PC-FEB22-PG23.1_Layout 1 09/02/2022 16:09 Page 23
PUMPS, VALVES & ACTUATORS
CONTROLLING FUGITIVE EMISSIONS
Chuck Erml, product manager, Swagelok, explains how low- emission valves can streamline your facility’s operations
hough the topic of fugitive emissions is not a new one, it remains essential to understand how these unwanted leaks can affect the long-term profitability of your chemical processing and refining facilities. Regulatory bodies are increasingly mandating reductions in fugitive emissions, which can have an impact on your supply chain as well as how you approach facility upgrading projects moving forward (Figure 1). Fugitive emissions are uncontrolled emissions of gases – particularly volatile organic compounds (VOCs) like benzene, methane, and ethanol – from process equipment that result primarily from leaky connections. Such leaks frequently occur at the dynamic and static seals on valves, pumps, or at flange connections. To help combat fugitive emissions, many facilities are installing low-emission (Low-E) valves (Figure 2). Low-E valves are tested to prevent leaks in excess of guidelines during thermal and pressure testing cycles, confirming that they will minimise fugitive emissions when installed. This article will review how the use of such valves – combined with a proactive leak-reduction program – can help to minimise the costs associated with fugitive emissions at your facility. Governmental regulators often provide guidance to companies on the current state of environmental requirements, laws, and regulations. It is preferred that companies comply voluntarily, but there are times when legal action must be taken against chemical plants and refineries, and the resolution often takes the form of a consent decree. Most consent decrees will specify actions that must be taken by an asset’s owner within
T
Figure 3: Ball valves © 2022 Swagelok Company
Figure 1: It’s essential to combat fugitive
emissions at refineries . Image credit: Shutterstock/
Christian Kobierski Figure 2:
Low-E valves © 2022 Swagelok Company
a particular time frame to avoid civil penalties, including steep fines. Frequently in consent decrees dealing with fugitive emissions, facilities are required to create an enhanced leak detection and repair (LDAR) program and only purchase Low-E valves. Facilities that seek to implement an enhanced LDAR program to comply with a consent decree often seek to lower fugitive emissions by instituting rigorous repair programs or reducing allowable leak limits for valves, connections, and pumps. Consent decrees often insist that future valve purchases, whether for maintenance, repair, or operations (MRO), must be Low-E valves. What constitutes a Low-E valve is left up to the facility to decide. Manufacturers will typically provide one of two types of written guarantees to prove their valves are Low-E, including confirmation that:
• The valve will not leak above 100 parts per million (ppm) for five years
• The valve has been tested pursuant to generally accepted good engineering practices and has been found to be leaking at no greater than 100 ppm
It is not always easy to understand which of
the two options is best for your application. Each has its advantages and disadvantages. While it may make sense to accept a manufacturer’s written guarantee that the valve will not leak in excess of 100 ppm, facility operators must take the bigger picture into account and consider what the facility’s responsibility is if the valves do leak despite the guarantee. Since there are industry-standard testing procedures to ensure low leak rates, it may make more sense for the operator to make use of those instead. These tests are available from the American Petroleum Institute (API) and International Standards Organization (ISO) and can help you decide if the valves you are purchasing should be classified as Low-E.
For best results, the tests should be administered by a third-party laboratory, which will allow for an impartial evaluation of the low emissions qualities of the valves. The lab should then produce a valve certification that highlights its seal, the testing location, and the results. Low-E certified valves will help you control fugitive emissions in new systems or as part of an enhanced LDAR program (Figure 3). By working with manufacturers who produce certified Low-E valves, you can avoid enforcement actions and the challenges of retrofitting your entire system after assembly. Whether you are trying to fix existing fugitive emissions issues or looking to prevent future leaks, working closely with manufacturers who offer the support services necessary to integrate Low-E valves into your operation is essential. They can provide you with Low-E certificates and other advice you may need to ensure your operations control fugitive emissions well into the future.
Swagelok Company
www.swagelok.com
FEBRUARY 2022 | PROCESS & CONTROL 23
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