Efficient and Reliable Compliance to the New Regulations Confidential • 3 Slide 3 Overview •...

Efficient and Reliable Compliance to the New RegulationsPressure Relief Device (PRD) Monitoring

Emerson Confidential • 2Slide 2

Overview• Regulations requires all critical PRDs to be

electronically monitored• Implementing a real time monitoring system

ensures compliance while providing operational benefits and cost savings

• Leading industries have implemented this technology and achieved immediate results

• How to get started

PRD Electronically Monitored









Monitoring of all PRDs handling Hazardous Air Pollutant (HAP) must be completed within three years of signoff

Key Facts from Regulations• Operators would install electronic monitors

on PRDs that vent to atmosphere or connected to an open system such as flares, to identify and record the time and duration of each pressure release

• Identify the source of release on the flare systems

• Corrective action required for any leakage of 500 ppm or greater

• Reporting emissions during startup and shutdown is now required

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Challenges With Compliance

• Manual monitoring – automated monitoring is now a preferred option

• Traditional electronic monitoring technology is expensive due to complex installation and commissioning requirements

• Identifying time and duration of releases using process information requires extensive data interpretation, time and expertise

• Locating the source of release in your flare system requires even more complex analysis and can result in increased emissions or production slowdown

Cabling and trenchingProcess shut down

Hard to reach locations

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Emerson is where technology

and engineering come together

to create solutions for the benefit

of our customers, driven without

compromise for a world in action.

Our Brand Promise

See your production through a new lens and operate more

successfully than ever before

Comply to Regulations and Improve Operational Performance With Pervasive Sensing™ Solutions


Complete Real-Time PRD Monitoring Solution Addresses Your Key Challenges 1. Emerson’s non-intrusive and wireless solution enables lowest cost implementation 2. Technology designed for PRD application delivers the information you need for compliance

accessible through your existing host system or historian3. Quickly and easily identify the source of release in your flare system

HSSE

1 2WirelessHART®

Gateway

3

Rupture DiscMonitoring

Relief Valve and Rupture Disc Monitoring

Relief ValveMonitoring


Rosemount 708 Wireless Acoustic Transmitter Features• Strap-on Installation• WirelessHART® Data Communication

– Acoustic – Temperature - for pipe surface– Operating Temperature - electronic board)– Battery Charge

• Long Battery Life – 1 to 60 Second Updates– 5.8 year @ 8 Second– 10 year @ 32 Second

Non-Intrusive Design

The non-intrusive sensor clamps directly onto the PRD vent pipe surface.It’s that simple!!! Install in just minutes.

1

Probe with Acoustic and Temperature Sensors


Benefits• Reduced Engineering• Reduced Labor• Reduced Materials• Faster Installation• Assured Reliability and

Performance

WirelessHART Communications 1

Traditional Method

Pervasive Sensing Solution

Relief ValveMonitoring


CAPEX Savings with Pervasive Sensing Solution

Total compliance and operational improvement at fraction of the cost of traditional method

(1) Estimated costs include monitoring of the wireless system, tamperproof secure data, and engineered services(2) Cost range dependent on application: PRV only or PRV with Rupture Disc monitoring

Total Cost of Implementation(1)

200 x PRDsTraditional Method Pervasive Sensing Solution(2)

Total Project Cost ($K) $3,520 $464 - $1,088Total Cost per PRD ($K) $18 $2.3 – $5.4

Savings - 69% - 87%

Field Installation Intrusive Non-Intrusive

Cabling and Trenches Required Yes NoTechnology Wired Wireless

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Technology Designed for PRD Applications

EPA Compliance

Record Release Time and Duration

Leaking Detection

Simmering and Chattering Detection Chattering

Easy Field Identification

Non-intrusive Installation When Disc Impulse Line is Available

Volume Calculation Based on PRD Capacity Based on PRD Capacity

Relief Valve* Relief Valve* and Rupture Disc Rupture Disc

2

*Recommended for spring-loaded operating valve, 20 psi set pressure and above. Solutions vary for other types of relief valves. Consult your local sales person for details.


