Fugitive Emissions: How to Prevent Potential Leak Points

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Fugitive Emissions

WIKA - Part of your business

Fugitive Emissions:

Fugitive emissions are often seen as an unavoidable byproduct of running a

refinery or petrochemical plant

Leaks may be overlooked because they are considered insignificant and

difficult to detect

Yet, the EPA doesn’t hesitate to levy fines

Unavoidable Byproduct of Doing Business?

Fugitive Emissions:

Fugitive emissions are even more dangerous

than combustion leaks because you can’t see

them without specialized detection equipment

Fugitive emissions are also:

A fire hazard

Dangerous to employee and community health

Lost product and profits

• Refineries lose more than $3 million in fuel

each year to fugitive emission leaks*

• That’s fuel that is never used or sold

The Dangers

* Source: “Direct Measurement of Fugitive Emissions of Hydrocarbons from a Refinery,”

J. Air & Waste Manage. Assoc. 58:1047–1056.

The Problems You Face

Fugitive emissions are hard to detect

A typical plant has more than 300,000 connections (potential leak points)

The Needle in the Haystack

More than 83% of controllable fugitive emissions come

from only 0.24% of the piping components*, such as:

Valves

Compressors

Pressure relief valves

Connectors

* Source: American Petroleum Institute

Rethinking Instrumentation

Tapping Potential Gauge Leaks

Focus on Gauges

One potential leak point that you may not have thought about is your

gauges, which comprise a significant portion of your connections

Potential Leak Point

WIKA welds its stainless steel case to its

stainless steel socket

Other manufacturers screw the socket

into the gauge with a rubber O-ring,

which is prone to wear out and create a

leak point

With hundreds of gauges in your

plant, it’s impossible to monitor

each one

That’s why WIKA has developed

solutions to protect against leaks

All-Welded System

Diaphragm seal and pressure gauge permanently welded

together to create a sealed pressure measurement system

Removes all threaded connections to provide dual

containment that helps eliminate potential leak paths

Helium leak tested; Helium is the smallest stable gas

molecule, so if we can contain it, we can contain your

Removes the possibility of misapplication or tampering

Complies with the EPA’s

“Dual Containment Requirements”

Fugitive Emissions: A Costly Nightmare... A Simple Solution

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Let The Instrument Experts Help

WIKA Services and Solutions

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Let us be your gauge experts

Full Audit Service Team

Gauges, if used properly, can help you

identify an issue before costly problems

develop

Our Full Audit Service Team (FAST) will

take care of your gauges to help

o Lower inventory costs

o Improve reliability

o Reduce gauge maintenance costs

And best of all, FAST is the only solution

you need—a total care services program

at no additional cost to you

WIKA’s FAST engineers helped a large chemical plant

address 50 years of gauge proliferation. Read the case

study to learn more.

Full Audit Service Team (FAST)

FAST Expertise

Expertise

250 Instrument

Audits

150K Instruments

Reviewed

A Full Suite of

Services at Zero Cost

FAST Program

Instrument

Turnaround

Instrument

Planning

Instrument

Failure Analysis

Instrument Safety

Training

WIKA’s Instrument

Audit provides expert

analysis and solutions

form our FAST

engineers who help you

put the right gauges in

place for your

applications to improve

reliability and lower

costs.

Our team performs an

Instrument Audit,

standardizes the

instruments you need

and sends the products

to you when you need

them... before your

turnaround begins so

you can avoid delays.

Send us your failed

gauge, and our

engineers will conduct

a root cause analysis.

By understanding the

mode of failure, our

FAST engineers can

recommend a reliable

solution.

Our FAST engineers

train your team to look

for signs of instrument

failure when completing

a scheduled evaluation

of your instrumentation.

FAST Instrument Audit

Visual inspection of pressure, temperature gauges to build a

comprehensive record of gauge installations and rate problematic

conditions

Data analysis to provide engineering-based recommendations that

improve, standardize and consolidate your population

Implementation support, including ERP imports, MOC

documentation, and Easy Order Guides

Improves reliability, and decreases inventory and maintenance costs

year after year

Establishes a Sustainable Gauge Maintenance

Program

Average FAST Audit Savings

$51,171Ɨ in first year savings,

Ongoing annual savings of $21,073ƗƗ

Less gauge failures and less time to replace

Correct gauges for processing conditions

Standardize on full scale ranges, options for gauges

Decrease Maintenance Costs*

Reduction in Inventory*

Increase in Reliability*

First year savings only includes engineering resources for physical audit, storeroom review, data compilation, and implementation support. Based on average audit of 1,000 installations, requiring two instrumentation engineers for one week ƗƗ Ongoing annual savings. Inventory savings based on industry averages for overhead, inventory management, shrinkage, obsolescence, inventory tax, and cost of capital *Based on results from more than 250 WIKA instrument audits

Our team performs a full Instrumentation

Audit and standardizes what

instruments you need...before your

turnaround actually begins

With this advanced preparation, we

ensure that the right instruments are at

your plant at the exact time you need

them – eliminating the risk of delay

Action plan with part number, IOM and

data sheet for each installation

FAST Turnaround Instrument Planning

Ensure the Right Instrumentation for

Start-up

FAST Instrument Failure Analysis

Getting to the Root of the Problem

If you have gauges that are continually

failing, then send them to us

Our FAST engineers will perform a root

cause analysis

Can alert you to problems with more

expensive equipment

Reduces likelihood of downtime and

decreases maintenance costs

WIKA’s FAST engineers accessed a recurring gauge

failure and identified a larger issue before costly repairs

were required. Learn how.

FAST Instrument Safety Training

Education and training are best tools to

maintain operational efficiency and

employee safety in your plant

Our Instrument Safety Training will teach

your team to look for warning signs

Held at your site or ours, the training helps

reduce maintenance costs and wrench

FAST FACT U.S. process plants lose more than $10 billion per year

from abnormal situations caused by human error.

Source: Abnormal Situation Management Consortium

FAST Instrument Safety Training

How much could you save with FAST

Audit?

Contact us for a Cost Savings Estimate or to

Learn More about WIKA’s FAST Services.

1-855-651-FAST

info@wika-fast.com

Fugitive Emissions: How to Prevent Potential Leak Points

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