Fugitive Emissions: How to Prevent Potential Leak Points

Fugitive Emissions www.WIKA-FAST.com 1
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
AND
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
 Pumps
 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
gases
 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

Best Practices www.WIKA-FAST.com 13
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.

Best Practices www.WIKA-FAST.com Full Audit Service Team (FAST)
14
FAST Expertise
Expertise
Over
250
Instrument
Audits
Over
150K
Instruments
Reviewed

Best Practices www.WIKA-FAST.com A Full Suite of
Services at Zero Cost
15
FAST Program
Instrument
Audit
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

25%
20%
30%
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
time
20
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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Fugitive Emissions: How to Prevent Potential Leak Points