National Emission Standards for Hazardous Air Pollutants for Source Categoriesn Standards for...

7/26/2019 National Emission Standards for Hazardous Air Pollutants for Source Categoriesn Standards for Hazardous Air Pollu

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Office

ofAir

Qua1ib'nited States

Environmental Protection

Agency

Planning

and

Standards

Research TriangletP.ark:NC 27711

Aprll 997

EPA-4531R-94..079a

Air

National Emission Standards for

Hazardous Air Pollutants for

Source Categories: Oil ,and Natural

Gas Production and Natural Gas

Transmission and t o r ~ g e

-

Background Information for

Proposed Standards

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TECHNIC L

REPORT

DATA

Please

read

Instructions on reverse before completing)

2.

3. RECIPIENT S

ACCESSION

NO.

EPA-453/R-94-079a

TITLE AND SUBTITLE

S.

REPORT

DATE

l Emission Standards for Hazardous Air Pollutants for Apri11997

oduction and Natural

and Storage - Background Information for

6. PERFORMING ORGANIZATION CODE

AUTHOR S)

8.

PERFORMING ORGANIZATION REPORT NO.

PERFORMING ORGANIZATION NAME AND

ADDRESS

10.

PROGRAM

ELEMENT NO.

.

U.S. Environmental Protection Agency

Office of Air Quality Planning and Standards

11.

CONTRACT/GRANT NO.

Research Triangle Park, NC 27711

68D60008

SPONSORING

AGENCY

NAME AND ADDRESS 13. TYPE OF REPORT

AND

PERIOD COVERED

Director

Office

of

Air Quality Planning and Standards

Office

of ir

and Radiation

14. SPONSORING AGENCY CODE

U.S. Environmental Protection Agency

EPA/200/04

Research Triangle Park, NC 27711

SUPPLEMENTARY NOTES

:used as background in

of

the two standards 1) National Emission Standards for Hazardous Air Pollutants from

ts from Natural Gas Transmission and Storage Facilities. A description

of

the industries, control

of controls, modeling used

in

the estimation of national emission estimates and

WORDS AND DOCUMENT

ANALYSIS

DESCRIPTORS

b. IDENTIFIERS/OPEN

ENDED TERMS

c. COSATI Field/Group

. Air Pollution control

DISTRIBUTION STATEMENT

19. SECURITY

CLASS

Report)

21. NO. OF

PAGES

Unclassified

124

Release Unlimited

20 SECURITY CLASS Page)

22. PRICE

Unclassified

.

2220-1 (Rev.

4-77

PREVIOUS

EDITION IS OBSOLETE


4/136


5/136

EPA-453/R-94-079a

Nat iona l

Emissions Standards

fo r

Hazardous Air Pol lu tan t s

fo r

Source Categor ies Oil

and

Natural Gas Product ion and

Natura l Gas

Transmiss ion

and Storage

Background

Informat ion fo r Proposed Standards

Emission Standards

Divis ion

U.S. Environmental Pro tec t ion Agency

Office of Ai r

and

Radia t ion

Off ice

o f

Air Qual i ty

Planning

.and Standards

Research

Triangle

Park North Caro l ina 27711

Apr i l

1997


6/136

DISCLAIMER

This r e p o r t has been reviewed

by the Emission

Standards

Divis ion

Off i ce

o f

Air Qua l i ty

Planning

and

Standards U.S.

Environmental

P r o t ec t i o n Agency and

approved fo r

pub l ica t ion .

~ i n t i o n o f t rade

names o r commercial product s i s not in tended to c ons t i t u t e

endorsement

o r

recommendation

fo r use. Copies

of

t h i s r epor t a re

ava i l ab le through the

Library

Serv ices Off ice

MD-35),

U.S.

Environmenta l Pro tec t ion Agency Research T r i a n g l ~ Park North

Carol ina

27711 o r from the

National

Technical

Inj :ormation

Serv ice s 5285

Port

Royal Road Spr ingf ie ld Vi rg in ia 22161.


7/136

1 . 0

2 .0

T BLE OF

CONTENTS

INTRODUCTION

1 . 1

PURPOSE OF DOCUMENT

1 . 2

ST TUTORY

BASIS OF RULE

1 . 3 SCOPE OF THE

SOURCE

CATEGORIES

1 .4

DOCUMENT CONTENTS

1 .5

DOCKET

REFERENCE

1 . 6 REFERENCES

THE OIL ND N TUR L G S PRODUCTION ND N TUR L G S

TRANSMISSION

ND

STOR GE SOURCE

CATEGORIES

2 . 1

2 .2

2 .3

2.4

INTRODUCTION

SOURCE C TEGORY CHARACTERIZATION

2 .2 .1

Product ion Wells

2 . 2 . 2 Dehydrat ion Units

2 . 2 . 3

Tank

Bat te r i es

2 .2 .4 Natura l Gas Process ing Plants

2 .2 .5 Offshore Product ion Plat forms

2 .2 .6 Natura l

Gas

Transmission and

Storage

Fa c i l i t i e s

EXTR CTED

STRE MS ND

RECOVERED PRODUCTS

2 .3 .1 Crude Oil

2 . 3 . 2

Condensates

2 .3 .3

Natura l

Gas

2 .3 .4 Produced Water

2 . 3 . 5 Other Recovered Hydrocarbons

2 .3 .6

H P Const i tuen ts

DESCRIPTION OF INDUSTRY

COMPONENTS

2 .4 .1 Product ion Wells

1 1

1 1

1 1

1 2

1 3

1 3

1-5

2 1

2 1

2-2

2-2

2-3

2-3

2-4

2 4

2 5

2 5

2 5

2 6

2 6

2 7

2 7

2 7

2 8

2 8

2 . 4 . 1 . 1

Wellhead

Assembly

2 .4 .1 .2

Product ion Methods

2 8

2 .

4

. 1 .

2 .1

Primary

Recovery

2 .4 .1 .2 .2 Secondary

Recovery

2-10

2 10

2 .4 .1 .2 .3

T er t i a r y

Enhanced)

Recovery

2-10

2-10

2-10

2-11

2 12

2 12

2 14

2-14

2 14

2 . 4 . 2 Dehydrat ion

2 .4 .2 .1 Glycol

Dehydrat ion

2 .4 .2 .2 So l i d

Desiccant Dehydrat ion

2 .4 .3 Tank Bat te r i es

2 .4 .3 .1 Separa tors

2 .4 .3 .2 Dehydrat ion

2 .4 .3 .3

Heater

Trea ters

iv


8/136

3.0

TABLE OF CONTENTS

Continued)

2 .4 .3 .4 Free Water Knockouts FWKOs)

2 .4 .3 .5 Gun Barre l Separa t ion

Tanks

2 .4 .3 .6

Storage Tanks and

Other Vessels

2 .4 .3 .7 Custody Transfer

2.4 .4 Natural Gas Process ing Plants

2 .4 .4 .1 Dehydration

2 .4 .4 .2

Sweetening and

Sul fur

Recovery

Processes

2 .4 .4 .3 Condi t ioning Processes

2 .4 .4 .4 Frac t iona t ion

2 .4 .4 .5 Product Transfer

and

Metering

2.4 .5

Offshore Product ion Plat forms

2.4 .6

Compressor Sta t ions

2.4 .7

Underground

Storage

2.4 .8

Other Processes

and Operat ions

2.5 HAP EMISSION POINTS

2 .5 .1 HAP Emission Points

2 .5 .1 .1

Process

Vents

2 .5 .1 .2 Storage

Vessels

2.5 .1 .3

Equipment

Leaks

2.6 BASELINE EMISSION ESTIMATES

2.6 .1 Basic

Methodology

2.6 .2 Fac i l i t y

Emission Est imates

2.7 REFERENCES

CONTROL

OPTIONS AND PERFORMANCE

OF CONTROLS

3.1 INTRODUCTION

3.2 PROCESS VENTS

3 .2 .1

Vapor

Recovery

3.2 .2 Combustion

3.2 .3 Pol lu t ion

Prevent ion

3.3 STORAGE VESSELS

3.4

EQUIPMENT

LEAKS

3 .4 .1 Leak Detect ion and Repair

3 .4 .1 .1 Summary of

Control

Techniques

Guideline

3 .4 .1 .2 Summary

of

New Source Performance

Standards

3 .4 .1 .3 Summary of

Equipment

Leak

Requirements

Under the Hazardous

Organic

NESHAP Regulatory Negot ia t ion

3.4.2

Equipment Modif icat ion

3 .4 .2 .1

Valves

3 .4 .2 .3 Pumps and

Compressors

3 .4 .2 .3 Sampling Connections

3 .4 .2 .4 Pressure R el ief Devices

3 .4 .2 .5

Open-Ended

Lines

3 .4 .2 .6 Connectors Flanges)

3.5

CONTROL

OPTIONS AND HAP EMISSION POINTS

3 6 REFERENCES

2-14

2-15

2-15

2-16

2-16

2-17

2-17

2-17

2-18

2-18

2-18

2-19

2-19

2-20

2-20

2-20

2-20

2-22

2-23

2-23

2-23

2-25

2-31

3-1

3-1

3-1

3-1

3-3

3-3

3-4

3-5

3-5

3-6

3-6

3-6

3-7

3-7

3-7

3-7

3-8

3-8

3-8

3-8

3-10


9/136


10/136

B.4

B.S

B.6

B.7

TABLE

OF CONTENTS Continued)

CONTROL OPTIONS . . . . .

