Cathodic protection and network management: find out more

With the valuable collaboration of Lluís Castaño, Product Manager at Kromschroeder, S.A. (Automa’s partner in Spain)

Biomethane represents a key resource for the energy transition, but its injection into distribution networks poses operational and technological challenges related to pressure and service continuity. In fact, before being injected, biomethane must meet strict quality standards regarding gas quality, measurement, treatment, pressure regulation, and odorization.

These challenges require innovative solutions. AUTOMA has therefore developed specific algorithms for its GOLEM system for dynamic gas pressure regulation in networks. The main application field of GOLEM was indeed the management of natural gas networks, but thanks to newly developed algorithms, now the system can also be applied to the biomethane sector with the aim of injecting biomethane into distribution networks while dynamically regulating the pressure of natural gas in the network.

Biomethane and distribution networks

The production of biomethane starts from waste produced by human activities, such as solid waste, sewage, livestock, and forestry residues. When biogas remains in the waste treatment plant, it is not advisable to release it into the atmosphere because it produces very harmful effects, such as the greenhouse effect.

This combustible gas can be treated in the plant itself through electricity generators to produce electricity, and if we have an electricity grid nearby, we can inject the electricity into the grid.

And what if there is no electricity grid nearby? What we can do with the excess gas is reach an agreement with gas distribution companies to inject biogas into their gas distribution networks.

This can only be done on the condition that such gas is treated to be interchangeable with the methane present in the network, thanks to a process called upgrading: biogas can be considered biomethane and thus injected into the gas distribution network.

A gas distribution network has a certain constant volume. At any point in the network, there can be consumption, while gas is injected at one or more points in the network to try to maintain a pressure defined by the set point of the pressure regulators at the injection points. In steady-state conditions, there is an equilibrium between the flows at the injection points and the flows at the consumption points. The result is a constant pressure.

The critical issues of biomethane networks

Most biomethane injection points are characterized by small diameter pipes and a not very high available gas volume dependent on production capacity, subject to daily and seasonal fluctuations. Since at low-capacity biomethane production points the flow is very limited, anomalous operations of traditional pneumatic pressure regulators can occur.

Essentially, the main identified critical issues are four:

1. Reduction in production: a decrease in production can lower pressure, compromising the continuous injection of biomethane into the network.
2. Service interruption: sometimes, the interruption of service is caused by failures in the upgrading system, which is unable to maintain sufficient pressure or provide consistent quality gas.
3. Overproduction of biomethane: an increase in production beyond operational limits can compromise the safety of the network and/or the contractual terms between producer and operator.
4. Overpressure in the network: a temporary and spontaneous increase in network pressure can cause the interruption of injection.

The normal operation of a pressure regulator consists of opening when it is necessary to reach a certain pressure point based on its set point. If this value is not reached, the regulator opens fully, consuming the available amount of biomethane in a very short time, if limited by the capacity of the biogas plant. As the available amount of biomethane is consumed, a rapid depressurization of the production system occurs. The immediate effect can be the suspension of biomethane injection.

The cause of all these problems is the way static pressure regulators operate. In this context, the ability to dynamically regulate the pressure upstream of the regulator becomes a strategic function to ensure continuity and quality of service.

The Automa solution: the GOLEM technology for dynamic management of biomethane injection

In this specific case we are illustrating, we have made an adaptation of GOLEM to the operational needs of a gas distribution company that requested a solution for the regulation of biomethane injection in a distribution network. GOLEM by AUTOMA allows for dynamic management of biomethane injection, improving service continuity and reducing operational risks.

Golem technology is based on a mechanical servomechanism that interacts directly with the pilot of the pressure regulators, supported by an advanced electronic system. Thanks to the intelligence incorporated in the system, Golem can operate in autonomous mode, reducing the need for manual interventions. The system is applicable to any controller model and can be easily integrated into existing networks thanks to custom-designed adapters.

The characteristics of the GOLEM system are represented by four types of pressure and flow modulation:

• Pressure modulation is the ability to vary and maintain pressure, based on the set point.
• Flow limitation is the ability to keep the flow below a certain maximum value, while always providing the maximum possible pressure value.
• A weekly programming of pressure values for time slots is possible, for example, at night the pressure is lower than during the day.
• It is possible to compensate the flow by applying pressure values to a portion of a given maximum flow.

