Module4 CAPP Fuel Gas

May 2008
Disclaimer
This publication was prepared for the Canadian Association of Petroleum Producers, the Gas
Processing Association Canada, the Alberta Department of Energy, the Alberta Energy
Resources and Conservation Board, Small Explorers and Producers Association of Canada and
Natural Resources Canada by CETAC-West. While it is believed that the information contained
herein is reliable under the conditions and subject to the limitations set out, CETAC-West and the
funding organizations do not guarantee its accuracy. The use of this report or any information
contained will be at the users sole risk, regardless of any fault or negligence of CETAC-West or
the sponsors.

Acknowledgements
This Fuel Gas Efficiency Best Management Practice Series was developed by CETAC WEST
with contributions from:
Accurata Inc.
Clearstone Engineering Ltd.
RCL Environmental
REM Technology Inc.
Sensor Environmental Services Ltd.
Sirius Products Inc.
Sulphur Experts Inc.
Amine Experts Inc.
Tartan Engineering

CETAC-WEST is a private sector, not-for-profit corporation with a mandate to encourage
advancements in environmental and economic performance in Western Canada. The corporation
has formed linkages between technology producers, industry experts, and industry associates to
facilitate this process. Since 2000, CETAC-WEST has sponsored a highly successful eco-
efficiency program aimed at reducing energy consumption in the Upstream Oil and Gas Industry.

Head Office
#420, 715 - 5th Ave SW
Calgary, Alberta
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Tel: (403) 777-9595
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Table of Contents

1. Applicability and Objectives 1

2. Basic Improvement Strategies 2

3. Fuel Consumption Associated with Flaring 3
3.1 Pilot Gas
3.2 Purge Gas
3.3 Make-up Gas

4. Measuring Fuel Consumption 10
4.1 Fuel Metering
4.2 Flare Metering

5. Reduction Opportunities 12
5.1 Extinguishing Pseudo-dormant Flares
5.2 Reducing Pilot Gas Consumption
5.3 Reducing Purge Gas Consumption
5.4 Reducing Make-up Gas Consumption

6. Record-Keeping 16

7. References 17

Tables
3.1 Average fuel gas consumption for energy efficient flare pilots
3.2 Typical minimum purge rates to avoid unsafe air infiltration

Figures
3.1 Typical schematic of a labyrinth style purge reduction seal
3.2 Typical schematic of a baffle type purge reduction seal
3.3 Minimum fuel gas to waste gas ratio required to attain a
combined net heating value of 20 MJ /m3

Background

The issue of fuel gas consumption is increasingly important to the oil and gas
industry. The development of this Best Management Practice (BMP) Module is
sponsored by the Canadian Association of Petroleum Producers (CAPP), the
Gas Processing Association Canada (GPAC), the Alberta Department of Energy,
Small Explorers and Producers Association of Canada (SEPAC) Natural
Resources Canada (NRC) and the Energy Resources and Conservation Board
(ERCB) to promote the efficient use of fuel gas in flaring operations used in the
upstream oil and gas sector. It is part of a series of 17 modules addressing fuel
gas efficiency in a range of devices.

This BMP Module:

identifies the typical impediments to achieving high levels of operating
efficiency with respect to fuel gas consumption,
presents strategies for achieving cost effective improvements through
inspection, maintenance, operating practices and the replacement of
underperforming components, and
identifies technical considerations and limitations.

The aim is to provide practical guidance to operators for achieving fuel gas
efficient operation while recognizing the specific requirements of individual flaring
systems and their service requirements.

EFFICIENT USE OF FUEL GAS
IN THE UPSTREAM OIL AND GAS INDUSTRY

MODULE 4 of 17: Flaring Operations

FIELD
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Efficient Use of Fuel Gas in Flaring Operations Rev Date 27/05/2008
Module 4 of 17 Page 1 of 17
1. Applicability and Objectives

This module provides guidance to operating staff to identify opportunities where
gas consumption associated with flaring operations can safely be reduced. The
determination of fuel gas efficiency in flaring is made by understanding the
sources of fuel gas use and making periodic assessments of performance and
comparing those with possible performance improvements.