MODEL

PL NT IMPACTS . . . . . .

B.S.1

Emissions .

B.S.2 Costs

.

B.S.3 Other

Impacts

NATIONAL IMPACTS ESTIMATE . .

REFERENCES . . . . . . . .

APPENDIX

C.

MONITORING INSPECTION RECORDKEEPING

ND

REPORTING COST METHODOLOGY . . . . . . . .

C.

1 INTRODUCTION . . . . . . . . . . . . . . . . . .

C 2

OST METHODOLOGY

C.2.1 Example Costs

or Major

Source

MIRR

C.

2 . 2

Number o Major Sources

. .

C.2.3 Example Costs

or

Area

Source MIRR

C.2.4

Number o Area Sources

C.2.5

Continuous

Monitoring

C.3 BASIS OF METHODOLOGY

C.4

REFERENCES .

v i i

B-3

B-4

. B-4

B-4

B-5

.

B-6

B-6

.

C-1

.

C-1

.

C-2

C-2

.

C-2

C-8

C-8

C-8

C-11

C-11


11/136


12/136

LIST

OF

TABLES Continued)

4-5 MODEL

OFFSHORE PRODUCTION

PLATFORMS

4-11

5-1 EXAMPLE NATIONAL

PRIMARY

AIR

POLLUTANT

IMPACTS

FOR

MAJOR

SOURCES

IN THE

OIL AND

NATURAL GAS

P R O D U T I O ~ J SOURCE

CATEGORY . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3

S-2

EXAMPLE

NATIONAL

PRIMARY

AIR

POLLUTANT I M P A C J ~ S FOR

MAJOR

SOURCES

IN THE NATURAL GAS

TRANSMISSION AND

STORAGE SOURCE

CATEGORY . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 EXAMPLE NATIONAL

PRIMARY

AIR

POLLUTANT

IMPACTS

FOR AREA

SOURCE GLYCOL DEHYDRATION

UNITS IN

THE OIL AliT NATURAL

GAS

PRODUCTION SOURCE

CATEGORY

. . . . . . . . . . . . . . . S-5

5-4

EXAMPLE

NATIONAL

SECONDARY

AIR

POLLUTANT

I M P l ~ T S

DUE TO

FLARING

FOR MAJOR AND AREA SOURCES IN THE OII s AND NATURAL

GAS

PRODUCTION

SOURCE

CATEGORY . . . . . 5-7

5-5 EXAMPLE

NATIONAL

ENERGY REQUIREMENTS

. . . . . . . .

5-9

6-1 EXAMPLE

CONDENSER

CAPITAL COSTS

FOR

MODEL GLYCOL DEHYDRATION

UNIT TEG-C . . . . . . . . . . . . . . . . . . . . . 6-7

6-2 EXAMPLE

CONDENSER

ANNUAL COSTS FOR MODEL GLYCOL DEHYDRATION

UNIT TEG-C . . . . . . . . . . . . . . . . . . . . . 6-8

6-3

EXAMPLE

CLOSED

VENT

SYSTEM

CAPITAL COSTS

FOR

MODEL

CONDENSATE TANK BATTERY

TB-G . . . . . . . . . . .

6-9

6-4 EXAMPLE CLOSED VENT SYSTEM ANNUAL

COSTS

FOR

MODEL

CONDENSATE

TANK BATTERY

TB-G . . . . . . . . . . 6-10

6-5 EXAMPLE

MODEL

PLANT COST

IMPACTS . . . . . . . . .

6-11

A-1 EVOLUTION

OF

THE BACKGROUND INFORMATION DOCUMENT . A-2

C-1

EXAMPLE ANNUAL MIRR COSTS PER

GLYCOL DEHYDRATION

UNIT

DESIGNATED

AS

OR LOCATED

AT

A MAJOR HAP EMISSION

SOURCE

. . . . . . . . . . . . . . . . . . . . . . . . .

C-4

C-2

EXAMPLE

ANNUAL

MIRR COSTS PER STORAGE VESSEL

OR

CONTAINER

LOCATED

AT A

MAJOR

HAP EMISSION SOURCE . . . . . . . . .

C-5

C-3 EXAMPLE ANNUAL

MIRR COSTS PER

LEAK

DETECTION

AND

REPAIR

LOCATED

AT A

MAJOR

HAP EMISSION

SOURCE

. . . . . . . . .

C-6

C-4 TOTAL

ESTIMATED

EXAMPLE

MIRR COSTS

FOR

MAJOR HAP

EMISSION

SOURCES IN

THE

OIL

AND

NATURAL GAS PRODUCTION

SOURCE

CATEGORY . . . . . . . . . . . . . . . . . . . C-7

x


13/136

LIST OF TABLES Continued)

C-5 EX MPLE

NNU L MIRR COSTS PER GLYCOL

DEHYDR TION

UNIT

DESIGNATED

S N

RE

H P

EMISSION SOURCE

C-9

C-6 TOT L

ESTIMATED MIRR COSTS FOR GLYCOL

DEHYDR TION

UNITS

IN

THE OIL ND N TUR L G S PRODUCTION SOURCE C TEGORY

DESIGNATED S RE SOURCES C-10


14/136


15/136

LIST

O

FIGURES

1 1

Oil

and Natura l

Gas

Indus t ry

2 1 Flow Diagram

of

Basic Glycol Dehydrat ion Uni t

1 4

2 13


16/136


17/136

1.0

INTRODUCTION

1.1 PURPOSE

OF

DOCUMENT

Nat iona l emiss ion s tandards fo r

hazardous

a i r po l lu t a n t s

NESHAP) a re being

developed

fo r the o i l and na tu ra l gas

produc t ion source ca tegory

and the na tu ra l gas t ransmiss ion

and

s to rage

source ca tegory by the U.S.

Environmental

Pro tec t ion

Agency EPA) . This

background

in format ion document BID)

descr ibes t echn ica l

in format ion

and ana lyses

suppor t ing

development

of the NESHAPs fo r proposal in the Federa l

Regis ter .

1.2 STATUTORY BASIS

OF

RULE

The NESHAPs fo r the

o i l

and na tu ra l gas and na tu ra l

gas

t ransmiss ion

and

s torage source

categories

are

being

developed

under

the au thor i ty

o f

112 d) of.

the Clean Air Act as

amended

in

1990 CAA) .

1

Sec t ion 112 d) of

the CAA

d i rec t s

the EPA

Adminis t ra tor to

promulgate r egu la t ions

es tab l i sh ing

hazardous

a i r po l lu t a n t HAP)

emiss ion

s tandards fo r each ca tegory of .majo r

and a rea

sources of HAP t ha t has been l i s t e d by the EPA fo r

regu la t ion under 112 c) . The 188 pol lu tan ts

t ha t r ~

des igna ted

as HAP a re l i s t e d in 112 b).

A major

source

i s

def ined as

a

s t a t i ona ry source o r

group

of

s t a t i ona ry sources

loca ted

with in a contiguous area and

under

common

cont ro l t ha t

emi t s , o r has the

po te n t i a l - t o - e m i t

PTE)

cons ider ing con t ro l s

10

tons

per

yea r

tpy)

o r gre a t e r of any

one HAP o r 25 tpy o r gre a t e r of any

combinat ion

of

HAP.

n a re a

source

i s any

s t a t i ona ry

source

t ha t

i s

not

a major

source .

Spec ia l

provis ions

in

112 n) 4) f o r . o i l and

gas wells and

pipe l ine

compressor and pump s t a t i o n f a c i l i t i e s

a f fec t

major

source de te rmina t ions fo r these f ac i l i t i e s and

a l so

i nd i c a t e

1-1


18/136


19/136

and process ing of

natura l

gas p r i o r to ente r ing

the

f ina l

p ipe l i ne of

the

loca l d i s t r i b u t i o n company

LDC)

t ha t de l ive r s

natura l gas

to

the

f ina l

end

user . The

scopes

o f

these

source

ca tegor i e s a re i l l u s t r a t e d

in Figure

1-1.

1.4

DOCUMENT CONTENTS

This BID i s

in tended to

provide

1) bas i c in format ion on

t he

process

opera t ions

and

H P emission

poin t s a s soc ia t ed with o i l

and na tu r a l gas product ion and

natura l

gas t ransmiss ion and

s torage and 2)

in format ion on cont ro l s and the

impacts of.

cont ro l s ava i l ab le to reduce

H P emissions from

i den t i f i ed H P

emiss ion poin t s . The desc r ip t ion and ana lys i s o f regula tory

a l t e rna t ive s w i l l be

presented

in

othe r EPA

documents.

Chapter 2.0 presen t s an overview of the source ca tegor ies .

Chapter 3.0 i den t i f i e s

cont rol

opt ions fo r HAPs

t ha t are

appl i cab le

to iden t i f i ed

H P

emiss ion

poin t s

in

the

source

ca tegor ies . Chapter 4.0 presen t s the model plan t s developed fo r

use

in es t imat ing

the impacts

of applying

the cont ro l

opt ions .

Chapter

5 .0 addresses

the

environmenta l and

othe r

impacts

r e su l t ing from applying

contro l

opt ions to i d e n t i f i e d H P

emiss ion poin t s

in

the

source ca tegor i e s . Chapter 6.0 pre s e n t s

the

cos t s and cos t -e f fec t iveness of the cont rol opt ions .

