Methane is the primary component of natural gas, making up over 90% of its composition. Methane leaks in the natural gas supply chain contribute significantly to greenhouse gas (GHG) emissions. While natural gas is a cleaner-burning fossil fuel, its primary component, methane (CH₄), is 86 times more potent than CO₂ over a 20-year period. Addressing these leaks is crucial for both environmental and financial sustainability.
Follow these steps to improve operational efficiency and reduce methane emissions.
Step 1: Identify Common Leak Sources
Methane leaks can occur throughout the natural gas and renewable natural gas (RNG) infrastructure. The most common sources include:
- Valves & Flanges – Over time, gaskets degrade, and improper installation or misalignment can lead to emissions.
- Compressors & Seals – High-pressure conditions can wear out seals, leading to fugitive leaks.
- Pneumatic Instruments – Many controllers and actuators vent methane as part of normal operation.
- Storage Tanks & Pipelines – Faulty seals or loose connections can allow methane to escape.
Key Fact: Fugitive equipment leaks alone accounted for 35 million metric= tons CO₂e in 2022.
Step 2: Use Advanced Sealing Solutions
Preventing leaks at the source is the most effective and cost-efficient way to reduce emissions. Upgrading to low-emission sealing technologies significantly lowers methane losses.
Upgrade to High-Performance Gaskets & Packing:
- TEADIT® 913M Spiral Wound Gasket – Designed for extreme conditions, reducing fugitive emissions.
- Teadit 2848 Valve Packing – Engineered for tight sealing around valve stems in both control and isolation valves, reducing methane leaks.
Ensure Proper Installation & Material Selection:
- Select gaskets and packing that meet low fugitive emission standards to ensure best-in-class sealing performance.
- Use proper bolt load or torque settings to maintain seal integrity over time.
- Avoid generic PTFE or graphite where process conditions require chemical or thermal resistance.
Key Fact: Facilities that replace conventional gaskets and valve packing with low-emission alternatives can cut methane leaks by 90–96%, based on typical leak rate reductions from 10,000 ppm to under 100 ppm.
Step 3: Implement Leak Detection & Maintenance
Detecting and addressing leaks before they become costly problems is essential. Best practices include:
Leak Detection Methods:
- Optical Gas Imaging (OGI): Cameras that visualize gas leaks in real-time.
- Ultrasonic Detectors: Identify high-frequency sounds produced by leaks.
- Methane Sniffers: Detect trace methane levels near equipment.
Best Practices for Leak Prevention:
- Establish a proactive inspection schedule (monthly or quarterly).
- Implement leak-tight installation standards to prevent future failures.
- Conduct preventive gasket replacements to avoid unexpected leaks.
Key Fact: Companies that implement routine leak detection & repair (LDAR) programs reduce emissions and improve equipment lifespan.
Step 4: Measure the Benefits
Reducing methane emissions not only protects the environment but also saves money and improves operational efficiency.
Financial Savings:
- A facility with 1,000 flange pairs and 100 valves can, roughly, save $50,000 or more per year by reducing lost product and avoiding emissions-related penalties.
- Lower maintenance costs from reduced equipment failures.
Environmental Compliance & Sustainability:
- Avoid penalties from upcoming EPA methane regulations and the “Waste Emissions Charges” (effective in 2025).
- Reduce carbon footprint while maintaining energy efficiency.
Operational Reliability:
- Longer equipment lifespan with high-performance gaskets & seals.
- Fewer unexpected shutdowns & costly downtime.
Key Fact: A facility with 1,000 flange pairs & 100 valves can cut fugitive emissions from 800 metric tons CO₂e to less than 30 metric tons CO₂e per year using advanced sealing solutions.
Take Action Today
Assess your current system for leak-prone areas. Upgrade to low-emission sealing solutions like Teadit 913M & 2848. Implement a leak detection & maintenance program to prevent future losses.
By following these steps, you can cut emissions, save money, and ensure long-term compliance.
For a more in-depth understanding of how to cut methane leaks, read the full article.
