1、STD=API/PETRO PUBL 310-ENGL 1997 m 0332290 ObO4bb3 ?SO m Health and Environmental Affairs Department Publication Number 310 November 1997 STD-API/PETRO PUBL 310-ENGL 1997 H 0732270 ObOqbbll b77 American Petroleum Institute American Petroleum Institute Environmental, Health, and Safety Mission and Gu
2、iding Principles ?- MISSION The members of the American Petroleum Institute are dedicated to continuous efforts to improve the compatibility of our operations with the environment while economically developing energy resources and supplying high quality products ana services to consumers. We recogni
3、ze our responsibility to work with the public, the government, and others to develop and to use natural resources in an environmentally sound manner while protecting the health and safety of our employees ana the public. To meet these responsibilities, API members pledge to manage our businesses acc
4、ording to the following principles using sound science to prioritize risks and to implement cost-effective management practices: PRINCIPLES o o o To recognize and to respond to community concerns about our raw materials, products and operations. To operate our plants and facilities, and to handle ou
5、r raw materials and products in a manner that protects the environment, and the safety and health of our employees and the public. To make safety, health and environmental considerations a priority in our planning, and our development of new products and processes. To advise promptly, appropriate of
6、ficials, employees, customers and the public of information on significant industry-related safety, health and environmental hazards, and to recommend protective measures. To counsel customers, transporters and others in the safe use, transportation and disposal of our raw materials, products and wa
7、ste materials. To economically develop and produce natural resources and to conserve those resources by using energy efficiently. To extend knowledge by conducting or supporting research on the safety, health and environmental effects of our raw materials, products, processes and waste materials. To
8、 commit to reduce overall emission and waste generation. To work with others to resolve problems created by handling and disposal of hazardous substances from our operations. To participate with government and others in creating responsible laws, regulations and standards to safeguard the community,
9、 workplace and environment. To promote these principles and practices by sharing experiences and offering assistance to others who produce, handle, use, transport or dispose of similar raw materials, petroleum products and wastes. STD*API/PETRO PUBL 310-ENGL 1997 0732290 0604665 523 m Analysis of Re
10、finery Screening Data Health and Environmental Affairs Department API PUBLICATION NUMBER 31 O PREPARED UNDER CONTRACT BY: HAL TABACK COMPANY 378 PASEO SONRISA WALNUT, CALIFORNIA 91 789 NOVEMBER 1997 American Petroleum Ins titute STD.API/PETRO PUBL 310-ENGL 1997 0732290 ObOYbbb YbT D FOREWORD API PUB
11、LICATIONS NECESSARILY ADDRESS PROBLEMS OF A GENERAL NATURE. WITH RESPECT TO PARTICULAR CIRCUMSTANCES, LOCAL, STATE, AND FEDERAL LAWS AND REGULATIONS SHOULD BE REVIEWED. API IS NOT UNDERTAKING TO MEET THE DUTIES OF EMPLOYERS, MANUFAC- TURERS, OR SUPPLIERS TO WARN AND PROPERLY TRAIN AND EQUIP THEIR EM
12、PLOYEES, AND OTHERS EXPOSED, CONCERNING HEALTH AND SAFETY RISKS AND PRECAUTIONS, NOR UNDERTAKING THEIR OBLIGATIONS UNDER LOCAL, STATE, OR FEDERAL LAWS. NOTHING CONTAINED IN ANY API PUBLICATION IS TO BE CONSTRUED AS GRANTING ANY RIGHT, BY IMPLICATION OR OTHERWISE, FOR THE MANU- FACTURE, SALE, OR USE