Addi t ional in format ion i s

presented

in

t h ree appendices

to

t h i s document. The appendices inc lude 1) Appendix A - Evolu t ion

o f

t he BID, 2)

Appendix

B -

National

Impacts

Methodology,

and

3)

Appendix C - Monitor ing, Inspect ions Recordkeeping, and

Report ing Cost Methodology.

1.5

DOCKET

REFERENCE

The docket for these regula tory ac t ions i s designated as

Docket No. A-94-04. The docket i s an organized and

complete

f i l e

of the

in format ion submit ted to

o r

otherwise cons idered

by

the

EPA

in

t he development

of

t h i s

proposed ru lemaking.

The

pr inc ipa l

purposes

of

the

docket

are

1) to al low i n t e re s t ed

pa r t i e s a means

t o iden t i fy

and l oca t e documents so t ha t they

can

e f f e c t iv e l y p a r t i c i p a t e i n

the rulemaking

process and 2) to

1-3


20/136

f 1

I

i }

Tank

BaHery

d

I

I

I

I

I

I

I

I

I

I

I

I

I

Natural

Gas

_

Tank

BaHery

I

I

I

HydrOC Irbon

: Liquids

I

I

~

~

Offshore State Waters

d

t

Gas

Plant

d

HydroCJirbon

Uquads

N TUR L

G S

TR NSMISSION ND STOR GE

SOURCE C TEGORY

~ ~ = =

}

ustody

l _ _ r ~ ~ ~ ~ ~ ~

p

Local

Distribution

Como

an

~ ~ e f i n e ~ I

l-lydrOCJirbon

Uquads

Custody ----------

Transfer

OIL ND N TUR L G S

PRODUCTION

n

I II \

r-

Tr- r \ .

r \ ,1

\:>UUt1\ JI::

vi 1::\:lUn

T

Land

LEGEND

d Dehydration Unit

*

OiiWell

GasWell

W Offshore Production Platform

Figure 1 1 . Oi l and Natura l

Gas ndus t ry


21/136

se rve as

the

record in

case

of j ud i c i a l

review (except fo r

i n t e ragency review mater ia ls (307(d) (7) A) of the CAA).

The docket i s ava i l ab le fo r

pub l ic in spec t ion

and

copying

between

8 : 3 0 a . m.

and 4 :30p .m . , Monday through Friday,

a t the

EPA s Air and Radia t ion Docket, Room M1500,

U.S. Environmental

Pro tec t ion

Agency, 401

M

St ree t ,

SW, Washington,

DC

2046.0.

A

reasonable fee

may be cha.rged fo r copying.

1 .6 REFERENCES

1 .

United Sta tes Congress. Clean Air Act

as

amended November

1990.

42 U.S.C. 7401, e t seq. Washington, DC U.S.

Government Pr in t ing Office . November 1990.

1-5


22/136


23/136

2.0 THE

OIL

ND

N TUR L

G S PRODUCTION ND

N TUR L G S TRANSMISSION ND STOR GE SOURCE CATEGORIES

2.1 INTRODUCTION

The

o i l and

na tura l

gas

produc t ion and na tura l gas

t ransmiss ion and s torage source categories inc lude the

separa t ion , upgrading,

s torage ,

and t r ans fe r of

ex t rac ted

s t reams

pr imar i ly hydrocarbons

t ha t

are recovered from produc t ion

wel ls .1

This

chapter inc ludes

a

summary charac te r iza t ion

of

these source categories ,

along with

desc r ip t ions o f

e x t r a c t e d

s t reams and recovered

produc ts ,

and the

bas ic

processes and

opera t ions involved wi th

o i l and na tu ra l gas produc t ion and

na tura l gas t ransmiss ion and s torage .

This

chapter a l so p resen t s

desc r ip t ions o f

i den t i f i ed

hazardous a i r po l lu t a n t HAP)

emission

po in t s a ssoc ia t ed with the process ing ,

s to r ing ,

and genera l

handl ing

of these mater ia l s and produc ts .

The

ex t rac ted st reams

and

recovered

products

fo r

t h ~ s

source ca tegor i es inc lude

crude o i l , condensate ,

na tura l gas , and

produced

water . The types of processes

and opera t ions in t hese

source ca tegor i es inc lude produc t ion

wells ,

dehydrat ion un i t s ,

t ank

ba t t e r i e s , na tu ra l gas

process ing plants ,

of f shore

produc t ion pla t forms , and p ipe l ine t ransmiss ion

f a c i l i t i e s ,

inc luding underground s torage opera t ions .

The

primary H P

emiss ion po in t s a ssoc ia t ed with these source ca tegor i es t ha t

a re

being evaluated inc lude process

vents , s torage vesse l s , and

equipment

l eaks .

Extracted st reams and recovered .produc ts , processes and

opera t ions , and H P emiss ion po in t s are descr ibed

below. This

chap te r

a l so addresses

HAPs assoc ia ted

with

these st reams

and

2-1


24/136

produc t s ,

f ac i l i t i e s ,

and emission

po in t s ,

and

inc ludes

base l ine

H P

emiss ion

es t imates .

2 .2 SOURCE C TEGORY

CHARACTERIZATION

The

o i l

and

na tu ra l

gas produc t ion source

c a t E ~ g o r y inc ludes

t he

process ing and upgrading

of

crude o i l

pr i o r

to

the

po in t o f

cus tody

t r a n s f e r

and

na tu ra l

gas

pr i o r

to

en te r ing the

p ipe l ine

sys tems as soc ia ted

with

the na tu ra l gas

t r ansmiss ion

and s to rage

source

ca tegory .

This source ca tegory

inc ludes

ofj:shore

produc t ion p la t forms

loca ted

in Sta te

waters .

F a c i l i t i e s

t h a t

handle

hydrocarbon l i qu ids a f t e r

the

po in t o f custody

t r a n s f e r

a re

inc luded

as pa r t o f the organic l i qu ids d i s t r i b u t i o n non

gaso l ine

source

ca tegory . For na tu ra l

gas

streams, the na tu ra l

gas

t r ansmiss ion

and s to rage source

ca tegory inc ludes

the

p i p e l i n e

t ranspor t , s to rage , and process ing of na tu ra l

gas

p r i o r

to

en te r ing

the

f i na l

p ipe l ine

of the

l oca l

d i s t r i b u t i o n

company

LDC) t ha t

de l ive rs na tu ra l gas to the f i na l end user .

The

scope

of these source ca tegor ies

a re

i l l u s t r a t e d

in

Figure 1-1

o f

Chapter

1.0

o f t h i s background informat ion documen1: BID).

2 .2 .1 Product ion Wells

In 1992, t he re were an

es t imated

590,000 crude o i l and

condensate produc t ion wel ls in the

U.S. ,

with a

t o t a l annual

produc t ion

o f over 2.6 b i l l i o n

bar re l s

and approxi tnate ly

3

t r i l l i o n cubic

fee t

o f co-produced

na tu ra l

gas .

This was

a

decrease of

3

percent in both the number of wel l s and in crude

o i l produc t ion

as

compared with 1991

l eve l s .2

Of t h i s

t o t a l

number of crude

o i l

and

condensate

produc t ion

wel l s ,

ove r 70 percent

are

c l a s s i f i e d

as

s t r i ppe r ~ ~ e l l s which

a re

produc t ion

we l l s t h a t a re 1) near ing dep le t ion o r

2) have a

produc t ion

r a t e o f

l e s s

than 10

bar re l s of

o i l per day

BOPD) .

St r ippe r wel l produc t ion accounts fo r

approximatel: t

14 pe rcen t o f

t o t a l domest ic crude o i l product ion .

In

add i t ion ,

fo r 1992, the re were an

es t imated

280,000

n a t u ra l

gas produc t ion wel l s in the

U.S. ,

with a

t o t a l

es t ima ted

annual

produc t ion

o f over 18

t r i l l i o n

cubic fee t . This es t imate

rep resen t s

a

3 pe rcen t i nc rea se in the number o f

wel l s

and

1

2-2


25/136

percent

increase in natura l gas product ion as compared with 1991

l eve l s . 3

2.2 .2 Dehydrat ion Uni ts

Once

the natura l gas has been separa ted

from

any l i q u i d

mater ia l s

o r

products crude

o i l , condensate , o r produced wate r ,

r es idua l

ent ra ined

water

vapor

i s

removed

from

the

natura l

gas

by

dehydra t ion . Dehydrat ion i s

necessary

because

water vapor may

form

hydra tes ,

t ha t a re i c e - l i ke s t ruc tu re s , t ha t

can

1) cause

cor ros ion o r

2) plug

equipment

l i ne s .

The Gas Research I n s t i t u t e GRI) es t imates t ha t

t he re

a re

over 44,000 dehydrat ion un i t s

in the

U.S.

Tr ie thy lene g lyco l

TEG) dehydrat ion un i t s account for most of t h i s es t ima ted

popula t ion of

dehydrat ion uni t s ,

with ethylene g lycol

EG),

die thylene glycol DEG) , and

so l id

des iccan t dehydrat ion un i t s

account ing

for

the

remaining

por t ion .4

TEG dehydrat ion un i t s may be 1) s tand-a lone un i t s t ha t

dehydra te

natura l

gas from

an individual

wel l o r seve ra l wel l s

o r

2) one

of var ious

process ing un i t s

a t

c o n d e ~ s t e t ank ba t t e r i e s ,

natura l gas process ing plan t s ,

offshore

product ion

pla t forms,

and

t r ansmiss ion

f a c i l i t i e s ,

inc lud ing

underground s torage s i t e s .