When a target pressure is assigned to the system that is higher or lower than the initial pressure read by the system, an algorithm with a condition analysis time is initiated. When it is necessary to increase or decrease the pressure, a motor movement is initiated. The period during which the engine moves is strictly controlled to ensure the amount of movement actually required, observing and analysing the variations in pressure and flow rate. A necessary, positive or negative movement is then appliedto increase or decrease the pressure and achieve the set target for the system.

This gradual approach will eventually lead to reaching or even exceeding the target pressure. If the target pressure is exceeded in the subsequent analysis, a countermeasure is decided upon for a time equal to half of the previous time. This progressive correction of the control screw movement ends when the target is reached within a given tolerance. The same logic of the algorithm is applied to maintain a flow restriction below a maximum value while always trying to maintain the highest possible pressure.

The GOLEM system examines the flow rate and pressure. If the flow rate is sufficiently high, but still within the safety range, the system will decide to open the regulator and deliver that amount of gas. In this way, the flow rate we had will tend to decrease, as will the inlet pressure. When the GOLEM system, continuously analysing these parameters, verifies that the pressure is approaching a value very close to the network pressure, it will close the gas transport to avoid the risk of gas flow interruption and thus redirect the biomethane to the storage tank of the upgrading system (overpressure condition).

As soon as the flow rate becomes dangerously low and approaches the lower limit, the GOLEM system reduces the gas flow to recover both the flow rate and the pressure. At some point, a constant flow should be reached.

The results of the Automa solution

Thanks to the implementation of GOLEM for the regulation of biomethane injection into the distribution network managed by our client, the dynamic flow management has kept pressures within the operating range even in the event of sudden production fluctuations, improving the overall stability of the network.

 Important results have therefore been achieved:

• Reduction of injection interruptions caused by pressure drops.
• Optimised management of biomethane overproduction.
• Greater resilience of the network in biomethane supply operations.

This paves the way for a safer, more efficient and sustainable management of the biomethane resource.

How was it possible to achieve these results? AUTOMA has been active since 1987 in the development of hardware and software solutions for the remote monitoring and control of gas transport and distribution networks, functional to their operational management.

Research and development of increasingly high-performance and innovative solutions is our daily commitment. To date, over 50,000 Automa devices are installed in more than 40 countries worldwide.

Do you want to manage the injection of biomethane in a more dynamic, flexible, and safe way?

Contact our team without obligation and we’ll tell you how we can optimise the control and management of your infrastructure.

European regulations have set the target of zero greenhouse gas emissions, such as methane, by 2050. To comply with these guidelines and therefore achieve the established sustainability goals, it is absolutely necessary to concretely pursue the energy transition objectives using technologically advanced solutions to progressively minimise gas losses in transport and distribution network.Leaks are normal (coming from pipes and joints, for example), but they still have a big impact: just think that we’re talking about leaks that can reach pressures of 4 or even 5 bar for 365 days a year.

Reducing natural gas emissions into the atmosphere and optimising the management of operating pressures in gas networks: this is the clear and ambitious objective, from which the Project 404 was born, which the Automa team is carrying out in synergy with 2i Rete Gas, a company of the Italgas Group.

Launched in 2024 and promoted by the Italian Regulatory Authority for Energy, Networks and Environment (ARERA), Project 404 is part of Resolution 404/2023/R/gas of ARERA, ‘Initiation of a procedure for defining measures aimed at reducing fugitive methane emissions in the natural gas distribution sector’.

In summary, Resolution 404/2023/R/gas aims to:

• Define tools and measures to reduce fugitive methane emissions in natural gas distribution networks;
• Establish monitoring, accounting, and reporting methods for such emissions;
• Promote the adoption of innovative technologies and practices aimed at environmental sustainability and the safety of infrastructures.

The central idea behind Project 404 is strongly innovative and ambitious: to implement the adoption of advanced technologies to dynamically modulate pressure in gas networks, automatically reducing it in real-time during periods of lower consumption.

For the implementation of the Project, Automa has employed the GOLEM system, a cutting-edge technological solution for intelligent pressure control.

This application of the GOLEM system introduces an approach to dynamic pressure management that is still little used not only in Italy but also internationally.

The Automa solution: the GOLEM technology applied to pressure control systems on off-take stations.

Automa’s GOLEM system, applied to pressure control systems in off-take stations, revolutionises the traditional static approach to pressure regulation. Unlike conventional methods that maintain a constant pressure based on the maximum annual demand of the plant, GOLEM dynamically modulates pressure based on the actual demand of the network. This allows to reach the highest pressure levels only when actually necessary, significantly lowering the average operating pressure and, consequently, reducing fugitive emissions.

