Appendix J.

Steam Measurement Best Practice August 7, 1995

J1.0 Steam Measurement Best Practice

Energy Management & Utilities Best Practice Team
Master - Dale Ehrbright 510 242 5459
Expert - Gary Roseme 510 242 3406

J2.0 Executive Summary

This best practice outlines a process to accurately measure steam flow to and from
the plot-limits of process and utility plants. This is achieved through continuous
meter validation utilizing balances, subbalances and maintenance. The goal of
steam system management is to eliminate waste and make the production and use
of steam as efficient and as low cost as possible. Accurate information, on which
sound operating and facilities planning decisions can be based, is integral to steam
system management.

J2.1 Steam Measurement Best Practice Outline:

1. The Value of Accurate Measurement
2. Balance Methodology
3. Balance Maintenance
4. Implementation Process

Appendices
1. Meter Survey, Repair and Compensation
2. Meter Selection
3. Drawings and Examples
4. Implementation Metrics

J2.2 The Value of Accurate Measurement

Accurate steam system measurement leads to operating cost reduction when:
• Operators can track steam production efficiency, optimize the steam system
and receive immediate feedback on the effects of their efforts.
• Unit operators can track their units’ energy performance, make operating
changes to achieve the best possible performance with current equipment and
know they are improving the profitability of the refinery.

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• Operating incidents may be avoided or minimized when operators have good

data available to trace system upsets back to the source.
• System inefficiencies are understood and plans are formulated to improve
performance.
• New project steam and power requirements are met by cost effectively
improving system efficiency rather than by just burning more fuel.

J2.3 Balance Methodology

If you can’t measure it, you can’t manage it. (EEBIT Report)1
The flow rate of steam should be measured at the plot-limits of all plants and to or
from major offplot equipment (Figure J-1). Appendix 2 (Meter Selection) should be
consulted if additional meters need to be added to achieve a balance.

Fig. J-1 Meter at Plot-Limits of All Plants and Major Equipment

Flow meters should be pressure and temperature compensated where necessary

using sensors installed near the flow meter or using data from the nearest meter to
enhance accuracy. If meters are not pressure and temperature compensated with live

1. Chevron Energy Efficiency Breakthrough Improvement Team Report - December, 1992

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Utilities Manual Appendix J

sensors the readings will be in error during upsets if the header pressure and temper-
ature departs significantly from design.
Each system should balance. If a system (e.g. the 150# steam header) does not
balance, a dedicated maintenance effort must be undertaken to achieve closure. See
Appendix 1 - Meter Survey, Repair and Compensation for methodology. Subbal-
ances should be used to track and help achieve closure if maintenance efforts are
unsuccessful.
Data from plot-limit meters is validated by balancing the entire header or by subbal-
ancing the plant plot-limit meters with "submeters" installed in the offplot headers
so as to form smaller balances or “subbalances”. (Experience has demonstrated
that balances or subbalances of greater than eight meters are difficult to maintain).
If subbalance meters are to be added, see Appendix 2 (Meter Selection) to help
decide which type of meter to install. For the purpose of this Best Practice, the term
“balance” is used to describe either a system balance, or a subbalance of a system.
The same method for achieving a balance (Figure J-1) is used whether you are
balancing an entire system or a subbalance to a system.
Figure J-2 shows a subbalance made up of six meters, four plant plot-limit meters
and two submeters. Meters #5 and #6 are the submeters, installed into the offplot
header, and measure flow into or out of the subbalance. The arrows show the direc-
tion of positive flow indicated by the meters (this directional choice is arbitrary).
Flow in the opposite direction from the arrows is negative (arrow direction is arbi-
trary). Using the flow directions shown, the subbalance calculated below should be
equal to zero +/- 5% if all meters are working properly.

Balance = flow5-flow1-flow2-flow3-flow4-flow6 = 0

Groups of meters that make up balances generally never sum to exactly zero. Expe-
rience shows that well maintained balances will trend near zero within about 5%1 of
the total flow of the balance. The Total Flow of the balance equals the flow into or
out of the balance. Since we don’t know if the measurement of the flow into or out
of the balance is accurate we can use our best guess which would be the average of
the flow in and the flow out of the balance. So, our approximation of the Total
Flow of a balance is one-half of the sum of the absolute value of all the metered
flows that make up the balance (or one-half of the sum of the flows into the balance
and the flows out of the balance. For example if we calculate the balance in
Figure J-2 above, it equals 40 mlb/hr. The approximate total flow of the balance
equals 200 mlb/hr which is found by summing the positive flow for each meter in
the balance and then dividing that sum by two. This “balance” is out of balance by
a positive 20 per cent (the meters say more steam is going into the balance than is
going out) which doesn’t meet the standard of balancing within plus or minus five
percent of the total flow of the balance.