Avai lab le in format ion ind ica tes t ha t , on average, t he re

i s one

TEG dehydrat ion un i t per

condensate

t ank ba t t e ry5 and

two

to

four

dehydrat ion un i t s TEG, EG, o r so l id desiccant per natura l gas

process ing

p lan t , depending

upon

throughput capac i ty and type

o f

process ing conf igura t ion .6

2 .2 .3 Tank B at t e r i e s

A t ank

ba t t e ry r e fe r s

to the co l l ec t i on of process

equipment

used

to

separa te , t r e a t , s to r e , and t r a n s f e r crude o i l ,

condensa te ,

natura l gas ,

and

produced water . These f a c i l i t i e s

t y p i c a l l y handle crude o i l , condensate ,

or natura logas

pr i o r to

t r an s f e r

to

a r e f i ne r y o r

na tura l

gas process ing

p lan t .

Based on an ana lys i s of two

s tud ies conducted

f o r the

American

Petroleum I n s t i t u t e API), the

U.S.

Environmental

Protec t ion Agency EPA) es t ima tes

t ha t

t he re

were approximately

94,000 t ank

ba t t e r i e s

in 1989.7 ,8 ,9 Over 8Spercent of

t ank

2-3


26/136

b a t t e r i e s

1

0 o r an es t imated

81,000

f a c i l i t i e s a re c l a s s i f i ed a s

b lack

o i l t ank ba t t e r i e s . Black o i l

r e fe r s

to crude o i l t ha t has

little if

any, assoc ia ted gas

product ion .

The remainder , o r

an

es t imated 13,000

t ank

b a t t e r i e s

a re

c l a s s i f i e d as condensate

t ank

b a t t e r i e s . Condensate, a l so

r e f e r r ed

to

as r e t rog rade

gas

cons i s t s

of

hydrocarbons

t ha t

a re

i n a gaseous

s t a t e

under r e s e rvo i r condi t ions but: become l i q u i d

i n

e i t h e r

t he wel lbore

o r

the produc t ion process .

2 . 2 . 4

Natura l Gas Process ing

Plan t s

The

main funct ions of na tura l gas

process ing

p l a n t s

inc lude

1) condi t ion ing t he

gas

by separa t ion of na tura l gas l iqu ids

NGL)

from f i e l d gas

and 2)

f r a c t i ona t i on

of NGL i n to

separa te

components. As o f

January

1,

1993,

the re

were

approx imate ly

700

na tu r a l gas process ing plan t s .11

2 .2 .5

Offshore Product ion Pla t fo rms

Offshore

product ion p la t forms

are used to produce , t r e a t

and

separa te crude

o i l

condensate ,

na tura l

gas

and produced

water

from

product ion

f i e l d s i n of f shore a reas . Processes

and

opera t ions a t offshore

product ion

pla t forms

a re

s imi la r to those

l oca t ed

a t

onshore f a c i l i t i e s

except t ha t

1) t he re

i s

genera l ly

little o r no s to rage capac i ty a t of f shore

pla t forms and

2) these

f a c i l i t i e s have l imi t ed ava i l ab l e

space .

In

1993, the U.S.

Department of In t e r io r s

Minera ls

Management

Service

MMS)

es t imated

t ha t

the re

w n ~

approx imate ly

3,800 of f sho re

product ion p la t forms

and

o the r

s t r uc tu r e s i n

Federa l

waters .12

The major i t y

of

t hese offshore product ion

p la t fo rms and othe r s t ruc tures a re loca ted in t he Cen t ra l and

Western Gulf

of Mexico, with

a

l imi ted

number

loca ted

in

othe r

Federa l

wa te r s . The of f shore f a c i l i t i e s loca ted :in Federa l

waters a re

under

t he j u r i s d i c t i o n of t he

MMS

fo r i3.ir emiss ions

r e gu l a t i on

and not the

EPA.13

There

are

an es t imated 300

of f sho re

product ion

pla t forms

in Sta t e waters

that

a re

under t he

EPA s j u r i s d i c t i o n for

a i r

emiss ions .

r egu la t ion

14

with

the

majo r i ty o f these f a c i l i t i e s loca ted in t he Sta t e waters offshore

o f

Texas, Louis iana and Alabama.

2-4


27/136

2.2 .6 Natura l Gas Transmission and

Storage

Fa c i l i t i e s

The

natura l gas

t ransmiss ion and s to rage

source

category

cons i s t s of ga the r ing l i ne s , compressor s t a t ions , and high

pressure t r ansmiss ion pipe l ine .

I t

i s est imated t ha t

there a re

approximately 1,900 compressor s t a t ions and over 480,000

ki lometers

300,000

miles)

of h igh-pressure t ransmiss ion

pipe l ine .15 ,16

In addi t ion, t h i s s ec to r

inc ludes

over

300

underground

s torage s i t e s . 17 ,18 These s i t e s are t y p i c a l l y used

as temporary s to rage

f a c i l i t i e s

to meet peak demand per iods ,

p a r t i c u l a r l y

dur ing

co lde r

weather months; Processes and

opera t ions t ha t may occur a t f a c i l i t i e s

in

t h i s source category

inc lude

dehydrat ion ,

s torage , and

pipe l ine pigging a c t i v i t i e s .

2.3

EXTR CTED

STRE MS ND RECOVERED

PRODUCTS

The

ex t rac ted

streams

and recovered

products from product ion

wel ls

have

d i f f e r ing cha rac te r i s t i c s tha t

can

in f luence the

l e v e l

of H P

emiss ions

genera ted

by

the emiss ion

poin t s

in the o i l and

natura l

gas

product ion

and

natura l gap

t r ansmiss ion

and

s torage

source ca tegor ies . This sec t ion Sect ion 2.3) desc r ibes t he

primary ex t rac ted

streams and

recovered

products assoc ia t ed with

the two source ca tegor i e s .

2 .3 .1 Crude

Oil

Each producing crude o i l and natura l gas f i e l d has i t s

own

unique proper t i es , in

tha t

the composi t ion of the crude

o i l

and

t he a t t endant

natura l

gas and r eservo i r f ie ld) cha rac t e r i s t i c s

are d i f f e ren t from t ha t of any other f i e ld .19

Crude o i l can

be broadly

c l a s s i f i ed as

pa ra f f in i c ,

naphthenic

or

asphal t -based) , o r

in termedia te .

General ly ,

p a r a f f i n i c crudes are used in

the manufacture of

lube o i l s and

kerosene

and

have high

concent ra t ion

of

s t r a igh t

chain

hydrocarbons

and a re r e l a t i ve ly

low

in

su l fu r compounds.

Naphthenic

crudes

a re gene ra l ly used in t he manufacture of

gaso l ines

and

aspha l t

and

have

high

concen t r a t ion

o f

o l e f i n

and

aromat ic

hydrocarbons and

may

conta in

high concent ra t ion

of

su l fu r

compounds. In termedia te crudes are those t ha t

are not

c l a s s i f i e d

in e i t h e r of the above ca tegor ies .20

2-5


28/136

Another

c l a s s i f i c a t i on measure

of

crude o i l a nd othe r

hydrocarbons i s by API grav i ty . API gr av i t y i s a weight per un i t

volume measure

of

a hydrocarbon

l i qu id

as

determined by

a method

recommended by

the

API.21 A heavy

o r p a r a f f i n i c

cirude o i l

i s

t y p i c a l l y one

with

an API

gra v i t y

of 20 o r l e s s ,

while

a

l i g h t

o r

naphthenic

crude

o i l ,

which t yp i ca l l y

f lows

f r ee ly

a t

atmospher ic condi t ions , usua l ly has

an

API gravity in the range

o f

t he

high

30 s t o the low 40 s .22

Crude o i l s recovered in the produc t ion

phase o f

the

pe t ro leum

indus t ry may

be

r e f e r r e d

to as l i v e crudes . Live

crudes con ta in

en t r a ined

o r disso lved gases which may

be

re l eased

dur ing process ing o r

s torage ,

whereas

dead crudes are those

t ha t

have gone

th rough

var ious sepa ra t ion

and

s torage phases and

con ta in

little if any,

en t r a ined o r

disso lved gases .23

2.3 .2

Condensates

Condensates by s t andard

indus t ry

def in i t i on) are

hydrocarbons t ha t a re

in a gaseous

s t a t e

under

r e s e rvo i r

cond i t ions ,

but become

l i qu id i n e i t h e r t he wel lbore o r the

product ion process .24 Condensates, inc luding vo la t i l e o i l s ,

t y p i c a l l y

have

an

API gra v i t y in

the 40

o r gr ea t e r degree

range .25 In add i t ion ,

condensates may

inc lude

hydrocarbon

l i qu ids recovered from gaseous

s t reams from

var ious o i l and

na tu r a l gas product ion

or na tura l gas

t ransmiss ion and

s to rage

processes

and

opera t ions .

