# Lessons Learned

from Natural Gas STAR Partners



# Options For Reducing Methane Emissions From Pneumatic Devices In The Natural Gas Industry

Executive Summary

Pneumatic devices powered by pressurized natural gas are used widely in the natural gas industry as liquid level controllers, pressure regula tors, and valve controllers. Methane emissions from pneumatic devices, which have been estimated at 51 billion cubic feet (Bcf) per year in the production sector, 14 Bcf per year in the transmission sector and <1 Bcf per year in the processing sector, are one of the largest sources of vented methane emissions from the natural gas industry. Reducing these emissions by replacing high-bleed devices with low-bleed devices, retrofitting high-bleed devices, and improving maintenance practices can be profitable.

Natural Gas STAR Partners have achieved significant savings and methane emissi on reductions through replacement, retrofit, and maintenance of high-bleed pneumatics. Partners have found that most retrofit investments pay for themselves in little over a year, and replacements in as little as 6 months. To date, Natural Gas STAR Partners have saved 36 .4 Bcf by retrofitting or replacing high-bleed with low-bleed pneumatic devices, representing a savings of $254.8 million worth of gas. Individual savings will vary depending on the design, condition and specific operating conditions of the controller.



## Technology Background

The natural gas industry uses a variety of control devices to automatically operate valves and control pressure, flow, temperature or liquid levels. Control devices can be powered by electricity or compressed air, when available and economic. In the vast majority of applications, however, the gas industry uses pneumatic devices that employ energy from pressurized natural gas.

Natural gas powered pneumatic devices perform a variety of functions in all three sectors of the natural gas industry. In the production sector, an estimated 400,000 pneumatic devices are used to control and monitor gas and liquid flows and levels in dehydrators and separators, temperature in dehydrator regenerators, and pressure in flash tanks. In the processing sector, about 13,000 gas pneumatic devices are used for compressor and glycol dehydration control in gas gathering/booster stations and isolation valves in processing plants (process control in gas processing plants is predominantly instrument air).



## Economic and Environmental Benefits

Method for Reducing Natural Gas Losses Volume of Natural Gas

Savings (Mcf/year) Value of Natural Ga s Savings ($/year) Implementation Cost ($) Payback (Months)

$3 per Mcf $5 per Mcf $7 per Mcf $3 per Mcf $5 per Mcf $7 per Mcf

Change to lowbleed device at end of life. 50 to 200 $150 to $600 $250 to $1,000 $350 to $1,400 $210 to $340 a 4 to 27 3 to 17 2 to 12

Earlyreplacement of high-bleed unit. 260 $780 $1,300 $1,820 $1,850 29 17 13

Retrofit 230 $690 $1,150 $1,610 per year $675 12 7 5

Maintenance 45 to 260 $135 to $780 $225 to $1,300 $315 to $1,820 Negligible to $500 Immediate to 8 Immediate to 5 Immediate to 4 General Assumptions:

a Incremental cost of low-bleed over high-bleed equipment. Replacement



## 1

# Options For Reducing Methane Emissions From Pneumatic Devices In The Natural Gas Industry (Cont’d)

In the transmission sector, an Definition of High-Bleed 

## estimated 85,000 pneumatic Pneumatic 

## devices actuate isolation Any pneumatic device that 

## valves and regulate gas flow bleeds in excess of 6 scfh (over 

## and pressure at compressor 50 Mcf per year) is considered a 

## stations, pipelines, and high-bleed device by the Natural 

## storage facilities. Non-bleed Gas STAR Program. 

## pneumatic devices are also found on meter runs at distribution company gate st ations for regulating flow, pressure, and temperature.

As part of normal operation, pneumatic devices release or bleed natural gas to the atmosphere and, consequently, are a major source of methane emissions from the natural gas industry. The actual bleed rate or emissions level largely depends on the design of the device.

