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Flow Solutions Group

Compressor Products & Services – Reduction of Methane Emissions

Krzysztof (Chris) Wasiak Compressor Seal & System Specialist

Today’s Agenda: • Environmental Benefits of Retrofitting From Wet to Dry Gas Seals • Flowserve

Today’s Agenda:

Today’s Agenda: • Environmental Benefits of Retrofitting From Wet to Dry Gas Seals • Flowserve Compressor
•

Environmental Benefits of Retrofitting From Wet to Dry Gas Seals

Benefits of Retrofitting From Wet to Dry Gas Seals • Flowserve Compressor Blow Down Gas Recovery

Flowserve Compressor Blow Down Gas Recovery System

•

Summary of Flowserve Global Compressor Products & Services

Flowserve Compressor Blow Down Gas Recovery System • Summary of Flowserve Global Compressor Products & Services

Flowserve Corporation Proprietary and Confidential

Compressor Seals - Gaspac Gaspac Dry Gas Seals in single/dual/tandem configuration • • Leading in

Compressor Seals - Gaspac

Compressor Seals - Gaspac Gaspac Dry Gas Seals in single/dual/tandem configuration • • Leading in high

Gaspac Dry Gas Seals in single/dual/tandem configuration

Leading in high pressure applications up to 450 bar

• • Leading in high pressure applications up to 450 bar Leading in high speeds: slow-roll

Leading in high speeds: slow-roll up to 240 m/s (800 ft/s) [ ~ 850 km/h (530 miles/hr) ]

Leading in high temperatures: -135 C up to 230 C

] Leading in high temperatures: -135 C up to 230 C • • Big diameters up

Big diameters up to 360 mm (e.g. for the LNG market)

• Big diameters up to 360 mm (e.g. for the LNG market) Gaspac Diameters 1.5‘‘ –

Gaspac

Diameters 1.5‘‘ – 14.5‘‘

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ADVANTAGES: DRY SEAL VS OIL SEALS  Reduced operating costs  Increased reliability  Increased
ADVANTAGES: DRY SEAL VS OIL SEALS  Reduced operating costs  Increased reliability  Increased

ADVANTAGES: DRY SEAL VS OIL SEALS



Reduced operating costs

Increased reliability

Increased efficiency

Maintenance advantage

Improved safety

Environmental impact

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JUSTIFICATION PROCESS TANGIBLE FACTORS Oil Consumption, waste management   Compressor and auxiliary efficiency 
JUSTIFICATION PROCESS TANGIBLE FACTORS Oil Consumption, waste management   Compressor and auxiliary efficiency 

JUSTIFICATION PROCESS

TANGIBLE FACTORS

Oil Consumption, waste management

TANGIBLE FACTORS Oil Consumption, waste management   Compressor and auxiliary efficiency  Maintenance,

Compressor and auxiliary efficiency

Maintenance, call outs and downtime

Losses due to process contamination

Fugitive emissions

Flowserve Corporation Proprietary and Confidential

FUGITIVE EMISSIONS Wet seals vent 50 to 100 times more than Dry Gas Seals 

FUGITIVE EMISSIONS

Wet seals vent 50 to 100 times more than Dry Gas Seals

Wet seals vent 50 to 100 times more than Dry Gas Seals  Cost of vented
Wet seals vent 50 to 100 times more than Dry Gas Seals  Cost of vented

Cost of vented gas from Wet seals can range $100,000 to $300,000 / year lossWet seals vent 50 to 100 times more than Dry Gas Seals  Environmental laws and

Environmental laws and governmental regulations could present additional costs:from Wet seals can range $100,000 to $300,000 / year loss  fines  carbon tax

fines

carbon tax

Flowserve Corporation Proprietary and Confidential

ECONOMIC JUSTIFICATION PROCESS RECIRCULATION LOSSES 3 Flowserve Corporation Proprietary and Confidential
ECONOMIC JUSTIFICATION PROCESS RECIRCULATION LOSSES 3 Flowserve Corporation Proprietary and Confidential