2 .3 .3

Natura l

Gas

Natura l

gas

i s a

mixture

of hydrocarbons and

vary ing

q u a n t i t i e s

o f non-hydrocarbons

t ha t

ex i s t s

in a gaseous phase o r

in s o lu t i on with crude o i l

o r

othe r hydrocarbon l i qu ids i n

na tu r a l underground

r e s e rvo i r s . Natura l gas may conta in

contaminants , such as

hydrogen su l f ide

2

S), carbon

dioxide

C02),

mercaptans , and en t r a ined so l ids .

Natu ra l

gas s t reams t ha t

con ta in

th resho ld concen t r a t ions o f

H

2

S

a re

c l a s s i f i e d as sour

gases

and_those

with

t l1reshold

concen t r a t ions o f co

2

are c l a s s i f i e d as ac id

gases . The

processes by which

these

two

contaminants are

removed from

the

2-6


29/136

natura l gas s t ream i s ca l l ed sweetening. The

most common

sweetening method i s amine t r ea t ing .

Sour

gas

conta ins a H

2

S concent ra t ion of

grea te r

than 0.25

gr a in per

100

s tandard cubic f ee t , along with

the

presence of

2

. Concent ra t ions of H2S and C02, along with organic s u l f u r

compounds,

vary

widely

among

sour gases .

Over

75

percen t

o f

t o t a l onshore natura l gas product ion and nea r ly

a l l

of of fshore

natura l

gas

product ion

i s c l a s s i f i ed as

sweet .26

Natura l gas may be

c l a s s i f i ed

as wet gas o r dry gas . Wet

gas

i s unprocessed o r p a r t i a l l y processed-natura l gas produced

from a r e s e r vo i r t ha t conta ins

condensable

hydrocarbons.27 Dry

gas

i s 1)

natura l gas whose water content has

been

reduced

through

dehydra t ion

o r 2)

na tura l gas t ha t conta ins littl o r

no

recoverab le

l i qu id

hydrocarbons.28

2.3 .4

Produced

Water

Produced water i s

the

water recovered from a product ion

wel l .29 ,

Produced water i s

separa ted from the

ex t rac ted

hydrocarbon streams

in

the var ious

product ion

processes

and

opera t ions

descr ibed

in

t h i s

chapter .

2.3 .5 Other

Recovered

Hydrocarbons

Various hydrocarbons may

be

recovered through the process ing

of the ext rac t ed hydrocarbon

s t reams.

These hydrocarbons inc lude

mixed NGL, natura l gasol ine ,

propane,

butane ,

and l i que f i ed

petroleum

gas

LPG) . Def in i t i ons

fo r these hydrocarbons

can

be

found

in Reference

27.

2.3 .6

H P

Const i tuen ts

The

pr imary

i den t i f i ed H P cons t i tuen t s

assoc ia t ed

with

o i l

and natura l gas product ion f a c i l i t i e s inc lude benzene, to luene ,

e thy l benzene, and

mixed

xylenes co l l ec t ive ly r e f e r r ed

to

as

BTEX), and n-hexane.30 In addi t ion,

r e fe rence

has

been

made to

the presence of

2 ,2 ,4- t r imethylpentane

i so-oc tane) , along with

genera l r e f e rence

to

the

presence of formaldehyde, aceta ldehyde,

and ethylene

glycol

i n ce r t a in process and emiss ion s t reams

assoc ia t ed with

o i l and

na tura l

gas

product ion .31 Also, BTEX,

carbon

d i su l f ide

cs

2

) , and carbonyl s u l f i de COS) may be presen t

2-7


30/136

in the

tail

gas s t reams assoc ia ted with amine t rea t ing un i t s and

s u l f u r recovery

un i t s

(SRUs) .32 ,33

Table 2-1

lists

H P cons t i t uen t s and concen t ra t i ons for

e x t r a c t e d

streams and recovered

produc ts for

t he two source

ca tegor i e s .

The

pr imary

sources of da ta used in t he development

of

t he

l i s t e d

H P

concen t ra t i on est imates

were

(1)

a

summary

of

t he i ndus t ry responses to the EPA s Air

Emissipn

Survey

Ques t ionnai res ,34

(2) a da ta base , prov ided by GRI,

of

na t u ra l

gas ana lyses

from

var ious

source

ca tegory opera t i ons ,35 and (3) a

da ta

base provided by API.36

2.4 DESCRIPTION

OF

INDUSTRY COMPONENTS

2.4 .1 Produc t ion Wells

A wel l ,

as def ined

by API

and

used in t h i s BID, i s the

ho le - in - the -g round d r i l l e d from t he po in t o f e n t ry

a t

the e a r t h s

su r face

to

the

t o t a l

depth

of t he

hole

for

the

recovery

of

crude

o i l ,

condensate ,

and

na tura l gas from

format ions

below the

e a r t h s sur face .37 The

recovered

produc ts

and

ext rac t ed streams

from produc t ion we l l s are na tu r a l l y

o r

a r t i f i c i a l l y brought to

the su r f ace where the

hydrocarbon

produc ts

(crude

o i l ,

condensate , and na tura l gas) are separa t ed from

produced

water

and othe r impur i t i e s , such

as

sand. Depending on the product ion

c h a r a c t e r i s t i c s o f

the

wel l , and

t he

recovery

r a t e s fo r crude

o i l ,

condensa te ,

and na tura l gas , a wel l

may o r may

not be put

i n to product ion .

2 .4 .1 .1 Wellhead

Assembly. The wellhead

assembly

i s the

su r face

equipment

used

to contro l t he produc t ion f:rom a wel l and

mainta in product ion

pressu re .

The wellhead asseml,ly

c ons i s t s

of

the

casinghead, tub ing head, Chris tmas t r ee , and pressu re

gauges .38

These components

a re

descr ibed below.

The

cas inghead

i s

the

co l l ec t i on o f f i t t i ngs t ha t suppor t

and

hold

the

cas ing in

p lace . The

tub ing head provides

suppor t

fo r t he tub ing .

The tub ing head

a l so sea l s o f f pressu re between

the

casing and tub ing , and provides connec t ions for

c on t ro l l i ng

the

f low of produced f lu ids

from

t he wel l . The Chris tmas t r e e i s

2-8


31/136

TABLE 2-1. AVERAGE HAP COMPOSITION OF

EXTRACTED STREAMS

AND

RECOVERED PRODUCTS

HAP composi t ion

o f

ex t rac t ed s t ream

o r

recovered

product

Natura l gas

(ppmv)b,c

HAP

Crude

o i l

Condensate

Produced

Direc t

(Weight )

(Weight

)

water

from

Wet

Otherd

ppmw) a

wells

Benzene

0.25

0.99 10 104 88 5

Toluene

0.48

3.50

6

56 44 6

Ethyl

0.12

0.48 6

6 4 l

benzene

Mixed

0.55

4.90 13

34 20

xylenes

n-Hexane

1 .50

2.80

4 420

410

66

BTEXe

1 .40

9.90 35

200 160

13

BTEX and

2.90

13.00

39

620 570

79

n-Hexane

a -

Par t s pe r mi l l i on weight .

b -

Based

on

a

review of the data

col lec ted

in the EPA s Air Emiss ions

Survey Ques t ionnaires

and

o the r r e fe rences , the

HAP

con ten t

of

the

pr imary

f r ac t iona ted

produc ts recovered

i n na tura l

gas proces s ing

opera t ions

inc luding

propane,

butane , and

l i q u i f i e d

pet ro leum

gas}

has

been i den t i f i ed

as

i n s i gn i f i can t .

c -

Par t s

per mi l l i on volume.

d - Natural

gas

processed and s to red a t

na tura l

gas t r ansmis s ion

f a c i l i t i e s

and

underground

s to rage

f a c i l i t i e s .

e - Benzene, to luene , e thy l

benzene,

and mixed xylenes .

Note: Total BTEX

and BTEX and n-hexane

values

have been rounded.

2-9


32/136

the c o l l e c t i on o f

va lves

and f i t t i n g s mounted on the cas inghead

and t ub ing head

t ha t

con t ro l s the f low o f produc t

from

t he we l l .

2 .4 .1 .2 Produc t ion Methods

2 .4 .1 .2 .1 Primary Recovery.

Primary

recover}r

of

hydrocarbon s t reams and

produced water from

a product ion

wel l

occurs

due

to

the

na tu ra l

pressures

t ha t e x i s t i n

a

product ion

r e s e rvo i r .

A f te r some

per iod , the

n a tu r a l p r s s u r ~ s

wi th in a

r e s e rvo i r w i l l

u s u a l l y

dec l ine to a po in t where o ther secondary

o r enhanced recovery methods

must

be

employed

to main ta in a

w e l l s produc t ion .

2 .4 .1 .2 .2

Secondary

Recovery.

When

the

n a tu r a l pre ssure

with in a r e se rv o i r i s not s u f f i c i e n t fo r product ion , secondary

recovery methods o r

a r t i f i c i a l

lift

methods such as

surface

pumping un i t s , gas lift o r subsurface

pumping)

are app l i ed to

inc rease the

y ie ld

of

recovered

product .

Waterf looding,

pre ssure

maintenance, sucker rod pumping, and gas lift a re common methods

o f secondary

recovery

and a r t i f i c i a l

l i f t . 39

2 .4 .1 .2 .3

Te r t i a ry

Enhanced) Recovery. Ter t i a ry ,

o r

enhanced,

recovery methods a re used to supplement

:natural

r e s e rvo i r forces when

primary

and secondary recovery of the

product

i s

no longer

economical .