Exhibit 1 shows a schematic of a gas pneumatic control system. Clean, dry, pressurized natural gas is regulated to a constant pressure, usually around 20 psig. This gas supply is used both as a signal and a power supply. A small stream is sent to a device that measures a process condition (liquid leve l, gas pressure, flow, temperature). This device regulates the pressure of this small gas stream (from 3 to 15 psig) in proportion to the process condition. The stream flows to the pneumatic valve controller, where its variable pressure is used to regulate a valve actuator.

To close the valve pictured in Exhibit 1, 20-psig pneumatic gas is directed to the actuator, pushing the diaphragm down against the spring, which, through the valve stem, pushes the valve plug closed. When gas is vented off the actuator, the spring pushes the valve back open. The weak signal continuously vents (bleeds) to the atmosphere. Electro-pneumatic devices use weak electric current instead of the weak gas stream to signal pneumatic valve actuation.

In general, controllers of similar design usually have similar steady-state bleed rates regardle ss of brand name. Pneumatic devices come in three basic designs:

 Continuous bleed devices are used to modulate flow, liquid level, or pressure and will generally vent gas at a steady rate;

 Actuating or intermittent bleed devices perform snap-acting control and release gas only when they stroke a valve open or closed or as they throttle gas flows; and 

## Exhibit 1: Pneumatic Device Schematic

 Self-contained devices release gas into the downstream pipeline, not to the atmosphere.

To reduce emissions from pneumatic devices the following options can be pursued, either alone or in combination:

1. Replacement of high-bleed devices with low-bleed devices having similar performance capabilities.

2. Installation of low-bleed retrofit kits on operating devices.

3. Enhanced maintenance, cleaning and tuning, repairing/replacing leaking gaskets, tubing fittings, and seals.

Field experience shows that up to 80 percent of all highbleed devices can be replaced with low-bleed equipment or retrofitted. Exhibit 2 lists the generic options applicable for different controller requirements.

In general, the bleed rate will also vary with the pneumatic gas supply pressure, actuation frequency, and age or condition of the equipment. Due to the need for precision, controllers that must operate quickly will bleed more gas than slower operating devices. The condition of a pneumatic device is a stronger indicator of emission potential than age; well-maintained pneumatic devices operate efficiently for many years.

2

# Options For Reducing Methane Emissions From Pneumatic Devices In The Natural Gas Industry (Cont’d)

Exhibit 2: Options for Reducing Gas-Bleed Emissions by Controller Type

Action Pneumatic Types

Level Controllers Pressure Controllers Positioners/ Transducers
Replacements

High-bleed with low-bleed
Retrofits

Install retrofit kits
Maintenance

Lower gas supply pressure/replace springs/re-bench Repair leaks, clean and tune
Change gain setting

Remove unnecessary positioners X

X

X

X

X X

X

X

X

X X

X

X

X X (electro

pneumatic)



## Economic and Environmental Benefits

Reducing methane emissions from high-bleed pneumatic devices through the options presented above will yield significant benefits, including:

 Financial return from reducing gas-bleed losses. Using a natural gas price of $7.00 per thousand cubic feet (Mcf), savings from reduced emissions can range from $315 to $1,820 or more per year per device. In many cases, the cost of implementation is recovered in less than a year.

 Increased operational efficiency. The retrofit or complete replacement of worn units can provide better system-wide performance and reliability and improve monitoring of para meters such as gas flow, pressure, or liquid level.

 Lower methane emissions. Reductions in methane emissions can range from 45 to 260 Mcf per device per year, depending on the device and the specific application.



## Decision Process

Operators can determine the gas-bleed reduction option that is best suited to their situation, by following the decision process laid out below. Depending on the types of devices that are being considered, one or more options for reducing pneumatic gas bleed may be appropriate.

Step 1: Locate and describe the high-bleed devices. Partners should first identify the high-bleed devices that are candidates for replacement, retrofit, or repair. The identification and description process can occur duringnormal maintenance or during a system-wide or facilityspecific pneumatics survey. For each pneumatic device, record the location, function, make and model, condition, age, estimated remaining useful life, and bleed rate characteristics (volume and whether intermittent or continuous).

