Appendix K.

Fuel Gas Measurement Best Practice August 7, 1995

K1.0 Fuel Gas Measurement Best Practice

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

K2.0 Executive Summary

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

K2.1 Fuel Gas Measurement Best Practice Outline:

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

Appendices
1. Meter Audit, Repair and Compensation
2. BTU Measurement
3. Meter Selection
4. Drawings and Examples
5. Implementation Metrics

K2.2 The Value of Accurate Measurement

Accurate fuel gas measurement leads to operating cost reduction when:
• Operators can track fuel gas production, optimize the fuel gas system, and
receive immediate feedback on the effects of their efforts.

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Appendix K Utilities Manual

• 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.
• Operating incidents may be avoided or minimized when operators have good
data available to trace system variation and upsets back to the source.
• System inefficiencies are understood and plans are formulated to improve
performance.
• New project fuel gas needs are met by cost effectively improving the system
efficiency rather than by just burning more fuel.

K2.3 Balance Methodology

If you can’t measure it, you can’t manage it. (EEBIT Report)1
The flow rate of fuel gas should be measured at the outlet of fuel gas mix drums
and at the plot limits of all plants (Figure K-1). Appendix 2 (Meter Selection)
should be consulted if additional meters need to be added to achieve a balance.

Fig. K-1 Plot Limit and Mix Drum Meters

BOILER CRUDE
PLANT UNIT

Plot Limit
Meter

Fuel Gas
Mix Drum

FCC

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

May 1996 K-2 Chevron Corporation

Utilities Manual Appendix K

Flow meters should be pressure, temperature and gravity compensated where neces-
sary using sensors installed near the flow meter or using data from the nearest
meter to enhance accuracy. If meters are not pressure, temperature and gravity
compensated with live sensors the readings will be in error during upsets if the
header pressure and temperature departs significantly from design.
Each system should balance. If a system (e.g. mix drum and group of plants) does
not balance, a dedicated maintenance effort must be undertaken to achieve closure.
See Appendix 1 - Meter Audit, Repair and Compensation for methodology. Subbal-
ances should be used to track and help achieve closure if maintenance efforts are
unsuccessful.

Fig. K-2 Subbalance and Submeters

If subbalance meters are to be added, see Appendix 3 (Meter Selection) to help

decide which type of meter to install. Data from plot-limit meters is validated by
subbalancing the plant plot limit meters with "submeters" installed in the offplot
headers so as to form a balance. (Experience has demonstrated that subbalances of
greater than eight meters are difficult to maintain). Figure K-2 shows a subbalance
made up of six meters, four plant plot-limit meters one submeter and one mix drum
meter. Meter #5 is a mix drum meter and meter #6 is a submeter that measure flow
out of the subbalance. The arrows show the direction of positive flow indicated by
the meters. Flow in the opposite direction from the arrows is negative (the direction

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Appendix K Utilities Manual

of the arrows is arbitrary). Using the flow directions shown, the subbalance calcu-
lated below should be equal to zero +/- 5% if all meters are working properly.

Subbalance = flow5-flow1-flow2-flow3-flow4-flow6

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 K-1) is used whether you are balancing an entire system or a
subbalance to a system. Experience shows that well maintained balances will add
to zero within about 5%1 of the total flow. (Total flow equals the flow into or out
of the balance which is also equal to one-half of the sum of the absolute value of all
the metered flows) For example if the absolute value of all the metered flows
equals 100 mscfh, then, one-half of that equals 50 mscfh which equals the flow into
the balance and the flow out of the balance. In this case a good metered balance
should trend around zero within +/- 5 mscfh.

Fig. K-3 Balance Trend

The balance sums are computer monitored and trended around zero to insure data
validity. Figure K-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
mscfh. After one meter is repaired the "balance" sums to about -25 mscfh (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.

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.

May 1996 K-4 Chevron Corporation

Utilities Manual Appendix K

K2.4 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, an instrument mechanic should be
assigned the responsibility for monitoring the balances and making the necessary
repairs in the field.
Figure K-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. K-4 Balance Trends

Figure K-5 shows trend number 2 from Figure K-4 but with additional trends of
three of the meters that make up the balance. It is easy to see that meter #3 made a
significant change at the same time the balance went off. The instrument mechanic
would then focus attention on meter #3. This method, which has been used at Rich-
mond for several years, has resulted in the elimination of most preventive mainte-
nance for meters. This has led to a reduction in meter maintenance support from
six mechanics to one. With a dedicated Instrument Mechanic 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. K-5 Balance Trend

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Appendix K Utilities Manual

K2.5 Implementation Process

In order to accurately measure fuel gas the individual systems must continually
balance. If they do not, the technique to improve the system is outlined in the chart
below:

Fig. K-6 Technique to Balance Fuel Measurement Systems

Assign Ownership

Collect & Validate Pertinent Fuel Gas Drawings

Set up computer Conduct

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

May 1996 K-6 Chevron Corporation

Utilities Manual Appendix K

K3.0 Appendix 1

K3.1 Meter Audit, Repair and Compensation

1. Conduct field and data sheet audits for each flow meter.
2. Obtain copies of all the fuel gas boiler feedwater and condensate 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.
• Is the pressure used to calculate the orifice plate calibration close to the actual
operating 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).
• Is the specific gravity of the gas used to calculate the orifice plate calibration
close to the actual operating gravity? If the gravity varies widely consider
measuring the gravity and compensating the flow meter for gravity variation
(see below).
• If meter is of critical importance during upset conditions then it should be
compensated for pressure, temperature and gravity using pressure, temperature
and gravity instruments near the flow meter.
• Perform orifice calculation to verify orifice data sheet.
• Confirm all units are the same (scfh, mscfh.).

K3.2 Field Meter Review

Focus field meter review on the following:
• Transmitters should be mounted above the orifice plate so that condensate will
drain back into the pipe line.
• Verify meter range matches orifice data sheet.

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Appendix K Utilities Manual

• For orifice meters, verify that the transmitter or recorder properly accounts for
the square root relationship between the flow and pressure drop.
• 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.
Compensation of orifice meters for pressure and temperature are accomplished
through the use of the following algorithm:
FY = F * CF
FY = Corrected flow rate (MSCFH)
F = Uncompensated flow rate (MSCFH)
CF = Correction factor = @SQRT ((P+PO/RP) *
(RT/(T+TO))*(RG/G))
P = Measured Actual Gauge Pressure (PSIG)
PO = Factor to convert P from PSIG to PSIA, (e.g. 14.696 PSIA at sea
level)
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)
RG = Orifice Data Sheet reference specific gravity
G = Measured specific gravity

May 1996 K-8 Chevron Corporation

Utilities Manual Appendix K

K4.0 Appendix 2

K4.1 BTU Measurement

With an ever changing fuel gas composition, it is necessary to frequently determine
the heating value of fuel gas. The following methods can be used to determine the
heating value of refinery fuel gas:
Calorimeter: On-line calorimeters are the most accurate (within 3 BTU/SCF)
means to determine the heating value of refinery fuel gas. Calorimeters on refinery
fuel gas systems are identified by Solomon Associates as a best energy technology.
Fluid Data Inc.’s FLO-CAL has been used with success at several company loca-
tions. The installed cost of a calorimeter is approximately $40,000 and requires
scheduled cleaning and calibration to remain effective. Utilize certified BTU stan-
dard gases, such as Scott Specialty Gases Inc., for periodic checks of the analyzer
calibration.
Specific Gravity Analyzer: The heating value of fuel gas can be continuously esti-
mated from an on-line specific gravity analyzer. The Utility Manual Appendix D
provides a correlation between fuel gas heating value and specific gravity. The
installed cost of a specific gravity analyzer is approximately $15,000. Sarasota
S.G. analyzers are utilized widely at our refineries. Specific gravity analyzers
require minimal maintenance to remain accurate. However, the concentration of
inert constituents such as nitrogen in refinery fuel gas must be considered. FCC
Units are large fuel gas producers and will generate fuel gas with a high nitrogen
concentration (always greater than 4% at the Hawaii Refinery). The accuracy of
the correlation between specific gravity and heating value will deteriorate as the
inert concentration varies from the assumed value.
Gas Chromatograph (GC): The composition of fuel gas can be determined
through the use of a refinery’s laboratory GC. However, spot samples can be very
misleading due to the constantly changing composition of refinery fuel gas.
Composite gas samplers such as YZ Industries DynaPak 2000 (installed cost
approximately $3000) can be utilized to document average fuel gas composition.
Accuracy of a GC is dependent on the instrument and calibration procedures, but is
clearly less accurate than a calorimeter in determining fuel gas heating value.

K5.0 Appendix 3

K5.1 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 fuel gas lines
because of the difficulty of removing such a line from service. Hot-tapping of live

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Appendix K Utilities Manual

fuel gas lines for the purpose of installing flow meters has been successfully done
at the El Segundo refinery.

K5.2 Meter Types

There are several types of fuel gas 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 tempera-
ture as well as enthalpy measurement. The table on the next page recommends
what meter to use depending on the situation and is followed by more details of the
various meter types.

