Industrial Flow Metering Solutions...
Gas Sub-Metering / Utility Auditing
 

Phone: (800) 332-3418 Fax: (770) 929-828 Email: FlowSolutions@crossco.com
In any industry, finding a better way to monitor and control your operating expenses is a sure way to improve your competitive position. The ability to monitor the amount of Natural Gas entering your facility and to accurately track it’s use throughout the individual areas of consumption, can give you the information you need to adjust for peak usage and to correctly assign costs when reviewing general operating expenses and specific product profitability.

Natural Gas is typically delivered to the end user at a predetermined pressure, through relatively small distribution lines. Consumption is measured in cubic feet, through a volumetric flow meter supplied by the gas company and then converted to Therms for billing purposes. 
But, beyond this general custody transfer, how much do you really know about your true overall consumption?   And... How do you determine where you can find cost savings?

Two ways... 1) Sub-metering at the point of entry gives you an accurate indication of overall consumption and 2) Sub-Metering at selected points within your facility provides a clearer picture of who, when and how much gas is being consumed at specific locations and/or work areas. This is the kind of information you need to analyze your ongoing expenses and to then refine your overall usage. 

Why should I audit the Gas Company’s readings for overall consumption?

Natural gas entering your facility is usually measured with a Positive Displacement (PD) flowmeter supplied by the Gas Company and metered in units of hundreds of cubic feet (CCF). 

Keep in mind that this is a volumetric measurement of the gas and merely serves as one part of the formula used to compute your consumption charges.   

What’s important for you to know is that although Natural Gas is measured in Cubic Feet, it’s sold in units of energy referred to as: Therms

Q)aaWhat's a Therm?  
A)aaA Unit of Energy consisting of 100,000 BTU's

To understand the concept of "Therms", you'll need to know a little about British Thermal Units or BTU's for short.  One (1) BTU is defined as the amount of energy required to raise the temperature of one pound of water, one degree (1°) at atmospheric pressure.

One Cubic Foot of natural gas has an average heating capacity of 1,025 BTU's.  This value differs slightly in different locations due to variations in the gas mix, but for our purposes, we'll stick with 1,025.  At that rate, a therm would consist of 97.56 Cubic Feet of Natural Gas or roughly 100 Cubic Feet when rounded up. (CCF... See the tie?) 


Gas Billing - (Finally, we get to the math...)  Your monthly bill is a product of net  consumption in cubic feet, multiplied by a factor representing the BTU content of the gas and then divided by 100,000.  Because the pressure at which your gas is delivered has a huge effect on it's density, this figure is adjusted one more time using a Density Factor. 
The

The process starts at your meter where the gas company records a net consumption of Natural Gas in Cubic Feet.  Next, Cubic Feet are converted to Therms using the following formula:
(Cubic Feet x 1,025) / 100,000= Therms  

Example: Acme Cookie Company's gas meter shows a net consumption of 1,500.000 Cubic Feet of gas used last month to fire the cookie ovens. 

(1,500,000 x 1,025) / 100,000 = 15,375.00 Therms

Remember...

A cubic foot of gas in this example contains about 1,025 BTU's and a Therm is equal to 100,000 BTU's. 

To correct for pressure, the following formula is used to create a factor to compensate for gas density: 

(Line Pressure + 14.7) / 14.7 = Density Factor 

Example: 
(2.5 + 14.7) / 14.7 = 1.170 

Usage/Density Factor: 

In this example, we're assuming a line pressure of 2.5 psig at the meter. 

Your bill would now be figured as follows:

(Therm Value($) x Therms Consumed) x Usage / Density Factor = Gas Charge
 ($1.00 x 15,375.00) x 1.170 = $17,988.75 To keep the math simple, we'll  assume a Per Therm Value of $1.00
But, what happens if the line pressure drops to 1/4 PSIG and your bill is still being based on 2.5 PSIG?  

Gas enters your meter at 1/4 PSIG, but the density factor on your bill is based on a system pressure of 2.5 PSIG. Does it make a difference?  Let's check back with the Bean Counters at Acme Cookie Company, who are already steamed over the $17,988.75 gas bill they received last month.  That bill was based on an incoming pressure 2.5 PSIG, but in reality the pressure had dropped to 0.25 PSIG.  Let's do the math one more time... 

15,375.00 Therms @ 0.25 PSI

15,375.00 Therms @ 2.5 PSI

(0.25 + 14.7) / 14.7 = 1.01 (Density Factor)

(2.5 + 14.7) / 14.7 = 1.170

($1.00 x 15,375.00) x 1.01 = $15,528.75 ($1.00 x 15,375.00) x 1.170 = $17,988.75
That's a difference of almost $2,460.00-representing a billing error of nearly 15%.

Can this type of billing 
error really happen? 

You bet it can and it happens every day. Pressure variations are inevitable in gas lines. Adjustments are made for new construction, lines are shut down for repairs... The list of reasons is endless! The Gas Companies do their best to correct for these inconsistencies, but without a more accurate way to measure the flow of gas into your facility, you're at their mercy at the end of each billing period.

How can you be sure you're only paying for your actual consumption?  The answer is simpler than you might think...

Gas measurement by mass rather than volume. Thermal Mass Flowmeters from EPI are temperature compensated and insensitive to changes in system pressure, so no additional calculations are required to obtain an accurate measurement of your gas consumption.  You just can’t do that with a volumetric flowmeter!

Thermal Mass Flow Technology...

Thermal mass flowmeters are solid state instruments that use the principle of convective heat transfer to directly measure mass flow.  EPI's sensors consist of two resistance temperature detectors (RTD's).  A forced null, Wheatstone bridge which preferentially heats  one RTD; while the other acts as the temperature reference.  The process gas flow dissipates heat from the first RTD, causing an increase in the power required to maintain a balance between the RTD's. This increase is directly proportional to the molecular rate of flow of the gas.


EPI produces a wide variety of thermal mass flowmeters for measurement and control of gas.
EPI Thermal Mass Flowmeters offer:

  • Direct measurement of mass flow or mass velocity without requiring temperature or pressure corrections.

  • Exceptional Turndown: 100:1 or more.

  • Integral or Remote Electronics 

  • Both 4-20mA & 0-5Vdc output signals

For additional information on EPI Thermal Mass Flow Meters for
Sub-Metering / Utility Auditing, contact Bill Michie at Cross Instrumentation!

Phone: (800) 332-3418 Fax: (770) 929-828 Email: FlowSolutions@crossco.com
EPI Thermal Mass Flow Meters
Utility Auditing via Thermal Mass
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Copyright © 2002 by Cross Instrumentation 
Specifications subject to change without notice - 10/01/02

 
NOTE: The information provided above  has been compiled and published as a convenience to our customers. All technical designs, advice, and recommendations, including but not limited to, that appearing on this document are rendered free of charge. As a result, Cross Instrumentation disclaims any responsibility or liability to the buyer or user of this information for any result obtained or damages incurred by reason of the use or application of the design or other information contained herein.

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