The Challenge
Pneumatic controllers are widely used to regulate pressure, temperature, and liquid levels, but many operate on natural gas sourced directly from the well. During normal operation, these devices vent methane as part of their control action. Poorly maintained controllers can exacerbate the issue by continuously venting fuel gas, even when no control response is required.
The Solution
Spartan Controls implemented a two‑part approach to eliminate methane emissions at the source. High‑bleed pneumatic controllers—defined as devices venting more than 6 scfh—were converted to low‑bleed controllers operating below 6 scfh, significantly reducing methane release during normal operation.
Where further emissions reduction was required, pneumatic control loops were retrofitted to operate on instrument air. This approach reduced on‑site air volume demand while eliminating greenhouse gas emissions from active dynamic loops, all without compromising process control or reliability.
Where further emissions reduction was required, pneumatic control loops were retrofitted to operate on instrument air. This approach reduced on‑site air volume demand while eliminating greenhouse gas emissions from active dynamic loops, all without compromising process control or reliability.
The Value
The combined low‑bleed conversion and instrument air retrofit delivered clear environmental and economic benefits:
- Up to 90% reduction in methane emissions from pneumatic control loops
- Significant fuel gas savings by eliminating continuous venting
- Lower operating costs through reduced gas losses and maintenance requirements
- Improved regulatory compliance, supporting methane‑reduction mandates
- Clear ROI, achieved without major process disruption