1. This is in contrast to a custody transfer meter where agreement between a sales meter and a company owned
check meter is desired to be within 2% with the variation tracked with a control chart to flag significant
changes.

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Fig. J-2 Subbalance and Submeters

The balance sums are computer monitored and trended around zero to insure data
validity. Figure J-3 is an example of a trended balance that at first does not balance
and after repairing two meters, does balance. Before the meters are working
correctly the sum of the meters does not balance, the meters sum to about 50
mlb/hr. After one meter is repaired the "balance" sums to about -25 mlb/hr (the
minus sign means that the sum of the metered flows out of the balance is greater
than the sum of the metered flows into the balance). After one more meter is
repaired the balance sums near zero. Once a balance balances regularly over a
period of time, each meter in that balance can be relied on to report accurate infor-
mation.

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Utilities Manual Appendix J

Fig. J-3 Balance Trend

J2.4 Balance Maintenance

Trends of the balances should be monitored and the meters repaired if they are out
of tolerance. Once the balances are in balance, ownership should be assigned with
the responsibility for monitoring the balances and making the necessary repairs in
the field. Assigning a dedicated instrument mechanic to maintaining the balances
has proven successful at multiple facilities.
Figure J-4 shows a group of balance trends. Note that trend number 2 was trending
around zero (balanced) for a period of time and then went out of balance.

Fig. J-4 Balance Trends

Figure J-5 shows trend number 2 from Figure J-4 but with additional trends of three
of the meters that make up the balance. It is easy to see that meter C made a signifi-

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Appendix J Utilities Manual

cant change at the same time the balance went off. This focuses attention on meter
C. This method, which has been used at multiple facilities for several years, has
resulted in the elimination of most preventive maintenance for meters. At Rich-
mond this has led to a reduction in meter maintenance support from six mechanics
to one. Using this method inaccurate/bad order meters are quickly identified and
repaired. Meter failures and repairs should be tracked so that recurring problems
can be found and eliminated.

Fig. J-5 Balance Trend

J2.5 Implementation Process

In order to accurately measure steam, the systems must continually balance. If they
do not, the technique to obtain and maintain balances is outlined in the chart below:
Use this flow chart as a guideline to develop a specific process for you facility. See
attachment for an example.

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Utilities Manual Appendix J

Fig. J-6 Technique to Obtain and Maintain Balance in Steam Measurement Systems

Assign Ownership

Collect & Validate Pertinent Utility Drawings

Set up computer Conduct

diagrams to track meter
Identify balances and any surveys
unmetered subbalances
lines at
plant plot
limits
Correct meter
Utilitize balances installations
Ensure that
to identify bad and repair
Accounting
order meters bad-order
utilizes
meters as
balance to
necessary
valdate
Add new
charges
meters as
required Repair
meters as
necessary

Balances
should trend
within 5%

If balances cannot be
maintained within target,
install additional meters to
construct new or
additional sub-balances

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J3.0 Appendix 1

J3.1 Meter Survey, Repair and Compensation

1. Conduct field and data sheet surveys for each flow meter.
2. Obtain copies of all the steam flow meters data sheets. Review the calibration
data and flow calculations of each meter.
Focus review on the following:
• All of the d/D ratios should be between 0.4 and 0.7.
• Determine meter differential at normal rates. If the normal differential is low
(less than 10 inches of water column), develop plan to install a smaller diam-
eter orifice plate or a different type of meter if pressure drop could be a
problem.
• Are the numbers on the data sheet accurate or have they been rounded off?
The mechanic will calibrate to the numbers on the sheet, if you need round
units for the range, manipulate the dp.
• Are the pressures used to calculate the orifice plate close to the actual oper-
ating pressure? If pressures vary widely consider measuring the pressure and
compensating the flow meter for pressure variation (see below).
• Are the temperatures used to calculate the orifice place calibration close to the
actual operating temperature? If temperatures vary widely, consider measuring
the temperature and compensating the flow meter for temperature variation
(see below).
• If meter is of critical importance during upset conditions then it should be
compensated for pressure and temperature using pressure and temperature
instruments near the flow meter.
• Perform orifice calculation to verify orifice data sheet.
• Confirm all units are the same (lbs/hr, M lbs/hr, etc.).

