LEAK LEAK DETECTIODETECTIO

NNAND AND

REPAIRREPAIRPresented Presented

By By Ashutosh Ashutosh

SoniSoniChEmiCAl ChEmiCAl

EnGg.EnGg.

Under Guidance Of – Mr. Harishankar SoniMr. Rahul GuptaMrs. Arshia Khan

INTRODUCTIONIt is the best way as the services provided by leak detection and repair are as refinery, chemical plants, hazardous waste, facility which r been compiled leak detection and repair. It includes various component like identifying (Bar Coding),Leak Definition monitoring , notifying facility and record keeping.

Identifying Components(Bar coding):

Weather resistant bar coding.

Time stamping of individual readings.

Leak flagged in software to expedite repairs.

BAR CODING

Leak Definition:

It is a way for fluid to escape a container.

Unintended and undesired.

Types : puncture, gash, rust and other corrosion hole.

Monitoring Components

Proper use and maintenance and monitoring and data collection instrumentation.

Use of LDAR data bases.

Work safely and efficiently in an operating facility.

Notifying Facility of Components:

Facility wide weak rate goal that will be a target on a process unit by process unit basis.

List of LDAR personnel.

Provide and require initial training and annual LDAR refresher.

Sources of Air Pollution: In discussions of air pollution sources, four

terms are routinely used: • mobile sources• stationary sources• point sources • area sources

What Are Fugitive Emissions

The term, fugitive emission, as used in air quality control, generally refers to any emission escaping from regulated processes (sources) other than via the designed release point (smoke stack, etc.). The point source for a fugitive emission is simply called "a leak." These leaks and emissions are most often associated with the equipment necessary for the movement of process fluids and gasses.

What Equipment is Regulated?The equipment regulated under fugitive

emission standards are:• pumps • product accumulator

vessels• valves • flanges (connectors)• compressors • agitators• pressure relief devices• sampling connections• open ended valves and lines

What Source Categories Are Regulated? Basically, any fugitive emission from within a

facility governed by New Source Performance Standards (NSPS), National Emission Standards for Hazardous Pollutants (NESHAP), Hazardous Organic NESHAP (HON), and Maximum Achievable Control Technology (MACT) rules is subject to regulation. These sources include SOCMI, petroleum refineries, benzene, and vinyl chloride facilities.

The agency LDAR program is implemented at three levels (Figure 1-3) as follows:1. Level 1: Pre-inspection record review at the agency office.2. Level 2: Onsite inspection of source records and a facility walk through and observation3. Level 3: Onsite inspection with the inspector conducting the monitoring and testing

Fugitive Emission SourcesMajor leaking componentsNSPS, NESHAP, and HON regulations identify the components in the process transport function that are to be inspected for fugitive emissions (leaks). Those components are:• Flanges/connectors• Valves• Pumps• Compressors • Pressure relief devices• agitators

Flanges and connectors There are many ways of joining piping

sections and process and transport equipment together but 3 common method are welds, flanges and threaded fittings.

1-Many piping connections are welded. 2-Bolted flanges. 3-Threaded fittings are used for joining small

diameter piping (under 2inches in diameter)

ValvesValves are used to control the flow rate, turn ON or OFF. Switch flows along the different routes of piping or control the direction of flow of gases or liquid.

Three points of leak 1-Valve Stem2-Bonnet/Housing Gasket3-Valve Flange

PumpsPumps are mechanical devices that import

energy to a fluid and are used to provide the power to transport a liquid from one location to another. There are 2 common types of pumps found in the petroleum and SOCMI industries are:

• Centrifugal pumps.• Positive displacement pumps.

CompressorsCompressors are used to compress and transport gases and liquid . From a "leak" standpoint, a compressor is the same as a pump. Mechanically, they are similar to pumps In that they are generally either reciprocating or centrifugal. Once again, the major source ofEmissions is the shaft and the compressor housing.

Pressure Relief DevicesPressure relief devices [also called pressure relief valves (PRVs) or pressure vacuumvalves (PV valves)] are valves that are made to release pressure from a vessel or relieve a vacuum on a vessel. They prevent damage to equipment and are safety feature on most vessels in a refinery.

AgitatorsAgitators are used to stir or blend chemicals. Like pumps and compressors, agitators mayleak organic chemicals at the point where the shaft penetrates the casing. Consequently,seals are required to minimize fugitive

emissions. The shaft of the agitator may either behorizontal or vertical.

Leak Detection and Repair Program

Scope-This study was initiated to evaluate new leak detection and measurement technologies and determine actual facility fugitive emission rates.

