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12th LDAR SymposiumMay 15-16, 2011New Orleans, LA Utilizing LDAR Data to Lower (Actual and Reported) Emissions at Your Facility Greg Wilson LDAR Coordinator LyondellBasell Houston Refinery Shane Kling Chemical Engineer Environmental intellect
LyondellBasell-Houston Refinery • Located in Houston, Texas • 372,000+ components in LeakDAS database • About 350,000 annual LDAR monitoring events
Where to Focus on Reducing Emissions? • A substantial percentage of annual reported emissions are from two sources • Unmonitored (not required) components • Misidentified components • Identification of these sources can allow a targeted approach to sizable reductions
What’s What? • Unmonitored components are ones for which no regulatory requirement exists • Misidentified components are those in your facility that are being calculated using an emissions factor for another class of component. For example, in accurately referring to a component class of “Other” rather than “Valve.”
Unmonitored Components • Light liquid (LL) and gas/vapor (GV) connectors that have no regulatory require-ment can contribute a great deal to calculated emissions and are the easiest targets • Which ones? • Built-in reports within the software (e.g., LeakDAS) • Homegrown tools to examine the data in order to make informed decisions
Unmonitored Components, cont. • LDAR software can assist in spotting trends or areas that you can address; i.e. “Top 50 Emitters” Report • Homegrown systems can be customized to your needs. We use a program that reports the Top 1000 emitters every day
Unmonitored Components, cont. • Using this data, analysis of specific areas or units for reduction opportunity can maximize effectiveness. • Voluntary monitoring of a subset of non-regulatory components can significantly reduce reported emissions in a large or small facility.
Unmonitored Components, cont. • Using refinery factors, a connector that is unmonitored and has no valid monitoring has an emissions rate equal to one that was monitored and left unrepaired at 1,026 ppm • Stated another way, monitoring 10,000 connectors and achieving a net of 50 ppm will reduce VOC emissions by about 22 TPY for a refinery.
Unmonitored Components, cont. • Using SOCMI factors for the same 10,000 components and the same 50 ppm net reading as an average, would result in a reduction of about 167 TPY for the facility. • A 1 wt% average benzene concentration for these components would result in greater than 1.6 TPY reduction in reported BZ emissions.
Can You Keep It That Way? • After a period of time, a single monitoring result is no longer valid. To maintain a reduction, these previously unmonitored components must become part of your schedule. Budget for them! • Make a habit of looking for “bad actors” within your program and fix them! • Create a “Voluntary Rule” and apply it to the ones you’ve selected
Other Ways to Reduce Emissions from Unmonitored Components? • Consider routing non-regulatory connectors with monthly/quarterly valve monitoring. • Incorporate non-regulatory monitoring as fill-in work when possible. • Got fin-fan plugs? • Non-regulatory connectors are DTM? SKIP THEM!!! • Remove the voluntary rule across the board before the end of the year. You’re finished!
Misidentified Components • Incorrect class description, stream speciation and other issues with the information in the data are prime culprits • Correct identification and field verification are key to having an accurate reporting foundation. • A key is to know where and what the components are in the field and on the P&ID’s
How Can Smart P&IDs Help Eliminate Misidentified Components? • Integrate refinery stream speciation into individual LDAR components on smart P&ID • Export P&ID data into LeakDAS (Stream, Chemical State, Component ID, P&ID No., etc.) • Use marked-up P&IDs with tag numbers labeled to expedite LDAR inventory process • Maintain P&ID with LDAR tags to account for regulated equipment • Long-term: update LeakDAS database automatically when smart P&ID is updated during MOC process
What is a “Smart P&ID?” (nothing more than a P&ID with underlying data)
Apply Stream Speciation to LDAR Equipment in sP&ID • Stream speciation data is exported from Aspen HYSYS into MS Excel format • Speciation data was imported into sP&ID using Ei’s software • Stream assignments were integrated into smart P&IDs for pipes, valves, etc. • Ei’s software generated LDAR determinations for all streams and all equipment in smart P&IDs
Import Smart P&ID data into LeakDAS • Data is exported from smart P&IDs into LeakDAS through the following steps: • Data for LDAR equipment is stored in an underlying P&ID database within AutoCAD P&IDTM • Nine P&ID data fields, including ‘Stream’, ‘Chemical State’, ‘Component ID’, ‘P&ID No. have been utilized • Data is exported from sP&IDs into a .csv format file with data columns that match LeakDAS database structure • Ei’s data was imported into LeakDAS to ‘Quarantine’ • Data is processed from ‘Quarantine’ into LeakDAS and then available for download into LeakDAS Mobile Note: any future changes to LeakDAS data can be exported to update the smart P&IDs (e.g., LDAR Tag No.)
Export P&ID data into LeakDAS (Stream, Chemical State, Component ID, P&ID No., etc.)
Long-Term: Connect LeakDAS with Smart P&IDs • Future efforts are being planned to link together smart P&IDs and LeakDAS – when the P&ID is changed during MOC, updates will be sent to LeakDAS automatically • Additional environmental compliance benefits for smart P&ID implementation: • Component counts for permitting project emissions • Marked-up P&IDs with LDAR tag numbers labeled • Improved LDAR inventory performance
Conclusions • If you can maintain a program that allows you to finish each period without burning the “midnight oil,” you can make a difference by monitoring voluntary components. • Accurate counts, classifications and speciation of components will enhance your ability to manage your program. • LDAR programs are meant to REDUCE EMISSIONS! These processes can help achieve that goal.
Conclusions • Smart P&IDs can help eliminate misidentified components and ensure accurate speciation. • The ability to manage change through data-driven processes can keep your LDAR program evergreen.
Questions? Greg Wilson, LyondellBasell Houston Refinery LDAR Coordinator firstname.lastname@example.org Shane E. Kling, Environmental intellect Owner, Engineering and Business Development Lead email@example.com