Flares are designed to dispose of intermittent or continuous volumes of
combustible gas which cannot economically be recovered or disposed of in
another manner. Although reducing the volume of waste gas which is disposed
of by flaring has economic and environmental benefits, this is the topic of other
BMPs
1
and will not be addressed here.

This module will focus on identifying opportunities for reducing fuel gas
consumption associated with operating flare systems. This includes fuel gas
used for operating flare pilots, purging the flare system and enriching waste gas
streams.

This module outlines the basic improvement strategies for reducing fuel
consumption in flaring and identifies sources of fuel consumption. Evaluation of
flare performance using metering of waste gas and fuel consumption will be
discussed with consideration to the identification of potential reduction
opportunities. The final objective of this module is to outline suggestions and
processes to develop a reduction program.
2. Basic Improvement Strategy

The chief elements for achieving safe, effective and lasting reductions to fuel
consumption associated with flaring operations are: application of best available
technology, implementation of operating and management systems, and
corporate commitment.

Fuel consumption is often necessary to ensure the safe and reliable operation of
flare systems. However, whenever it is economically and technically feasible to
do so, fuel consumption should be minimized or eliminated. Achieving fuel
efficiency in flaring requires:

understanding the sources of fuel consumption in flaring operations,
periodic checking of fuel consumption rates to evaluate system
performance and make adjustments as required,
assessment of opportunities to upgrade or replace underperforming
systems,
maintaining adequate records to support the companys flaring fuel
reduction program.

3. Fuel Consumption Associated with Flaring
Operations

Achieving efficiency with respect to the use of fuel in flaring systems requires an
understanding of where fuel consumption occurs in these systems. The sources
of fuel gas consumption typically associated with flaring include pilot gas, purge
gas and make-up gas. This section of the module discusses these sources and
presents methodology for estimating the expected fuel consumption rates. In all
cases the fuel consumption rates provided by system designers and equipment
manufacturers and/or actual site measurements are preferred for identifying
substandard performance and evaluating reduction opportunities.

3.1 Pilot Gas

Many flares are outfitted with continuously burning gas pilots to ensure ignition of
flared gases. The number and type of pilots required depends on the flare size,
stream composition and wind conditions. Typical pilot requirements and fuel
consumption rates are summarized in Table 3.1. These rates assume an
average pilot fuel consumption rate of 1.98m
3
/h/pilot which is reasonable for
energy efficient pilots fueled by sales quality natural gas
2
. However, actual
consumption will depend on burner design and fuel properties.

Table 3.1
Average Fuel Gas Consumption for Energy Efficient Flare Pilots

Flare Tip Diameter Average Pilot Gas
Consumption
Inches mm
Number of
Pilot Burners
m
3
/h 10
6
m
3
/y
1 10 25.4 254 1 1.98 17.3
12 24 304.8 609.6 2 3.63 31.8
30 60 762 1524 3 5.95 52.1
>60 >1524 4 7.93 69.5
Adapted from [EPA CH1]
3.2 Purge Gas

Typically the header of an intermittent flare system is continuously purged with
fuel gas to prevent air ingress into the flare system. Additional benefits of
purging include mitigating fouling and damage resulting from burn back and
displaced products that have been released into the flare header. Purging the
flare system is necessary to ensure safe operation. However, purge rates above
those required to maintain safe reliable operation are undesirable and should be
avoided. The required purge rate will depend on the type of seal used, stack
diameter, properties of the gas as well as ambient and system conditions.

For plain end flares the purge gas required to avoid unsafe air infiltration can be
estimated using the Husa purge model. Equation 3.1 is an adaptation of the
Husa purge model that can be used to estimate minimum purge gas
consumption rates for flare systems.
3

( ) [ ]
5 . 1
46 . 3
2
96 . 28 / 75 . 0 1
21
%
ln MW
Ls
KD O
Q
= (3.1)

Where:
Q is the purge gas consumption in m
3
/h,
K is 5.26 x 10
-8

D is the internal diameter of the stack in mm,
O
2
% is the acceptable oxygen concentration at Ls in % (note 6% is
usually acceptable),
Ls is the distance into the stack where the safe condition is met in
m (note the lesser of 7.62 m or 10 stack diameters is usually
acceptable),
MW is the molecular weight of the purge gas (note 19.5 is typical
for natural gas).

