce risk for fire Reduce risk for explosions safer environment for neighbors 7

9 Why? 3) Regulations To be in accordance with the National and/or International regulations - EPA, IPPC, CEN, ADNOC,.. : code of practice, Corporate guidelines / policies Alignment with SHE program Alignment with Responsible Care programs Permit requirements 8

10 Why? 4) Cost savings by LDAR First zero monitoring campaign: define base line Perform first repair attempt Re-monitoring after repair Reducing Emissions will lead to - cost savings (less product loss) - Less raw material spill - Better process optimalization - Improved working environment - Image building 9

11 Product losses on refineries are between 205 and ton per year 10

12 Kg/year Benchmark LDAR savings for European crackers Nul Measurement After first repair round Cracker 1 Cracker 2 Cracker 3 Cracker 4 Cracker 5 Cracker 6 Cracker 7 Cracker 8 Cracker 9 Within the first year, Fugitive Emissions were in average reduced by 50% or ~ kg per year 11

13 Benchmark: LDAR benchmarking on crackers Comparison Cracker installations Top 3 source-type loss kg/yr For a typical cracker, 85% of the Fugitive Emissions are on average created by Stems, Connections and Flanges 0 CRACKER 1 CRACKER 2 CRACKER 3 CRACKER 4 CRACKER 5 CRACKER 6 CRACKER 7 12

14 Summary of fugitive emissions sources NL/EU/UAE/KUWAIT/QATAR No limitations per size Valves, - Stem of manual valve - Stem of control valve Flanges, Pump seals, Open ended lines, Compressor- and agitator seals, Pressure relief valves: outlets, Sample points, Connectors. 13

15 Benchmark: LDAR benchmarking on crackers 14

16 SFEMP Historical Overview 1997 : V1 - VB4 & MS Access 97-1 GB data storage limit 2001 : V2 - VB6 & MS Access GB data storage limit 2003 : V3 New environment legislation - NER / VLAREM 2008 : Sfemp.Net in SQL 2010 : Full web based application 15

17 LDAR data management tool: SFEMP Sniffers Fugitive Emission Management Program Build in Microsoft.Net environment based on Microsoft SQL Server database Layer/Module based Data storage Parameter / Master data!!!! Data Maintenance and QA module Analysis engine Reporting engine Multi-user (concurrently), multi-site Multi language Windows based user interface Fully flexible reporting engine Web based access from the client site Customer support desk at TS (5 IT professionals) Interface with Plant-4D and with SAP Supports NER, VLAREM, CEN, EPA, IPPC, SHEM 13.06, ADNOC. 16

18 Sfemp.Net - Configuration Citrix Client Stand-alone Database Internet Citrix Terminal Server Application Server MS Internet Information Server Web Client MS Biztalk Server MS SQL 2005 Server Client/Server 17

19 Extra SFEMP features 1. Strong reporting engine 2. Stream indication and LEC indication on an extra layer on Autocad 3. Link P&ID's with the software (SFEMP) 4. Link photos and P&ID extract with a repair order 5. Quality check on P&ID's 6. SFEMP external interface (MS Office, SAP, Autocad, ) 18

20 1. Strong reporting engine 19

21 1. Strong reporting engine 20

22 Special software (SFEMP) is necessary to manage your LDAR program 21

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28 Extra SFEMP features 1. Strong reporting engine 2. Stream indication and LEC indication on an extra layer on Autocad 3. Link P&ID's with the software (SFEMP) 4. Link photos and P&ID extract with a repair order 5. Quality check on P&ID's 6. SFEMP external interface (MS Office, SAP, Autocad, ) 27

29 2. Autocad with stream and lec info This option can be done in AutoCad or Microstation We have even the possibility to do this reporting in the Plant 4D software Coloring of the P&ID s All inventoried equipments get a unique number on the drawing (new layer) - Use of a new layer so that the original P&ID drawing will not be modified - With version adjustments/control, information always stays up to date - A one time cost with durable solution All process lines with VOC s are colored on the P&ID, every phase, (Gas, Light Liquid, Heavy Liquid) with a different color (new layer) 28

30 STR001-LL STR002-G 29

31 Extra SFEMP features 1. Strong reporting engine 2. Stream indication and LEC indication on an extra layer on Autocad 3. Link P&ID's with the software (SFEMP) 4. Link photos and P&ID extract with a repair order 5. Quality check on P&ID's 6. SFEMP external interface (MS Office, SAP, Autocad, ) 30

32 3. Link P&ID s with SFEMP 31

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34 Extra SFEMP features 1. Strong reporting engine 2. Stream indication and LEC indication on an extra layer on Autocad 3. Link P&ID's with the software (SFEMP) 4. Link photos and P&ID extract with a repair order 5. Quality check on P&ID's 6. SFEMP external interface (MS Office, SAP, Autocad, ) 33

