Technical

White Paper

6 THINGS TO CONSIDER IN FLARE AND COMBUSTOR

GAS MEASUREMENT:
APPLICATIONS, REGULATIONS, AND CHALLENGES

A TECHNICAL WHITE PAPER FROM FOX THERMAL

Ria Edens, Marketing Communications Manager, Fox Thermal

Precision Mass Flow Measurement

An ONICON Brand

www.foxthermal.com • 831-384-4300 Rev. C

 6 THINGS TO CONSIDER IN FLARE AND COMBUSTOR GAS MEASUREMENT:
APPLICATIONS, REGULATIONS AND CHALLENGES
A Fox Technical White Paper
Ria Edens, Marketing Communications Manager, Fox Thermal

PURPOSE

To provide a convenient and easy-to-follow

method of finding the right flow meter
technology for flare and combustor gas flow
measurement in the Oil & Gas, Industrial, and
agricultural sectors. Use these 6 considerations
to guide you through the process to choose a
flow meter technology right for your specific
flare gas application.

#1: TYPE OF FLARE GAS MEASUREMENT:

FLARES VS COMBUSTORS

Flare gas systems are used in a wide variety

of applications and are generally used to burn
off excess gas, usually hydrocarbons. A flare
gas system may contain open flame flares or
flame-enclosed combustors; the differences without causing danger to any surrounding
between the two are highlighted in the table equipment, landscape, or personnel. A
below. combustor, on the other hand, may be much
shorter and have a wider diameter in order to
It is generally easy to tell the difference fully enclose the combustion process.
between a flare and a combustor on site. A
flare will usually be thin and very tall to allow Whether using a combustor or a flare, the
room for the open flame to burn high above purpose of these types of equipment is to burn

FLARES VS COMBUSTORS
FLARES COMBUSTORS
Open flame Flame enclosed
Lights up the night sky Flame hidden, fewer public complaints
Tall flare stack structure Low profile
High noise level upon burning Lower noise level
Releases CO2 into the atmosphere Releases CO2 into the atmosphere

Flares are defined as open flame flaring devices and Combustors are enclosed combustion devices.

Fox Thermal • [email protected] • White Paper Page 2

off excess combustible gas from a system. For wells, the “fracking” method of horizontal
instance, flaring may be a precaution to keep drilling and hydraulic fracturing in the shale
pressure at safe levels in a system, or it may rock formations deep underground has taken
be to remove gas that cannot be processed over the industry. Fracking increases access to
from a storage vessel that must make room oil and gas reserves from fewer access points
for the inflow of more oil. If the waste gas is and extends production capacity dramatically
not burned off, it could be vented directly to at each well site.
the atmosphere, which adds large quantities
of unburned hydrocarbons. Shale formations are made up of a porous
rock material holding vast amounts of
Flow meters for flares or combustors will need trapped methane and hydrocarbons deep
to measure the flow of gas to it at the time underground. Bore holes at well sites must
when burn-off of the waste gas occurs. The be drilled deeper than traditional oil wells to
flow may fluctuate between very high and reach shale. To release the trapped resources,
very low velocities before, during, and after the shale must be fractured by a powerful
burn off of the gas. electric charge. The charge causes fissures to
open and a pressurized water/sand/chemical
slurry is pushed down into the crevices. The
#2: CONSIDERATIONS FOR COMMON
sand collects in the fissures allowing the slurry
FLARE GAS APPLICATIONS
to pass through and mix with the oil and gas
OIL & GAS PRODUCTION trapped in the shale. This mixture is pumped to
the surface as “flowback” that is harvested at
Both on and offshore, crude oil extraction the well head. The flowback must go through a
wells have been exhausted through vertical separation process to isolate the components
drilling. To increase production in existing