The pneumatic device’s bleed rate can be determined through direct measurement or from data provided by the manufacturer. Direct measur ement might include bagging studies at selected instru ments, high-volume sampler measurements (see “Directed Inspection and Maintenance at Compressor Stations” Lessons Learned) or the operator's standard leak measurement approach. Operators will find it unnece ssary to measure bleed rates at each device. In most case s, sample measurements of a few devices are sufficient. Experience suggests that manufacturers' bleed rates are understated, so measurement data should be used when it can be acquired.

Appendix A lists brand, model, and gas bleed information—as provided by manufacturers—for various pneumatic devices. This is not an exhaustive list, but it covers the most commonly used devices. Where available, actual field data on bleed rates are included.

Step 2: Establish the technical feasibility and costs of alternatives. Nearly all high-bleed pneumatic devices can be replaced or retrofitted with lower-bleed equipment. Consult your pneumatic device vendor or an instrumentation specialist for availability, specifications an d costs of suitable devices. Low-bleed devices ca n be requested by specifying bleed rates less than 6 standard cubic feet per hour (scfh). It is important to note that not all manufacturers report bleed rates in the same manner, an d companies should exercise

Five Steps for Reducing Methane Emissions from Pneumatic Devices: 1. Locate and describe the high-bleed devices; 2. Establish the technical feasibility and costs of alternatives; 3. Estimate the savings; 4. Evaluate the economics; and 5. Develop an implementation plan.



## 3

# Options For Reducing Methane Emissions From Pneumatic Devices In The Natural Gas Industry (Cont’d)

caution when making purchas es of low-bleed devices.

Appendix B lists cost data for many low-bleed pneumatic devices and summarize s the compatibility of retrofit kits with various controllers. This is not an exhaustive list, but it covers the most co mmonly used devices.

Maintenance of pneumatics is a cost-effective method for reducing emissions. All companies shou ld consider maintenance as an important part of their implementation plan. Cleaning and tuning, in addition to repairing leaking gaskets, tubing fittings, and seals, can save 5 to 10 scfh per device. Tuning to operate over a broader range of proportional band often reduces bleed rates by as much as 10 scfh. Eliminating unnece ssary valve positioners can save up to 18 scfh per device.

Some high-bleed devices, however, should not be replaced with low-bleed devices. Contro l of very large valves that require fast and/or precise response to process changes often require high-bleed controllers. These are found most frequently on large compressor discharge and bypass pressure controllers. EPA re commends contacting vendors for new fast-acting devices with lower bleed rates.

Step 3: Estimate the savings. Determine the quantity of gas that can be saved with a low-bleed controller, using field measurement of the highbleed controller and a similar lo w-bleed device in service. If these actual bleed rates are not available, use bleed specifications provided by manufacturers.

Gas savings can be monetized to annual savings using $7.00 per Mcf and multiplying bleed reduction, typically specified in scfh, by 8,670 hours per year.

Gas Savings = (High-bleed, scfh) — (Low-bleed, scfh)

Annual Gas Savings = Gas Savings (scfh) * 8,760 hrs/yr * 1 Mcf/1000scf * $7.00/Mcf

Step 4: Evaluate the economics.
The cost-effectiveness of replacement, retrofit, or maintenance of high-bleed pneumatic devices can be evaluated using straightforward economic analysis. A cost -benefit analysis for replacemen t or retrofit is appropriate unless high-bleed characteristics are required for operational reasons. Exhibit 3 illustrates a cost-benefit analysis for replacement of a high-bleed liquid level controller. Cash flow over a five-year period is analyzed by showing the magnitude and timing of costs (shown in parenthesis) and benefits. In this example, a $513 initial investment buys a level controller that saves 19 scfh of gas. At $7.00 per Mcf, the low-bleed device saves $1,165 per year. Annual maintenance costs for the new and old controllers are shown. The maintenance cost for the older high-bleed controller is shown as a benefit because it is an avoided cost. Net present value (NPV) is equal to the benefits minus the costs accrued over five years and discounted by 10 percent each year. Internal rate of return (IRR) is the discount rate at which the NPV generated by the investment equals zero.