35 4. Link photo and P&ID extract with SFEMP 34

36 Extra SFEMP features 1. Strong reporting engine 2. Stream indication and LEC indication on an extra layer on Autocad 3. Link P&ID's with the software (SFEMP) 4. Link photos and P&ID extract with a repair order 5. Quality check on P&ID's 6. SFEMP external interface (MS Office, SAP, Autocad, ) 35

37 5. Quality check on P&ID s 36

38 Extra SFEMP features 1. Strong reporting engine 2. Stream indication and LEC indication on an extra layer on Autocad 3. Link P&ID's with the software (SFEMP) 4. Link photos and P&ID extract with a repair order 5. Quality check on P&ID's 6. SFEMP external interface (MS Office, SAP, Autocad, ) 37

39 Sfemp Object Interface 6. SFEMP external interfaces User interface Web interface ERP Systems : SAP Application framework CAD systems : Database services Analysis & reporting services Business Logic Plant 4D, Autocad, SQL Server MS Office : word, excel, Pdf, 38

40 Critical succes factors of an LDAR program A rigorous set of procedures to link the measurements and the data management on a constructive way is critical - A bigger site can quickly contain measure points, which means real chaos without clear and organized procedures There is a critical need for adjusted data management software to - Save, to process and to control the load of information (zero measurement and repeated measurements) A graphical link from the information to the physical location on the site (Autocad) is important - Analyze the information and to make all relevant reports (eg. not all measured points are reported) 39

41 Management means: 1. Traceability a. Data and results b. Historical results per source c. Maintenance actions and priorities 2. Financial feasibility a. Historical overview and reductions b. Financial payback 3. Reporting LDAR measuring LDAR = management a. Corporate/site/unit/section/product/source 40

42 LDAR Awareness 41

43 SMART LDAR WHAT IS SMART LDAR? On top of an LDAR program, the quick scanning with an INFRARED CAMERA to improve safety and health by identifying large and very large VOC leakages 42

44 The Sniffers IR monitoring The Sniffers uses infrared cameras currently for 2 different applications. Quick Scanning (Screening for large gas leaks) Monitoring of steam/energy systems (with thermal camera) BLOWING STEAM 43

45 IR absorption technique Most VOC s absorb IR waves (example butane & propane). IR camera Wave length Operates from 3 to 5 µm (fixed on 3,4 µm). Wave length is chosen so that most products used in refineries and chemical companies are possible to measure at highest performance. Gas leaks are visualized by camera as dark or white clouds (compared to a steam leak) Example of IR spectra of propane and butane Peak in the absorption band around 3-5 µm. 44

46 What happens after a leak is found? Inventory of the leaking equipment Attachment of a yellow steal tag Numbering the leaking equipment on P&ID Measurement of the leak with portable FID Inclusion in a tightening round You will receive a full report with all leaks and calculated losses as well as all repair orders. 45

47 Some examples Heat exchanger (nafta mix) Where is the leak? Not visible with normal camera!! 46

48 Some examples 1. Heat exchanger (NAFTA mix) Leak before insulation is being removed! FILMED WITH IR LEAK CAMERA Leak after insulation is being removed! 47

49 Some examples 2. Propane Tank (propane) Leak invisible with the naked eye!!? 48

50 Some examples 2. Propane Tank (propane) But with an infrared leak camera 49

51 Some examples 3. Cooling van (LPG / AROMATICS MIX) Is this connection leaking? 50

52 Some examples 3. Cooling van (LPG / AROMATICS MIX) Or this one? 51

53 Some examples 3. Cooling van (LPG / AROMATICS MIX) Or maybe both? 52

54 Examples of IR scanning of tanks 53

55 Conclusions concerning IR camera In the context of LDAR, the current generation of IR camera's are insufficiently accurate and reliable to perform standard fugitive emission measurements - Leaks below ppm were almost never detected in our tests and leaks between ppm and ppm are mostly not detected - The context of IPPC/EPA requires an accuracy in measurements of 1000 ppm or less - Camera is internationally not perceived by legislators as a full LDAR method The results can strongly influenced by external factors (f.e. bursts of wind, ) IR camera is very useful for quick scanning for large leaks (> ppm) IR camera is the only alternative for non accessible equipments and tanks SMART LDAR, THE COMBINATION OF LDAR AND QUICK SCANNING WITH IR CAMERA COMBINES THE BEST OF BOTH WORLDS - LDAR will be able to detect all leaks from accessible points - Quick scanning allows to monitor tanks and non accessible points - Quick scanning is faster and can be done yearly to improve health and safety, while the LDAR (re)measurements can be spread over more years 54

56 CONCLUSION LDAR Bottom up program Detection limit 9 ppm Detailed program and detailed analysis SMART LDAR Top down program Detection limit +- 50,000 ppm Focus on bigger leaks Time efficient 55

57 Working together for a better environment THE SNIFFERS NV / SA Industriezone Driehoek Poeierstraat 14, 2490 Balen, Belgium Tel.: +32 (0) Fax: +32 (0) info@the-sniffers.be Website: 56