Fox Thermal • [email protected] • White Paper Page 3

 NATURAL GAS PRODUCTION
Associated Petroleum Gas (APG)
APG, or Associated Gas, is a form of Although most natural gas production
natural gas which is found with deposits of happens onshore at gas plays such as Barnett,
petroleum, either dissolved in the oil or as a Haynesville, and Marcellus, some occurs in
conjunction with oil drilling on rigs in the
free “gas cap” above the oil in the reservoir.
US Gulf of Mexico. Flaring is a necessary
Historically, this type of gas was released part of the process in order to maintain a
as a waste product from the petroleum safe production facility and comply with
extraction industry. Due to the remote environmental regulations.
location of many oil fields, either at sea or
on land, this gas is simply burnt off in gas NATURAL GAS PROCESSING
flares. When this occurs the gas is referred
When hydrocarbon gases are extracted,
to as flare gas. especially from hydraulic fracking, it is
The gas can be utilized in a number of necessary to process it further to achieve
ways after processing: be sold and included pipeline quality natural gas. The natural gas
in the natural gas distribution networks, must be separated from the water and other
hydrocarbons. This is part of natural gas
used for on-site electricity generation with
processing. This may be done at a processing
engines or turbines, reinjected for enhanced plant or on a skid-mounted processing system.
oil recovery, or used as feedstock for the A VRU (vapor recovery unit) may be used to
petrochemical industry. capture gas for delivery to a pipeline. Flares
are often used in these processes.

BIOGAS FROM DIGESTERS AND LANDFILLS

of solids, water, oil, gas, and other matter.
Flares and combustors are used at well sites Organic materials from methane-producing
to burn off vapors from the drilling, collection, facilities like wastewater treatment plants are
and storage of the gases produced in this placed in digesters that trap organic matter
process. Any storage tanks must be vented or and allow it to decompose in the absence of
flared as new product is injected. oxygen. During this process, a biogas mixture
(usually about 60% methane and 40% carbon
STORAGE TANKS / TANK BATTERIES dioxide) is produced. Natural gas primarily
consists of methane, so this biogas is an
Volatile Organic Compounds (VOCs) are the important energy source. After trapping and
primary emissions from storage tanks used in collecting digester gas, it can be used as fuel
oil & gas production. The reduction of these instead of allowing it to accumulate in the
emissions is now being regulated by the US atmosphere causing a greenhouse effect.
EPA as they are considered hazardous air
pollutants (HAP). These emissions happen
from venting (flash gas) due to pressure or
temperature changes and the introduction of
more product. Flares are used to make room
in storage tanks when new product is injected.

Fox Thermal • [email protected] • White Paper Page 4

 be measured, recorded, and reported in
categories such as refineries, offshore drilling
rigs, natural gas plants, landfills, and other
sources. Specifically, 40 CFR Part 98 Subpart
W requires the emissions from both onshore
and offshore petroleum and natural gas
production sites. Monitoring devices used
for these purposes are required to have an
accuracy of ±5%. Subpart W includes the
monitoring of emissions from processing
plants, storage, transmission, and distribution.
Since this ruling was published in 2010, a mass
of CO2, CH4, and N2O emission data has been
collected and published. This data reflects
emissions from equipment leaks, vented
sources, and flare gas emissions.

Perhaps due to the overwhelming data

amassed from these reports, the EPA has begun
to regulate the amount of emissions allowed
in certain industries. Recently, the Natural
Dairy and swine operations are beginning Gas Production industry has been required to
to turn manure, a plentiful by-product of reduce their emissions by 95% in some cases
the animals, into a valuable resource by in order to comply with the Quad O regulation.
substituting biogas for natural gas or propane This 2012 ruling requires that waste gas be
as fuel for their generators. Landfill waste recovered using Vapor Recovery Units (VRUs)
produces significant amounts of methane as or combusted using flares, combustors, or
it decomposes under the capping soil layer. other combustion devices to cut down on the
There are efforts being made to collect this
gas and burn it to produce electricity. Flares
are often needed as a part of these biogas
digester and landfill gas systems.

