Lessons Learned from the 

Natural Gas STAR Program 

Options for Reducing Methane 

Emissions from Pneumatic Devices 

Producers Technology Transfer Workshop 

Newfield Exploration Company,
 

Anadarko Petroleum Corporation,
 

Utah Petroleum Association,
 

Interstate Oil & Gas Compact Commission,
 

Independent Petroleum Association of Mountain States
 

Vernal, UT 

March 23, 2010 

epa.gov/gasstar 

Pneumatic Devices: Agenda 

Methane Losses
 

Methane Recovery
 

Is Recovery Profitable?
 

Industry Experience
 

Discussion Questions
 

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1 
2007 Production Sector Methane Emissions 

Storage Tank Venting
 

Well Venting and Flaring 5 Bcf
 

7 Bcf
 

Meters and Pneumatic Devices 

43 Bcf Pipeline Leaks
 

8 Bcf
 

Compressor 

Fugitives, Venting,
 

And Exhaust
 

12 Bcf
 

EPA. Inventory of U.S. Greenhouse Gas Emissions and Sinks 1990 – 2007. April, 2009. Available on the web at: 

epa.gov/climatechange/emissions/usinventoryreport.html 2 Note: Natural Gas STAR reductions from gathering and boosting operations are reflected in the production sector. 

Offshore Operations 

29 Bcf 

Other Sources 

7 Bcf 

Dehydrators 

and Pumps 

12 Bcf 

What is the Problem? 

Pneumatic devices are collectively a major source

of methane emissions from the natural gas industry 

Natural gas powered pneumatic devices used

throughout the oil and natural gas industry
 

Natural Gas Systems Petroleum Systems 

Production and 

Gathering1 411,000 379,436 

Processing1 11,000 -

Transmission and 

Storage1 85,000 -

1 - Inventory of U.S. Greenhouse Gas Emissions and Sinks 1990 - 2008 

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2 
Methane Emissions 

As part of normal operations, pneumatic devices

release natural gas to atmosphere
 

High-bleed devices bleed in excess of 6 scf/hour 

Equates to >50 Mcf/year 

Typical high-bleed pneumatic devices bleed an average of

140 Mcf/year 

Actual bleed rate is largely dependent on device’s

design 

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Location of Pneumatic Devices at 

Production Sites 

Wellheads 

SOV = Shut-off valve (Unit isolation) 

LC = Level control (Separator, contactor, flash tank 

separator, TEG regenerator) 

TC = Temperature control (Regenerator fuel gas) 

FC = Flow control (TEG circulation, compressor 

bypass) 

PC = Pressure control (FTS pressure, compressor 

suction/discharge) 

PC PC 

SOV SOV

LC 

SOV 

Separator Dehydrator 

Unit Compressor To

Pipeline 

FC 

LC TC FC PC 

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6 

Pneumatic Device Schematic 

Pneumatic 

Controller 

Process 

Measurement 

Liquid Level 

Pressure 

Temperature 

Flow 

Weak Signal Bleed 

(Continuous) 

Strong Signal Vent 

(Intermittent) 

Process Flow Control Valve 

Valve Actuator 

Strong 

Pneumatic 

Signal 

Weak Pneumatic 

Signal (3 to 15 psi) 

Regulator 

Gas 

100+ psi 

Regulated Gas Supply 

20 psi 

psi = pounds per square inch 

How Can Methane Emissions be 

Recovered? 

Option 1: Replace high-bleed devices with low-bleed

devices 

Option 2: Retrofit controller with bleed reduction kits 

Field experience shows that up to 80% of all high-bleed 

devices can be replaced or retrofitted with low-bleed 

equipment 

Option 3: Maintenance aimed at reducing losses 

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4 
 

Option 1: Replace High-Bleed Devices 

Most applicable to
 

Controllers: liquid-level and pressure
 

Positioners and transducers
 

Suggested action: evaluate replacements
 

Replace at end of device’s economic life
 

Early replacement
 

Norriseal Fisher 

Pneumatic Liquid Electro-Pneumatic 

Level Controller Transducer 

Source: www.emersonprocess.com Source: www.norriseal.com 

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Option 1: Cost to Replace High-Bleed

Devices 

Costs vary with size:
 

Typical costs range from $700 to $3,000 per device
 

Incremental costs of low-bleed devices are modest ($150 

to $250) 

Gas savings often pay for replacement costs in short 

periods of time (2 to 8 months) 

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5 
Option 2: Retrofit with Bleed Reduction 

Kits 

Applicable to most high-bleed controllers 

Suggested action: evaluate cost-effectiveness as

alternative to early replacement
 

Retrofit kit costs ~ $675 

Payback time ~ 9 months 

10 

Option 3: Maintenance to Reduce 

Losses 

Applies to all pneumatic devices 

Suggested action: add to routine maintenance

procedures
 

Field survey of controllers 

Where process allows, tune controllers to minimize bleed 

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6 
 

 

Option 3: Maintenance to Reduce 

Losses (cont’d) 

