Both oil & gas producers and industrial facilities can achieve significant energy savings, improve productivity, and enhance competitiveness with natural gas flow meters from Fox Thermal. Gain insight into fuel usage with accurate thermal mass flow meters for natural gas flow measurement.
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Fox Thermal natural gas mass flow meter technology provides direct flow readings in mass units, including Standard Cubic Feet per Minute (SCFM), Normal Cubic Meters per Hour (NM3/Hr), Pounds Per Hour (lbs/Hr) or Kilograms per Hour (Kg/Hr).
Changes in process pressure and temperature can cause significant measurement errors in volumetric flow meters, which require additional temperature and pressure compensation for accurate readings. Thermal gas mass flow meters require none.
Fox Thermal's thermal mass flow meters provide wide turndown for accurate and repeatable measurement over the entire operating range of the boiler or burner to maintain optimum combustion. Up to 1000:1, 100:1 typical.
In the Oil & Gas industry, accurate measurements of natural gas flows are required for many operations across the extraction and refining process, including:
For these and other Oil & Gas flow measurement applications, users can manually input the percentage of each individual gas found in the pre-refined natural gas in the Gas-SelectX® Oil & Gas menu.
Help Me Choose A Flow Meter
Industrial facilities and organizations with multiple buildings or processes use natural gas submetering in order to improve efficiency, detect natural gas leaks, reduce emissions, and meet regulatory reporting requirements.
Unlike volumetric flow meters, Fox Thermal's flow meters deliver a direct reading of gas mass flow rate - without needing temperature and pressure compensation - and provide a simple, reliable, and cost-effective method for tracking and reporting fuel consumption.
Direct mass flow monitoring of natural gas and other fuel gases is the key to optimizing combustion processes and streamlining accounting procedures.
Non-oil & gas applications include:
When measuring natural gas flow, it's important that the flow meter is calibrated to the actual gas composition. Fox Thermal has developed the Gas-SelectX® gas selection feature to allow flexibility for measuring natural gas flows in different types of applications.
While the largest component of natural gas is methane, not all natural gas contains the exact same chemical composition. For industrial processes, utility companies deliver an NAESB standard natural gas composition that is achieved from a refining process.
But "natural gas" is a term that is also used to describe the mixed gases that come from the upstream oil and gas sector before they go through refinement. The reality of natural gas composition is that it can differ widely from one source to another.
Natural gas users in the industrial market can choose the Gas-SelectX® pure gas menu choice for "Natural Gas" which is set to the NAESB standard composition. For applications in the oil & gas sector, users can select the mixed gas or oil & gas menu of Gas-SelectX® and enter the gas composition of the pre-refinement natural gas in 0.1% increments of each component for a more accurate reading.
Help Me Choose A Flow Meter
If you're not sure which natural gas flow meter is right for your needs, our Help Me Choose app walks you through a short series of questions to help you choose the ideal meter.
Next, enter your process data and measurement requirements into our automated product configurator. Drop-down menus and Help icons will guide you to answer each question.
Save the data you entered into the configurator to create a PDF with a model code and application ID. When you're ready, submit your application to Fox Thermal, and one of our experts will contact you with a quote.
The Model FT1 thermal flow meter is available with Gas-SelectX® and can be easily reprogrammed in the field with the help of DDC-Sensor™ for calculating accurate gas correlations. It can measure a single gas or a mixture of up to 5 specified gases. The CAL-V™ Calibration Validation test feature ensures the meter retains its original NIST calibration.
This versatile gas flow meter is available with CAL-V™ Calibration Validation, DDC-Sensor™, and Gas-SelectX®. These features allow it to be reprogrammed in the field to measure any combination of gases in the gas mix menu in 0.1% increments to create a custom gas mix.
The Model FT4X features CAL-V™ Calibration Validation, DDC-Sensor™, and Gas-SelectX®. For oil & gas applications affected by BLM 3175 and API 14.10, the FT4X is accuracy compliant. It also comes with a built-in data logger for advanced record-keeping and data retention that maintains a 7-year history.
Natural gas flow meters are extensively used for sub-metering utility natural gas feeds to identify usage and potential leaks across different buildings or processes. This practice allows industrial facilities to monitor and manage their natural gas consumption more effectively, helping to detect abnormalities and inefficiencies. For example, a large manufacturing plant might install flow meters at various points in its gas distribution system to track consumption in different departments. By analyzing the data, the facility can identify areas with unusual gas usage patterns, which might indicate leaks or opportunities for energy-saving measures.
