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Field GHG Reduction Projects GHG Reduction Opportunity Assessment Tool January 14, 2016 1
Field GHG Reduction Projects
GHG Reduction Opportunity Assessment Tool
January 14, 2016 1
The Opportunity
When you are an energy producer, it can be easy to be an energy waster! To put things into perspective: - Fuel gas required to produce/gather/process natural gas and conventional
crude oil represents ~7% of total raw gas production. - This calculates to be approximately 28 million cubic meters per day!
The value of this fuel gas is approximately $900,000,000/year! (@ $2.50/Mscf)
Facility Type Count
Gas Plants ~600
Compressor Stations ~5,000
Single/Multi Gas/Oil Batteries ~25,000
Gas Gathering Systems ~3,000
Oil & Gas Wells >130,000
Source: ST110-2012 – ERCB Alberta Fuel Gas Efficiency in the Upstream Gas and Conventional Oil Industry Report (March 2012) Alberta’s Upstream Oil and Gas Assets Inventory Study, Cap-Op Energy, September 30, 2013
Opportunity…
January 14, 2016 2
The Problem
• A massive distributed facility base (Thousands of facilities!!!) • all utilize similar unit operations, and hence offer similar opportunities
• The tools and expertise to make improvements are out there… • Integrated Energy Audit Services • CAPP’s Fuel Gas Best Management Practices • Independent Consultants • Textbooks
• But very few companies apply a value to energy consumption, and/or
have resources (and capital) available to chase this energy efficiency opportunity!
WE NEED A “RIGHT-SIZED” AND EASY TO USE ASSESSMENT TOOL!
January 14, 2016 3
What did we set-out to do?
• Selected two small sweet gas plants • Representative of a “typical” small gas plant • Employs “typical” unit operations we may see at other facilities
• Engines & Compressors • Fired Heaters • Dehydration • Refrigeration & Fractionation • Fugitive Emissions
• 2 different fields, and 2 different vintages (20yr/40yr) • Close to Calgary
• Assembled an industry “expert” team • Each member with specialized knowledge/skill-set
• Office Preparation (drawing assessment, information request sheet development)
• Field “GHG Reduction Opportunity Assessment” performed (1 day/facility)
• Office Analysis/Report Preparation
January 14, 2016 4
Results!
January 14, 2016 5
GHG Reduction Opportunity was Found!
The assessment at just 2 gas plants, has resulted in an expected GHG savings of
~6,500 tCO2e/yr, and has resulted in the development of a GHG Reduction
Opportunity Assessment Tool!
GHG Reduction Opportunity Assessment Tool (GROAT)
A series of checklists, with a “simplified” focus on the largest opportunity unit operations:
• Pneumatic Instruments and Chemical Injection Pumps (*) • Flaring/Incineration and Venting (intentional and unintentional) (*) • Engines/Compressors (*) • Dehydration (TEG/DEG) (*) • Refrigeration and Fractionation • Fired Heaters • Lighting • Building Heating
January 14, 2016 6
Next Steps
• Wider-scale internal implementation of the newly-developed GROAT • Refinement & tuning (facility type applicability) • Improving “ease of use”
• Pre/post-turnaround utilization • Quick/easy/cheap assessment tool for operations/engineering
• Plan to integrate the GROAT with the CPC GHG Opportunity Database • Identifying, logging/tracking GHG reduction opportunities within our operations • Assists with near/long-term GHG reduction strategy planning
• Industry release of the GROAT tool…
January 14, 2016 7
Field GHG Reduction Projects
Engine Management Systems with Air Fuel Ratio Control
January 14, 2016 8
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January 14, 2016 10
Data obtained from Alberta Fuel Gas Efficiency in the Upstream Gas and Conventional Oil Industry - ERCB
600 MMscfd OR
17,000 e3m3/d!! *Industry-wide AB
Opportunity
Opportunity
January 14, 2016 11
400k HP Optimize
775 Gas Driven
Engines
Opportunity Win-Win
Program Outline
EXECUTE Install several
REMVue Engine Management Systems with
Adaptive AFRC
PURPOSE Reduce GHG Emissions &
Maintain NOx Compliance.
TRACK Monitor GHG Reductions &
Fuel Gas Savings
REDEEM Obtain GHG
Credits through AB Offset System
SHARE Communicate
our Learnings & Successes with
industry
January 14, 2016 12
Frank Zahner P.Eng, MBA
• Oil and gas industry since 1991 as a specialist in rotating equipment.
• Over 15 years in the commercial construction industry in various capacities.
• His educational background in engineering and business is complimented by extensive work experience in management, marketing, sales, engineering and trades applied to the service, fabrication and construction industry sectors.
