With global temperatures reaching record levels in 20241 (about 34.79 F [1.55 C] above preindustrial levels and above the target limit set by the Paris Agreement), there is a growing imperative for governments and businesses to reduce greenhouse gas emissions.
The production, transport and processing of oil and gas results in just under 15% of global energy-related greenhouse gas emissions, according to the International Energy Agency (IEA).2
Despite the shift toward renewables, the oil and gas industry is set to remain at the center of the world’s energy supply for many more years. It needs to cut its emissions by more than 60% by 2030 from today’s levels to align itself with a global temperature rise of 34.7 F (1.5 C). The emissions intensity of global oil and gas operations must also be near zero by the early 2040s, warns the IEA.
For oil and gas companies, cutting emissions from operations should be the number one task as part of their transition strategies, according to the IEA.3 A key emissions offender is methane, one of the most potent greenhouse gases. Around 80 metric tons (mt) of methane is emitted annually by the world’s top 10 emitting countries. The most recent findings from the IEA’s global methane tracker said emissions from the energy sector remain at a “near record high.”4
The U.S. is the biggest emitter. According to recent aerial data from the Environmental Defense Fund, U.S. emissions are much higher than previously thought, and aggregate emissions from the 12 largest production basins could amount to 7.5 million mt a year.5 Statistics show that easing methane emissions in the oil and gas industry is highly cost-effective, and roughly 40% of methane emissions could be eradicated at no net cost.
While methane is a potent gas, it is also a valuable resource. More than 260 billion cubic meters (bcm) of natural gas is currently wasted worldwide through flaring and methane. With the appropriate policies and implementation, around 200 bcm of extra gas could be brought to market.
The IEA is optimistic that the oil and gas industry is well positioned to scale up some critical technologies for the clean energy transition. This article will examine the electrification, digitization and automation of upstream processes, including operational and decarbonizing opportunities.
Using Intelligent Actuators in Upstream Processes
Methane emissions can be slashed by more than 75% with simple solutions such as leak detection, repair programs and upgrading leaky equipment to include intelligent electric actuators. Typically, oil and gas infrastructure has employed spring-return and diaphragm actuators powered by processed gas, particularly in isolated or extreme conditions. If operators shift to electrically powered flow control, they can benefit from uptime and reduced risk, while also reducing upstream methane emissions.
Low-energy electric flow control solutions can use less power and control the flow of liquids and gases more accurately, eradicating vented gas like methane. They only consume electricity when in operation and do not vent. Using well-stream gas as their motive power means typical pneumatic diaphragm actuators release methane every time the valve is stroked. To reduce these emissions, some operators have replaced well-stream gas with air compressors, but these require a great deal of power.
The design of electric actuators also means they are less susceptible to environmental factors like air quality fluctuations and temperature variations, which affect pneumatic actuators more due to their intricate structure.
Electric actuators may be used in applications ranging from gas metering and processing to production tree, saltwater disposal and gas lift systems. As low-powered alternatives, they can help improve safety and prevent the risk of damage to plant equipment. Many of them come with fail-to-position options, which automatically return valves to a predetermined position in the event of emergencies or power loss.
They also include advanced diagnostic features to enable remote monitoring of conditions, performance and potential problems. For operators, this is critical, as it means any potential issues can be spotted and resolved earlier, averting unforeseen failures and downtime. An intelligent flow control system can also automatically adjust valve conditions to cut energy use and emissions.
The Value in Data Gathering
In today’s data-driven age, capturing valuable data is critical to sustainable business operations. Better data provides oil and gas operators with a clearer picture of their flow control systems, enabling more effective operations.
Where intelligent solutions can help:
- Production trees: Also known as the Christmas tree, this is an assembly of valves, spools and fittings that regulate the flow of oil or gas from a well. A production choke valve controls the flow of well fluids and regulates downstream pressure.
- Production processing: While many operators now use air compressor units at production sites as an alternative to methane-producing well-stream process gas, electric control valve actuators support net-zero emissions while also cutting overall life cycle costs compared to the instrument air actuator alternative.
- Gas metering and LACT skids: Natural gas production metering and lease automotive custody transfer (LACT) skids connect upstream operations to midstream gathering infrastructure. To automate large control valves with high-pressure ratings, a high output actuator provides greater linear thrust and stroke length.
- Gas lift systems: A gas lift system lifts the fluids to the surface when extracting oil from underground wells. Key to this is a reliable supply of high-pressure gas injected into the well, with flow and pressure modulated by a control valve.
- Saltwater disposal systems: Produced water (the largest liquid created in the oil and gas industry) is carried through a gathering line network to recycling tanks or saltwater disposal units. Actuated valves and back-pressure control valves are critical to this intricate system.
The IEA has warned that most oil and gas companies are “watching the energy transition from the sidelines.” Considering intelligent solutions such as electric actuators is one way to take that all-important first step toward cleaner energy and a cleaner world.
References
- wmo.int/news/media-centre/wmo-confirms-2024-warmest-year-record-about-155degc-above-pre-industrial-level
- iea.org/reports/the-oil-and-gas-industry-in-net-zero-transitions/executive-summary
- iea.org/reports/global-methane-tracker-2024/key-findings
- edf.org/media/new-data-show-us-oil-gas-methane-emissions-over-four-times-higher-epa-estimates-eight-times
- iea.blob.core.windows.net/assets/f065ae5e-94ed-4fcb-8f17-8ceffde8bdd2/TheOilandGasIndustryinNetZeroTransitions.pdf
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