Efficient and Reliable
Compliance to the New
EPA Regulation
Pressure Relief Device (PRD) Monitoring
for Refineries
Overview
• EPA Regulation requires all critical PRDs
to be electronically monitored in the next
three years
• Complying to the new regulation requires a
change to the traditional PRD monitoring
processes done today
• Implementing a real time monitoring system
ensures compliance while providing
operational benefits and cost savings
• Leading refineries have implemented this
technology and achieved immediate results
[File Name or Event] • Emerson Confidential • 3/16/2016 • Slide 2
PRD Electronically Monitored
Key Facts from EPA Regulation
• Operators would install electronic monitors
on PRDs that vent to atmosphere to identify
and record the time and duration of each
pressure release
• Identify the source of release on the flare
systems
• Corrective action required for any leakage
of 500 ppm or greater
• Reporting emissions during startup and
shutdown is now required
Monitoring of all PRDs handling Hazardous Air Pollutant
(HAP) must be completed within three years of signoff:
September 30, 2015
[File Name or Event] • Emerson Confidential • 3/16/2016 • Slide 3
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Challenges With Compliance
• Manual monitoring – automated monitoring
is now a preferred option
• Traditional electronic monitoring technology is
expensive due to complex installation and
commissioning requirements
Cabling and trenching
Process shut down
Hard to reach locations
• Identifying time and duration of releases using
process information requires extensive data
interpretation, time and expertise
• Locating the source of release in your flare
system requires even more complex analysis
and can result in increased emissions or
production slowdown
Unit A
Unit B
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Unit C
[File Name or Event] • Emerson Confidential • 3/16/2016 • Slide 4
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Complete Real-Time PRD Monitoring Solution
Addresses Your Key Challenges
HSSE
1.
2.
Emerson’s non-intrusive and wireless solution enables lowest cost implementation
Technology designed for PRD application delivers the information you need for compliance
accessible through your existing host system or historian
3.
Quickly and easily identify the source of release in your flare system
3
Relief Valve
Monitoring
Rupture Disc
Monitoring
WirelessHART®
Gateway
1
Relief Valve and Rupture
MonitoringConfidential • 3/16/2016 • Slide 5
[File Name or Event]Disc
• Emerson
2
WirelessHART Communications
1
Traditional Method
Pervasive Sensing™ Solution
[File Name or Event] • Emerson Confidential • 3/16/2016Relief
• Slide
6
Valve
Monitoring
Benefits
• Reduced Engineering
• Reduced Labor
• Reduced Materials
• Faster Installation
• Assured Reliability and
Performance
Acoustic Transmitter Provides Insight Into Your
PRD Release Without Complex Data Analysis
Traditional PRD Monitoring Process
Emerson’s PRD Monitoring Solution
•
•
Observe upstream pressure peaks and valleys
around the pressure limit
Challenges of monitoring with process pressure
•
Peaks and valleys make it difficult to determine
when the PRD is actually opened or closed
Observe downstream acoustic signature of PRD
installation
Benefits of monitoring with acoustic signature
• Time and duration of each release clearly shown
• Valve simmering, chattering, leakages and malfunctions
also identifiable
Acoustic
Process Pressure
PRD monitoring using process data
[File
Name or Event]
• Emerson
• 3/16/2016to
• Slide
7
analysis
can
takeConfidential
from hours
days
2
Easy to identify time and duration of
each pressure release
Identifying the Source of Release in Your Flare
System, Done in a Fraction of the Time
Challenge
•
•
Using process information to identify where
the release is coming from requires hours to
days of expert data analysis and exposure to
what may be a hazardous area
Every minute spent identifying which PRD is
releasing leads to increasing emissions,
regulatory fines and lost production
Unit A
Unit B