Larger flares are often outfitted with seals which reduce the continuous purge
rate required to avoid unsafe air infiltration into the stack. Purge reduction seals
do not physically isolate the stack from the surrounding atmosphere. Instead,
they utilize proprietary internals, either baffle-type or labyrinth-type, to reduce the
ability for buoyant movement of air into the stack. Typical schematics of the seal
internals are provided in Figures 3.1 and 3.2. Equation 3.2 can be used to
estimate typical purge requirements for flare systems outfitted with baffle-type
seals and Equation 3.3 can be used to estimate the typical purge gas
consumption associated with labyrinth-type seals. Actual purge rates will depend
on the seal design and should be obtained from the manufacturer.

2 5
* 10 447 . 3 D Q

= (3.2)

Where:

3
/h,
Assuming:
The average required purge velocity for flares outfitted with baffle-
type purge reduction tips is 0.0122 m/s (0.04 fps).

2 6
* 10 618 . 8 D Q

= (3.3)

Where:
3
/h,

Assuming:
The average required purge velocity for flares outfitted with
labyrinth-type purge reduction tips is 0.0030 m/s (0.01 fps).

Figure 3.1
Typical Schematic of a Labyrinth Style Purge Reduction Seal

Figure 3.2
Typical Schematic of a Baffle Type Purge Reduction Seal

Typical purge consumption rates calculated using the above formulas are
presented in Table 3.2.

Table 3.2
Typical Minimum Purge Rates to Avoid Unsafe Air Infiltration

Purge Gas Consumption Rate (m3/h) Flare
Diameter
(NPS)
1
Plain End
2

Baffle Type
Seal
3

Labyrinth
Type Seal
4

2 0.07 0.09 0.02
3 0.17 0.21 0.05
4 0.34 0.36 0.09
6 0.93 0.82 0.20
8 1.83 1.42 0.35
10 3.19 2.23 0.56
12 4.98 3.20 0.80
14 6.35 3.90 0.98
16 8.98 5.17 1.29
18 12.16 6.62 1.65
20 15.92 8.24 2.06
24 25.34 12.02 3.01
26 31.04 14.18 3.54
30 44.57 19.03 4.76
36 82.87 27.63 6.91
42 142.76 37.84 9.46
48 228.39 49.65 12.41
54 345.39 63.06 15.77
60 499.74 78.07 19.52

Standard wall pipe

Calculated according to Equation 3. assuming a stack
condition of 6% oxygen at the lesser of 10 stack
diameters or 7.62 m from the open top and a purge
gas molecular weight of 19.5

Calculated according to Equation 3.2

Calculated according to Equation 3.3

Prevention of flare tip damage resulting from burn back may necessitate purge
rates greater than those required to prevent air infiltration. Burn back occurs
when the flame regresses into the stack due to inadequate purge velocities. A
visible flame under purge-only conditions is an indication that purge rates are
sufficient to prevent burn back. Smaller flare tips do not normally experience
burn back problems
3
. Header sweep is another consideration which may require
purge rates in addition to the minimum requirements to prevent air infiltration or
burn back. This is especially important when the potential for corrosive gases to
enter the header exists.
3.3 Make-up Gas

Make-up fuel is sometimes required to raise the calorific value of flared waste
gas to levels that will support stable and efficient combustion. The ERCB
4

requires the combined net heating value (i.e. lower heating value) of flared gases
and make-up fuel to meet or exceed 20 MJ /m
3
except for existing flares with a
history of stable operation and emergency flare systems in sour gas plants where
the heating value may be as low as 12 MJ /m
3
. In all cases Alberta Ambient Air
Quality Objectives must be met and flares which are subject to AENV approval
may have more stringent requirements for minimum heating values.
Equation 3.4 or Figure 4.1 can be used to estimate minimum make-up gas
requirements.

r m
w r
w m
LHV LHV
LHV LHV
Q Q
= (3.4)

Where:
Q
f
is the fuel gas flow rate,
Q
w
is the waste gas flow rate,
LHV
r
is the required combined net heating value (i.e. 20 MJ /m
3
),
LHV
m
is the lower heating value of the make-up gas,
LHV
w
is the net heating value of the waste gas.