## Exhibit 3: Cost-Effectiveness Calculation for Replacement

Type of Costs Year 0 Year 1 Year 2 Year 3 Year 4 Year 5 Implementation Costs, $ (Capital Costs) a (513)

Annual Savings, $ (New vs. Old) b
Maintenance 1,165 1,165 1,165 1,165 1,165

Costs, $ (New Controller) c Avoided (34) (34) (34) (34) (34)

Maintenance, $ (Replaced Controller) c 70 70 70 70 70

Net Benefit (513) 1,202 1,202 1,202 1,202 1,202

NPV d = $4,042 IRR = 234%

Notes:

a Quoted cost of a Fisher 2680 device. Adjusted to 2006 equipment costs. See Appendix B.

b Annual savings per device calculated as the change in bleed rate of 19 scfh x 8,760 hrs/hr = 167 Mcf/ yr at $7/Mcf.

c Maintenance costs are estimated.

d Net Present Value (NPV) based on 10% discount rate for 5 years.


## Exhibit 4 illustrates the range of savings offered by proven methods for reducing gas bleed emissions. For simplicity, it is assumed that the cost of maintenance of the pneumatic device will be the same before and after the replacement, retrofit, or enhanced maintenance activity.

As seen in Exhibit 4, sometimes more than one option to reduce gas bleed may be appropriate and cost-effective for a given application. For the listed options, please note that the payback period with respect to implementation cost can range from less than one month to two years.

4

# Options For Reducing Methane Emissions From Pneumatic Devices In The Natural Gas Industry (Cont’d)

Exhibit 4: Economic Benefits of Reducing Pneumatic Device Emissions

Action Cost a ($) Bleed Rate Reductions b (Mcf/ yr/device) Annual Savings c ($/year) Payback Period (months) IRR d (%)

Replacement

Level Controllers
High-bleed to low-bleed 513 166 1,165 6 226

Pressure Controllers High-bleed to low-bleed

Airset metal to soft-seal 1,809

104 228

219 1,596

1,533 14

<1 84

>1,400

Retrofit

Level Controllers

Mizer
Large orifice to small
Large nozzle to small 675

41

189 219

184

131 1,533

1,288

917 6

<1

3 226

>3,100

>450

Pressure Controllers Large orifice to small 41 184 1,288 <1 >3,100

Maintenance
All types
Reduce supply pressure
Repair leaks, retune 207

31 175

44 1,225

308 3

2 >500

>900

Level Controllers Change gain setting 0 88 616 Immediate

—-
Positioners
Remove unnecessary 0 158 1,106 Immediate

—-

a Implementation costs represent average costs for Fisher brand pneum atic instruments installed.

b Bleed rate reduction = change in bleed rate scf/hr x 8,760 hr/yr.

c Savings based on $7.00/Mcf cost of gas.

d Internal rate of return (IRR) calculated over 5 years.



## The case studies in Exhibit 5 on the next page present analyses performed and savings achieved by two Natural Gas STAR Partners who installed retrofit kits at gas production facilities.

Step 5: Develop an implementation plan. After identifying the pneumatic devices that can be profitably replaced, retrofitted or maintained, devise a systematic plan for implementing the required changes. This can include modifying the current inspection and maintenance schedule and prioritizing replacement or retrofits. It may be most co st-effective to replace all those devices that meet the technical and economic criteria of your analysis at one time to minimize labor costs and disruption of operation.

Where a pneumatic device is at the end of its useful life and is scheduled for replacement, it should be replaced with a low-bleed model instead of a new high-bleed device whenever possible.

When assessing options for replacement of high-bleed pneumatic devices, natural gas price may influence the decision making process. Exhibit 6 shows an economic analysis of early replacemen t of a high bleed pneumatic device with a lower bleed device at different natural gas prices.

