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The Role of Gas Seal Technology In Reducing Methane Emissions

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A United Nations panel examining the critical role gas will play in achieving the international organisation’s Sustainable Development Goals has invited an expert from John Crane to showcase how the firm’s technology is reducing methane emissions in sectors of the natural gas industry by up to 95%.

Published in: Engineering

The Role of Gas Seal Technology In Reducing Methane Emissions

  1. 1. THE ROLE OF GAS SEAL TECHNOLOGY IN REDUCING METHANE EMISSIONS United Nations Economic Commission for Europe Group of Experts on Gas Paul Hosking March 27 2017, Geneva
  2. 2. Executive Summary In regard to the natural gas industry, centrifugal compressors equipped with oil seal technology are generally acknowledged as a leading source of methane emissions in offshore and onshore operations. This equipment is an area of focus in such programs as Global Methane Initiative, US Natural Gas STAR and the United Nations Environment Programme, Climate and Clean Air Coalition, Oil and Gas Methane Partnership There are three technologies available to reduce methane emissions from existing oil seal equipped centrifugal compressors. Gas Seal Technology is proven and available and proposed as the Best Available Technology for reducing methane emissions from centrifugal compressors equipped with oil seals A number of operators have had success over the past 15 years in upgrading from oil seal technology to gas seal technology This presentation also showcases the Lifecycle Cost Calculator (LCC) decision support tool that evaluates the three options from an economic perspective 2
  3. 3. Presentation outline Background The options for methane emissions reduction Introducing gas seal technology The role of the Lifecycle Cost Calculator (LCC) Illustration Summary 3
  4. 4. The Challenge 4 Source: US EPA Natural Gas STAR
  5. 5. Why is this relevant? 5 2018 Projected Onshore Methane Emissions from US Natural Gas Industry (Source: ICF/EDF March 2014) Centrifugal Compressors (Oil Seals) 5.9% I am not here to convince you why we need to focus on emissions from oil seal equipped centrifugal compressors I am are here to discuss the best available technology to reduce methane emissions from this equipment
  6. 6. Where is this equipment? Natural Gas Processing Natural Gas Transmission Natural Gas Storage 6
  7. 7. Compressor shaft sealing solutions - options Oil seal with captured emissions vented to flare Oil seal with enhance gas separation and rerouting to alternative use Dry gas seal 7
  8. 8. Compressor shaft seal technology - overview 8 Gas seals are fundamentally a superior seal Oil seals are a contacting seal technology Gas seals are a non contacting seal technology • Significantly reduced emissions by design • Lower operating costs • No liquid required for lubrication • No liquid required for cooling • No liquid supply system required • No wear – long life and reliability • Safer – no gas entrapment • Very little power consumed • Reduced space and weight
  9. 9. Gas seals A technology that is proven and widely deployed* 9 Centrifugal Compressor Original Equipment Manufacturers Operating Facilities Gas Seals – The choice of Blue Chips globally *John Crane’s use of the above marks is for informational purposes only and should not be construed as sponsorship or endorsement of John Crane or any of its products or services by the respective trademark owners.
  10. 10. The determining factors 10 Economic Technical Environmental
  11. 11. Qualitative Economic Comparison Oil Seal routed to flare vs oil seal routed to capture/use vs gas seal retrofit 11 Oil Seal routed to flare Oil Seal routed to capture / use Oil Seal to Gas Seal Retrofit Initial Investment Methane Saving Operational Saving
  12. 12. Economic payback 12 Time (Yrs) Oil Seal routed to capture / use (Range dependent upon application specifics) Oil Seal to Gas Seal Retrofit (Range dependent upon application specifics) CumulativeFinancialReturn Oil Seal routed to flare
  13. 13. Economic payback 13 Time (Yrs) Oil Seal routed to capture / use (Range dependent upon application specifics) Oil Seal to Gas Seal Retrofit (Range dependent upon application specifics) CumulativeFinancialReturn Oil Seal routed to flare The role of Lifecycle Cost Calculator
  14. 14. Lifecycle Cost Calculator 14 Compressor Data - Driver - Power - Efficiency - Number of seals - Shaft Size Process Data - Methane content - Flow rate - Pressure - Operational hours - Process gas value Utilities Data - Driver fuel value - Electricity value - Purge gas value Seal Data - Frictional power - Leakage rate - Gas injection source - Leakage destination Seal Support System Data - Power requirements - Cooling configuration Reliability Data - Planned maintenance costs - Unplanned maintenance costs - Spare parts cost - Lost production time - MTBR Retrofit / Upgrade Data - New seals and spares costs - System upgrade/replacement costs - Equipment modification costs - Electrical and instrumentation costs - Site materials and installation costs - Decommissioning and disposal costs - Lost production time
  15. 15. Lifecycle Cost Calculator outputs 15 One-Time Costs - Total retrofit costs - Payback Costs Calculated Annual Operating Costs - Maintenance cost - Value of leaked gas - Consumables - Energy consumed by seal - Energy consumed by seal system Present Value - Present value of annual operating costs over lifespan remaining Total Life Cycle Cost
  16. 16. Illustration 16 Pipeline compressor Natural Gas: 96% Methane $3.00 / Mcf Flow: 50,000 scfm (1416 m3/min) Pressure: 600 psig (41.3 Barg) Suction 1,100 psig (75.8 Barg) Discharge Shaft Speed: 9,000 RPM Driver: Gas Turbine 10,500 hp (7,800 kW) Shaft Diameter: 5” (127 mm) Operational hours: 4,000 hr/year (167 days/year) Spared: Yes Equipment operator owns the compressed gas
  17. 17. Lifecycle Cost Calculator Summary output 17
  18. 18. Experience 18
  19. 19. Summary 19 Why is gas seal technology the Best Available Technology for reducing methane emissions from centrifugal compressors equipped with oil seals? • Gas seal technology is proven and the current industry standard for all new equipment including natural gas applications • Oil seal to gas seal retrofits are not new and are applicable in the majority of cases • While the actual benefit is specific to a given compressor • Retrofit with gas seal technology offers the maximum environmental benefit • Retrofit with gas seal technology offers the industry safety benefit • Retrofit with gas seal technology offers the maximum reliability benefit • Retrofit with Gas Seal Technology offers the maximum operational savings Gas Seal Technology Best Available Technology, Applicable, Executable

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