Fig. K-7 Meter Selection Guide (1 of 2)

Insertion Pitot Tube
Orifice Insertion Turbine (Annubar) Insertion Vortex Shedder
(First Choice) (Second Choice) (Third Choice) (Fourth 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.
Install if line cannot be
shutdown or if flow varies
by more than 3:1
Insure that line can be
safely hottapped.
Install if flow is steadily
over 175 ft/sec or has
regular excursions higher
than 250 ft/sec.
Insure that line can be
safety hottapped.
Install if flow is normally
over 175 ft/sec or has
regular excursions higher
than 250 ft/sec.
Insure that line can be
safety hottapped.

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 pressure
drop for improved accu-
racy
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 liquid in fuel Liquid can build up
gas line. behind orifice plate and
cause inaccuracies
Don't use a turbine meter
on lines where changes
in fuel gas 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 overspeed
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 liquid will
destroy a 1.5 inch diam-
eter turbine wheel
Insure that the normal Insure that the normal
flow rate will be in the flow rate will be in the
upper two-thirds of the upper two-thirds of the
meter range. meter range.
Specify 3 inch flanges on Specify 3 inch flanges on
the meter and use a three the meter and use a three
inch full port valve. 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 pressure
drop for improved accu-
racy
If low DP's are expected
use a smart DP cell that
maintains accuracy at
low ranges.
Liquid will plug the lower Liquid shouldn't hurt the
holes of the annubar vortex meter but will
cause inaccuracies

Recommendation: Eliminate condensate Eliminate condensate Eliminate condensate Eliminate condensate

from fuel gas lines with from fuel gas lines with from fuel gas lines with from fuel gas lines with
adequate knock out pots. adequate knock out pots. adequate knock out pots. adequate knock out pots.

Installation while Shut down required for Can be hot tapped Can be hot tapped Can be hot tapped
system is on-line installation

May 1996 K-10 Chevron Corporation

Utilities Manual Appendix K

Fig. K-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 inter- depending on density
polation software

Accurate at low flow No Yes No No

rates?

Accurate at high flow Yes Yes Yes Yes

rates? If meter is sized for lower Insertion turbine meters
normal flow rate then should not be used if the
pressure drop could be normal flow rate is regu-
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 operation. serviced during operation. serviced during operation.

K5.3 Orifice Meters

Orifice meters are the most common fuel gas 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 fuel gas 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 fuel gas 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 fuel gas 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 inser-
tion type meters are used.

K5.4 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,
turbine meter rotors should last about two years.

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Appendix K Utilities Manual

Condensate in the line is death to turbine meter rotors. Condensate in fuel gas lines
is also not good for the lines themselves and the equipment the lines serve. With
proper drip legs and traps condensate 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.

K5.5 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).

K5.6 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.

K6.0 Appendix 4

K6.1 Drawings and Examples

Accurate drawings of the fuel gas, bfw, and condensate systems are necessary for
the understanding and management of those systems. Listed below are descriptions
of four types of fuel gas drawings:

Required or
Drawing Type Description Desirable
1. Offplot P&ID Offplot P&ID's schematically represent the Required
complete fuel gas distribution system up to the
plot-limit of each plant in the refinery.
2. Offplot Maps Offplot Maps geographically represent the Desirable
offplot fuel gas 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.
3. Offplot Utility Offplot UFD's are simplified versions of the Desirable
Flow Diagrams p&id's that also indicate typical flow information
not covered on the p&id's.

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Utilities Manual Appendix K

Required or
Drawing Type Description Desirable
4. On-plot P&ID’s On-plot P&ID’s (or equivalent such as UF&CD’s) Required
or equivalent schematically represent the fuel gas distribution
such as On- system inside the plant plot limit. The fuel gas
Plot Utility Flow system includes fuel gas lines, mixdurms,
& Control knockout pots, analyzers, and meters or instru-
Diagrams ments. UF&CD’s are intended to show all major
fuel gas 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 equip-
ment blinding and isolation planning.

The offplot UF&CD and the onplot UF&CD’s also detail the location of flow,
temperature, and pressure meters and analyzers that form the basis of the measure-
ment and validation system. Examples of the above drawings with design criteria
are attached.

K7.0 Appendix 5

K7.1 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, subbalances
monitored & trended on
computer.
9. Computer diagrams set up to
track balances & subbalances.

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Appendix K Utilities Manual

RICH EL SEG PASC EL PASO SLT LKE HAW

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. Fuel gas systems continually
balances within target.

Status Codes
00 Refinery decided against implementation
0 Not applicable to this facility
1 No plans underway
2 Evaluating applicability, feasibility and incentives for imple-
menting 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

May 1996 K-14 Chevron Corporation