These

methods inc lude chemical

and thermal methods and gas i n j ec t ion .

2 .4 .2 Dehydrat ion40,41

As

s t a t e d

above,

once

the n a tu r a l

gas has been

sepa ra t ed

from l i q u i d mater ia l s and product s , r es idua l en t ra ined water

vapor i s

removed from

the

n a tu r a l

gas

s t ream

by dehydrat ion in

order

to

1) meet con t rac t sa les spec i f i ca t ions ,

2)

l im i t

hydra te

format ion,

o r 3) improve fue l hea t ing va lues .

The

fo rmat ion

o f hydra tes wi th in a

n a tu r a l gas

s t ream i s

promoted

by

na tu ra l gas

a t

o r below its

water

dew po in t ,

with

l i q u i d

water presen t . Temperatures below

the

hydra te fo rmat ion

t empera tu re , h igh opera t ing pressures , high v e l o c i t y o r a g i t a t i on

through

p i p i n g , o r

equipment,

presence o f

a

small seed c rys t a l

of

hydra te , and presence

of

H

s o r

which

are more so lub le in

water

than hydrocarbons)

a l so

inf luence the

format ion

of hydra tes

2-10


33/136


34/136


35/136

1\.

I

w

WET

Gf\8 -----------I

IN

------------,

c

0

N

T

A

c

T

I

I

I

I

I

I

RY

Gf\8

T 8AlES

COOL

RICH

Gl. ICOL

HOT

RICH

HOT lEAN

REBOILEA

FLASH

TANK

I

I

I

VENT

~ M I S S I O N S

L ~ C O N O E N S I \ l E

ACCUMULATOR

KEY

Glycol

~ G a s

0 Heal Exchanger

Figure 2 1.

Flow Diagram

of

Basic Glycol Dehydration Unit


36/136

b a r r e l separa t ion t anks s torage t anks and l ease automat ic

cus tody t r a n s f e r

(LACT)

un i t s . Each

piece

of equipment

i s

addressed below.

2 .4 .3 .1 Separators . The

separa t ion

of hydrocarbon products

from bas ic sediment and water

(BS W)

i s accompl ished by

product ion

separa to rs .

Basic

sediment

r e f e r s to

the gas

sand

sediment

and

o ther impur i t i e s mixed with the o i l .

Depending on

produc t

cha rac t e r i s t i c s product ion separa to rs

may

be

two-phase o r three-phase

separa to r s .

Two-phase separa to rs

separa te

the

product i n to l i qu id and

gas st reams.

The l i qu i d

s t ream

conta ins crude o i l and

produced

water . Three-phase

separa to rs

separa te

the produc t i n to crude o i l o r condensate

na tu r a l

gas

and o ther

gas st reams

and produced water .

Mult i -wel l f a c i l i t i e s may a l so

inc lude

t e s t separa to rs

which

operate

in pa ra l l e l

to

product ion

separa to rs

to

determine

the

produc t ion r a t e

composi t ion qua l i ty

and produc t ion

c h a r a c t e r i s t i c s of indiv idua l wel ls .

2 .4 .3 .2

Dehydrat ion.

The dehydrat ion processes

t ha t may

occur

a t

t ank ba t t e r i e s

are

the

same

as those discussed

in de ta i l

in Sect ion

2 .4 .2

of t h i s

BID.

2 .4 .3 .3

Heater Treaters . Heater t r ea t e r s are p res su re

vesse l s used to break

t i gh t emulsions

and

remove water and

gases

from crude o i l . A hea te r

t r e a t e r

i s a combination of a hea te r a

f ree water knockout

and

an

o i l

and

gas

separa tor

The i n l e t emulsion en te rs the hea te r t r e a t e r a t the top

which

a l lows the re l ease

of

gas en t ra ined in

the l i qu i d to t r ave l

to

the vapor space a t the

top of

the column.

The

emulsion f lows

to

the

bottom o f the

vesse l through

a

downcomer

pipe . Heat i s

app l ied

to

the

emulsion a t the bottom of the

vesse l . Some

f a c i l i t i e s

add a

chemical

demuls i f ier

to

the procE: SS s t ream

to

a s s i s t

in

the

breaking of

emuls ions .

2 .4 .3 .4 Free Water Knockouts (FWKOs).

I f

l a rge amounts of

water a re

produced with the crude

o i l addi t ional

separa t ion may

be accomplished

by

use

of a FWKO.

Removing

the f ree

water

e a r ly

2-14


37/136

in t he sepa ra t ion process reduces

the

heat ing requirements and

des ign

throughput requirements

of the subsequent f i e l d equipment.

WKOs may

incorpora te

two-phase l iquid/gas} o r

th ree -phase

crude oi l /wa te r /gas )

separa t ion. Heat o r chemicals may

be

app l i ed

to

the

incoming s t ream pr io r to

the

WKO to a s s i s t

in the

sepa ra t ion

process .

2 .4 .3 .5 Gun Barre l Separa t ion

Tanks.

Gun

ba r re l

sepa ra t ion

tanks , o r wash tanks , a re cy l i nd r i ca l vesse l s

opera t ing

a t

a tmospher ic pressu re

t ha t separa te

the product ion s t ream emulsion

i n to

crude

and

produced

water . Gun ba r re l s may be used f o r

unstable emulsions t ha t

wi l l

na tu ra l ly separa te due to g rav i ty ,

i

adequate s e t t l i ng t ime

i s provided.

2 .4 .3 .6

Storage Tanks

and Other Vessel s .

Crude o i l

from

the sepa ra t ion

processes i s t yp ica l ly d i r ec t ed to s torage

tanks

or

other

s torage vesse l s ) for

temporary

s torage .

The

l a rge

major i ty of

s to rage

t anks used a t crude o i l product ion f a c i l i t i e s

a re f ixed- roof

s torage tanks . In

addi t ion, over 95

percen t

of

the

s torage t anks used

a t t ank ba t t e r i e s

range i n s i ze from 200

to 1,000

ba r re l

capac i t i e s .48 Vapor l osses

from

the s torage

t anks are

e i t h e r vented

to the atmosphere or

captured

by vapor

recovery device .

Storage tanks

are

a l so used for

temporary

s torage of

produced water

and

s lop

o i l . Produced water i s t y p i c a l l y

disposed of in

in j ec t ion

wel ls , where water i s

i n j ec t ed

back

i n t o

the producing formation

fo r enhanced recovery appl ica t ions ,

t r ans fe r r ed o f f - s i t e fo r t rea tment

and

di sposa l , o r in

very

l im i t ed cases) used

for

bene f i c i a l purposes .

Slop

o i l i s o i l t ha t does not

meet

qua l i ty

spec i f i ca t ions .

This o i l i s e i t he r

1) recycled i n to

the sepa ra t ion

and

t r ea tmen t

process o r

2)

so ld to an o i l rec lamat ion f a c i l i t y fo r

t rea tment

and

recovery

of

re s idua l

crude

o i l

product .

Tank ba t t e r i e s may

have

var ious

types

of

surface

impoundments pi t s and sumps) loca ted on-s i t e . These p i t s

and

sumps are t yp ica l ly c l a s s i f i ed as emergency o r product ion . Most

2-15


38/136

p i t s and sumps are c l a s s i f i e d as

emergency

pi t s / sumps

and

are

only used dur ing

process

upse t s i tua t ions .49

However, product ion p i t s and

sumps

may a l so be

used

fo r

s ep a r a t i o n

processes

a t t ank b a t t e r i e s .

Most of

product ion

su r face impoundments are loca ted in

se lec ted

heavy crude

o i l

produc t ion a rea s o f

Cal i fornia .SO

2 . 4 . 3 . 7

Custody Transfe r . LACT u n i t i s

usua l ly used

to

meter t h e amount o f crude o i l

o r

condensate produced a t

a t ank

ba t t e ry . LACT

un i t i s

an automated device t ha t decreases the

need

fo r

the

presence of personnel to

handle

the t r a n s f e r of

crude o i l o r condensate . The u n i t records the amount o f

product

t r a ns f e r r e d and product temperature .

Automat ic

sampl ing can be

i ncorpora t ed i n to the LACT un i t

to determine produc t

qua l i t y . 51, 52,53

Trans fe r o f ex t r ac t ed

s t reams

o r

recovered

product s

i s

usua l ly accomplished in p ipe l ines . However, t r a ns f e r

may

a l so

invo lve

loading

crude o i l condensate , o r produced

water i n to

t ank

t r u ck s r a i l c a r s and barges through

the

use

o f

sp lash

loading

o r submerged

ill

t echn iques .

2 .4 .4 Natura l

Gas

Process ing Plan t s

Natura l gas

produced

from

the well i s sepa ra t ed

from

hydrocarbon product s

crude

o i l

and

condensate)

and BS W a t t ank

b a t t e r i e s and

then

t rans fe r red v ia p ipe l ine to

a

na tu ra l gas

process ing

p l a n t .

Typical

processes

and

ope ra t ions

a t

na tu ra l

gas process ing p l a n t s are

descr ibed

below. Deta i l ed desc r ip t ions

o f

processe s and ope ra t ions

a t n a tu r a l gas

process ing

p l a n t s are

presen ted

in

References 41

and

42.

