Discover how Revere Control Systems delivers end-to-end solutions for renewable natural gas (RNG) facilities—from design and instrumentation to multi-site integration and CARB-compliant reporting—that streamline operations, reduce risk, and power a cleaner future.
For the Revere Control Systems team, every opportunity to contribute to work that makes the world a better place is exciting. In partnership with a leading developer and operator in the Renewable Natural Gas (RNG) sector, Revere is helping to protect the environment by reducing greenhouse gas emissions and providing a sustainable energy source.
The RNG process focuses on the capture of methane emissions from dairy farm manure. If left unchecked, methane is a potent greenhouse gas. By upgrading this methane into pipeline-quality biogas that can be injected directly into natural gas pipelines for heating homes or other uses, RNG facilities give the methane a productive purpose, preventing it from contributing to greenhouse gas emissions. By effectively “removing” methane from the atmosphere, carbon credits are generated—a key financial driver for RNG projects.
As both a developer and an operator, Revere’s client in this space brings together the various players who make RNG initiatives possible in the following ways:
- Connecting dairy farmers—who supply the manure that generates methane—with off-takers, and ultimately, end users who pay for the clean, pipeline-grade natural gas.
- Securing funding and investments to bring these projects to life.
- Managing the facilities long-term, ensuring they operate efficiently and profitably.
From our perspective, this client stands out in the industry because of their strategic approach to construction and infrastructure planning. Unlike many other RNG developers, they recognize the value of detailed engineering and documentation. They align each facility’s design with its operational and financial goals, setting their projects up for success from the start.
One challenge that RNG projects face is that facilities often need to be built in remote locations with limited infrastructure while still requiring precise, CARB (California Air Resources Board)-compliant data to operate. Many RNG sites also lack proper electrical and construction documentation, which can lead to significant gaps during commissioning. By bringing us on board as one of their partners, this client is able to leverage their industry knowledge alongside our electrical and data collection expertise.
Reducing Risk Through Early Problem-Solving
Every successful project begins with strong design, which is why our client chooses to involve us early on in their projects. By collaborating from the start we’re able to help avoid costly delays and inefficiencies later on by maintaining a big-picture perspective on end-to-end facility performance. Equipment standardization and compatibility can be particularly challenging in the RNG space. As a relatively new segment of the oil and gas industry, RNG lacks some of the established standards seen in other longer-established sectors. On one project, we noticed early on that a skid manufacturer was supplying Siemens-based controls, while the rest of the plant was built around Allen-Bradley systems—a mismatch that could have complicated integration. By recommending FactoryTalk SE to unify the control systems during the FEL 2 phase, we ensured smooth communication across the facility
A Revere Business Development Manager explained why catches like this can be so important:
“Every hour spent planning saves days during commissioning. By catching mismatches or overlooked specifications upfront, we eliminate frustration and keep the project moving forward. We love working with this partner, because they realize the value in this proactive approach ”
Beyond controls, we are also able to standardize hardware, instrumentation specifications, and network designs for them, creating a foundation for efficiency and reliability.
Revere’s One-Stop Shop: A Partner for Full-Facility Integration
Revere serves as part of a broader team of partners supporting this particular client’s RNG projects, but one thing that they value most in the partnership is Revere’s ability to act as a one-stop shop for their electrical and data collection needs. We handle everything from PLC/HMI design and engineering to SCADA systems and centralized data management, balance of plant controls, electrical panel design and construction, and network design and security. By managing all aspects under one roof, we eliminate delays, handoffs, and accountability gaps, ensuring seamless integration and operation.
Beyond these core capabilities, Revere integrates systems that power every aspect of an RNG facility, including:
- Full CARB reporting
- Business KPIs
- Anaerobic digestion
- Feedstock handling and multi-stream management
- Dewatering
- Membrane systems
- Amine systems
- Plant utilities
- Flare systems
- Compression
- Virtual pipeline systems
We are also able to deliver critical infrastructure solutions—like our prefabricated E-Houses—to address the challenges of working in remote environments. RNG facilities are often built on farmland, where there is little existing infrastructure and weather can swing from one extreme to another. These modular structures can be deployed quickly and are designed to withstand everything from freezing Michigan winters to scorching Arizona summers.