0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0 2 4 6 8 10 12 14 16 18 20
Net heating value of the waste gas (MJ/m
3
)
M
i
n
i
m
u
m

f
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e
l

g
a
s

t
o

w
a
s
t
e

g
a
s

r
a
t
i
o
Typical Natural Gas (LHV =34.6 MJ /m3) Low Heat Content Natural Gas (LHV =31.9 MJ /m3)
High Heat Content Natural Gas (LHV =38.5 MJ /m3)

Figure 3.3
Minimum Fuel Gas to Waste Gas Ratio Required to Attain a Combined
Net Heating Value of 20 MJ/m3
4. Measuring Fuel Consumption

When evaluating opportunities for reducing fuel consumption actual site
measurements are helpful for identifying substandard performance and
supporting economic evaluations. Depending on the source, fuel consumption
can metered independently or as part of the total flare stream.

4.1 Fuel Metering

Pilot gas, purge gas and make-up should be metered independently wherever
possible. These streams are of known composition and flow rates are generally
quite stable so conventional metering technologies are appropriate.

4.2 Flare Metering

Flare meters are excellent diagnostic tools which can be used to identify
excessive purge rates and/or leakage into the flare system that might otherwise
go unnoticed. The ERCB mandates metering of continuous or routine flare
sources at all oil and gas production and processing facilities
4
where average
total flared and vented volumes exceed 0.5 x 10
3
m
3
/d and recommends the use
of flare meters at larger oil and gas batteries, pipeline facilities and gas
processing plants where there are multiple connections to the flare system even
when the aforementioned average flaring rate is not exceeded
4
. At a minimum,
sufficient fittings should be installed to facilitate spot checking of the residual flare
rate if continuous flare metering is not required or deemed necessary.

Flare streams are particularly challenging to meter because of the high variability
in flow and composition. In applications where metering is required by the ERCB
the meter must have an accuracy of 5 percent over the entire range of flows and
compositions encountered
5
. Generally, flare meters should be composition
independent and exhibit accuracy over a high turndown (i.e. 1:100 or better).
Metering technologies which meet these requirements include: ultrasonic meters,
micro-tip vane velocity probes and optical velocity probes. Thermal dispersion
probes have adequate turndown but are highly composition dependant. Most
traditional metering technologies used in the oil and gas industry (e.g. differential
pressure, turbine, positive displacement) fail to meet one or both of these
requirements. Traditional metering technologies may be applicable for flare
measurement under certain circumstances where the composition and/or flow
rate are adequately stable. If no flare metering is in place the residual flare rate
(i.e. purge and leakage) can still be spot checked using a portable velocity probe
or tracer test to establish if excessive purge rates or leakage are occurring. In
order to conduct a tracer test it is necessary to have fittings on the flare line for
injecting trace gas and withdrawing a sample. The injection point must be
located somewhere on the flare line where there is flow and the sampling point
needs to be sufficiently downstream of the injection point and all tie-ins to allow
for good mixing of the entire flare stream and the tracer gas. Most portable
velocity probes can be inserted into the flare piping through a NPS full port
valve. Velocity measurements should be taken downstream of all tie-ins in a
straight section of pipe.
5. Reduction Opportunities

When evaluating reduction opportunities it is important to base decisions on
reliable data using a systematic and consistent approach. Safety is paramount
and must be considered ahead of economics and operability when evaluating
reduction opportunities.

Any case where the actual fuel consumed in flaring operations exceeds required
or manufacturer recommended rates represents an opportunity to conserve fuel
by correcting the deficiency or replacing the underperforming equipment. Other
opportunities to reduce fuel consumption include extinguishing pseudo-dormant
flares and application of best available technology. This section of the module
discusses these reduction opportunities.

5.1 Extinguishing Pseudo-dormant Flares

Appreciable quantities of fuel gas are consumed in the operation of pilot and
purge gas systems to maintain flares in a pseudo-dormant state. In situations
where gas is not continuously or routinely flared and the probability of an
emergency depressurization is low, an opportunity exists to conserve fuel gas by
extinguishing the flare.

