Fugitive Emissions Test Standards

Since the introduction of the U.S. Clean Air Act in 1963, the U.S. Environmental Protection Agency (EPA), as well as individual states, have set increasingly stringent restrictions regulating fugitive emissions from industrial facilities.

Fugitive emissions are any chemical in a physical form that can unknowingly leak from an installation. Valves account for more than 51 percent of all fugitive emissions, including greenhouse gas. Eighty percent of these emissions come from the valve stem—representing more than 300,000 tons annually. It is generally estimated that a high proportion of emissions come from hydrocarbon gasses such as methane.

The consequences of these losses are far-reaching. They include the loss of product in terms of the cost of fugitive emissions, cleanup costs, loss of production time and labor costs to repair leaks.

Plants handling fugitive emissions are expected to implement leak detection and repair (LDAR) protocols monthly.

The EPA monitors leak detection using “sniffing” technology. Although alternate test methods are being used, fines for falling out of compliance can cost some companies millions. So, reducing fugitive emissions not only protects the environment but also saves money for industrial facilities.

Recently, there has been a focus on replacing the “repair” in LDAR with a more proactive, preventative approach that focuses on valve design and low emissions (low E) performance at the manufacturing level.

We rely on valves to stop and seal the flow of media in its various forms: solids, liquids, and  gases. Leakage of solids or liquids is relatively easy to spot, but some gas leakage isn’t something that can be detected by the naked eye.

With the help of testing, we are made aware of the failure of a valve to sufficiently stop gases from escaping. With this knowledge, we can improve our processes by upgrading problem valves.

Row of Butterfly Valves 

The Importance of Test Standards Organizations Quality standards for valve and packing tests are set by industry organizations such as ANSI, API, ISO, MESC, and TA-LUFT.

Today, we’ll focus on API pressure testing standards. The American Petroleum Institute (API) was founded in 1919 after World War I. The war raised awareness of the vital role the petroleum industry holds in the United States, so the API was formed to bolster and secure domestic oil and gas production.  Over 700 API standards have been put in place to promote efficiency, sustainability, and safety for both operations and the environment.

3 Types of API valves Testing

API 622 – Tests process valve packing for levels of fugitive emissions.

API 624 – Tests rising stem valves equipped with graphite packing for any fugitive emissions.

API 641 – Tests quarter-turn valves for levels of fugitive emissions.

Because API 622 is the first in the series of embedded low E valve and packing standards, it’s what we’ll cover today. For valves tested at API 641, packing must first qualify for the API 622 test. Also, for the packing used in an API 624 test, the valve must have been tested with API 622 first.

Why Are Fugitive Emission Tests Necessary?

Depending on what is leaked, fugitive emissions can be costly. There is concern surrounding methane gas emissions because this gas is flammable, considered to be harmful to the environment, and is a commodity. Not only is fugitive methane emission an environmental concern, but it’s also a financial loss when seeping valuable methane or incurring costly governmental fines.

With valves being to blame for over 50% of fugitive emissions, they are the main focus for testing. The Natural Resources Defense Council estimates that leak monitoring and repair could potentially account for 18% of methane emission reduction. When plant operations call for fugitive emissions monitoring, LDAR (leak detection and repair) is typically part of a monthly testing protocol.  

The good news is that as natural gas production has increased, emissions from this production continue to decrease. These improvements are due to voluntary action, compliance with regulations, or both. Advancements in technology along with improved testing are how we continue to mitigate fugitive emissions.