Moreover, it should be noted that the installation of GOLEM is of the Plug&Play type, indeed, it does not require significant interventions on the mechanical and pneumatic part of the system. Meaning that it is not necessary to modify the existing mechanical and pneumatic part of the pressure regulator, it is sufficient to install the GOLEM on the pilot using the specially designed support brackets. The installation process of GOLEM is therefore quick, simple, and low operational impact.

This ease of integration has allowed the adoption of the system within Project 404, where, after an initial phase of laboratory testing, GOLEM has been implemented in the field, demonstrating its effectiveness without compromising service continuity.

The Project provided for the installation of the GOLEM system on a complex configuration represented by 2 interconnected off-take stations serving the same plant.

In this context, the system operates through two algorithms that act in parallel to ensure intelligent and stable management of the stations.

The ultimate goal is the complete automation of the system, with the aid of predictive software capable of anticipating the gas demand of the network.

This will lead to optimal and safe gas distribution management.

How dynamic regulation applied to project 404 works

The uniqueness of the project lies in the ability to make two stations ‘talk’ to each other without the need for any physical connection between them. Indeed, the stations communicate with each other and operate autonomously.

To better understand the operational context, it is useful to distinguish between the different types of off-take stations: the so called ‘antenna’ networks, typically intended to supply confined areas such as a neighbourhood or small municipalities, and those ‘meshed’, integrated into more complex networks, capable of serving larger and more articulated urban areas.

In Project 404, dynamic pressure regulation is implemented on two ‘meshed’ stations, respectively:

• Primary Station: represents the main station that sets and controls the pressure of the network. In meshed networks, there is a Primary Station, while in antenna networks, each station operates as Primary.
• Secondary Station: represents the support station that modulates the gas flow rate delivered based on the parameters detected. In a meshed network, multiple Secondary Stations can coexist.

Both types of stations independently analyse the parameters detected by the network, such as pressure and flow rate, and act independently. Although the two stations follow two different algorithms, both read the same network parameters and this allows them to collaborate and create a single ‘regulation organism’.

As can be seen from the graph, before installing the Smart Regulator, a static condition occurs. The pressure remains constant, maintaining the level corresponding to the maximum demand of the plant.

Project 404 develops through three main phases:

Phase 1

The first phase (already completed) provided for the application of dynamic regulation in defined time slots, modulating the pressure based on the actual gas demand. The aim was to validate the concept of pressure reduction during low consumption periods, such as during the night.  The following graph shows the trend of pressure over 24 hours, varying from 4 bar maintained during the day to 2 bar at night.

Phase 2

The second phase involves two stations in a meshed network and requires them to be able to operate adapting in real-time to the variations of the network, thanks to an intelligent algorithm capable of responding quickly to different operating conditions. This phase has already been tested and is currently operational in several stations across Italy, demonstrating the reliability and robustness of the solution. The following graph shows how the pressure is maintained between 2 and 2.5 bar for most of the day, only increasing around 8:00 PM, corresponding to the peak demand from users.

A particularly significant element in the operation of the system is the way in which the secondary station, while operating with autonomous control logic, actively contributes to maintaining the overall balance of the network. Its ability to adapt to the pressure set by the primary station and to dynamically modulate the flow rate according to configurable time slots makes it possible to avoid critical situations, such as the reversal of roles between the two stations.

This collaborative behaviour translates into a continuous balance between the flows delivered: when the primary station reduces its contribution, the secondary station increases in a complementary manner, and vice versa. The result is an almost instantaneous response to changes in the network, ensuring system stability and intelligent, distributed flow management.

The following graph clearly shows how the two stations interact: the curve of the secondary station rises exactly when that of the primary station falls, demonstrating effective compensation between the two nodes. An additional graph, showing only the secondary station, allows us to appreciate the specific behaviour of the individual element within the system.

Phase 3

The third phase involves the integration of a predictive algorithm based on artificial intelligence, capable of estimating the demand and flow rate of gas for the following days, further optimising the efficiency of the system.

What can we expect once all three steps of Project 404 are implemented?

To significantly reduce gas losses, actively contributing to the reduction of emissions into the atmosphere. Although the Project is still in the testing phase, the initial results are extremely promising.

With the approval of the competent authorities, this methodology could become a new regulatory standard. Thanks to this innovation, Automa and 2i Rete Gas, a company of the Italgas Group, are charting a path towards a more efficient and sustainable management of gas networks, demonstrating that ecological transition is possible through intelligent and cutting-edge technological solutions.