January 14, 2016 13
Technology Description
• Introduction to technology
• Proprietary technology by Spartan Controls • Adaptive air fuel ratio control • Rich to lean conversions • Old vs new engines
• How does the technology work? • Stoichiometric (rich burn) converted to lean burn • Control turbocharger speed and fuel supply • Eco Plugs (pre-chambered spark plugs)
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Technology Description
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Technology Description
0
1
2
3
4
5
6
7
8
0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2
Excess Air - Lambda
Rel
ativ
e C
once
ntra
tion
NOx CO
Fuel
FG Consumption/Engine Emissions vs. Air-Fuel Ratio
Rich Burn – LOW NOx High Fuel Consumption
Stoichiometric– HIGH NOx Lean Burn – LOW NOx Lower Fuel Consumption
RICH BURN Fuel > Air LEAN BURN Air > Fuel
January 14, 2016 16
Technology Description
Precise Control
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Technology Description
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Precise Flow Measurement
Waste Gate Control Actuator / Positioner
Precise Flow Control
Engine Management Control System
Technology Description
Turbo AFTER Turbo BEFORE
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Technology Description
Technology Scorecard & Realizing the Win-Win
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• Field execution experience • Installed upgrade to 25 units under CCEMC Program over 5 years • $150k-$250k; Averaged $220k per installation • 3-5 days per installation
*Based on 20 year project life*
SAID DID Installations 20 25
GHG Reduction [tCO2e/yr] 10,526 17,550
Cost Abatement [$/tCO2e] $15.58 $15.67
PURPOSE Reduce GHG Emissions &
Maintain NOx Compliance.
• Environmental benefits • Exceeded GHG emission reduction on an average per unit basis!! • Reduce NOx emissions & maintained compliance • Reduce unburned hydrocarbons by shifting from rich to lean-burn operation
• Fuel gas reduction of 287 e3m3/year per engine ($3/mcf = >$30,000!!) • Optimized control system – easier starting, reduced downtime, remote
capability
Successes & Learnings
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Golden Nugget #1 - Consistency
• Focus on consistent engines make and model • Waukesha: L7042GSI, L5108GSI, F3521GSI
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• Standardized Panel Template • Outage opportunities • Reactive preparedness
• Specialized Installation Crew • Accelerated learnings
Golden Nugget #2 – Training
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• Proper training & awareness for operations • Utilize Technology
• Maximize Opportunity
• Technology Champions
Golden Nugget #3 – Data Collection
January 14, 2016 25
• Pre-Audit • Benchmark • Identify True Scope
• Post-Audit • Quantify Results
• Continuous Annual Collection • Obtain credit • Unbiased Information
User Beware Be-Aware
January 14, 2016 26
• Asset Health • Required/Desired Upgrades
• Intercooler • Pneumatic Panel • Ignition
• Piggy-backing Work • Higher potential for
increased costs • New Technology gets
blamed easily
• Electrical Assessment • Increased Load Requirement • VDROP <3% Required • Area Classification/FE Study
Field GHG Reduction Projects REMVue SlipStream
January 14, 2016 27
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Opportunity
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Opportunity
• Current practice for installations
• Natural gas from several vent sources currently emit to the atmosphere
*Qualitatively displays a packing vent with moderate wear*
$ $
$
$
January 14, 2016 30
How Impactful Can This Be?
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• Supplement Fuel Gas • Reduce/Remove Emissions • Increase Sales Gas
*Data provided by Spartan Controls
• Designed to operate in the background
Technology Description
• Introduction to technology
• Capture natural gas vented to atmosphere • Introduce it to the engine for use as fuel • Replace primary engine fuel with captured
vents
• How does the technology work? • Vents captured and piped to engine air
intake • Turbocharged engines work best to draw in
the vented gas • AFR in the air inlet duct is maintained less
than stoichiometric and LEL conditions • Individual sources managed separately for
flow, pressure and safety
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33
Misc. Equipment
Fuel Gas to Engine
Vented Gas
Control System
Air to Turbo’s
Engine with RemVue Only
Technology Description
January 14, 2016
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Misc. Equipment
Fuel Gas to Engine
Captured Gas
Control System
Air to Turbo’s
RemVue plus SlipStream
Up to 20%+ depending on vent sources
Technology Description
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Technology Description
Technology Description
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Technology Description
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Technology Description
Technology Description
Compressor Packing Vents per Throw
Vent
Rat
e [S
CFM
/Thr
ow]
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Technology Scorecard & Realizing the Win-Win
• Field execution experience • 5 systems installed under CCEMC program
• 4 compressor packing / 1 of which included instrument vents • 1 dehydrator still column (Huge Success!)
• $115k-$316k
*Based on 20 year project life. **Data Collection ongoing – some data approximated using average packing vent rate for representation.
• Environmental benefits • 100 percent reduction strategy! • Vented raw natural gas and GHG emission reduction
• Significant fuel gas reduction • Ongoing indicator of packing condition
PURPOSE Reduce GHG Emissions &
Maintain NOx Compliance.
SAID
DID COMP
DID DEHY
Installations 11 4 1 GHG Reduction [tCO2e/yr] 7,811 6,163 1,791 Cost Abatement [$/tCO2e] $4.98 $9.11 $4.14
January 14, 2016 40
Successes & Learnings
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Golden Nugget #1 – Be Creative
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• Available sources • Dehydrator overheads
• Instrument vents • Compressor packing vents
Golden Nugget #2 – Training
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• Proper training & awareness for operations • Utilize Technology
• Maximize Opportunity
• Technology Champions
Golden Nugget #3 – Data Collection
January 14, 2016 44
• Pre-Audit • Benchmark • Identify true scope • Identify available sources & potential
• Post-Audit • Quantify results
• Continuous Annual Collection • Obtain credit • Unbiased information
User Beware Be-Aware
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• Assess Opportunity • Number of available sources will vary
• Abatement cost/source • Site layout challenges • Package vintage challenges
• Manage the Perception of the Unknown • Understand the benefits • Understand the safety measures
• Decreased recovery on vent rates
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PANEL DISCUSSIONS