Becker 

Single-Acting 

Suggested action (cont’d): 

Re-evaluate the need for pneumatic Valve Positioner 

positioners 

Repair/replace airset regulators
 

Reduce regulated gas supply 

pressure to minimum
 

Routine maintenance should 

include repairing/replacing 

leaking components
 

Costs are low Source: www.bpe950.com 

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Five Steps for Reducing Methane

Emissions from Pneumatic Devices 

Locate and INVENTORY high-bleed devices 

ESTIMATE the savings 

EVALUATE economics of alternatives 

DEVELOP an implementation plan 

ESTABLISH the technical feasibility and 

costs of alternatives 

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Suggested Analysis for Replacement 

Replacing high-bleed controllers at end of their 

economic life 

End of economic life when major overhaul cost avoided 

Determine incremental cost of low-bleed device over highbleed equivalent 

Determine gas saved with low-bleed device using 

manufacturer specifications 

Compare savings and cost 

Early replacement of high-bleed controllers 

Compare gas savings of low-bleed device with full cost of 

replacement 

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Economics of Replacement
 

Replace at 

End of Life 

Early Replacement 

Level Control Pressure Control 

Cost ($) 1 210 – 340 2 513 1809 

Annual Gas Saving 

(Mcf) 50 - 200 166 228 

Annual Value of 

Gas Saved ($) 3 350 - 1400 1165 1596 

Paybacks 

(months) 3 - 8 6 14 

IRR (%) 4 138 - 933 226 84 

1 - All data based on partners’ experiences. See Lessons Learned for more information 

2 - Range of incremental costs of low-bleed over high bleed equipment 

3 - Gas price is assumed to be $7/Mcf 

4 - Internal Rate of return IRR calculated over 5 years 

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8 
 

Suggested Analysis for Retrofit 

Retrofit of low-bleed kit 

Compare savings of low-bleed device with cost of conversion kit 

Retrofitting reduces emissions by average of 90% 

Level Controllers Pressure Controllers 

Mizer Large to small 

orifice 

Large to small 

nozzle Large to small orifice 

Implementation Costs1 

($) 675 41 189 41 

Bleed rate reduction 

(Mcf/device/year) 219 184 131 184 

Value of gas saved

($/year) 2 1533 1288 917 1288 

Payback (months) 6 <1 3 <1 

IRR (%) 3 226 >3100 >450 >3100 

1 - All data based on partners’ experiences. See Lessons Learned for more information 

2 - Gas price is assumed to be $7/Mcf 

3 - Internal Rate of return IRR calculated over 5 years 16 

Suggested Analysis for Maintenance 

For maintenance aimed at reducing gas losses 

Measure gas loss before and after procedure 

Compare savings with labor (and parts) required for 

activity 

Reduce Supply

Pressure 

Repair &

Retune 

Change

Settings 

Remove Valve 

Positioners 

Implementation Cost ($) 1 207 31 0 0 

Gas Savings (Mcf/year) 175 44 88 158 

Value of gas saved

($/year) 2 1225 308 616 1106 

Payback (months) 3 2 immediate Immediate 

IRR 3 >500% >900 --- ---

1 - All data based on partners’ experiences. See Lessons Learned for more information 

2 - Gas price is assumed to be $7/Mcf 

3 – Internal rate of return (IRR) calculated over 5 years 17 

9 
Industry Experience – Chesapeake Energy 

Level controllers retrofitted with 

Mizer components
 

Hi-flow sampler used to measure Fisher 2500, 2506 

Retrofit w/ Mizer, bracket, emissions reduction from tubing & relay plug 

retrofits 

Invalco 415, 215, 402 Cemco/WellMark 6900 Retrofit w/ Mizer valve, Retrofit w/ Mizer Valve block & gauges 18 

Industry Experience – Chesapeake Energy
 

District 

Retrofits Done 

Thru 

31-Mar-09 

Total Capital 

($) 

Daily Reduction

(MCF) 

Annual Reduction 

(MMCF) 

Anadarko 1264 685,088 885 324 

Arkansas 100 54,200 70 26 

N. Mid Continent 467 253,114 327 98 

Southern Oklahoma 372 201,264 260 99 

W. Mid Continent 47 25,474 33 13 

Gulf Coast 161 87,262 113 41 

Louisiana 17 9,214 12 4 

N. Permian 93 20,406 65 24 

S. Permian 149 80,578 104 22 

Total 2,670 1,447,140 1869 651 

Average Installation Cost = $542 

Using $3.50/MCF, the simple payback is 7 months 

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10 
 

Lessons Learned 

Most high-bleed pneumatics can be replaced with

lower bleed models 

Replacement options save the most gas and are

often economic
 

Retrofit kits are available and can be highly costeffective
 

Maintenance is low-cost and reduces gas loss 

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Discussion Questions 

To what extent are these opportunities being

implemented?
 

How could these opportunities be improved upon or

altered for use in your operation? 

What are the barriers (technological, economic, lack

of information, regulatory, focus, manpower, etc.)

that are preventing you from implementing these

practices? 

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