ECONOMIC JUSTIFICATION PROCESS

RECIRCULATION LOSSES

3
3

Flowserve Corporation Proprietary and Confidential

EXAMPLE OF WET SEAL EMISSIONS 80 70 60 50 40 30 20 10 0 50%
EXAMPLE OF WET SEAL EMISSIONS 80 70 60 50 40 30 20 10 0 50%

EXAMPLE OF WET SEAL EMISSIONS

80 70 60 50 40 30 20 10 0
80
70
60
50
40
30
20
10
0

50%

UT

100%

UT

80 MM @ $4.5/MSCF

60scfm120scfm 150scfm

120scfm60scfm 150scfm

150scfm60scfm 120scfm

= $360K / Year

40 MM @ $4.5/ MSCF

= $180K / Year

20 MM @ $4.5 / MSCF

= $ 90K / Year

Flowserve Corporation Proprietary and Confidential

JUSTIFICATION PROCESS INTANGIBLE FACTORS  Lost production due to contamination  Efficiency loss due to
JUSTIFICATION PROCESS INTANGIBLE FACTORS  Lost production due to contamination  Efficiency loss due to

JUSTIFICATION PROCESS

INTANGIBLE FACTORS

JUSTIFICATION PROCESS INTANGIBLE FACTORS  Lost production due to contamination  Efficiency loss due to

Lost production due to contamination

Efficiency loss due to contamination of pipeline, exchangers, catalysts

Safety and asset risk management

Flowserve Corporation Proprietary and Confidential

Compressor Seal Fundamentals GASPAC Flowserve Corporation Proprietary and Confidential

Compressor Seal Fundamentals

GASPAC

Compressor Seal Fundamentals GASPAC Flowserve Corporation Proprietary and Confidential

Flowserve Corporation Proprietary and Confidential

Compressor Seal Fundamentals GASPAC Flowserve Corporation Proprietary and Confidential
TANDEM SEAL WITH INTERSTAGE LABYRINTH = GASPAC L Flow Solutions Group - Compressor Seals Flowserve

TANDEM SEAL WITH INTERSTAGE LABYRINTH = GASPAC L

Flow Solutions Group - Compressor Seals Flowserve Corporation Proprietary and Confidential
Flow Solutions Group - Compressor Seals
Flowserve Corporation Proprietary and Confidential
Compressor Seal Fundamentals + ~ 25 special sized modules , eg. for screw compressors Flowserve
Compressor Seal Fundamentals + ~ 25 special sized modules , eg. for screw compressors Flowserve

Compressor Seal Fundamentals

Compressor Seal Fundamentals + ~ 25 special sized modules , eg. for screw compressors Flowserve Corporation

+ ~ 25 special sized modules , eg. for screw compressors

Flowserve Corporation Proprietary and Confidential

Vent Header

Vent Header Common Sources of Vented Gas Compressor Dry Gas Seal Leakage Reciprocating Compressors: Leakage From

Common Sources of Vented Gas

Vent Header Common Sources of Vented Gas Compressor Dry Gas Seal Leakage Reciprocating Compressors: Leakage From
Vent Header Common Sources of Vented Gas Compressor Dry Gas Seal Leakage Reciprocating Compressors: Leakage From
Compressor Dry Gas Seal Leakage
Compressor Dry
Gas Seal Leakage

Reciprocating Compressors: Leakage From Distance Piece

Reciprocating Compressors: Leakage From Distance Piece Instrument Vented Gas: Relief Valves, Control Valves, Vent
Reciprocating Compressors: Leakage From Distance Piece Instrument Vented Gas: Relief Valves, Control Valves, Vent
Reciprocating Compressors: Leakage From Distance Piece Instrument Vented Gas: Relief Valves, Control Valves, Vent
Reciprocating Compressors: Leakage From Distance Piece Instrument Vented Gas: Relief Valves, Control Valves, Vent
Reciprocating Compressors: Leakage From Distance Piece Instrument Vented Gas: Relief Valves, Control Valves, Vent

Instrument Vented Gas: Relief Valves, Control Valves, Vent Valves

Vented Gas: Relief Valves, Control Valves, Vent Valves Compressor Wet / Oil Seal Trapped Gas via
Vented Gas: Relief Valves, Control Valves, Vent Valves Compressor Wet / Oil Seal Trapped Gas via
Vented Gas: Relief Valves, Control Valves, Vent Valves Compressor Wet / Oil Seal Trapped Gas via

Compressor Wet / Oil Seal Trapped Gas via Degasser Tank

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Flowserve Corporation Proprietary and Confidential