5

# Options For Reducing Methane Emissions From Pneumatic Devices In The Natural Gas Industry (Cont’d)

Exhibit 5: Case Studies on Retrofit To Reduce Gas Leaks at Natural Gas STAR Partner Sites

Study Impleme ntation Costs ($) Emissions Reductions

(Mcf/yr) Annual Savings

($/ year) Payback (months) IRR (%)

Company 1:

Platform 1

Platform 2

Retrofit Liquid-level controllers
Company 2:

Per device 8,988

13,892

5,452

702 2,286

3,592

1,717

219 16,002

25,144

12,019

1,533 7

7

6

6 177

180

220

218 

## Exhibit 6: Gas Price Impact on Economic Analysis

$3/Mcf $5/Mcf $7/Mcf $8/Mcf $10/Mcf

Value of Gas Saved Payback Period (months) Internal Rate of Return (IRR) Net Present Value ( i

=10%) $780

29

31%

$1,107 $1,300

18

64%

$3,078 $1,820

13

95%

$5,049 $2,080

11

110%

$6,035 $2,600

9

139%

$8,006



## Other Technologies

Instrument air, nitrogen gas, electric valve controllers, and mechanical control systems are some of the alternatives to gas powered pneumatics implemented by Partners.

 Instrument Air. These systems substitute compressed, dried air in place of natural gas in pneumatic devices, and thus eliminate methane emissions entirely. Inst rument air systems are typically installed at facilities where there is a high concentration of pneumatic control valves and fulltime operator presence (for example, most gas



## Nelson Price Indexes

In order to account for in flation in equipment and operating & maintenance costs, Nelson-Farrar Quarterly Cost Indexes (avail able in the first issue of each quarter in the Oil and Gas Journal ) are used to update costs in the Lessons Learned documents. The “Refinery Operation Index” is used to revise operating costs while the “Machinery: Oilfield Itemized Refining Cost Index” is used to update equipment costs. To use these indexes in the future, simply look up the most current Nelson-Farrar index number, divide by the February 2006 Nelson-Fa rrar index number, and, finally multiply by the appropriate costs in the Lessons Learned. processing plants use instrument air for pneumatic devices). The major costs a ssociated with instrument air systems are capital and energy. Instrument air systems are powered by el ectric compressors, and require the installation of dehydrators and volume tanks to filter, dry and store the air for instrumentation use. Genera lly, Partners have found that cost-effective implemen tation of instrument air systems is limited to field sites with available utility or self-generated electrical power. The Lessons Learned study, “Covert Gas Pneumatic Controls to Instrument Air,” provides a detailed description of the technical and economic decision process required to evaluate conversion from gas pneumatic devices to instrument air.

 Nitrogen Gas. Unlike instrument air systems that require capital expenditures and electric power, these systems only require the installation of a cryogenic liquid nitrogen cylinder, that is replaced periodically, and a liquid nitrogen vaporizer. The system uses a pressure regulator to control the expansion of the nitrogen gas (i.e., the gas pressure) as it enters the control system. The primary disadvantage of these systems stems from the cost of liquid nitrogen and the potential safety hazard associated with using cryogenic liquids.

 Electric Valve Controllers. Due to advances in technology, the use of electronic control instrumentation is increasing. These systems use small electrical motors to operate valves and therefore do not bleed natural gas into the atmosphere. While they are reliant on a constant

6

# Options For Reducing Methane Emissions From Pneumatic Devices In The Natural Gas Industry (Cont’d)

The average methane content of natural gas varies by natural gas industry sector. The Natural Gas STAR Program assumes the following methane content of natural gas when estimating methane savings for Partner Reported Opportunities.

Production 79 %
Processing 87 %

Transmission and Distribution 94 % 

## Methane Content of Natural Gas

supply of electricity, and have high associated operating costs, they have the advantage of not requiring the utilization of natural gas or a compressor to operate.

 Mechanical Control Systems. These devices have been widely used in the natural gas and petroleum industry. They operate using a combination of springs, levers, flow channels and hand wheels. While they are simple in design and require no natural gas or power supply to operate, their application is limited due to the need for the control valve to be in close proximity to the process measurement. Also, these systems are unable to handle large flow fluctuations and lack the sensitivity of pneumatic systems.

