The Challenge
Pneumatic controllers are essential for regulating pressure, temperature, liquid levels, and other critical process variables, but many legacy devices operate using natural gas. During normal operation, these controllers continuously vent methane as part of their control action. High‑bleed controllers—defined as devices venting more than 6 scfh—can be a particularly significant source of emissions, while poorly maintained controllers may vent fuel gas continuously, even when no control response is required.
The Solution
Spartan Controls worked with operators to eliminate methane emissions at the source by modernizing pneumatic control infrastructure. This approach focused on converting high‑bleed pneumatic controllers to low‑bleed devices and retrofitting gas‑driven control loops to operate on instrument air. By deploying the LCO Air Compressor, operators were able to reduce on‑site air volume demand while maintaining reliable and responsive control performance.
Replacing fuel gas with instrument air eliminated methane emissions from active dynamic loops without disrupting operations. The solution improved maintainability reduced long‑term emissions risk and allowed operators to meet environmental objectives with a clear and defensible return on investment.
Replacing fuel gas with instrument air eliminated methane emissions from active dynamic loops without disrupting operations. The solution improved maintainability reduced long‑term emissions risk and allowed operators to meet environmental objectives with a clear and defensible return on investment.
The Value
By replacing gas‑driven pneumatic controllers with low‑bleed and instrument air solutions, operators achieved measurable environmental and operational improvements, including:
- Up to 90% reduction in methane emissions from pneumatic control loops
- Elimination of continuous fuel gas venting, reducing operating costs
- Improved regulatory and ESG compliance with a clear ROI justification
- More reliable and maintainable pneumatic control systems