AUTOMA has been active since 1987 in the development of hardware and software solutions for the remote monitoring and control of gas transport and distribution networks, functional to their operational management. To date, over 50,000 Automa devices are installed in more than 40 countries worldwide.

Do you need to optimise the pressure regulation of gas networks, making it safe and efficient?

Contact our team without obligation and we will tell you how we can intervene.

Ensuring gas flow rates always within the meter rangeability acting on the automatic regulation pressure value: in this article we tell you about the challenge won by AUTOMA’s GOLEM technology with the installation on an off-take station serving an antenna gas distribution network.

A project that ensures compliance with resolution 512/2021/R/gas, issued by the Italian Regulatory Authority for Energy, Networks and the Environment (ARERA), which requires the gas flow to be maintained within the limits allowed by the meter’s measurement range and, consequently, requires accurate monitoring and adequate flow control.

The Automa solution: GOLEM technology applied to flow control

The GOLEM technology, which is characterised by the ability to make the regulation of gas pressure dynamic and automatic without requiring substantial changes to existing systems, is based on a mechanically coupled servo mechanism which manages the adjustment screw of the regulator and makes it controllable.

Thanks to this innovative adaptation technology, the System can be applied to any pressure regulator, piloted or direct-acting, with a simple retrofit intervention. A solution that can be readily adapted and implemented, and which contributed to our client’s choice of GOLEM.

In this specific case, the operating logic of the GOLEM System has been modified to enable it to keep operating flow rates within the correct rangeability for which the meter was designed.

Considering that it cannot directly influence the plant’s gas demand – since this is determined by the downstream collection –, the System intervenes directly on the network pressure, modifying it to adapt the flow rate in cubic meters to the rangeability of the meter. Specifically, lowering the pressure lowers the flow rate in cubic meters and vice versa. This ability to directly regulate the pressure in the off-take station allows, actually, a direct control over flow rate in cubic meters to the meter.

In addition, the GOLEM operating logic has been optimised to allow flow rate control simultaneously with the management of an hourly pressure profile. Specifically, the pressure is lowered during the night and then brought back up to the desired range during the day, with a consequent significant reduction in fugitive emissions. 

Furthermore, to guarantee the safety and continuity of the System’s service, in addition to GOLEM’s internal algorithmic logic, there are mechanical limit switches that constantly monitor the pressure, ensuring that it does not exceed the set thresholds. Mechanical limit switches offer additional safety compared to algorithmic logic alone, protecting against any system anomalies. Indeed, when a limit switch is reached, the system stops and returns the pressure to its origin.

The results obtained thanks to GOLEM by AUTOMA

The implementation of GOLEM can be defined Plug&Play, as it does not require significant interventions on the mechanical and pneumatic part of the system. It is not necessary to modify the motorisation pressures or review existing connections, which considerably simplifies the installation process, and therefore the subsequent management and maintenance of the plant. This was a first, very important advantage for our customer.

From the very first months of activity, following the tuning phase in which the System was calibrated, the implementation of GOLEM on the off-take stations has allowed us to:

•  get a significant reduction in out-of-threshold measurements
•  make the measurement system more efficient
•  significantly reduce the economic sanctions for measures outside the threshold
•  significantly reduce fugitive emissions

Even the maintenance of the system proved to be extremely simple for our client to manage. In fact, with a simple action on a screw, it is possible to manually regulate the controller pilot or remove the servo motor and restore the reduction system to its original configuration in about 10 seconds. This greatly facilitates the work of maintenance technicians, allowing them to intervene on the pressure regulator, pilots, monitors and other components of the off-take station to carry out maintenance work in full compliance to current regulations.

The implementation of GOLEM in this project has produced extremely satisfactory results for our customer, while also improving operational efficiency.

With the AUTOMA solution it is possible to benefit from an immediate increase in efficiency and precision of pressure regulation, resulting in reduced gas leaks and operating costs. In addition, thanks to GOLEM, the system is able to reduce inefficiencies linked to changes in gas supply and demand. With a view to a possible integration of renewable sources, GOLEM is designed to also manage the injection of biomethane within natural gas networks, unlike many other solutions on the market.

AUTOMA has been active since 1987 in the development of hardware and software solutions for the monitoring and the remote control of gas transportation and distribution networks, functional to their operational management. As yet over 50,000 Automa devices are installed in more than 40 countries in the world.

Do you want to ensure that you regulate the gas network pressure safely and efficiently?

Contact our team without obligation and we’ll tell you how we can optimise the control and management of your infrastructure.