Gas Plant Leak Detection and Repair (LDAR) Program

Gas Plant Leak Detection and Repair (LDAR) Program

Challenge:   

Antea Group was contracted to develop a Leak Detection and Repair program for a natural gas plant in Wyoming to comply with New Source Performance Standard EPA 40 CFR 60 Subpart a requirements. One portion of this project involved uniquely identifying and physically tagging potentially leaking components (valves, flanges, etc.) that are subject to the leak detection rules. The challenge to accurately track and maintain the required database of identified leaks, required records of follow-up repairs, and all associated inspection details is a common task in many industries. The gas plant is required to perform monthly leak inspections using an IR camera, and to track and monitor each leak and repair among nearly 4,000 identified components, requiring an efficient identification and data management system.

Solution:     

Antea Group mobilized a four person team to complete the physical tagging process for nearly 4,000 components within seven field days. This included redlining existing P&IDs provided by the client to correlate component locations, and physically attaching tags to equipment in a safe and secure manner. The project team developed a tagging system using Teflon coated metal tags with unique ID codes and corresponding QR codes. During inspections, applicable component QR codes, measured values, and inspector field notes were recorded and scanned through an app on the inspector’s mobile device, outfitted with an intrinsically safe case. Information is transmitted and received back at the office in a format that is easily input into the LDAR database created for this client. Information is easily routed to either Antea Group or client personnel via email, text, or report, based on client needs.

Result:    

Results of this identification system comply with the EPA OOOO requirements and go above and beyond the client’s expectations. This system allows the client to identify trends through the ability to sort collected data by leak detection date ranges, component type, repair status, identification numbers, etc.  The results can be easily organized and reported in any manner the client wishes, and meets record keeping requirements with minimal effort. This results in increased efficiency and cost savings for plant personnel. The client has already identified several other areas of operations other than environmental compliance where the asset tracking/information management solution will be helpful in identifying plant trends and complying with maintenance requirements.

The Plant supervisor stated that he believes Antea has “a good plan and am anxious to learn more about how we can work to leverage your process into other compliance items at the plant.”