Acoustic Transmitter Provides Insight Into Your PRD Release Without Complex Data Analysis

Emerson’s PRD Monitoring Solution• Observe downstream acoustic signature of PRD

installationBenefits of monitoring with acoustic signature

• Time and duration of each release clearly shown• Valve simmering, chattering, leakages and malfunctions

also identifiable

Traditional PRD Monitoring Process • Observe upstream pressure peaks and valleys

around the pressure limit Challenges of monitoring with process pressure • Peaks and valleys make it difficult to determine when

the PRD is actually opened or closed

PRD monitoring using process data analysis can take from hours to days

2

AcousticProcess Pressure

Easy to identify time and duration of each pressure release

Presenter

Presentation Notes

Monitoring downstream, or outlet, is the most assertive method to confirm flow coming of the valve. It confirms valve open or close condition. Downstream is very specific and particular to that valve. A valve whistling is nothing more then a rudimentary downstream monitoring. Unfortunately not all valves whistling is long enough to allow pinpoint what device is releasing or lauder enough to be listened across the plant. Neither helps to pinpoint a valve connected to enclosed system, such as a flare system header. On the other hand, the valve upstream, or Inlet, is sharing the same process conditions among other devices and units, so upstream monitoring is not particular to that valve. Monitoring a system and looking for a picks or spikes of pressure might be an indication that a PRD has released, however it is not conclusive and it is based on interpretation and assumption. The pressure drop could have happened due the action of any other devices or units that is sharing the same process conditions. According customers, upstream monitoring might take hours and days until eliminating all possibilities before pinpoint the bad actor with confidence. This chart shows a test comparing downstream acoustic monitoring versus upstream pressure monitoring. Note the test was very generous with the upstream pressure monitoring, because the only device in the system is the PRD, therefore the pressure reading is specific to valve inlet. The blue chart is the pressure. (- Ask your audience: how many pressure releases are them seeing?) (- They will answer you: Two. It’s because the two peaks. Show them the two peaks to confirm the right answer) (- Now…ask them what the duration of each release is. They will guess the duration of the first release is somewhere between the two peaks. You should expect your audience having difficult to determine the second release duration. That is the indication the Process Pressure reading is interpretative.) (- And then, challenge them to tell you when the valve is simmering.) (1st click) Now you are presenting the yellow chart, which is downstream with acoustic monitoring. (- Show them how sharp and easy is to indicate the duration of each release. There is no interpretation when the valve has opened and closed) (- Show them the base of the chart before each release, that little “stair” before the counts going all way up to the saturation. That little stair is when the valve is simmering. We have cases when the customer got that simmering condition and was able to avoiding a release.) Now…here is where the two monitoring transmitters complement one to the other: If customer’s application requires released gas volume calculation, then the Acoustic Transmitter will tell the exactly duration of the release and the Pressure Transmitter will allow customer to calculate the released volume during that period! Conclusion: Upstream monitoring is interpretative; therefore require extensive data interpretation knowledge to pinpoint the bad-actor. Downstream monitoring is not interpretative and extremely easy and fast to pinpoint the bad-actor. Upstream and downstream monitoring is a perfect combination when customer needs to quantify a release volume. …However this is not the whole story…we haven’t seen a leakage yet. So, let’s check the next slide.


Easily Access Your PRD Information

The Rosemount 708*

combines ultrasonic signatures and surface temperature measurement from the vent pipe surface

Gateway connects the information directly to operators host system or historian for notification and reporting

PRV Unit Monitoring PRV PRV Active PRV State Change PRV Acknowledged Transmitter HealthWind Direction South EastUnit 1 PRV-001-009 Yes Yes Yes GoodUnit 2 PRV-002-001 No NO No BadUnit 3 PRV-003-001 No Yes No GoodUnit 4 No No No Good

2

* Additional configuration options available. Consult your local sales person for details.

PRD information is sent to a Gateway through the WirelessHART® protocol• Acoustic magnitude• Pipe surface temperature• Battery Life


64

Seconds

…And Integrate PRD Alerting and Reporting into Your Host System or Historian

• Alert on threshold• Visually inspect trend

for verification• Add location and

contextual information

• Easily access and share results

2

Unit 1

In this process application, an estimated 100 lbs* of VOC was released with wind conditions south by south east. Release was acknowledged and recorded.

*Relief valve and process constants: Spring-loaded operating relief valve, set pressure = 90 psig, valve capacity = 268 SCFM (Square Cubic Feet Per Minute) and gas temperature = 212 ˚F.