#3: COMPLIANCE WITH REGULATORY

AGENCIES FOR FLARE MONITORING

EPA REGULATIONS ON FLARE MONITORING

Flares must be monitored to be compliant with

a number of EPA regulations: most notably, 40
CFR Part 98 and 40 CFR Part 60 Subpart OOOO
(Quad O). These regulations cover emissions
from various parts of the Oil & Gas Industry Fox model FT4X thermal mass flow meter and temperature transmitter.
and other industrial emitters. Flow Accuracy, air: ±1% of reading, ±0.2% of full scale;
Flow Accuracy, other gases: ±1.5% of reading, ±0.5% of full scale
Turndown ratio: up to 1000:1
40 CFR Part 98 requires that emissions Available in insertion, inline, and remote styles.

Fox Thermal • [email protected] • White Paper Page 5

 Flow meters used to report emissions for this
purpose must operate at a Tier 3 accuracy
level which means that they must measure at
±7.5%. It is also mandatory that the measuring
device be validated for calibration accuracy at
periodic intervals.

COMPLIANCE WITH BLM 3175

Public lands leased for use in oil & gas

production are governed by the Bureau of
Land Management (BLM). Oil & gas activities
loss of these gases to the atmosphere. The on leased lands must conform to BLM 3175
hope is that these gases can be recovered which defines gas flow meter accuracy and
and sold to cover the costs of complying with features for determining royalty payments.
the regulation. As part of this ruling, flares or Data from the flow meter is used for this
combustors used to reduce emissions must royalty determination. This includes the gas
include monitoring instruments that have an composition, gas density, and the gross
accuracy of ±2% or better. heating value. A highly accurate measurement
of the flow of gas in daily totals must be
recorded with storage of that data over time.
COMPLIANCE WITH EU DIRECTIVES

The European Union introduced the

Emissions Trading Scheme (ETS) in 2005
as part of an overall climate change policy. Thermal Mass Flow Meter Benefits
The ETS requires that emissions be reported Direct Mass Flow Measurement
to the Environment Agency each year. The Fox flow meters do not require pressure or
European commission allocates carbon
temperature compensation.
credits to participating countries (spread
across many installations) which allow for a Outstanding Rangeability
predetermined amount of CO2 to be released Fox flow meters’ low-flow sensitivity
into the atmosphere. At the end of each year, improves measurement accuracy over a wide
there may be a surplus of allocated credit range of conditions.
or the emissions may have exceeded the
allocation. Surplus credits may be sold and Rugged, Low-Maintenance Design
over-emitters must buy excess allocations Fox flow meters’ no-moving-parts design
from other installations with surplus credits. makes them relatively immune to oils
Each year, when the credits are distributed, the and particulates and reduces service
credit allocation is reduced which allows time requirements.
for industries to make small improvements
each year to reduce their emissions. Over Low Installed Cost
time, this results in the gradual reduction of Fox flow meters are available in both
harmful gases and emissions, not a drastic insertion and inline versions to suit and
and expensive overhaul of processes all at application.
once.

Fox Thermal • [email protected] • White Paper Page 6

#4: OVERCOMING CHALLENGES OF
MONITORING FLARE AND COMBUSTOR
GAS

Flare and combustor gas is generally waste

gas that must be evacuated at high flow rates
and at various intervals. This abrupt change,
or upset condition, has always proved difficult
for most flow meter technologies to measure.
In order to measure accurately, the meter must
be able to measure very low flow rates while
the flare or combustor is in normal operation,
and measure just as accurately when the flow
increases to a very high flow rate. The ratio
between the minimum and maximum flow
values is called the “turndown ratio”. When
the difference between them is quite large, as
in flare or combustor gas measurement, the
turndown ratio is wide, for instance 800:1.
When considering what meter to use in your
flare application, the turndown ratio must
be high enough to account for these upset
Fox DDC-Sensor™ sensor illustrating the thermal mass flow meter
conditions. principle of operation.

