A Leak-Free Scenario Made Possible Through A Responsive End-User/Vendor Relationship

1. 13thLDAR SymposiumMay 21-23, 2013New Orleans, LA A Leak-Free Scenario Made Possible Through A Responsive End-User/Vendor Relationship David W. Reeves, sealinhandbolting@gmail.com Retired Senior Specialist for Bolting and Sealing Technology Carlos Veiga, jccveiga@teadit.com.br Teadit North America

2. The Good and the Bad The Good News: • The technology exists to cost effectivelyeliminate just about all LDAR leaks from bolted connections. • The Bad News • You may not be the right person in your organization to drive the needed change. • EPA is listening……………….

3. In the Beginning…

4. Bench Mark Fugitive Emissions A leak rate higher than 3.5% is the “Level of Shame” Top 10% with the lowest leak rates.

5. Bench Mark Fugitive Emissions

6. Bench Mark Fugitive Emissions

7. Bench Mark Fugitive Emissions Or to put it another way, the chance of having a valve packing leak in this facility >500 PPM in 2010 was 1.4 per 1,000, or 433 out of 311,874 inspection!

8. Fugitive Emissions Testing Matt Wasielewski, Yarmouth Research

9. Packing Test Results

10. Chevron Packing Test • Off the Shelf Valve • Test Media: Methane gas • Test Pressure: 600 psig (41 Bar) • Test Temperature: 500 degrees F at the stuffing box (260C) • Thermal Cycles: 10 cycles, 70F to 500F and back to 70F every 500 cycles • No. of Cycles: 5,000 fully open to fully close, or until 500ppmv is reached the third time, Hot Torqued after first 30 cycles • Test Valve: ANSI Class 300, API 600, NPS 4, Carbon Steel Gate Valve • Leak Detection Method: EPA Method 21 • Minimum number of Tests: Two for each valve manufacturer

11. The 4 Secret Words: Below shows fugitive emissions testing on 2 valves. Which one would you buy?

12. Facility 2 Fugitive Emissions

13. Bench Mark Fugitive Emissions

14. Spiral Wound Gaskets Data from José Carlos C. Veiga, Teadit

15. Spiral Wound Gaskets Data from José Carlos C. Veiga, Teadit

16. Spiral Wound Gaskets Data from José Carlos C. Veiga, Teadit

17. Spiral Wound Gaskets Data from José Carlos C. Veiga, Teadit

18. KAG Pipe Flange Gasket Data from José Carlos C. Veiga, Teadit

19. Pipe Flange Field Data

20. Graphite Oxidation Test Results

21. SW Crush Test Results

22. Flange Loading

23. Flange Loading

24. Why Testing is Imperative You can’t tell performance differences without direct comparative testing Every time you buy a valve, gasket or packing, you are voting with your companies dollars as to the quality of that product, and you will get what you pay for! The dirty little secret is, if the product fails to perform, you own the problem and the cost to correct it, not the manufacturer!

25. The 4 Secret Words: Show Me The Data!!! (Must be comparative.) In God We Trust! Everyone Else, Bring The Data!

26. Low Emission TechnologyDevelopment Laboratory

27. Gate Valve Testing: API 624 API 622 (simulation) Chevron ISO 15848-1 VDI 2440

28. Control Vale Testing2 inch Class 150 Control Valve ISO 15848-1 Mechanical cycles: 100.000 Test medium: Methane Pressure: 285/175 psig Thermal cycles: 4 Temperature: 480ºF (250ºC)

29. Gasket TestingSealability (Methane/Helium/Nitrogen) Flange Bending Hot Blow-out Thermal Cycling (room to 400ºC – 750ºF) • Steel Flanges • 6” Class 900 • 4” Class 1500 • 8” Class 1500 • 3” Class 150 • 2” Class 300 • 4” Class 2500 • GRP - 3” Class 150

30. UGR • DIN 3535 • (Sealability Test) • DIN 2809 • (Compressibility)

31. Teadit Low Emissions Products Control Valve Packing Style 2237 (Patent Applied) ePtfe Dynamic-Loaded Packing System (Patent Applied) Gate Valve Packing Style 2236 Spiral-Wound Gaskets Style 913M-LE

32. STYLE 2236 API 622 2nd Ed. – 1/4” Test Fixture

33. STYLE 2236 ChevronTexaco – 1/4” 4 inch Class 300 Gate Valve

34. STYLE 2236 API 624 – 1/8” 3/4 inch Class 800 Gate Valve

35. STYLE 2237 ISO 15848-1– 1/4” 2 inch Class 150 Control Valve

36. STYLE 2236

37. Teadit Low Leak Technology Development Papers

38. Would EPA agree with these statement? • Reducing fugitive emissions is an engineering problem. • EPA has seen companies that can achieve very low emission levels. • Maximum allowable emission levels will likely drop at some point in the future. • Companies with really poor emissions performance are more of a focus for EPA.

39. The Problem with LDAR • LDAR is about using whatever components you want to (primarily gasket and packing), then finding and fixing the leaks. • There is another approach: Design it so it wont leak.

40. Packings That Have Passed the Chevron Fugitive Emissions Test

41. Top 3 Performing Packings

42. Packing Test Results

43. LE Gaskets That Have Passed the Chevron Fugitive Emissions Test • Teadit • Lamons • Leader • Klinger

44. What it takes to implement change The products and technology exists to easily reduce LDAR emissions below 0.25%. It comes down to: • Your own motivation • What your boss and management is willing to support • Your ability to influence your own company

45. What it takes to implement change

46. Acknowledgements • Sage Environmental Services • Teadit • Kitz Valve • Nippon Pillar • Advanced Sealing