As s t a t e d above, the primary

func t ions of a

na tu ra l gas

process ing p lan t

inc lude

1)

condi t ioning

the

n a tu r a l

gas by

s ep a r a t i o n o f

NGL from the f i e l d gas and

2) f r a c t i o n a t i o n

o f

NGL

i n t o

s ep a r a t e

components.

NGL may

be f rac t iona ted

i n t o

e thane

propane,

butanes and

n a tu r a l

gaso l ine

produc ts .

These product s

a r e

t hen

t r anspor ted p r imar i ly

in

p:j.peline systems,

to

r e f i n e r i e s and

o ther po in t s

of

t r a ns f e r o r

sa le .

2-16


39/136

2 .4 .4 .1 Dehydrat ion.

General ly na tura l gas

i s

dehydrated

pr io r

to

the

o the r

processes a t a

na tu ra l

gas process ing p l an t .

The na tura l

gas

dehydrat ion

process t ha t

may

occur

a t a na tura l

gas process ing plant

i s

the

same as na tu ra l gas dehydrat ion

processes t ha t may

occur

a t o ther loca t ions . Dehydrat ion

processes

a re

discussed

in

Sect ion

2.4 .2

of

th i s

BID.

2.4 .4 .2 Sweetening and

Sul fu r

Recovery

Processes . As

s t a t e d

ea r l i e r

in Sect ion 2 .3 .3 some

production

f i e l ds

produce

sour o r ac id gases . Sour

gas

i s

na tu ra l gas

t ha t

con ta ins

th reshold concen t ra t ions

of H

2

s. Hydrogen s u l f i de

i s a t ox i c

corros ive substance which i s usual ly removed by sweetening

opera t ions

t ha t occur

immediately a f t e r the

na tura l

gas has been

separa ted

and

dehydrated.

Acid gases

are

those t ha t

con ta in

th reshold concentra t ions of co

2

The

most

widely

used

method

of

sweetening

these

gases

i s

amine

t r ea t i ng . Amine t r ea t i ng uses an amine/water so lu t ion to

absorb

the

H

2

s and co

2

from the na tu ra l gas s t ream. The r i c h

amine

s o lu t ion i s

then regenera ted by steam s t r i pp ing

to remove

the

sour gas . The l ean amine

i s

r e c i r c u l a t e d t o

the absorber .

The

system

i s

s im i l a r

in des ign to a

glycol dehydrat ion un i t .

Natura l gas f i e l ds

may produce

enough H

2

s so t ha t t

i s

be ne f i c i a l to

recover

su l fur .

Sul fu r

recovery may

be used

a t

na tura l

gas process ing f a c i l i t i e s and offshore produc t ion

pla t forms .

Afte r the H

2

s

i s removed from the na tura l gas s t ream

in

the

sweetening process the gas i s in troduced i n to a

S U

fo r

fu r the r process ing . At the s u l fu r

recovery

p la n t the s u l f u r

in

the

H

2

s

i s

converted to elemental

su l fur .

The recovered su l fu r

can

be e i t h e r

so ld

commercially

o r disposed of

proper ly . Any co

2

conta ined in

the

gas

s t ream

w i l l pass through

the

S U una l t e red

and

vented wi th the t a i l

gas.

Concentra ted co

2

s t reams from

t he

sweetening

process

may be vented o r f l a red

to

des t roy

any

re s idua l hydrocarbons.

2 .4 .4 .3 Condit ioning Processes . Na tural gas process ing

p la n t s may be charac te r i zed by the

type

of

condi t ioning

process

used

a t

the p la n t .

The

condi t ioning processes

most of ten used

2-17


40/136


41/136


42/136

de l i ve ry of

na t u ra l

gas .59 Processes and opera t i ons t ha t

may

be

l oca t ed a t

underground

s to rage f a c i l i t i e s inc lude , but are not

l i m i t e d

to , compression

and

dehydra t ion .

2.4 .8 Other Processes and Opera t ions

n opera t ion

t ha t may

occur throughout these source

ca tegor i e s

i s

pipe l ine

pigging . Pipel ine

pigging

involves

i n se r t ing a

p ig ,

which i s a cy l i nd r i ca l

dev ice

made with p l i ab le

d isks t h a t it

the

i n t e r na l

diameter

of a pipel ine ,

i n to

a

p ipe l i ne f o r

the

purpose of c leaning the l i ne . Pipe l ine p ressu re

moves

the pig through the

l i ne .

Water vapor and

hydrocarbon

l i qu id s ,

such

as

condensate , may condense and r e s t r i c t o r

block

p ipe l i ne f low,

thus ,

l ead ing to

t he

necess i ty of p igging .

As

the

p i g approaches t he rece iv ing s t a t i o n o f a pipe l ine ,

co l l ec t ed f l u id s

inc luding hydrocarbon

l iqu ids )

are

drained to

a

sump

o r

o t he r

s to rage vesse l

t ha t

i s

usua l ly

r e f e r r ed t o

as

a

s lug ca tche r .60 Pigging

of

pipe l ines i s

a common pr ac t i ce

fo r

p ipe l i nes from offshore

product ion

pla t forms because of the

low

seabed

t emperatures

encountered

by t he o f f shore

pipe l ines , which

causes l i qu ids t o

condense.

Pigging

of

pipe l ines a t

onshore

f a c i l i t i e s

may be u t i l i z e d dur ing seasons with lm rer ambient

t emperatures , such as f a l l

and winter .

2 .5

H P

EMISSION POINTS

2 . 5 . 1 H P

Emission Poin ts

The t h ree

i den t i f i ed

H P emiss ion

po in t s

t ha t may be

assoc ia t ed

with

o i l and

na tura l gas produc t ion

and

na tura l gas

t r ansmiss ion and

s torage include

(1)

process vents ,

(2) s to rage

vesse l s , and

(3)

equipment

l eaks .

Table 2-2

presen t s the bas i c

f a c i l i t i e s

desc r ibed above along

with

the

i den t i f i ed

H P emiss ion

po in t s .

2 .5 .1 .1

Process

Vents . A process

vent i s

a vent from a

process u n i t

t ha t discharges

a gas

s t ream

i n to the

atmosphere

dur ing

opera t ion .

Gas

s t reams from

process

ven t s may be

discharged

d i r ec t l y to the atmosphere o r dischargred th rough a

produc t recovery

device .

2-20


43/136

T BLE 2 2 . B SIC F CILITY TYPES ND

SSOCI TED H P EMISSION POINTS

Fac i l i t y type

Stand a lone

g lyco l

dehydra t ion

un i t

Condensate t ank ba t t e r y

Natural gas proces s ing p lan t

Offshore product ion pla t form in

Sta te waters

Natural gas t r ansmis s ion

and

underground s torage

H P emiss ion

po in ts

Glycol dehydrat ion

un i t r ebo i l e r

vent

and f la sh

t ank ven t

Glycol

dehydra t ion un i t r ebo i l e r

vent and f la sh t ank ven t

Storage v ~ s s l s

Glycol

dehydrat ion un i t r ebo i l e r

vent and f l a s h t ank ven t

Storage vesse l s

Equipment

leaks

Glycol

dehydrat ion u n i t r ebo i l e r

ven t

and f la sh t ank ven t

Glycol dehydrat ion

un i t r ebo i l e r

vent

and

f la sh tank

ven t

2 21


44/136

The g lyco l dehydra t ion un i t r ebo i l e r vent i s

a

source

of H P

emiss ions .

In the g lyco l con tac t tower , g lyco l

no1:

only absorbs

water bu t

a l s o

absorbs se l ec t ed hydrocarbons,

i n c l ~ d i n g

BTEX and

n-hexane. The water

and hydrocarbons

a re boiled-o:Ef in t he

r e b o i l e r and,

un less

a

con t ro l dev ice

i s

presen t ,

~ e n t e d to

the

atmosphere .

The GCG sepa ra tor

o r f l a sh

t ank i s a l so a po ten t i a l H P

process ven t

emiss ion poin t .

H P

emiss ions wi l l

occur i

the

g lyco l

dehydrat ion un i t inc ludes

a

f l a s h

t ank

in

t he system

des ign and any separa t ed gases are vented to t he atmosphere,

i n s t e a d o f

be ing

e i t h e r

1) recycled to t he

header

system,

2)

used

f o r

fue l , o r

3) used as a

s t r i pp i ng

gas .

A process vent

assoc ia ted

with na tura l

gas

sweetening

opera t ions i s the ac id gas vent . This s t ream may conta in high

concen t r a t ions o f

hydrogen

su l f ide

and

carbon

dioxide . In

addi t i on , BTEX,

cs

2

,

and

COS

may

be

presen t

in

t h i s s t ream.

I f

high

concent ra t ions

of H

2

s a re p resen t ,

a

s u l f u r recovery p l a n t

i s i n s t a l l e d to produce

e lementa l

su l fur . Otherwise , t he s t ream

i s

f l a r ed .

Recent

r e sea rch

conducted by GRI

i nd ica t e s t he po ten t i a l for

s ign i f i can t

H P emiss ions

pr imar i ly BTEX

from arrtine-based gas

sweetening

processes .61 ,62 The EPA

i s conduct ing

fol lowup to

t h i s

r e sea rch

in

an

e f f o r t to determine

emiss ion

l eve l s of t h i s

p o t e n t i a l

H P

process

vent

emiss ion

poin t .

2 . 5 . 1 . 2 Storage

Vessel s .