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Identifying the Source of Release in Your Flare SystemChallenges• Not all releases are audible to human detection even when the PRD is releasing to the

atmosphere• Using process information to identify where the release is coming from requires hours to

days of expert data analysis and exposure to what may be a hazardous area

Every minute spent identifying which PRD is releasing leads to increasing emissions, regulatory fines and lost production

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Identifying the Source of Release in Your Flare SystemSolution• Comprehensive PRD monitoring for closed recovery and flare systems enables immediate

identification and response to source

Eliminate the need to slow down production and ensure minimal emissions with clear visibility to your full system

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In Addition to Compliance, Fast Detection of Releases and Leakages Saves You Money

• Undetected PRD leakages happen quite often

• Even a small leak (0.1% from PRV flow area) can cause tens of thousands of dollars per year of material losses

Leakages caused by PRD malfunctions can waste large amounts of valuable product, along with the energy required to produce these products.

unseated valve

Leakage


Value Model PRD Monitoring Solution

Number of critical PRDs not currently monitored 200

Potential PRDs not operating properly Small Leak Large Leak

Bypass Valve open

Percentage of PRDs not operating properly 5% 2% 0.50%

Annual losses per PRD not operating properly ($K) $25 $100 $1,000

Annual preventable losses from all leaking PRDs ($K) $250 $400 $1,000

Value Model Based on Fines and Production LossesAvoidable fines due to fugitive emissions ($K) $350

Increased throughput due to reduced process safety limits ($K) $1,200

OPEX Savings Possible with this Pervasive Sensing Solution

Potential Annual Savings = $3,200,000

Presenter

Presentation Notes

($137/day)


• Simple and accurate regulations compliance• Minimum capital expenditure• Increased throughput• Improved productivity and safety• Greater insight into overall process• Establishes infrastructure for future operational improvements using Pervasive Sensing solutions

Summary of PRD Monitoring Solution Benefits


Additional Operational Excellence Opportunities with Pervasive Sensing Solutions…

(1) Savings based on 250k bpd refinery

Application AnnualSavings ($M)

Implementation Cost ($M) ROI (Months)

Heat Exchanger Monitoring $2.7 - $3.6 $ 0.62 3 months

Cooling Tower Monitoring $0.3 - $0.5 $ 0.16 4 months

Steam Trap Monitoring $2.5 - $3.3 $ 1.48 5 months

PRD Monitoring $2.4 - $3.2 $ 1.09 6 months

Pump Monitoring $0.5 - $0.6 $ 0.55 11 months

Air Cooled Heat Exchanger Monitoring $0.9 - $1.1 $ 1.20 13 monthsMobile Workforce $1.6 - $2.1 $ 0.40 3 monthsSafety Shower & Eye Wash Monitoring Per incident $ 0.39 Safety

TOTAL(1) $ 10.9 - $ 14.4 $ 6.40 5 months

More than $10M of savings possible every year









Customer Experience HSSE

RESULTS

Detected at least 200 incidents.Identified 20 “bad actors” and the problems were resolved within an hour.

Increased throughput and revenue of the units.One Year ROI: 270%

CHALLENGEDetecting PRV releases and leaks, current work process on average detected the source within 48-72 hrs. up to weeks. Environmental fines are levied on H2S releases to flare.

Non-intrusive wireless solution utilizing acoustic / temperature transmitters to detect the PRV release in real-time.

SOLUTION

“The increased throughput and revenue was an unexpected bonus”

Major U.S. Refinery


WirelessHART - Proven Across Many Sites

Emerson has installed hundreds ofthousands of wireless applications across major customer sites


Billions of hours ofoperating experience

Thousands of Smart Wireless field devices

Thousands of Wireless Field Networks

Wireless Field-Proven Technology









Unit PRD TAG

PRD Type

Line Pressure

ProcessType

Gas or Liquid

WirelessHART Infrastructure

A 101 PRV 300 psia H2S Gas Yes

A 102 PRV + RD

300 psia H2S Gas Yes



How to Get Started

1. Collect the following basic information for your critical PRDs and send to Emerson for a proposal

Thank You!

Date post:	03-Apr-2018
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