Accuracy over such a wide flow range is

also important for flare and combustor gas
regulations that require the meter meet
measurement, especially when there are
a certain accuracy spec. Most flow meter
technologies operate more accurately at the
higher end of their flow range, but errors
increase at the low range. The average flare
or combustor will operate at the lower end of
its flow range for most of its life, so the need
for accuracy at the low end is critical when
choosing the flow meter technology to use.

Gas composition is another challenging aspect

of flare and combustor gas. The variability
in gas composition makes it imperative that
the flow meter be calibrated to measure the
mixture of flare/combustor gas constituents
at each site. Likewise, a method of verifying
the calibration of a meter at periodic intervals
allows operators to be confident that they are
collecting the most accurate information at
A Fox Thermal flow meter in a remote configuration used to measure
flare gas at an offshore drilling rig. each site.

Fox Thermal • [email protected] • White Paper Page 7

#5: CHOOSING THE RIGHT TECHNOLOGY: THERMAL MASS FLOW

Thermal mass flow meters operate by the constant temperature differential method and provide a
direct mass flow rate without the need for temperature or pressure compensation.

OTHER TECHNOLOGIES MODEL FT4X THERMAL MASS FLOW

Flow Measurement Other technologies require Direct mass flow measurement of air and gases in standard
of gases multiple instruments to determine volumetric units (ie MSCFD, SCFM, or NM3/H) or mass units
the volumetric flow rate at (ie LBS/M or KG/H). Each meter has the option for the user to
reference conditions. select a variety of flow units (see Operating Specs on product
datasheets).

Pressure or Differential pressure flow meters No additional pressure or temperature compensation

temperature require pressure and temperature is required. This is a time and cost saving measure. No
compensation compensation. additional calculations or equipment are needed to calculate
flow because the meter measures the mass flow rate.

Turndown Vortex meters are only suitable for Repeatability and exceptionally broad measurement range:
very high flow rates. up to 1000:1 (100:1 typical). Whether the flow is at a very
DP meters do not have good high or low velocity, Fox Thermal mass flow meters can
turndown. measure it.

Pressure Drop If a DP meter is used to measure Low pressure drop. The pressure drop of a thermal mass flow
low velocity flow, a very small meter is negligible.
orifice is required, resulting in high
pressure drop.

Moving Parts A meter with moving parts, like a No moving parts which means no problems with wear,
Turbine meter, will need regular binding, etc.
maintenance.

Price Ultrasonic meters are especially Cost effective. Thermal mass flow meters offer a low cost
expensive. alternative.

Installation Some meter technologies are Easy to install with insertion and inline configurations.
complicated and difficult to install, Insertion meters are easy to install, inline meters come
require additional equipment, equipped with flow conditioners to help reduce the straight
or long straight pipe run run requirements. Communication options available and
requirements. intrinsic to meter electronics.

Operation Most manufacturers build Microprocessor based, field rangeable electronics. Fox
meters for a single purpose, gas Thermal pioneered the use of microprocessors in thermal
calibration, or application. The mass flow meters and continues to create innovative
customer must sift through pages solutions to measurement needs across many industries and
of specs to find the right meter applications. Gas-SelectX®, available in the Model FT4X,
for their application. This is time allows the user to change the gas selection in the field.
consuming and ineffective. Displays with configuration panels and free software allow
users to interact and program the meter in the field. Using
the online Product Configurator, the customer can enter
process data into the system for an instant FOX Product
recommendation: no need to search a list of meters for the
one that’s right for you!

Fox Thermal • [email protected] • White Paper Page 8

 the meter to be calibrated on a single gas in
the factory while providing the user the ability
to select other gases in the Gas-SelectX® gas
menus.

Competitors’ sensors utilize fragile,

cantilevered elements, whereas the sensor
elements of the DDC-Sensor™ are welded
to the sensor window at both ends for extra
stability and strength. This enhanced design
eliminates the sensor element vibration -
A portable Fox Thermal flow meter kit used at oil and condensate
found most often at high flow rates - which can
storage tanks for emissions requirements. potentially lead to metal fatigue and failure.