When considering extinguishing flares operators should carefully assess the
probability of all possible relief cases. At a minimum the following conditions
should be satisfied prior to extinguishing a flare:

There should be no continuously or routinely flared streams.
The stack should be fitted with a glycol/water seal or other positive sealing
device which will isolate the flare header from the atmosphere. This will
prevent oxygen from entering the flare header and enable monitoring of
leakage into the header.
The maximum allowable working pressure of the piping and pressure
vessels should be greater than the potential supply pressure from any
connected sources (e.g. wells, compressors, etc.).
No active injection or cycling schemes should be taking place or planned
for any pools with wells connected to the facility.
Pressure Safety Valves (PSV) connected to the flare system should be
outfitted with upstream rupture disks and a pressure gauge should be
installed between the PSV and rupture disk to enable detection of a disk
rupture.
Manual depressurizing valves connected to the flare should be double
blocked, tagged and carsealed closed to mitigate the possibility of an
accidental opening and/or leakage.
Emergency shutdown valves should not be configured to depressurize
equipment to the flare.

ERCB approval is required prior to extinguishing sour flares. Guidelines and
requirements for submitting a request to extinguish a sour flare can be found in
the ERCB Directive 060
4
.

When the flare is extinguished flammable gases remaining in the flare system
are a potential hazard. To remove this hazard shutdown of the flare should be
immediately followed by an inert gas purge. If the flare system is restarted
another inert gas purge should be conducted to remove air from the stack and
flare header prior to lighting the pilot.

5.2 Reducing Pilot Gas Consumption

The use of electronic ignition devices and/or energy efficient flare pilots can
minimize the amount of fuel gas used to sustain flare pilots.

Electronic Ignition Devices

Electronic ignition devices that ensure continuous flare ignition by systematically
producing high voltage electric sparks can often be used in place of gas operated
pilots. Electric consumption is low and is typically supplied by solar recharged
batteries. The ERCB allows the use automatic ignition devices in place of gas
pilots to ensure reliable continuous ignition of acid gas and sour flares at all
facilities except sour gas plants which require the use of both devices
4
.

Energy Efficient Pilots

In situations where pilots cannot be replaced by electronic ignition devices the
fuel efficiency of the gas pilot should be evaluated and consideration given to
installing a more energy efficiency design. Efficiency of pilots can be maintained
by ensuring that wind shielding and pilot nozzles are in good condition. Some
vendors offer designs that consume as little as 0.57m
3
/h/burner of fuel gas.

5.3 Reducing Purge Gas Consumption

An opportunity may exist to reduce fuel consumed to continuously purged flare
systems by installing purge reduction seals, using instrumentation to control
purge rates, switching to an inert gas purge and/or reducing purge rates in
response to leakage into the flare system. When evaluating purge gas
reductions the purge rate required to maintain a safe stack condition (i.e. prevent
air ingress) should be considered in conjunction with purge requirements to
prevent burn back and provide adequate header sweep.
Purge Reduction Seals

Purge reduction seals use proprietary internals, either baffle-type or labyrinth-
type, to reduce the ability for buoyant movement of air into the stack. This
reduces the purge velocity required to avoid air infuriation and can lead to a
significant reduction in purge gas consumption especially on larger diameter
stacks. These devices should be considered in most situations where flare
systems are continuously purged.

Instrumentation to Control Purge Rate

The minimum purge rate required to avoid unsafe air ingress into the stack is not
only a function of the stack diameter and purge gas but is dependent on changes
in ambient temperature, pressure, wind speed and temperature of products in the
flare header. In order to compensate for the dynamic nature of these
dependencies, continuous purge rates are often set above the minimum value
required for the conditions under which the flare usually operates. An alternative
to specifying an excessive purge rate is to use instrumentation to monitor critical
parameters in the flare system (e.g. oxygen concentration, temperature, etc.) and
automatically adjust purge rate accordingly to maintain a safe stack condition. In
regards to instrumented purge rate control systems, an adequate purge rate is
essential to system safety, redundancy and fail safe operation. The reliability,
regular calibration and preventive maintenance are critical to the success of the
instrumentation.