Crude o i l and condensate a re

t y p i c a l l y s tored in f ixed- roof s torage tanks . Emissions a re a

r e s u l t o f

working, breath ing , and

f l a s h

losses .

Working l osses

occur

due

to

t he

emptying

and f i l l i n g of

s to rage

tanks . Brea th ing

lo sses a r e

t he re l ease of

gas

assoc ia t ed with da i l y

t empera tu re f luc tua t ions and

othe r

equ i l ib r ium

e f fec t s .

Flash l osses occur

when a

l i qu id

with

en t r a ined

gases

i s

t r ans f e r r ed

from

a

vesse l

with

h i g h e ~

pressure

to

a

vesse l with

lower

pressu re ,

thus

a l lowing en t r a ined

gases

o r

a

por t i on of the

l i qu id to vapor ize

o r f l a sh .

In

the o i l and

na tura l gas

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product ion source category , f l a sh ing occurs

when

l i ve

crude o i l s

o r

condensa tes f low

i n to

a s torage t ank from a process ing vesse l

opera ted

~

a higher

pressure .

Typica l ly , the

l a rge r

the

pressu re drop, the

more f lashing emiss ions w i l l occur in the

s torage s tage .63

Temperature

of the

l i qu id

may a l so inf luence

the

amount

of

f l a s h

emissions .

In addi t i on , HAP emissions may

occur

when

hydrocarbon

l iqu ids , co l l ec t ed by

s lug

catchers64 during p ipe l i ne

pigging

cleaning) opera t ions , a re

t r ans f e r r ed to

s to rage

t anks o r other

vesse l s .65 HAP emissions may occur with the f l a sh ing of

these

hydrocarbon l i qu ids

due to

a reduct ion

in

pressu re as co l l ec t ed

f lu ids

are dra ined to a sump o r

othe r s to rage

vesse l .

2 .5 .1 .3

Equipment

Leaks.

Equipment leaks

fug i t ive

emissions) are emissions emanating

from valves ,

pump sea l s ,

f langes ,

compressor

sea ls ,

pressure

r e l i e f

valves ,

open-ended

l ines , and

othe r

process and

opera t ion

components. The

amount

of

HAP emiss ions from equipment leaks

i s

propor t iona l

to

1) t he

type

and

number of

equipment

components

and

2)

the concent ra t ion

of

HAP

cons t i tuen t s of the stream

in

the components .

Since t ank

ba t t e r i e s are usua l ly

small f a c i l i t i e s as

compared with

othe r

i ndus t r i a l

opera t ions , they

are

ge ne ra l l y

cha rac t e r i zed by a smal ler number of components. Natura l gas

pr.ocessing

p lan t s , e s pec i a l l y those us ing r e f r ige ra t ed

absorp t ion , t end to

have

a l a rge number of components .

2.6 BASELINE EMISSION ESTIMATES

2.6 .1 Basic

Methodology

Based on ava i l ab le informat ion,

es t ima tes

were

developed

fo r

HAP,

vo l a t i l e organic

compound VOC),

and

methane66

emissions

from i den t i f i ed HAP emiss ion poin t s

in

the

o i l

and

na tu r a l gas

product ion and natura l gas

t ransmiss ion

and s torage source

ca tegor ies . Est imates of emissions before

the

implementat ion o f

a na t iona l emiss ions s tandard for hazardous a i r

po l lu t an t s

NESHAP) are r e f e r r ed t o as base l ine .emiss ion es t ima tes .

Table

2-3 presen t s base l ine

HAP,

VOC and methane na t i ona l

emission

es t ima tes for each

f a c i l i t y

type in the

o i l and

na tu r a l

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TABLE

2-3 . BASELINE

NATIONAL

EMISSION

S T I ~ ~ T S

FOR

ALL IDENTIFIED HAP EMISSION SOURCES IN THE

OIL AND NATURAL GAS PRODUCTION SOURCE

CATH:GORY

MAJOR AND AREA

HAP

SOURCES)

Baseline

emission

estimates

Megagrams per

year

Faci l i ty

type

H P

voc

Methane

Glycol

55,000

130,000

16,000

dehydration

uni tsa

Storage tanks

a t

6 ,300

20,000

11,000

condensate

tank

bat ter ies

Natural gas

3,200

10,000

7,000

processing

plantsb

Total

65,000

160,000

34 ,000

a -

Includes estimated emissions

from a l l

glycol

dehydrat ion uni ts

including

s tand

alone

units and

those located a t condensate

tank

bat ter ies natural gas processing plants , and offshore production

platforms in State waters. Does not include those

uni1:s

in the natural

gas transmission and storage source category.

b -

Only includes emissions

from

storage

tanks

and equipment

leaks.

~

Numbers

may

vary

due

to

rounding.

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47/136

gas product ion source category . These e s t i m t ~ s are based on

model

p lan t parameters t ha t have

been developed for the

var ious

types of f a c i l i t i e s in t h i s source category

see

Chapter 4.0 o f

t h i s BID).

Tables 2-4

and

2-5

present a breakdown

of these

emiss ions based on

po ten t i a l

major versus area source HAP

emiss ion

designat ions

for

the

o i l and

n t u r ~

gas

product ion

source category .

Table 2-6 presen t s base l ine

HAP

VOC

and

methane nat iona l

emiss ion

es t imates

fo r each bas ic f a c i l i t y

type

in the na tu r a l

gas

t r ansmiss ion

and

s to rage

source category .

These

es t imates

a re based on model

TEG

dehydrat ion un i t

parameters t ha t

have been

developed

for var ious

f a c i l i t y types in t h i s source

category

see

Chapter 4.0

of

t h i s

BID).

Tables 2-7 and 2-8 presen t

a

breakdown

of these

emiss ions

based

on poten t ia l

major versus area source

HAP

emiss ion

designat ions

for

the

natura l

gas

t r ansmiss ion

and

s torage source category .

These

es t ima tes

were developed using

a

model

plan t approach.

In t h i s approach, emissions were f i r s t est imated for model

p lan t s

s e l ec t ed to charac . ter ize

the range

of f a c i l i t i e s in

the source

ca tegor ies .

Nat ional es t ima tes

were

developed

by ex t rapo la t ing

from model plan t es t imates . The

methodology

fo r developing

na t ionwide emiss ion es t ima tes

i s fu r ther

descr ibed in Chapter 5 .0

and

Appendix

B

of t h i s BID.

2.6 .2

Fac i l i t y Emission

Est imates

For glycol dehydra t ion

un i t s

emiss ions are based on r e s u l t s

genera ted from GRI-GLYCalc Version 3.0) .67 This i s

a

per sona l

computer-based screening

program

developed by

GRI fo r

eva lua t ing

HAP and VOC

emiss ions

from TEG and EG dehydra t ion un i t s .

VOC

emiss ions from

product ion

s to rage

t anks have been

evalua ted prev iously and these

f ac tor s have

been app l i ed to

the

es t ima ted

popula t ions

o f

these tanks

in

these

source ca tegor ies

and

used as the

bas i s

for es t ima t ing

HAP and

methane emiss ions

from

s torage t anks .68 Fugi t ive emissions

from

components

are

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T BLE

2-4.

BASELINE NATIONAL EMISSION ESTIMATES FOR

IDENTIFIED

M JOR H P EMISSION SOURCES

IN

THE

OIL

ND N TUR L G S PRODUCTION

SOURCE

C TEGORY

Baseline

emission

estimates

Megagrams per year

Faci l i ty type

H P

voc

Methane

Glycol

36,000

85,000

6,200

dehydration

uni ts a

Storage

tanks

a t

1,800

5,900

3,200

condensate

tank

ba t t e r i es

Natural gas

770

2,500

1,800

processing

plantsb

11 Total

39,000

94,000

11,000

a -

Includes estimated emissions

from

a l l glycol dehydrat.ion

uni ts

inc luding s tand

alone

uni t s and

those located a t condensate tank

bat ter ies natural gas processing plants ,

and

offshore production

platforms

in State waters designated as or located at: major sources of

H P emissions. Does not include those units in

the

natural gas

t ransmiss ion and

storage

source

category.

b - Only includes emissions from

storage

tanks

and

equipment leaks.

~

Numbers may

vary due to rounding.

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T BLE 2-5. BASELINE NATIONAL EMISSION ESTIMATES FOR

IDENTIFIED RE H P

EMISSION SOURCES IN

THE

OIL

ND N TUR L G S PRODUCTION SOURCE C TEGORY

Basel ine

emiss ion es t imates

Megagrams per year)

Fac i l i t y type

H P

voc

Methane

Glycol

19,000 43,000

9,600

dehydrat ion

un i t s

a

Storage tanks a t

4,500

14,0.00

8,100

condensate

t ank

ba t t e r i e s

Natural gas

2,400

7,800

5,000

proces s ing

p lan t sb

Tota l

26,000

65,000

23,000

a Includes

es t imated emissions

from a l l

g lyco l

dehydrat ion

un i t s

inc lud ing s tand

a lone u n i t s and those l oca ted

a t condensate

tank

ba t t e r i e s

na tu ra l gas

process ing

p lan ts and offshore

produc t ion

plat forms in

Sta te

waters tha t

are

not des ignated

as

po t en t i a l major

sources

of H P emiss ions . Does

not

include those u n i t s

in t he

na tu ra l

gas t r ansmis s ion and

s torage source

category.

b Only

includes emissions

from

s to rage

tanks and

eq

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