13、OF ANY METHOD, APPARATUS, OR PRODUCT COV- ERED BY LETTERS PATENT. NEITHER SHOULD ANYTHING CONTAINED IN THE PUBLICATION BE CONSTRUED AS INSURING ANYONE AGAINST LIABIL- ITY FOR INFRINGEMENT OF LETERS PAENT. All rights reserved. No part of this work my be reproduced, stored in a retrieval system, or tr
14、ansmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the publisher, API Publishing Services, 1220 L Street, N.W., Washington, D.C. 20005. Copyright O 1997 American Petroleum Institute iii - STD.API/PETRO P
15、UBL 310-ENGL 1997 m 0732290 Ob04bb7 3Tb m ACKNOWLEDGMENTS THE FOLLOWING PEOPLE ARE RECOGNIZED FOR THEIR CONTRIBUTIONS OF TIME AND EXPERTISE DURING THIS STUDY AND IN THE PREPARATION OF THIS REPORT: API STAFF CONTACT Karin Ritter, Health and Environmental Affairs Department STATIONARY SOURCE EMISSIONS
16、 RESEARCH SSER) WORKGROUP FUGITIVE EMISSIONS OVERSIGHT (FEO) COMMITEE Lee Gilmer, SSER Chairperson, Exxon Jeff Siegell, FEO Chairperson, Texaco Miriam Lev-On, ARCO Dan VanDerZanden, Chevron HAL TABACK COMPANY Kelvin Lu, Computer Analyst H.J. Taback, PE, DEE, QEP, REA, Principal Investigator and Proj
17、ect Manager ABSTRACT This report presents the findings and recommendations of a study of fugitive emissions from piping components (valves, flanges, etc.) at seven Los Angeles California refineries over a period of five and one-half years. These screening measurements, taken to determine the estimat
18、ed fugitive emissions of volatile organic compounds (VOC) from those refineries, were collected and analyzed. These screening measurements comprise the detection portion of a leak detection and repair (LDAR) program designed to reduce fugitive emissions from components in process unit piping. The st
19、udy was conducted to determine whether a more cost effective LDAR protocol could be developed. The study was expected to clarify the cause(s) of leaks by identifying the repeat leakers and high-rate leakers and by investigating the design and operational characteristics of those leaking components.
20、High leakers (components screening 210,000 ppmv) were found to occur randomly and repeat leakers (components screening - 1,000 ppmv more than once within a year) were negligible. This finding indicates that there is not an easily identifiable cohort of leakers within the population of refinery compo
21、nents subject to LDAR. Overall, only O. 13 percent of the components were high leakers, but they accounted for 92 percent of the reducible VOC emissions. Based on the current findings, a leak detection protocol that would concentrate on locating high rate leakers may be more cost effective than the
22、current practice of monitoring all components. STDmAPIlPETRO PUBL 310-ENGL 1797 m 0732290 0604667 179 m TABLE OF CONTENTS Section Pap;e EXECUTIVE SUMMARY S-1 1 . 2 . 3 . 4 . 5 . INTRODUCTION 1 . 1 BACKGROUND I- 1 OBJECTIVE . 1-2 APPROACH . 1-2 REPORT ORGANIZATION 1-3 DATA FROM THE LOS ANGELES REFQER
23、ES . 2- 1 ACQUISITION . 2- 1 PROCESSING 2-3 DATA ANALYSIS 3-1 HIGH AND REPEAT LEAKERS 3- 1 DISTRIBUTION OF EMISSIONS BY SCREENING RANGES 3- 1 1 DISTRIBUTION OF EMISSIONS BY COMPONENT CATEGORY . 3-1 1 PROCESS UNIT VARIATIONS . 3- 13 REFINERY -TO-REFINERY VARIATIONS 3.22 GREATER LEAK TENDENCY OF COMPO