J3.2 Field Meter Review

Focus field meter review on the following:
• Transmitters should be mounted below the orifice plate so that condensate will
build up and protect the dp cell from high temperatures.
• Orifice meter drip legs require freeze protection in cold climates. Steam
tracing can work but can cause problems with measurement if the tracing
causes the water legs to boil off. Consider pumping legs with glycol or electric
tracing as alternatives.

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• Root valves for orifice meters should come off the upper half of the pipe to
reduce scale and other debris plugging the legs.
• The highest points of the condensate legs for the upstream and downstream
pressure taps should be level with each other.
• Verify meter range matches orifice data sheet.
• For orifice meters, verify that the transmitter or recorder properly accounts for
the square root relationship between the flow and pressure drop.
• For orifice meters insure that the condensate “legs” are of equal length.
• For orifice meters insure that condensate legs have no places where air pockets
can form.
• Check that orifice plate is stamped with the size shown on the orifice meter
data sheet.
• Check that meter reads zero by closing valve on one meter lead and opening
the equalizing valve on the 3-valve manifold. Also, use this zero test to insure
that the meter you are working on in the field is the correct meter in the moni-
toring computer.
• Verify piping is the diameter shown on the orifice data sheet.
• Verify sufficient lengths of straight run of piping both before and after the
sensing element.
• Ensure no leaks in the root valves, legs, or dP cell manifold.
• Insure safe blowdown valves are installed to keep root valves and legs clear.
• Verify positive flow direction of the meter. For DP meters, insure that the high
leg (+) on the DP cell is connected to the upstream side of the orifice in the
positive flow direction, or if this is difficult, block in one root valve and
partially blow down the leg to drive the meter to 100% positive or negative.

J3.3 Flow Meter Compensation Algorithm

Compensation of orifice meters for pressure and temperature are accomplished
through the use of the following algorithm:
FY = F * CF
FY = Corrected flow rate (Mlbs/hr)
F = Uncompensated flow rate (Mlbs/hr)
CF = Correction factor = @SQRT(((P+PO)/RP) * (RT/(T+TO)))
P = Measured Actual Gauge Pressure (PSIG)
PO = Factor to convert P from PSIG to PSIA, (e.g. 14.696 PSIA at sea
level)

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RP = Orifice Data Sheet reference pressure (PSIA)

RT = Orifice Data Sheet reference temperature (degree R)
T = Measured temperature (degree F)
TO = Factor to convert to absolute temperature (459.69 F)

J4.0 Appendix 2

J4.1 Meter Selection

In many cases new meters may have to be installed because there is no existing
meter, the existing meter is inoperative, or a submeter is required to force closure of
the balance. Plot-limit meters can either be installed during a unit shutdown (if the
plot-limit block valves will hold pressure) or hot-tapped into the line during opera-
tion. Submeters are generally (but not always) hot-tapped into offplot steam lines
because of the difficulty of removing such a line from service. Hot-tapping of live
steam lines for the purpose of installing flow meters has been successfully done at
the El Segundo, Philadelphia, Richmond, Salt Lake and Port Arthur refineries. The
steam lines at pressures of 500 psig (nominal) and below have been hot-tapped for
meter installation. Higher pressures are generally avoided for safety concerns, but
some have been done.

J4.2 Meter Types

There are several types of steam flow meters used for both plot-limit and submeter
use including orifice plate meters, venturi meters, flow nozzle meters, insertion
turbine meters, insertion pitot tubes (Annubar), and insertion vortex-shedder
meters. These meters can all be installed with pressure and temperature sensors for
use in compensating the flow rate for variation in pressure and temperature as well
as enthalpy measurement. The following section recommends what meter to use
depending on the situation and is followed by more details of the various meter
types.