Each of these options has specific advantages and disadvantages. Where Natural Gas STAR Partners do install these systems as re placements to gas powered pneumatic devices, they should report the resulting emissions reductions and recognize the savings.



## One Partner’s Experience
Union Pacific Resources re placed 70 high-bleed pneumatic devices with low-bleed pneumatic devices and retrofitted 330 high-bleed pneumatic devices. As a result, this Partner has estimated a total reduction of methane emissions of 49,600 Mcf per year. Assuming a gas price of $7 per Mcf, the savings corresponds to $347,200. The costs of replacing and retrofitting all the devices, including materials and labor, is $166,300 at 2006 costs, resulting in a pay back period of less than
one year. 

## One Partner’s Experience Marathon Oil Company surveyed 158 pneumaticcontrol devices at 50 production sites using the HiFlow Sampler to measure emissions. Half of these controllers were identified as non-bleed devices (e.g., weighted dump valves, spring operated regulators, enclosed capillary temperature controllers, non-bleed pressure switches). High-b leed devices accounted for 35 of 67 level controllers, 5 of 76 pressure controllers, and 1 of 15 temperature controllers. Measured gas emissions were 583 scfh tota l; 86 percent of emissions came from level controllers, with leaks up to 48 scfh, and averaging 7.6 scfh. Marathon concluded that “control devices with hi gher emissions can be identified qualitatively by sound prior to leak measurement, making it unnecessary to quantitatively measure methane emissions using technologically advanced equipment.”



## Lessons Learned

Natural Gas STAR Partners of fer the following Lessons Learned:

 Hear it; feel it; replace it. Where emissions can be heard or felt, this is a sign that emissions are significant enough to warrant corrective action.

 Control valve cycle frequency is another indicator of excessive emissions. When devices cycle more than once per minute, they can be replaced or retrofitted profitably.

 Manufacturer bleed rate specifications are not necessarily what users will experience. Actual bleed rates will generally exceed manufacturer’s specifications because of operating conditions different from manufacturer’s assumptions, installation settings and maintenance.

 Combine equipment retrofits or replacements with improved maintenance activities. Do not overlook simple solutions such as re placing tubes and fittings or rearranging controllers.

 The smaller orifices in low-bleed devices and retrofit kits can be subject to cloggi ng from debris in corroded pipes. Therefore, pneumatic supply gas piping and tubing should be flushed out before retrofitting with

7

# Options For Reducing Methane Emissions From Pneumatic Devices In The Natural Gas Industry (Cont’d)

smaller orifice devices, and gas filters should be well maintained.

 When replacing pneumatic control systems powered by pressurized natural gas with instrument air or other systems, do not forget to account for the savings from the resulting methane emission reductions.

 Include methane emission reductions from pneumatics in annual reports submitted as part of the Natural Gas STAR Program.



## References

Adams, Jim, Norriseal, personal contact.
Burlage, Brian, Fisher Controls International, Inc., personal contact.
Colwell, Chris, Masoneilan, personal contact.

Fisher Controls International, Inc. Pneumatic Instrument Gas Bleed Reduction Strategy and Practical Application

. Garvey, J. Michael, DFC Becker Operations, personal contact.
Hankel, Bill, Ametek - PMT Division, personal contact.
Henderson, Carolyn, U.S. EPA Na tural Gas STAR Program, personal contact.
Husson, Frank, ITT Barton, personal contact.
Loupe, Bob, Control Systems Specialist Inc., personal contact.
Murphy, John, Bristol Babcock, personal contact.
Radian Corporation. Pneumatic Device Characterization . Draft Final Report, Gas Research Institute and U.S. Environmental Protection Agency, January 1996.
Tingley, Kevin, U.S. EPA Natural Gas STAR Program, personal contact.
Wilmore, Martin R., Shafer Valve Company, personal contact.
Ulanski, Wayne. Valve and Actuator Technology . McGraw-Hill, 1991.