The main drivers for this study are: Increase production & reduce costs by

recovering lost gas CAPP Fugitive Emission Management BMP Increase operations Health & Safety Reduce GHG emissions / Carbon Credits Part of CPC Energy Efficiency Program, Gas

Star Program, and the Best-in-Class Initiative

22 facilities from various asset areas were assessed for fugitive emissions. This included 9 gas plants and 13 compressor stations.

BackgroundIn 2005, Burlington Resources purchased an infrared camera to study hydrocarbon leaks from gas processing facilities. The camera, GasfindIR, is an optical emission technology. It is an infrared video camera with hydrocarbon/VOC filter that provides visible images of hydrocarbon gas emissions in real-time.

Detection Technology The GasFindIR infrared video camera is the first commercial optical leak detection camera and is priced at $75,000.00 USD. The benefits of optical leak imaging include: • Cost-effectively scan hundreds of components

simultaneously.• Identify exact source of leaks in real-time with

video record.• Assessments performed without interruption of

operations.• Scan hard-to-reach components from a distance.• Conduct aerial leak surveys over large areas.

Measurement TechnologyAfter a leak is detected, it is then measured to determine the size of the leak using a HiFlow Sampler. The Leak Detection technician will first determine a qualitative measurement by estimating the severity of the leak (low, medium, high).

Source Summary The study identified a total of 144 fugitive emission sources within the facilities. The leaks had an average size of 0.77 cfm with a total cumulative annually amount of 58.26 mmcf/y.

LDAR For GASINTRODUCTION- Over the decades infrared cameras have revolutionized maintenance in many industries, proving to be the most superior technology for finding electrical and mechanical hidden faults –even before they occur.

Infrared cameras can also play a major role in helping to decreaseenvironmental damage. It detect not only the gases harm environment but it detects many of gases including SF6 - a gas24,000 times more environmentally dangerous than CO2.

The Mid Wave GasDetection Camera

Oil Refining-The typical refinery consists of twotypes of process, separation and conversion.

Petrochemical- The industries that makehydrocarbon substances using base feedstocksfrom the oil refining.

Chemical- The production of non-hydrocarbonor inorganic chemicals from base feed stocks.

Power Generation- The production anddistribution of electric power.

Natural Gas- The production, storage,transportation and distribution of natural gas.Service ProvidersRegulators

ApplicationLeak Location-The camera can be used to

detect gas from many different sources in the petrochemical industry but some of the most common leak paths are from:

• Flanges • Valve stems • Plugs and Caps • Machinery • Couplings • Pump seals • Holes • Passing valves • Drain covers • Instrument Connections

The Long Wave GasDetection Camera

Electrical Utility–A large amount of the equipment used in the distribution of high voltage electrical power uses Sulphur Hexafluoride (SF6) as an insulating gas.Petrochemical–The industries that make hydrocarbon substances using base feedstocks from the oil refining.Chemical–The production of non-hydrocarbon or inorganic chemicals from base feed stocksService Providers

SF6 Detection

Application

ApplicationChemical Industries

Refrigerant Gases

Application

Spectral Response and Detectable Gases

• Sulphur Hexafluoride• Anhydrous Ammonia• Ethyl Cyanoacrylate (‘Superglue’)• Chlorine Dioxide• Acetic Acid• FREON-12• Ethylene• Methyl Ethyl Ketone (MEK)

Application

LDAR For LIQUID

Utilities can no longer tolerate inefficiencies in water distribution systems and the resulting loss of revenue associated with underground water system leakage . Increases in pumping, treatment and operational costs make these losses prohibitive. To combat water loss, many utilities are developing methods to detect, locate, and correct leaks.

Benefits of Leak Detection and Repair

The economic benefits of leak detection and repair can be easily estimated. For an individual leak, the amount lost in a given period of time, multiplied by the retail

value of that water will provide a dollar amount. Remember to factor in the costs of developing new water supplies and other “hidden” costs.

Causes of Leaks Types of leaks, including service line leaks, and valve leaks, but in most cases, the largest portion of unaccounted-for water is lost through leaks in the

mains. There are many possible causes of leaks, and often a combination of factors leads to their occurrence.

Leak Detection and Repair StrategyThere are various methods for detecting water distribution system leaks. These methods usually involve using sonic leak-detection equipment, which identifies the sound of water escaping a pipe. These devices can include pin- point listening devices that make contact with valves and hydrants, and geophones that listen directly on the ground. In addition, correlate devices can listen at two points simultaneously to pinpoint the exact location of a leak.

Beyond Leak Detection and Repair Detecting and repairing leaks is only one water conservation alternative others include: meter testing

and repair/replacement, rehabilitation and replacement programs, installing flow- reducing devices, corrosion control, water pricing policies that encourage conservation, public education programs, pressure reduction, requests for voluntary cutbacks or bans on certain water uses, and water recycling.

ThAnK YOu