24、NENTS IN LPG STREAMS 3-28 RECOMMENDATION FOR COST EFFECTIVE LDAR 4-1 REFERENCES . 5-1 APPENDIX A MATRIX TABLE OF RESULTS . A- 1 LIST OF FIGURES Figure Pane 3- 1. Average Per Component Emissions for High Leakers, Repeat Leakers 3-4 and Total Components for Aggregate of All Components and Services 3-2
25、. Average Per Component Emissions for High Leakers, Repeat Leakers 3-4 and Total Components for Valves in Light Liquid Service 3-3. Average Per Component Emissions for High Leakers, Repeat Leakers 3-5 and Total Components for Valves in Gas Service 3-4. Average Per Component Emissions for High Leaker
26、s, Repeat Leakers 3-5 and Total Components for Pumps in Light Liquid Service 3-5. Average Per Component Emissions for High Leakers, Repeat Leakers 3-6 and Total Components for Connectors in Light Liquid Service 3-6. Average Per Component Emissions for High Leakers, Repeat Leakers 3-6 and Total Compo
27、nents for Connectors in Gas Service 3-7. Percentage of Total Emissions for High Leakers, Repeat Leakers, and Other Leakers . 3-8 for Aggregate of All Components and Services 3-8. Percentage of Total Emissions for High Leakers, Repeat Leakers, and Other Leakers . 3-9 for Valves in Light Liquid Servic
28、e 3-9. Percentage of Total Emissions for High Leakers, Repeat Leakers, and Other Leakers . 3-9 for Valves in Gas Service 3-10. Percentage of Total Emissions for High Leakers, Repeat Leakers, and Other Leakers . 3-10 for Pumps in Light Liquid Service 3-1 1. Percentage of Total Emissions for High Leak
29、ers, Repeat Leakers, and Other Leakers . 3-10 for Connectors in Light Liquid Service 3-12. Percentage of Total Emissions for High Leakers, Repeat Leakers, and Other Leakers . 3-1 1 for Connectors in Gas Service 3- 13. Distribution of Component Count and Estimated Emissions by Screening Range .3- 12
30、Average of All Component Types, Service Types for 5.5 Years 3-14. Percentage of Total Emissions for High Leakers and Repeat Leakers 3-15 in Refinery Processes for Aggregate of All Components and Services 3-15. Percentage of Total Emissions for High Leakers and Repeat Leakers 3-16 in Refinery Process
31、es for Valves in Light Liquid Service LIST OF FIGURES (Continued) Fimire Page 3-16. Percentage of Total Emissions for High Leakers and Repeat Leakers in 3-16 Refinery Processes for Valves in Gas Service 3-17. Percentage of Total Emissions for High Leakers and Repeat Leakers in 3-17 Refinery Processe
32、s for Pumps in Light Liquid Service 3- 18. Percentage of Total Emissions for High Leakers and Repeat Leakers in 3- 17 Refinery Processes for Connectors in Light Liquid Service 3-19. Percentage of Total Emissions for High Leakers and Repeat Leakers in 3- 18 Refinery Processes for Connectors in Gas Se
33、rvice 3-20. Percentage of Total Components for High Leakers and Repeat Leakers in 3-19 Refinery Processes for Aggregate of All Components and Services 3-21. Percentage of Total Components for High Leakers and Repeat Leakers in 3-19 Refinery Processes for Valves in Light Liquid Service 3-22. Percenta
34、ge of Total Components for High Leakers and Repeat Leakers in 3-20 Refinery Processes for Valves in Gas Service 3-23. Percentage of Total Components for High Leakers and Repeat Leakers in 3-20 Refinery Processes for Pumps in Light Liquid Service 3-24. Percentage of Total Components for High Leakers
35、and Repeat Leakers . 3-21 in Refinery Processes for Connectors in Light Liquid Service 3-25. Percentage of Total Components for High Leakers and Repeat Leakers in 3-21 Refinery Processes for Connectors in Gas Service 3-26. Emission Factors by Processes for Aggregate of All Components and Services .