8

# Options For Reducing Methane Emissions From Pneumatic Devices In The Natural Gas Industry (Cont’d)

Appendix A

The following chart contains manufacturer-reported bleed rates. Actual bleed rates have been included whenever possible. Discrepancies occur due to a variety of reasons, including:

 Maintenance.

 Operating conditions.

 Manufacturer vs. operating assumptions.

It is important to note that manufacturer information has not been verified by any third party and there may be large differences between manufacturer-reported bleed rates and those found during operations. Until a full set of information is available, companies should be careful to compare bleed rates in standard units (CFH) when comparing manufacturers and models. During this study we found that manufacturers reported information in a wide range of different units and operating assumptions.



## Gas Bleed Rate for Various Pneumatic Devices

Controller

Model Type Consumption Rate (CFH)

Manufacturer Data Field Data (where available) High-Bleed Pneumatic Devices

**Fisher 4100 Series Pressure controller (large orifice) 35

**Fisher 2500 Series Liquid-level controllers (P.B. in mid range) 10-34 44-72

*Invalco AE-155 Liquid-level controller 44-63

*Moore Products—Model 750P Positioner 42

*Invalco CT Series Liquid-level controllers 40 34-87

**Fisher 4150/4160K Pressure controller (P.B. 0 or 10) 2.5-29

**Fisher 546 Transducer 21

**Fisher 3620J Electro-pneumatic positioner 18.2

Foxboro 43AP Pressure controller 18

**Fisher 3582i Electro-pneumatic positioner 17.2 **Fisher 4100 Series Pressure controller (small orifice) 15

**Fisher DVC 6000 Electro-pneumatic positioner 14

**Fisher 846 Transducer 12

**Fisher 4160 Pressure controller (P.B. 0.5) 10-34

**Fisher 2506 Receiver controller (P.B. 0.5) 10

**Fisher DVC 5000 Electro-pneumatic positioner 10

**Masoneilan 4700E Positioners 9

**Fisher 3661 Electro-pneumatic positioner 8.8

**Fisher 646 Transducer 7.8

**Fisher 3660 Pneumatic positioner 6

**ITT Barton 335P Pressure controller 6

*Ametek Series 40 Pressure controllers 6

Low- or No-Bleed Pneumatic Devices

**Masoneilan SV Positioners 4

**Fisher 4195 Series Pressure controllers 3.5

**ITT Barton 273A Pressure transmitter 3

**ITT Barton 274A Pressure transmitter 3

**ITT Barton 284B Pressure transmitter 3

**ITT Barton 285B Pressure transmitter 3

**Bristol Babcock Series 5457-70F Transmitter 3

**Bristol Babcock Series 5453-Model 624 -II Liquid-level controllers 3

**Bristol Babcock Series 5453-Model 10F Pressure controllers 3

**Bristol Babcock Series 5455 Model 624 -III Pressure controllers 3

**ITT Barton 358 Pressure controller 1.8



## 9

# Options For Reducing Methane Emissions From Pneumatic Devices In The Natural Gas Industry (Cont’d)

**ITT Barton 359 Pressure controller 1.8

**Fisher 3610J Pneumatic positioner 16

**Bristol Babcock Series 502 A/D Recording pneumatic controllers <6

**Fisher 4660 High-low pressure pilot <5

**Bristol Babcock Series Transducers 0.42 9110-00A Fisher 2100 Series Liquid-level controllers 1

**Fisher 2680 Liquid-level controllers <1

*Norriseal 1001 (A) (snap) Liquid-level controller 0.2 0.2

*Norriseal 1001 (A) Liquid-level controller 0 0 (‘Envirosave’) *Norriseal 1001 (A) (throttle) Liquid-level controller
Double-acting pilot 0.007 0.007

**Becker VRP-B -CH pressure control system (replaces controllers and positioners) 0-10

**Becker HPP-5 Pneumatic positioner (Double-acting) 0-10

**Becker EFP

2.0 Electro-pneumatic positioner Single-acting pilot 0

**Becker VRP

SB pressure control system (replaces controllers and positioners) 0

**Becker VRP

SB GAP Controller Replaces pneumatic “gap” type controllers Single-acting pilot pressure control 0