Inert Purge Gas

Inert gases can be used in place of fuel gas for purging flare systems. Inert
purges have a safety advantage over enriching purges because in addition to
preventing oxygen infiltration, combustible gases are also swept from the system.
However, inert purges can extinguish pilots and may cause the combined heating
value of flared streams to drop below required levels to maintain reliable and
stable combustion. Additionally, inert gas is typically more expensive than
natural gas so inert purges are not normally used.

Reducing Purge Rates in Response to Leakage

Leakage into the flare system can be difficult to identify and often necessitates a
plant shutdown to correct. During the time it takes to find and repair a leaking
component all or part of the losses can be mitigated by using the leak as a purge
source and reducing the supply of purge gas up to the volume of the leak rate.

5.4 Reducing Make-up Gas Consumption

The quantity of fuel gas used to raise the calorific value of waste gas streams
can be reduced by using incinerators in place of flares or installing
instrumentation to automatically adjust the delivery of make-up gas.

Replacing Flares with Incinerators

Incinerators are an alternative to flares that can be considered for disposing of
steady continuous waste gas streams with low heating values. These devices
maintain waste gases in the presence of oxygen at higher temperatures for
longer residence times than flares. As such destruction efficiencies are higher
and gases with lower calorific values can be more efficiently combusted.

In many cases waste gas streams that do not meet the calorific requirements to
maintain reliable and stable combustion in a flare can be disposed of using an
incinerator without adding any fuel gas. Even in situations where incinerators do
require fuel gas to treat a waste stream the amount of fuel consumed is minimal
compared to the make-up gas that would be required to sufficiently enrich the
stream for disposal using a flare.

Although incinerators offer a number of benefits they are not viable alternative to
flares in all situations. Incinerators have lower turn down (i.e. typically only 10:1)
and higher capital cost than flares.

Instrumentation to Control Make-up Gas Delivery

Instrumentation including online calorimeters and flow meters may be used to
regulate the delivery of make-up gas to ensure calorific requirements of the
combined stream are satisfied while minimizing fuel gas consumed. This may be
particularly beneficial in situations where the composition and flow of the waste
gas are variable.
6. Record Keeping

Operators should have a record program to support the companys flaring fuel
consumption reduction program. Proper record keeping should assist in
ensuring that underperforming systems are identified and that appropriate follow-
up actions are implemented. This information will also assist in establishing the
checking/testing frequency for each flare, to achieve cost-effective fuel gas
reductions.

Although each company will define its record keeping system, consideration
should be given to recording and retaining the following information:

expected fuel gas consumption by each flare,
records of changes/upgrades that have been performed,
actual fuel consumption measurements,
the economic analysis performed to evaluate reduction opportunities
where flares have not been adjusted/modified on economic grounds.
7. References

1.
Canadian Association of Petroleum Producers, Best Management
Practices - Facility Flare Reduction, December 2006. Accessed:
September 2007 Available at:
http://www.capp.ca/default.asp?V_DOC_ID=763&PubID=114231

2.
United States Environmental Protection Agency, EPA Air Pollution Control
Cost Manual Sixth Edition, Section 3.2 VOC Destruction Controls,
Chapter 1 Flares (EPA/542/B-02-001), September 2000: Accessed:
September 2007, Available at: http://www.epa.gov/ttn/catc/dir1/cs3-
2ch1.pdf

3.
David Shore, Making the Flare Safe, J ournal of Loss Prevention in the
Process Industry, Volume 9, Number 6, November 1996 , pp. 363-381.

4.
Alberta Energy and Utilities Board, Directive 060: Upstream Petroleum
Industry Flaring, Incinerating, and Venting, November 2006, Accessed:
September 2007, Available at:
http://www.eub.ca/docs/documents/directives/Directive060.pdf

5.
Alberta Energy and Utilities Board, Directive 017: Measurement
Requirements for Upstream Oil and Gas Operations, May 2007,
Accessed: September 2007, Available at:
http://www.eub.ca/docs/documents/directives/Directive017.pdf

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May 2008

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