As a Revere Business Development Manager put it:
“Many companies can handle one piece—like electrical engineering or panels—but very few can deliver the whole package—engineering panels, integration, commissioning—without handoffs. Our client gets scale and expertise, but with the care and focus of a boutique partner.”
Precision Instrumentation for CARB Reporting
For Revere’s client, success depends on accurate, CARB-compliant reporting, which allows them to generate carbon credits and it’s our systems that provide the precision instrumentation required to collect and automate this data.
Here’s the type of operational data we help them to track:
- Feedstock and Input Data: Volume, composition, and flow rates of manure
- Digester Performance: Biogas production, methane content, temperature, and pH levels
- Gas Upgrading and Treatment: Gas quality, flow rates, and pressure
- Energy Usage: Electricity consumption and efficiency metrics
- Environmental Monitoring: Emissions (CO₂, methane)
By automating data collection and reporting, we help eliminate the need for manual calculations, delivering clean, actionable data that our partner can rely on—accurate, automated, and ready for CARB reporting.
Centralizing Operations: Multi-Site Integration
Looking to the future, thai partner aims to centralize reporting and operational data across multiple RNG facilities. As these sites often have different ownership structures, they require a system that provides a unified view while maintaining restricted access for joint-venture partners. We’re actively working alongside them to develop this multi-site integration solution. Once complete, it will enable them to monitor, compare, and manage each facility from a single platform while ensuring that individual partners only access data relevant to their ownership.
The Automation Department Manager at Revere, described how this works:
“Imagine you have Farm A through Farm D—Farm A might be fully owned by our client, while Farm B is a joint venture with another partner, and Farm C has yet another ownership structure. The client needs a hierarchical system that gives them a clear view of all their facilities, allowing them to compare performance and efficiency across sites, while ensuring that individual partners can only access data relevant to their ownership. This level of visibility and control will be a game changer for operational decision-making.”
This system will enable the client to track key performance indicators (KPIs) across facilities like SCFM (standard cubic feet per minute)—allowing them to identify the most and least efficient sites and take action accordingly. Beyond performance comparisons, Revere’s we’ll aim to simplify other tasks as well:
- Accounting and Reporting: automating calculations for emissions, production, and performance metrics, to deliver clean, actionable summaries that analysts can use immediately.
- Streamlined Compliance: collecting, processing, and transforming raw data into ready-to-file reports, saving time and reducing manual work.
A member of the Revere team explained the potential impact of these automations:
“We plan to automate the reporting side so they can see their emissions and production data in one place. Their analysts will no longer have to scrub data or run complex calculations manually—our systems will do the heavy lifting for them.”
The result will be a unified, intuitive view of the client;s entire fleet, delivered through tools like OSI PI dashboards. These dashboards will provide both detailed, facility-level insights and a high-level view of overall operations, empowering them to make data-driven decisions that improve efficiency and profitability.
Technical Overview
- Multi-Site Integration: Future vision to centralize data and reporting across multiple facilities.
- High-Performance Graphics: Designed operator-friendly HMIs using the ISA-101 Grayscale Standard to highlight critical alarms and improve usability.
- Automated CARB Reporting: Simplified emissions reporting with automated data collection, calculations, and summaries for compliance.
- Instrumentation and Controls: Provided end-to-end solutions for process control, SCADA systems, and precision instrumentation.
- Infrastructure Solutions: Supplied pre-fabricated E-Houses to protect critical systems in remote environments.
- Standardization and Documentation: Bridged gaps in equipment compatibility and delivered detailed engineering plans and as-builts.
- Full-Process Expertise: Supported all phases of RNG production, including feedstock handling, gas upgrading, compression, and flare systems.