Why energy operators should be addressing the issue of fugitive emissions and how they can go about it

In April, KCI’s Engineering Director, Graham Steele, attended the SPE Workshop: The Future of Well Integrity in Amsterdam. The key topic of discussion was greenhouse gases, mainly methane, and how critical it is that the energy industry contributes to reducing emissions.

It was clear that this industry is under increasing pressure to introduce actionable steps to reduce its contribution to methane emissions.

In conjunction with this, we have witnessed a significant increase in enquiries for our gate valve isolation solution as operators address this issue.

How does methane get into the atmosphere?

The most common way methane is released into the atmosphere is through flaring or venting natural gas. However, it can also be released through fugitive oil and gas production emissions. 

These leaks are predominantly on Christmas trees and the wider process plant, but leaks from stem seals on gate valves can significantly contribute to the level of methane emitted.

So, what causes these leaks?

When the gate valves age, stem seals become brittle, less flexible, and wear out due to excessive use or pitted stems, creating a rough surface and an uneven seal. As the stem travels through the seals, gas can escape via the weep hole or telltale vent on the valve bonnet or migrate back through the actuator housing.

Leaks in manual valves are quite a common problem. The valve stem typically remains in the same place but is rotated back and forth to open the valve, sometimes up to 120 turns each way, creating wear spots at the interface between the stem and seals.

Why should operators care?

The SPE event clearly shows methane emissions are a hot topic in the energy industry. The industry is in the spotlight as one of the main contributors to methane levels. As figures become more available to the public, they will be used to structure emissions reduction tactics and influence investment, thus creating an economic incentive for operators to repair leaking systems or plug inactive ones.

Scientific and political communities are increasingly recognising that methane is much more harmful than carbon dioxide in contributing to global warming, and reduction is, therefore, critical in fighting climate change. It is estimated that one tonne of methane has about 80 times the warming potential and heat trapping ability of one tonne of CO2.

What can operators do about it?

We have a range of specialised sealing products that can be applied to various leak situations. These products allow leaks to be sealed quickly with little to no downtime.

Our unique leak-sealing products, created in our own research and development laboratory, isolate and protect the current ageing well stock and the environment.

Our products can isolate gate valves and stem seal leaks, allowing the valve to continue operating.

Our chemical engineering range has enabled operators to achieve substantial savings quickly, safely, and cost-effectively on a wide range of maintenance, integrity, and production issues.

Why is our solution better than traditional methods?

Traditional methods for repairing a leak involve shutting down the well or plant, setting downhole plugs or venting off any internal pressures to obtain suitable barriers to break containment, and replacing the damaged item. The new equipment would then have to be commissioned before the well or plant was brought back online.

This process is expensive, time-consuming work that involves multiple disciplines.

Our rigless isolation solutions can be carried out quickly and efficiently with minimal footprint and team, dramatically reducing costs and minimising downtime.
In addition, our solutions also assist customers in reducing overall emission levels to as near zero as possible.

We have extensive experience sealing leaks with a high success rate and little to no disruption to production.

Get in touch with KCI at www.kciltd.co.uk/contact-kci to discuss how we can support your next project.

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