Typical Flow of Vented Gas in a Sealing System DRY SEAL SYSTEM RECYCLED 98 SCFM
Typical Flow of Vented Gas in a Sealing System DRY SEAL SYSTEM RECYCLED 98 SCFM

Typical Flow of Vented Gas in a Sealing System

DRY SEAL SYSTEM

RECYCLED 98 SCFM SUPPLY GAS 100 SCFM/SEAL VENT TO ATM. 45 SCFM/SEAL SEAL VENT TO
RECYCLED
98 SCFM
SUPPLY GAS 100
SCFM/SEAL
VENT TO ATM.
45 SCFM/SEAL
SEAL
VENT TO ATM.
2 SCFM/SEAL
255 SCFM/SEAL TO
SUCTION
(MAY BE VENTED!)
WET OR
DRY
WET SEAL SYSTEM
Entrained Gas is
approx. 15%
GAS OUT
HP DEGASSER
300SCFM/SEAL
TANK

15% GAS ENTRAINMENT IN OIL

HP DEGASSER 300SCFM/SEAL TANK 15% GAS ENTRAINMENT IN OIL WET SEAL SYSTEMS VENT 20 – 100
HP DEGASSER 300SCFM/SEAL TANK 15% GAS ENTRAINMENT IN OIL WET SEAL SYSTEMS VENT 20 – 100

WET SEAL SYSTEMS VENT 20 – 100 TIMES MORE GAS THAN DRY GAS SEAL SYSTEMS

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LP DEGASSER

TANK

Flowserve Corporation Proprietary and Confidential

Emissions Example: Mechanical Dry Gas Seals • A pipeline compressor fitted with two 150 mm
Emissions Example: Mechanical Dry Gas Seals • A pipeline compressor fitted with two 150 mm

Emissions Example: Mechanical Dry Gas Seals

• A pipeline compressor fitted with two 150 mm shaft seals operating at a pressure of 25 bar will leak approximately 120 Nl/min

• Assuming utilization factor of 0.8, in a year of operation, the compressor seals will contribute 4.2 million liters to hydrocarbon emissions

of operation, the compressor seals will contribute 4.2 million liters to hydrocarbon emissions Source: Duke Energy

Source: Duke Energy Inc.

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Flowserve Corporation Proprietary and Confidential

Vented Gas Recovery System INTEGRATED PLC A Gases PI FI K1 H PT FT L

Vented Gas Recovery System

Vented Gas Recovery System INTEGRATED PLC A Gases PI FI K1 H PT FT L A
INTEGRATED PLC A Gases PI FI K1 H PT FT L A TO PROCESS V2
INTEGRATED
PLC
A
Gases
PI
FI
K1
H
PT
FT
L
A
TO PROCESS
V2
VENT HEADER
V1
Accumulator /
Vessel
Dampener
A
K2
A
A
A
HEADER V1 Accumulator / Vessel Dampener A K2 A A A Flow Monitoring of All Recovered

Flow Monitoring of All Recovered

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Flowserve Corporation Proprietary and Confidential

System Description Page 16 Flowserve Corporation Proprietary and Confidential
System Description
System Description
System Description Page 16 Flowserve Corporation Proprietary and Confidential
System Description Page 16 Flowserve Corporation Proprietary and Confidential

Page 16

Flowserve Corporation Proprietary and Confidential

System Description • Available configurations to recover variable volume and pressure of vented gas •

System Description

System Description • Available configurations to recover variable volume and pressure of vented gas • Built

• Available configurations to recover variable volume and pressure of vented gas

• Built in redundancy – two compressors providing non- stop operation
Built in redundancy – two compressors providing non-
stop operation

Mean time between compressor maintenance (MTBCM) – not less than 12 month– two compressors providing non- stop operation With built in redundancy (0.5 utilization factor) – MTBCM

With built in redundancy (0.5 utilization factor) – MTBCM is not less than 24 month.

Flowserve Corporation Proprietary and Confidential

Draw Down Gas Recovery System • At shutdown pipeline compressor and isolated piping contain, on
Draw Down Gas Recovery System • At shutdown pipeline compressor and isolated piping contain, on

Draw Down Gas Recovery System

At shutdown pipeline compressor and isolated piping contain, on average, 10 000 scf / 285 Nm3 of natural gas.

contain, on average, 10 000 scf / 285 Nm3 of natural gas. • This gas is
• This gas is usually vented into atmosphere.
This gas is usually vented into atmosphere.