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Utilities Manual
Fig. J-7 Meter Selection Guide (1 of 2)
Orifice
(First Choice)
Application Install if line can be shut-
down and if the normal
flow rate doesn't vary by
more than a factor of 3:1.
Design Recommenda- Insure that the normal
tions flow rate will be in the
upper two-thirds of the
meter range.
Insure that the normal
flow rate results in a
"significant" pressure
drop across the orifice.
Use a smart DP cell to
measure orifice pres-
sure drop for improved
accuracy
If low DP's are expected
use a smart DP cell that
maintains accuracy at
low ranges.
See Chevron Instrument
Manual for further
design information.
Effect of water in steam Water can build up
line. behind orifice plate and
cause inaccuracies
Recommendation: Eliminate water from
steam lines with
adequate drip legs and
trapping
Installation while system Shut down required for
is on-line installation
Chevron Corporation
Insertion Turbine
(Second Choice)
Install if line cannot be
shutdown or if flow
varies by more than 3:1
Insure that line can be
safely hottapped
Don't use a turbine
meter on vents,
letdowns and deaera-
tors or where large, fast
changes in steam flow
occur.
Specify 3 inch flanges
on the meter and use a
three inch full port valve.
Initially install a 5 or 10
degree rotor and
monitor the rotor
frequency to insure that
the rotor does not over-
speed
If the frequency is
normally greater than
600 hertz with a low
pitch rotor then consider
installing an annubar or
a vortex shedding meter.
Slugs of water will
destroy a 1.5 inch diam-
eter turbine wheel
Eliminate water from
steam lines with
adequate drip legs and
trapping
Can be hot tapped
J-11
Insertion Pitot Tube
(Annubar)
(Third Choice)
Install if flow is steadily
over 175 ft/sec or has
regular excursions
higher than 250 ft/sec.
Insure that the normal
flow rate will be in the
upper two-thirds of the
meter range.
Specify 3 inch flanges
on the meter and use a
three inch full port valve.
Insure that the normal
flow rate results in a
"significant" pressure
drop across the flow
element.
Use a smart DP cell to
measure orifice pres-
sure drop for improved
accuracy
If low DP's are expected
use a smart DP cell that
maintains accuracy at
low ranges.
See Chevron Instrument
Manual for further
design information.
Water will plug the
lower holes of the
annubar
Eliminate water from
steam lines with
adequate drip legs and
trapping
Can be hot tapped
Appendix J
Insertion Vortex Shedder
(Fourth Choice)
Install if flow is normally
over 175 ft/sec or has
regular excursions
higher than 250 ft/sec.
Insure that the operating
temperature remains at
500 F or below.
Insure that the normal
flow rate will be in the
upper two-thirds of the
meter range.
Specify 3 inch flanges
on the meter and use a
three inch full port valve.
Water shouldn't hurt the
vortex meter but will
cause inaccuracies
Eliminate water from
steam lines with
adequate drip legs and
trapping
Can be hot tapped
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Appendix J Utilities Manual

Fig. J-7 Meter Selection Guide (2 of 2)

Insertion Pitot Tube
Orifice Insertion Turbine (Annubar) Insertion Vortex Shedder
(First Choice) (Second Choice) (Third Choice) (Fourth Choice)

Accurate over wide No, 4:1 turndown Yes No Yes

range of flow rates?

Yes, 16:1 turndown with 30:1 Turndown when 4:1 Turndown 20:1 to 30:1 Turndown
two dp cells. used with nonlinear depending on density
interpolation software

Accurate at low flow No Yes No No

rates?

Accurate at high flow Yes Yes Yes Yes

rates?

If meter is sized for Insertion turbine meters

lower normal flow rate should not be used if the
then pressure drop normal flow rate is regu-
could be too high larly over 175 fps

Service ability Requires a shutdown to Can be removed and Can be removed and Can be removed and
check orifice. serviced during opera- serviced during opera- serviced during opera-
tion. tion. tion.

J4.3 Orifice Meters

Orifice meters are the most common steam flow meters in a refinery. Orifice
meters are normally the meter of choice in the installation of a new refinery oper-
ating unit. The most common problem with orifice meters (and other differential
type flow meters) for steam management is that many times the actual flow rate is
low, less than one-third of the full scale flow rate of the meter. This problem occurs
when the meter is sized for the maximum possible flow rate that the meter could
see. For steam management purposes the accuracy of the reading is important and
therefore the meter should be sized so that the normal flow rate is in the upper third
of the meter range. If a higher turndown range (16:1) is desired an office meter can
be used with two dp transmitters. For submeters, orifice meters can only be
installed if the steam line to be metered can be taken out of service. In many cases
the lines that require meters (especially submeters) cannot be taken out of service
or, even if they could be, the block valves may leak. For these cases insertion type
meters are used.