Another common application of natural gas flow meters is monitoring the gas feed to burners in combustion equipment. These meters play a critical role in optimizing the air-to-fuel ratio for better efficiency and reduced emissions. For instance, in a power plant, flow meters can be used to ensure that the right amount of natural gas is delivered to the boilers. By continuously adjusting the gas feed based on real-time measurements, the plant can achieve optimal combustion efficiency, leading to lower fuel costs and a significant reduction in harmful emissions.
Using natural gas flow meters to optimize furnaces, boilers, and ovens helps ensure that the air-to-fuel ratio is maintained at an ideal level. This optimization leads to better combustion efficiency, resulting in reduced fuel costs and lower emissions. It also helps to maintain consistent temperatures, which is crucial for the quality of products being processed.
In heaters and kilns, natural gas flow meters can be used to regulate the gas feed precisely. This regulation ensures that these systems operate at peak efficiency, providing uniform heating and processing. Optimizing these pieces of equipment can lead to significant energy savings and improved product quality.
For smelters and dryers, natural gas flow meters play a critical role in controlling the gas supply to maintain the necessary temperatures for efficient operation. Proper optimization helps in reducing energy consumption and minimizing operational costs. It also ensures that the end products meet stringent quality standards.
Heat-treating systems benefit immensely from the precise control provided by natural gas flow meters. By optimizing the gas feed, these systems can achieve the exact temperatures required for specific treatments, ensuring the desired properties of the materials being treated. This leads to higher-quality products and reduced energy usage.
In backup power systems, natural gas flow meters help in monitoring and optimizing the fuel supply to generators. This optimization ensures that the generators operate efficiently during power outages, providing reliable backup power while conserving fuel and minimizing emissions.
Natural gas flow meters are crucial in emission reduction systems like thermal oxidizers and Selective Catalytic Reduction (SCR) systems, where precise control of the gas feed helps in reducing harmful emissions. By optimizing the gas feeds, these systems can operate more effectively, ensuring compliance with environmental regulations and contributing to a cleaner environment.
Natural gas flow meters can help you track usage across multiple buildings or processes by providing detailed monitoring of your natural gas consumption. By installing flow meters at various points in your gas distribution system, you can obtain precise data about the gas usage in different departments or buildings. This enables you to detect inefficiencies, identify potential leaks, and take corrective actions. For example, a manufacturing plant could use this information to pinpoint areas with high consumption and implement energy-saving measures, ensuring efficient and cost-effective operations.
The main component of natural gas is methane, although it often includes other gases in smaller quantities. "Pipeline quality" natural gas is defined as natural gas that meets specific standards for commercial use. It contains at least 90% methane by volume and must adhere to other criteria such as delivery pressure, delivery temperature, thermal content (BTU), and acceptable levels of trace gases and elements.
According to the North American Energy Standards Board (NAESB), the typical composition of natural gas includes methane (94.9%), ethane (2.5%), propane (0.2%), nitrogen (1.6%), carbon dioxide (0.7%), and trace gases (0.1%) such as iso-butane, normal butane, oxygen, iso-pentane, hexanes+, and hydrogen.
When ordering a flow meter, it's important to consult with the manufacturer regarding the gas composition settings they use for calibrating the meter for "natural gas." The factory settings might differ from your specific process needs, making it necessary to provide a gas composition analysis to ensure the calibration matches your process conditions.
The default composition of "Natural gas" in the Gas-SelectX® menu is based on the North American Energy Standards Board (NAESB) average for natural gas chemical composition. More specifically, what's programmed is 94.9% methane, 2.5% ethane, 0.3% propane, 1.6% nitrogen, and 0.7% carbon dioxide, but if your natural gas composition differs, the correct gas analysis percentages should be programmed into the gas mix menu. The menus are accessed from the meter's front display panel, software, or Modbus RS485.
California Assembly Bill 32 (AB32) regulates and aims to reduce greenhouse gas emissions, with the Air Resources Board enforcing compliance. Accurate flow measurement devices are essential for facilities to monitor emissions, keep records, and meet AB32 reporting and reduction standards.
EPA's 40 CFR Part 98 requires specific facilities and suppliers to report greenhouse gas (GHG) emissions under the Greenhouse Gas Reporting Program (GHGRP). This helps monitor emissions, identify ways to reduce pollution, and cut costs. Natural gas flow meters assist operators in meeting these requirements.
Better accuracy, wide rangeability (turndown), reliability, very low-pressure drop, Calibration Validation and the Gas-SelectX® gas selection feature make Fox Thermal flowmeters the best choice for natural gas applications.
It is important to understand what makes different types of flow meters unique and the features that are most important for your needs. Fox Thermal offers both insertion and inline natural gas flow meter models.
For more information on Fox Thermal natural gas flow meters, download product sheets, whitepapers, case studies, application optimizers and more.