Flowserve Corporation Proprietary and Confidential

Draw Down Gas Recovery System PLC PI H PT L K1 COMPRESSOR TO PIPELINE Page

Draw Down Gas Recovery System

Draw Down Gas Recovery System PLC PI H PT L K1 COMPRESSOR TO PIPELINE Page 19
Draw Down Gas Recovery System PLC PI H PT L K1 COMPRESSOR TO PIPELINE Page 19
PLC PI H PT L K1
PLC
PI
H
PT
L
K1
Draw Down Gas Recovery System PLC PI H PT L K1 COMPRESSOR TO PIPELINE Page 19

COMPRESSOR

TO PIPELINE

TO PIPELINE

Recovery System PLC PI H PT L K1 COMPRESSOR TO PIPELINE Page 19 Flowserve Corporation Proprietary
Recovery System PLC PI H PT L K1 COMPRESSOR TO PIPELINE Page 19 Flowserve Corporation Proprietary

Page 19

Flowserve Corporation Proprietary and Confidential

Draw Down Gas Recovery System Page 20 Flowserve Corporation Proprietary and Confidential

Draw Down Gas Recovery System

Draw Down Gas Recovery System Page 20 Flowserve Corporation Proprietary and Confidential
Draw Down Gas Recovery System Page 20 Flowserve Corporation Proprietary and Confidential

Page 20

Flowserve Corporation Proprietary and Confidential

Draw Down Gas Recovery System Technical Data: Minimum Drawdown Pressure: Atmospheric Recommended Drawdown Pressure: 2

Draw Down Gas Recovery System

Draw Down Gas Recovery System Technical Data: Minimum Drawdown Pressure: Atmospheric Recommended Drawdown Pressure: 2 to

Technical Data:

Minimum Drawdown Pressure: Atmospheric Recommended Drawdown Pressure: 2 to 4 bar Injection (Pipeline Pressure): up to 400 bar

Operating Temperature Range: +5 to +45 o C Compression Units Capacity: 200 to 1200 L/min

Electrical Area Classification:

Capacity: 200 to 1200 L/min Electrical Area Classification: Class 1 Div. 1 and 2 Page 21

Class 1 Div. 1 and 2

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Flowserve Corporation Proprietary and Confidential

Why Recover? • Provides compliance with Kyoto Accord, eliminates emission and requirement to purchase additional
Why Recover? • Provides compliance with Kyoto Accord, eliminates emission and requirement to purchase additional

Why Recover?

Provides compliance with Kyoto Accord, eliminates emission and requirement to purchase additional credits

•

Provides reduction in cost for HC emission reporting as per EPA 2011 requirements and provides compliance with future emission reduction legislations

•

Provides compliance with pending Canadian Emission Control legislation

•

Provides compliance with existing and pending EU Regulations (ER4, ER5 and ER6)

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Flowserve Corporation Proprietary and Confidential

Compressor Seals – Seal Support Systems A Leader in Compressor Seal Solutions… • Industry’s broadest
Compressor Seals – Seal Support Systems A Leader in Compressor Seal Solutions… • Industry’s broadest

Compressor Seals – Seal Support Systems

A Leader in Compressor Seal Solutions…

• Industry’s broadest core products and services:

– Control Systems

– Gas Conditioning Systems

– Application Design

– System Upgrades

– System commissioning

• Conditioning systems

– Large array of systems designed to solve unique problems

• Dew point, pressure variation, particles

Cleanpac TM , Drypac TM , Ampliflow TM

particles – Cleanpac T M , Drypac T M , Ampliflow T M Flowserve Corporation Proprietary

Flowserve Corporation Proprietary and Confidential

Krzysztof (Chris) Wasiak Compressor Seals Specialist Eastern Europe, Balkans, Israel, Russia, Caspian Countries E-mail
Krzysztof (Chris) Wasiak Compressor Seals Specialist Eastern Europe, Balkans, Israel, Russia, Caspian Countries E-mail

Krzysztof (Chris) Wasiak

Compressor Seals Specialist Eastern Europe, Balkans, Israel, Russia, Caspian Countries E-mail kwasiak@flowserve.com Tel/fax +48 32 253 01 38

Cell

+48 601 99 44 20

Thank you for your attention.

Flowserve Corporation Proprietary and Confidential