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Train Named Executive President of Emerson Automation Solutions


Emerson recently named new senior leadership appointments to its Office of the Chief Executive who now report directly to chairman and CEO David N. Farr, and help develop and guide the company’s global strategies.

Michael H. Train’s new title is executive president of Emerson Automation Sol...


All-Pro Fasteners Receives Monogram Licensing


All-Pro Threaded Products, an All-Pro Fasteners company, received the official API Q1 registration and on September 23, 2016 become the second of only two within the industry to have obtained both the API 20E & 20F monogram licenses.

The American Petroleum Institute (API) has confirmed that All-Pro...


New 2017 Construction Starts Increasing 5% to $713 Billion


The 2017 Dodge Construction Outlook predicts that total U.S. construction starts for 2017 will advance 5% to $713 billion, following gains of 11% in 2015 and an estimated 1% in 2016.

Manufacturing plant construction will increase 6%, beginning to recover after steep declines in 2015 and 2016 that refle...


U.S. Natural Gas Production Gives Back August Gains in September


U.S. natural gas production levels in the lower 48 states declined by nearly 1.2% in September 2016 compared to August 2016 levels, according to analysis from IHS Markit. September’s decline drops year-to-date production levels 1% compared to the same period in 2015.

Overall, lower 48 U.S. dry ga...


BCG: Technology Matters to Economic Growth


Despite its starring role in business and everyday life, many economists openly question whether technology is visible in traditional economic metrics such as GDP, productivity, and corporate profits.

The Boston Consulting Group (BCG) shows that, on the contrary, declines in technology investment are f...


Mid-Atlantic Manufacturing Activity Expands More Than Expected


Results from the Federal Reserve Bank of Philadelphia’s October Manufacturing Business Outlook Survey suggest that regional manufacturing conditions continued to improve. Indexes for general activity, new orders, and shipments were all positive this month. But firms in the Mid-Atlantic region re...


Process Control Goes Green

Oil and natural gas operators can help reduce methane and other emissions—and increase revenue—by replacing traditional pneumatic devices with energy-responsible pneumatic pressure and level control devices.


An estimated $20 billion or more in revenue is lost each year globally due to methane emissions. Coupled with this lost revenue, global greenhouse gas emissions (GHG), of which methane comprises a substantial portion, have been gaining ever increasing visibility from a variety of agencies, special interest groups, national and international companies, politicians and the general public. It’s clear that a substantial problem exists. Many companies, however, are looking to alleviate that problem by changing their methods of operations and sharing best practices with each other.


Countless studies have analyzed the net effects greenhouse gases have on our environment and have resulted in a diverse range of views on the subject. However, one accepted fact is that methane is the most potent of the global greenhouse gas (GHG) emissions. Each year significant amounts of methane—the primary constituent of natural gas—are emitted into the atmosphere. These emissions cause concern because of the increasing negative effects on the environment as a whole, as well as the large amounts of revenue lost as a result. The importance of reducing methane emissions cannot be understated; but with innovative technology and implementation of best practices, the entire world’s industries can shift toward using more environmentally responsible products for process control functions. This shift in thinking will also result in cost savings and increased revenue.

Many owners and operators at oil and gas production, processing and transmission facilities have already taken initiatives to eliminate or reduce methane emissions. One shining example, which illustrates the widespread collaboration among companies, is the EPA Natural Gas STAR program. This program is a voluntary partnership between the U.S. Environmental Protection Agency and numerous natural gas companies, which provides a way to share best practices for reducing emissions among member companies. Currently, the program includes 23 of the top 25 natural gas producing companies which constitute 62% of the production, processing, transmission and distribution of natural gas. It also constitutes 62% of the production, processing, transmission and distribution of natural gas. As Figure 1 illustrates, in the 14 years since the program was established, more than 577 billion cubic feet of methane emissions, at a value of $3.4 billion, have been eliminated through voluntary initiatives by the member companies—initiatives that have also provided these companies cost savings and increased operational efficiency.(1)

This article provides examples of opportunities to reduce methane emissions in oil and natural gas applications, and highlights the significant cost savings that can be realized by implementing available technologies in the process control market. The primary methane emissions mitigation method discussed in this article is identification and replacement of high-bleed pneumatic pressure and level control devices.


Continuous bleed pneumatic controllers are used in the oil and natural gas industry to regulate level, flow-rate, temperature or pressure. Given the infrastructure for installing these devices, natural gas may be the only option for a supply medium in places where it is not possible, economical or convenient for installing compressed air systems.
Nearly all pneumatic devices use the same basic design principle, which consists of a nozzle-flapper mechanism (Figure 2, left) that executes throttling control and exhibits continuous or intermittent bleed of the supply medium. Varying the separation between the flapper and nozzle alters the resistance to gas flow. Increasing the distance between the nozzle and the flapper reduces nozzle resistance and output pressure, while decreasing the distance has the opposite effect. In most pneumatic devices that use this concept, the inherent design of the nozzle flapper mechanism is the only reason the supply medium bleeds to the atmosphere.

Controllers that use a three-way valve for proportional band control also introduce another way for supply gas to bleed to the atmosphere (Figure 2, right). Some pneumatic controllers are designed to bleed only when the unit is in transient operation, or cycling, while others bleed both during steady-state conditions and transients. The steady-state bleed tends to dominate the emissions reduction focus; however, consumption during transients should not be underestimated because of the potentially significant effect on the total amount of gas consumed by the device.

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