The sensor elements are in direct contact with

the process flow. In applications where slag,
#6: CHOOSING A MANUFACTURER: ice or other foreign particles are traveling
BENEFITS OF USING FOX THERMAL MASS down the pipe, cantilevered elements are
FLOW METERS subject to damage requiring factory repair.

Fox Thermal has been a leader in thermal

GAS-SELECTX® GAS SELECTION MENU
mass flow innovation for over 20 years; Fox
Thermal was the first manufacturer to offer The model FT4X offers three gas menus to
a thermal mass flow meter using an onboard choose from. Users can choose from over
microprocessor. The Fox Thermal model 11 gases in the Pure Gas menu or create a
FT4X was designed specifically with flare custom gas mix through the combination of
and combustor gas monitoring for the Oil & gases available in the Mixed Gas and Oil & Gas
Gas industry in mind. The model FT4X is a Menus.
state-of-the-art flow meter offering direct
mass flow measurement, exceptional low-flow Gases can be mixed in 0.1% increments to
sensitivity, fast response, and low maintenance create a truly custom gas mix to fit the gas
requirements. composition on-site. This action can be
performed on demand and in the field for
optimum convenience and to avoid sending
ADVANCED DDC-SENSOR™ DESIGN
the meter back to the factory for a re-
The DDC-Sensor™ sensor, a Direct Digitally calibration service.
Controlled sensor, is unlike other thermal
For flare and combustor applications, this
flow sensors available on the market. Instead
is especially valuable as the composition of
of using traditional analog circuitry, the
the gas can vary quite substantially between
DDC-Sensor™ is interfaced directly to the
sites and over time. Operators can change the
meter’s microprocessor for more speed and
programmed gas mix using the configuration
programmability.
panel on the display or by using the FT4X
The DDC-Sensor™ provides a technology View™ software whenever the results of
platform for calculating accurate gas gas sample analysis shows a change in gas
correlations. The correlation algorithms allow composition.

Fox Thermal • [email protected] • White Paper Page 9

 ACCURACY, SIZING, AND INSTALLATION

The model FT4X is very accurate at low flow

rates and at high velocities – up to 60,000
SFPM - with a turndown ratio up to 1000:1
and a flow accuracy of ±1% of reading and
±0.2% of full scale for air (±1.5% of reading
and ±0.5% of full scale for other gases).

The model FT4X is available in insertion, inline,

and remote styles. The insertion meter is easily
installed with a weld-o-let and compression
fitting with the option of a retractor assembly.
The inline model is available in ¾-inch to 6-inch
Sample screen view of the FT4X View™ software tool used to configure sizes and includes built-in flow conditioners
the model FT4X Thermal Mass Flow Meter & Temperature Transmitter.
that eliminate the need for long, straight pipe
runs. Fox Thermal flow meters can be ordered
ADVANCED DATA LOGGER to fit almost any application, even large pipes
or complex mixed gases.
Every Fox Thermal model FT4X comes
equipped with an intrinsic Data Logger for RUGGED, RELIABLE PERFORMANCE
advanced record-keeping and data retention.
The Data Logger records flow rate totals and The model FT4X is a rugged instrument with a
other events and alarms. dual-compartment, explosion-proof enclosure
housing the instrument electronics. An
The advanced features of the model FT4X Data standard on-board 2 line x 16 character backlit
Logger include: display includes a configuration panel for field
• 40 daily totals (24-hour totals) configuration of the meter’s settings. Settings
• Settable Contract Time defines Contract such as 4-20mA and pulse output scaling,
Day
pipe area, zero flow cutoff, flow filtering or
• Time/date stamped alarm & event logs; 7
year history damping, diagnostics, alarms, and data logs
• Power off totalizer; power failure creates may be accessed via the configuration panel.
event log entry
COMMUNICATION OPTIONS
The logs in the model FT4X Data Logger also
give information about the meter’s settings Fox offers a free software interface, FT4X
and functionality: View™, to connect via a USB port to a laptop
• View the meter’s gas or gas mix composition or computer. This software provides complete
• View the meter’s configuration and other configuration and remote process monitoring
meter settings functions allowing the user to adjust meter
• View Calibration Validation historical test configuration, evaluate transmitter alarm
data
conditions, collect process data, and view
• View and print logs of events and alarms
measurements from your PC or control station.
The Data Logger can be accessed with a HART and Modbus RTU (RS485) are available
MODBUS RTU (RS485) communication option communication protocols with all digital
and the free FT4X View™ Software. communication isolated for EMI immunity.

