The Challenge
The facility could not be started due to combustion safety hazards identified during the Process Hazard Analysis (PHA), driven by highly variable fuel gas composition supplying three fired heaters. While heating value remained stable on a mass basis, significant volumetric BTU swings caused incomplete combustion and unsafe operating conditions that existing controls could not manage. Traditional analyzers introduced further risk through long lead times, slow response, and added uncertainty, forcing operators to rely on manual adjustments, resulting in emissions exposure, elevated safety risk, and a projected five‑month startup delay.
The Solution
Spartan Controls recommended installing Coriolis mass flow meters on each fired heater to directly measure fuel flow on a mass basis. This approach eliminated sensitivity to fuel gas composition changes and enabled mass‑based combustion control that automatically compensated for BTU variability.
Coriolis meters were selected not only for accuracy and fast response, but also to minimize project risk. With lead times of 12–16 weeks, significantly shorter than GC analyzers, the solution supported an accelerated schedule. The customer further expedited delivery by sourcing spares from existing inventory, enabling rapid implementation and commissioning.
Coriolis meters were selected not only for accuracy and fast response, but also to minimize project risk. With lead times of 12–16 weeks, significantly shorter than GC analyzers, the solution supported an accelerated schedule. The customer further expedited delivery by sourcing spares from existing inventory, enabling rapid implementation and commissioning.
The Value
The Coriolis‑based fuel gas control upgrade delivered measurable safety, operational, and financial results:
- Eliminated combustion safety hazards identified in the PHA
- Improved heater reliability and emissions performance by removing guesswork from combustion control
- Reduced startup timeline from 5 months to 1 month
- Approximately $2.1 million in total project savings through accelerated startup and avoided delays
- Lower project risk, avoiding long lead‑time analyzers and complex correlations