Proven Results

Achieving Compliance and Fuel Gas Savings Through Pneumatic Optimization

August 4, 2026

Eliminate methane emissions while improving operational efficiency through pneumatic controller retrofits and instrument air conversion.

Pneumatic controllers are widely used to regulate critical process variables, including pressure, temperature, and liquid level control.

Challenges included:

High-bleed pneumatic controllers continuously consuming natural gas during operation.
Methane emissions released through active control loops.
Poorly maintained pneumatic devices potentially venting fuel gas continuously.
Increasing pressure to reduce emissions and meet environmental compliance requirements.
Lost fuel gas creating unnecessary operating costs.

The Solution

Implemented a pneumatic controller optimisation strategy focused on emissions reduction and operational efficiency.

Key actions included:

Converting high-bleed pneumatic controllers (>6 scfh) to low-bleed controllers (<6 scfh).
Retrofitting pneumatic systems to operate on instrument air rather than fuel gas.
Reducing overall air volume demand across the site.
Eliminating greenhouse gas emissions from active dynamic control loops.
Supporting environmental compliance initiatives while improving control system performance.

The solution delivered measurable operational and environmental benefits by:

Eliminating methane emissions from pneumatic control applications.
Reducing operational costs associated with fuel gas consumption.
Improving fuel gas savings across the facility.
Supporting environmental and regulatory compliance requirements.
Delivering a measurable return on investment through emissions reduction and operating cost improvements.