Solution
•
Comprehensive PRD monitoring for closed
recovery and flare systems enables
immediate identification and response to
source
Unit C
Eliminate the need to slow down production and ensure minimal emissions with
clear visibility to your full system
[File Name or Event] • Emerson Confidential • 3/16/2016 • Slide 8
3
CAPEX Savings with Pervasive Sensing Solution
Total Cost of Implementation(1)
200 x PRDs
Traditional Method
Total Project Cost ($K)
Total cost per PRD ($K)
Savings
Field Installation
Cabling & Trenches Required
Technology
Pervasive Sensing Solution
$3,520
$18
$464 - $1,088
$2.3 – $5.4
-
69% - 87%
Intrusive
Non-Intrusive
Yes
Wired
No
Wireless
(2)
Total compliance and operational improvement at fraction of the cost of traditional method
(1) Estimated costs include monitoring of the wireless system, tamperproof secure data, and engineered services
(2) [File
Cost range
application:Confidential
PRV only or PRV
with Rupture
Disc9monitoring
Namedependent
or Event]on
• Emerson
• 3/16/2016
• Slide
OPEX Savings with Pervasive Sensing Solution
Value Model PRD Monitoring Solution
Number of critical PRDs not currently monitored
200
Small Leak
Large
Leak
Bypass Valve
open
Percentage of PRDs not operating properly
5%
2%
0.50%
Annual losses per PRD not operating properly ($K)
$25
$100
$1,000
Annual preventable losses from all leaking PRDs ($K)
$250
$400
$1,000
Potential PRDs not operating properly
Value Model Based on Fines and Production Losses
Avoidable fines due to fugitive emissions ($K)
Increased throughput due to reduced process safety limits ($K)
Potential Annual Savings = $3,200,000
[File Name or Event] • Emerson Confidential • 3/16/2016 • Slide 10
$350
$1,200
Summary of Pervasive Sensing Solution Benefits
•
•
•
•
•
•
Simple and accurate EPA compliance
Minimum capital expenditure
Increased throughput
Improved productivity and safety
Greater insight into overall process
Establishes infrastructure for future operational
improvements using Pervasive Sensing solutions
[File Name or Event] • Emerson Confidential • 3/16/2016 • Slide 11
Customer Experience
HSSE
Major U.S. Refinery
CHALLENGE
SOLUTION
RESULTS
Detecting PRV releases
and leaks, current work
process on average
detected the source
within 48-72 hrs. up to
weeks. Environmental
fines are levied on H2S
releases to flare.
Non-intrusive wireless
solution utilizing
acoustic / temperature
transmitters to detect
in real-time the PRV
release.
Detected at least 200 incidents.
Identified 20 “bad actors” and
the problems were resolved
within an hour.
Increased throughput and
revenue of the units.
One Year ROI: 270%
“The increased throughput and revenue
was an unexpected bonus”
[File Name or Event] • Emerson Confidential • 3/16/2016 • Slide 12
How to Get Started
• Collect the following basic
information for your critical1
PRDs and send to Emerson for
quotation
Unit
PRD
TAG
PRD
Type
Line
Pressure
Process
Type
Gas or
Liquid
WirelessHART
Infrastructure
A
101
PRV
300 psia
H2S
Gas
Yes
A
102
PRV
+ RD
300 psia
H2S
Gas
Yes
A
103
PRV
300 psia
H2S
Gas
Yes
A
104
PRV
300 psia
H2S
Gas
Yes
1All
refineries completed a critical PRD assessment in
2011 for EPA’s Information Collection Request (ICR)
[File Name or Event] • Emerson Confidential • 3/16/2016 • Slide 13
To Learn More About Additional Operational Excellence
Opportunities with Pervasive Sensing Solutions…
Application
Annual
Savings ($M)
Implementation
Cost ($M)
ROI (Months)
Heat Exchanger Monitoring
$2.7 - $3.6
$ 0.62
3 months
Cooling Tower Monitoring
$0.3 - $0.5
$ 0.16
4 months
Steam Trap Monitoring
$2.5 - $3.3
$ 1.48
5 months
PRD Monitoring
$2.4 - $3.2
$ 1.09
6 months
Pump Monitoring
$0.5 - $0.6
$ 0.55
11 months
Air Cooled Heat Exchanger Monitoring
$0.9 - $1.1
$ 1.20
13 months
Mobile Workforce
$1.6 - $2.1
$ 0.40
3 months
Per incident
$ 0.39
Safety
$ 10.9 - $ 14.4
$ 6.40
Safety Shower & Eye Wash Monitoring
TOTAL(1)
(1) Savings
5 months
based on 250k bpd refinery
Contact your local Emerson representative or visit www.emersonprocess.com
[File Name or Event] • Emerson Confidential • 3/16/2016 • Slide 14
Thank You!