36、3-22 3-27. Aggregated Quarterly Emissions from High Leakers, Repeat Leakers and . 3-23 Total Components for Refinery A 3-28. Aggregated Quarterly Emissions from High Leakers, Repeat Leakers and . 3-24 Total Components for Refinery B 3-29. Aggregated Quarterly Emissions from High Leakers, Repeat Leak
37、ers and . 3-24 Total Components for Refinery C 3-30. Aggregated Quarterly Emissions from High Leakers, Repeat Leakers and . 3-25 Total Components for Refinery D 3-3 1. Aggregated Quarterly Emissions from High Leakers, Repeat Leakers and . 3-25 Total Components for Refinery E LIST OF FIGURES (Continu
38、ed) Figure Page 3.32 . Aggregated Quarterly Emissions from High Leakers. Repeat Leakers and . 3-26 Total Components for Refinery F 3.33 . Aggregated Quarterly Emissions from High Leakers, Repeat Leakers and . 3-26 Total Components for Refinery G 3.34 . Refinery by Refinery Comparison of Average Emis
39、sions of High Leakers. Repeat . 3-27 Leakers. and Total Components for Aggregate of All Components and Services 3.35 . Refinery by Refinery Comparison of Percentage of Components That Are High Leakers. 3-27 Repeat Leakers. and Other Components for Aggregate of All Components and Services LIST OF TAB
40、LES Table 2.1 . 3.1 . 3.2 . 3.3 . 3.4 . 3.5 . 3.6 . 3.7 . A.1 . A.2 . A.3 . A.4 . A.5 . Pap;e Summary of the Screening Data Collection Effort . 2-2 Screening Results for Seven Refineries (5.5 years) . 3-2 Valve and Connector Emissions Distribution 3-7 Distribution of Emissions by Component Category
41、. 3-13 Process Unit Description 3-13 Contribution to Total Emissions by Process Unit High and Repeat Leakers . 3-15 Comparison of Various Refinery Performance; Average Emissions, lbhr-component 3-23 Proportion of High Leakers in Low Pressure Gas Line Components for Refinery A 3-28 Combined Matrix fo
42、r Leakers with Value = 500 A-2 Combined Matrix for Leakers with Value = 1, O00 . A-4 Combined Matrix for Leakers with Value = 10, O00 . A-6 Combined Matrix for Leakers with Value = 50, O00 . A-8 Combined Matrix for Leakers with Value = 100, O00 . A-10 - - STD=API/PETRO PUBL 310-ENGL 1997 0732290 Ob0
43、4b73 bTT EXECUTIVE SUMMARY This report presents the findings and recommendations of a study of fugitive emissions from piping components (valves, flanges, etc.) at seven Los Angeles California refineries over a period of five and one-half years. Screening measurements, taken to determine the estimat
44、ed fugitive emissions of volatile organic compounds (VOC) from those refineries, were collected and analyzed. These screening measurements comprise the detection portion of a leak detection and repair (LDAR) program designed to reduce those fugitive emissions from components in process unit piping.
45、The study was conducted to determine whether or not a more cost effective LDAR protocol could be developed. Data were analyzed to determine if certain component designs or component applications (e.g., gate valves vs. globe valves, different process units, or different frequencies of actuation) tend
46、 to produce more high leakers (i.e., screening 2 10, ppmv) or repeat leakers (i.e., screening 2 1, ppmv more than once in a four- quarter period). The data were analyzed to identify the repeat leakers and high leakers by component type, generic process unit, and refinery, as well as on an aggregated
47、 basis for all refineries. BACKGROUND Since the early 1980s, the U. S. Environmental Protection Agency (USEPA) has supported the development and eventually required the implementation of LDAR programs under its New Source Performance Standards. Also, many states have adopted LDAR as part of their St
48、ate Implementation Plan. As the result of the adoption of the National Emission Standards for Hazardous Air Pollutants from Petroleum Refineries (40 CFR Part 63 Subpart CC), known more commonly as “Refinery MACT Rule” (MACT is an acronym for Maximum Available Control Technology), every U.S. refinery
49、 is required to implement LDAR for the processes and streams described in this rule. The LDAR procedure (EPA Method 21) involves placing an instrument probe at the surface of a component seal and measuring the VOC concentration as the probe is moved over the surface of the seal. A correlation has been established relating the mass rate of VOC leaking from the component to the maximum concentration measured by the instrument. EPA and some state agencies have established the level of VOC concentration which determines a leak. If the concentration of a component i