Fox Thermal • [email protected] • White Paper Page 10

 CALIBRATION VALIDATION
OTHER THERMAL
TYPICAL REQUIREMENTS OF COMPETITIVE MODELS FLOW METERS FT4X WITH CAL-V™
Stop the flow
Remove meter from pipe
Disconnect wires from flow meter
Look up data on flow meter’s calibration certificate
Required Not Required
Measure electrical characteristics with volt ohm meter
Perform calculations to evaluate flow meter performance
Set process pressure to manufacturer’s calibration pressure
Connect auxiliary test equipment and/or test gases to flow meter

CALIBRATION agencies. The Model FT4X meets and exceeds

these requirements with its high accuracy,
All Fox meters are calibrated with NIST Calibration Validation feature, and advanced
traceable flow standards. The Fox Calibration Data Logger.
Lab employs a wide range of gases, mixtures,
temperatures, pressures, and line sizes to Direct mass flow measurement, exceptional
simulate actual fluid and process conditions. low-flow sensitivity, fast response, and low
This approach improves accuracy and maintenance requirements distinguish the
minimizes measurement uncertainty in the Fox Model FT4X. Virtually immune to changes
field. in temperature and pressure, the flow meter
delivers repeatable, accurate mass flow
measurement under varying loads.
CALIBRATION VALIDATION

The model FT4X offers Calibration Validation

Disclaimer: Fox Thermal has made every effort
with CAL-V™ to verify that the calibration to provide an accurate interpretation of the
of the meter is still valid. Providing a Pass/ regulations mentioned in this paper; however
Fail result, CAL-V™ can help to reduce the Fox cannot be held responsible for errors, local
added cost and inconvenience of annual differences, or recent changes. Contact the U.S. EPA
factory calibrations. If these tests are initiated or other regulatory body for the latest information
using the free Fox FT4X View™ software tool, on these laws and regulations.
CAL-V™ Calibration Validation Certificates can
be produced at the conclusion of the test. This
feature is of particular value for compliance AUTHOR BIOGRAPHY/CONTACT INFO
with emissions monitoring applications where
periodic calibration validation is mandated. Ria Edens, Marketing Communications Manager
at Fox Thermal, has a decade of experience
CONCLUSION
in technical writing, marketing strategy, and
Flare and combustor gas flow monitoring market development of industrial mass flow
requires a flow meter that meets the measurement instrumentation.
accuracy and periodic calibration verification
requirements set by local environmental Email: [email protected]

Fox Thermal • [email protected] • White Paper Page 11

Fox Model FT4X
Thermal Mass Flow Meter
• Measures gas mass flow rate and
temperature
• DDC-Sensor™ state-of-the-art
sensor technology
• Gas-SelectX® gas selection feature
• Advanced Data Logger
• Equipped with CAL-V™ Calibration
Validation feature
• 2 line x 16 character backlit LCD
display
• Housing: NEMA 4X Indoor/Outdoor
• Standard Outputs: 2 x 4-20mA for
Flow and Temperature, Pulse Output
• USB port standard
• Communication Options: HART or
Modbus RTU (RS485)
• Approvals:
CE, FM, FMc, ATEX, IECEx
See FT4X Datasheet for more product information.

Precision Mass Flow Measurement

An ONICON Brand

399 Reservation Road

Marina, CA 93933
Phone: (831) 384-4300
Fax: (831) 384-4312
[email protected]
www.foxthermal.com