**Becker VRP- system specifically SB-PID designed for power 0 Controller plant type feeds (replaces controllers and positioners) Single-acting pilot

**Becker VRP

SB-CH pressure control system (replaces controllers and positioners) 0

**Becker HPP

SB Pneumatic positioner (Single-acting) 0 Actuator Model Size Manufacturer Data Field Data

*Shafer RVSeries Rotary Vane Valve Actuators 33” x 32” 1,084

36” x 26” 768

26” x 22” 469

25” x 16” 323

20” x 16” 201

16.5” x 16” 128

14.5” x 14” 86

12.5” x 12” 49

12” x 9” 22

11” x 10” 32

9” x 7” 12

8” x 6.5” 8

6.5” x 3.5” 6

5” x 3” 6

Actuator

Model Size Number of Snap-acting Strokes per CF Number of Throttling

Strokes per CF **Fisher Valve Actuators **Fisher Valve Actuators **Fisher Valve Actuators **Fisher Valve Actuators **Fisher Valve Actuators 20

30

34/40

45/50

46/50 21

12

6

3

2 39

22

10

5

3

* Last updated in 1996. ** Last updated in 2001.



## 10

# Options For Reducing Methane Emissions From Pneumatic Devices In The Natural Gas Industry (Cont’d)

Appendix B

Controllers Compatible with MIZER Retrofits

Type Brand/Model Number
Liquid-level controllers C.E. Invalco — 215, 402, AE-155
Norriseal — 1001, 1001A

Pressure controllers Norriseal — 4300 Suggested Retail Prices for Various Brand Low-Bleed Pneumatic Devices

Brand/Model Price per Device (Estimates Based on Best Information Available at Time of Publication)

**ITT Barton 335P (pressure controller) $920 **ITT Barton 273A (pressure transmitter) $1,010
**ITT Barton 274A (pressure transmitter) $1,385
**ITT Barton 284B (pressure transmitter) $1,605
**ITT Barton 285B (pressure transmitter) $1,990

**ITT Barton 340E (recording pressure controller) $1,400
**ITT Barton 338E (recorder controller) $2,800 **Ametek Series 40 (pressure controllers) $1,100 (average cost)

**Becker VRP-B-CH $1,575.00

**Becker HPP-5 $1,675.00

**Becker VRP-SB $1,575.00-$2,000.00

**Becker VRP-SB-CH-PID $2,075.00

**Becker VRP-SB-CH $1,575.00

**Becker HPP-SB $1,675.00

**Mizer Retrofit Kits $400-$600 **Fisher 67AFR (airset regulators) $80
**Fisher 2680 (liquid-level controllers) $380
**Fisher 4195 (pressure controllers) $1,340

**Bristol Babcock Series 9110-00A (transducers) $1,535-$1,550
**Bristol Babcock Series 5453 (controllers) $1,540
**Bristol Babcock 5453 40 G (temperature controllers) $3,500

**Bristol Babcock Series 5457-624 II (controllers) $3,140

**Bristol Babcock Series 502 A/D (recording controllers) $3,000

**Bristol Babcock Series 5455-624 III (pressure controllers) $1,135

**Bristol Babcock Series 5453-624 II (liquid level controllers) $2,345

**Bristol Babcock Series 5453-10F (pressure controllers) $1,440
* Last updated in 1996. ** Last updated in 2001.



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# Options For Reducing Methane Emissions From Pneumatic Devices In The Natural Gas Industry (Cont’d)

United States Environmental Protection Agency Air and Radiation (6202J) 1200 Pennsylvania Ave., NW Washington, DC 20460

October 2006

EPA provides the suggested methane em issions estimating methods contained in this do cument as a tool to develop basic methane e missions estimates only. As regulatory reporting demands a higher-level of accuracy, the methane emission estimating methods and terminology contained in t his document may not conform to the Greenhouse Gas Reporting Rule, 40 CFR Part 98, Subpart W methods or those in other EPA regulations.



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