J4.4 Insertion Turbine Meters

Insertion turbine meters can overcome the problem of the normal flow rate being
low in the operating range of the meter. Turbine meters are linear with flow rate
and they have a larger turndown ratio than orifice, averaging pitot tubes, or vortex-
shedders. The turbine meter can be used with turbine blades with blade angles of
from five to forty degrees to suit the flow rate.
The biggest problem with turbine meters is that they are a mechanical device and
the rotors will fail eventually. With proper application of the right rotor blade angle
for the range of flow rates seen and, if slugs of condensate aren’t thrown at it,

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Utilities Manual Appendix J

turbine meter rotors should last about two years. Condensate in the line is death to
turbine meter rotors. Condensate in steam lines is also not good for the lines them-
selves and the equipment the lines serve. With proper drip legs and traps conden-
sate problems can be controlled. If the flow in the line is very high, such that it
would overspeed a five degree rotor then an insertion averaging pitot tube or vortex-
shedding meter should be used.

J4.5 Insertion Averaging Pitot Tubes (Annubars)

Averaging pitot tubes are useful in services where high flow rates are the norm.
High flow rates produce pressure differences that are high enough to measure with
good quality "smart" Dp cells. Averaging pitot tubes have no moving parts but
their small sampling holes can plug. Averaging pitot tubes, like the orifice meter,
have a low turndown ratio (about 4 to 1).

J4.6 Insertion Vortex-shedders

Insertion vortex-shedding meters are also not good at very low flow rates and have
about a 20 to 1 turndown ratio. Insertion vortex-shedders have a temperature limit
of 500 F.

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J5.0 Appendix 3

J5.1 Drawings and Examples

Accurate drawings of the steam system is necessary for the understanding and
management of those systems. Listed below are descriptions of four types of steam
drawings:

Required or
Drawing Type Description Desirable
1. Onplot Utility Onplot UF&CD's schematically represent the Required
Flow & Control steam distribution system inside the plant plot-
Diagrams (or litdmit. UF&CD's are intended to show all major
G2/Mesa)(1) steam lines and all branches off these lines.
Because UF&CD's are not as detailed as
P&ID's, they are not adequate by themselves
for equipment blinding and isolation planning.
2. Offplot P&ID Offplot P&ID's schematically represent the Required
complete steam distribution system up to the
plot-limit of each plant in the refinery.
3. Offplot Maps Offplot Maps geographically represent the Desirable
offplot steam distribution system up to the plot-
limit of each plant in the refinery. They show
the physical routing of lines, and the location of
main valves and meters. They are intended to
be used to locate lines, valves, meters, etc. in
the field, but not for purposes requiring a
detailed representation of the system (e.g. line
isolation plans). For these purposes, the offplot
p&id's should be consulted.
4. Offplot Utility Offplot UFD's are simplified versions of the Desirable
Flow Diagrams p&id's that also indicate typical flow informa-
or equivalent or tion not covered on the p&id's.
G2/Mesa(1)
(1) G2/Mesa is a steam management/optimization computer program that schematically represents the
entire refinery steam system.

The offplot UF&CD and the onplot UF&CD’s (or G2/Mesa) also detail the location
of flow, temperature, and pressure meters that form the basis of the measurement
and validation system. Examples of the above drawings with design criteria are
attached.

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J6.0 Appendix 4

J6.1 Implementation Metrics

The following table will be used for implementations status reporting and is
included in the EM&U BP and Energy 530 Status Data Base on Lotus Notes.

RICH EL SEG PASC EL PASO SLT LKE HAW

1. Assign Ownership.
2. Collect & validate pertinent
utility drawings.
3. Identify unmetered lines at
plot-limits.
4. Identify unmetered offplot
major equipment.
5. Additional meters installed
as appropriate.
6. Conduct meter surveys.
7. Correct meter installations
and repair bad-order meters
as necessary.
8. Meters, balances, subbal-
ances monitored & trended
on computer.
9. Computer diagrams set up to
track balances & subbal-
ances.
10. Utilize balances to identify
bad order meters.
11. Maintenance procedure in
place utilizing balances to
insure continuing accuracy.
12. Balances trend within plus
or minus five percent of total
balance flow.
13. Accounting utilizes balances
to validate charges.
14. Steam system continually
balances within target.

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Status Codes
00 Refinery decided against implementation
0 Not applicable to this facility
1 No plans underway
2 Evaluating applicability, feasibility and incentives for implementing in
facility
3 Developing/updating plans to implement
4 Implementing plan, <50% completed
5 Implementing plan, >50% completed
6 Fully implemented and completed; not confirmed by formal audit or other
means
7 Fully implemented and completed; confirmed by formal audit or other
means

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