I ntroducing: Cleaner Air More Profits Easier Predictive Maintenance
W ith M-Squared’s Packing Leak Detector and the Modular Em issions Control System
Leaking compressor packing often goes unnoticed for some time. Often the lost methane is sent into the atmosphere where it contributes to Green House Gases Or the gas is sent to be burnt, costing lost profits. A leak as small as one cubic foot a minute will result in over $200 in lost revenue/month at $5.00 per mcf. In a study by the EPA, a Natural Gas STAR partner reported one compressor rod leaking 900 scfh. A rate that high equals over $3200 in lost profit per month, at $5.00 per mcf. Compressors often go for weeks or months with substantial leaks, because it isn’t easy or inexpensive for a mechanic to tell the rate of a leaking packing case.
Packing Leak Detection: Present A mechanic uses his hand or ear to determine a leaking packing case. Neither is an accurate way to know how much gas is being vented. Or, the case is tubed to a vent line and the quantity lost is undetermined.
Packing Leak Detection: Future M ‐ Squared’s Packing Leak Detector is a simple, inexpensive device that is tubed up to the packing vent. It is set for a predetermined allowable limit of leakage. As the rate approaches the limit, a visual indicator rod extends from the unit. Additionally an optional analog electronic signal can be sent to an offsite computer. Before the packing is replaced, the vented gas can be sent to a stock tank for recovery or sent to the flare.
What Will it Do for You? With the PLD PLD installed, for the first time you will be able to: • Easily detect escaping methane emissions • Easily and inexpensively quantify and measure the amount of leakage • Determine when it is most cost effective to replace leaking packing • Gather trends for predictive maintenance • Be a good Corporate Citizen to the Environment • Sell more gas
Economics of Packing Leaks All packing leaks. New packing has been reported to leak as much as 11.5 scfh. Gas producers all establish acceptable leak amounts. Some use the mechanic’s judgment. Others establish acceptable leak rates based on the economics of replacing packing. If a producer has an acceptable leak rate of 100 scfh, when the packing leak rate is higher than 100 scfh, the packing is scheduled to be replaced. However, using this method can cost the producer in lost profits and add to the GHGs, which may need to be reported. How can a producer know when it is cost effective to replace the packing?
Economic Replacement Threshold (scfh) In a recent study on packing leaks, the EPA proposed that producers use an Economic Replacement Threshold in scfh to determine when is the time to change packing. The Economic Replacement Threshold can be determined by dividing the cost to replace the packing by the gas revenue loss that equates to a breakeven point. Economic Replacement Threshold (scfh) = CR / LR Where: CR = Cost of replacement ($) LR = Lost Revenue in ($) LR is figured by multiplying the vented gas in mcf/month by current gas price/mcf. ERT is figured in number of months to breakeven.
Some Average Breakeven Points The charts below are based on cost of packing from AAVOLYN Corp. and may be lower than OEM packing. They include two hours of labor at $60 an hour. Breakeven Point in Months to Replace Packing Cost to Replace Packing Leak Rates on scfh (P&L) @ $4.00/mcf 60 70 80 90 100 150 200 300 500 900 1 1/8" rod $ 321.62 1.9 1.6 1.4 1.2 1.1 0.7 0.6 0.4 0.2 0.1 1 1/2" rod $ 328.13 1.9 1.6 1.4 1.3 1.1 0.8 0.6 0.4 0.2 0.1 2" rod $ 297.66 1.7 1.5 1.3 1.1 1.0 0.7 0.5 0.3 0.2 0.1 2 1/4" rod $ 307.82 1.8 1.5 1.3 1.2 1.1 0.7 0.5 0.4 0.2 0.1 2 1/2" rod $ 337.50 2.0 1.7 1.5 1.3 1.2 0.8 0.6 0.4 0.2 0.1 Cost to Replace Packing Leak Rates on scfh (P&L) @ $6,00/mcf 60 70 80 90 100 150 200 300 500 900 1 1/8" rod $ 321.62 1.2 1.1 0.9 0.8 0.7 0.5 0.4 0.2 0.1 0.1 1 1/2" rod $ 328.13 1.3 1.1 0.9 0.8 0.8 0.5 0.4 0.3 0.2 0.1 2" rod $ 297.66 1.1 1.0 0.9 0.8 0.7 0.5 0.3 0.2 0.1 0.1 2 1/4" rod $ 307.82 1.2 1.0 0.9 0.8 0.7 0.5 0.4 0.2 0.1 0.1 2 1/2" rod $ 337.50 1.3 1.1 1.0 0.9 0.8 0.5 0.4 0.3 0.2 0.1
Breakeven Point in Months to Install PLD PLD on Compressor Cylinder The time below includes one hour labor at $60 an hour. Months to Pay for Installed PLD Cost to Replace Packing Leak Rates on scfh (P&L) @ $4.00/mcf 60 70 80 90 100 150 200 300 500 900 1 1/8" rod $ 545.00 3.2 2.7 2.4 2.1 1.9 1.3 0.9 0.6 0.4 0.2 1 1/2" rod $ 545.00 3.2 2.7 2.4 2.1 1.9 1.3 0.9 0.6 0.4 0.2 2" rod $ 545.00 3.2 2.7 2.4 2.1 1.9 1.3 0.9 0.6 0.4 0.2 2 1/4" rod $ 545.00 3.2 2.7 2.4 2.1 1.9 1.3 0.9 0.6 0.4 0.2 2 1/2" rod $ 545.00 3.2 2.7 2.4 2.1 1.9 1.3 0.9 0.6 0.4 0.2 Cost to Replace Packing Leak Rates on scfh (P&L) @ $6,00/mcf 60 70 80 90 100 150 200 300 500 900 1 1/8" rod $ 545.00 2.1 1.8 1.6 1.4 1.3 0.8 0.6 0.4 0.3 0.1 1 1/2" rod $ 545.00 2.1 1.8 1.6 1.4 1.3 0.8 0.6 0.4 0.3 0.1 2" rod $ 545.00 2.1 1.8 1.6 1.4 1.3 0.8 0.6 0.4 0.3 0.1 2 1/4" rod $ 545.00 2.1 1.8 1.6 1.4 1.3 0.8 0.6 0.4 0.3 0.1 2 1/2" rod $ 545.00 2.1 1.8 1.6 1.4 1.3 0.8 0.6 0.4 0.3 0.1
Beyond the PLD PLD The M ‐ Squared PLD is part of a modular approach to lowering methane emissions. Once a gas leak is detected, it can be manifolded and sent with other compressors’ emissions to a control panel that will either send it to a flare, vent, etc., or, at a predetermined amount, send it to a holding vessel where it can be recompressed by the M ‐ Squared VRU and then sent to sales.
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