Panametrics flare.IQ Generation 2 User manual

flare.IQ
Generation 2
Operation and maintenance manual

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flare.IQ
Generation 2
Operation and maintenance manual
910-350 rev A
June 2020
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Product registration
Thank you for purchasing your flare.IQ from Panametrics.
Please register your product at https://info.bakerhughes.
com/New-Product-Registration-LP.html for product support
such as the latest software/firmware upgrades, product
information and special promotions.
Services
Panametrics provides customers with an experienced
staff of customer support personnel ready to respond to
technical inquiries, as well as other remote and on-site
support needs. To complement our broad portfolio of
industry-leading solutions, we offer several types of flexible
and scalable support services including: training, product
repairs, extended warranties, service agreements and more.
Please visit https://www.bakerhughesds.com/panametrics/
flow-measurement/flow-measurement-services for
more details.
Terms and conditions
Sales terms and conditions for your recent purchase of
a Panametrics product, including the applicable product
warranty, can be found on our website at the following link:
https://www.bakerhughesds.com/sales-terms-conditions
Typographical conventions
Note: These paragraphs provide information that provides
a deeper understanding of the situation but is not essential
to the proper completion of the instructions.
IMPORTANT: These paragraphs provide information that
emphasizes instructions that are essential to proper setup
of the equipment. Failure to follow these instructions
carefully may cause unreliable performance.
CAUTION!
This symbol indicates a risk of potential
minor personal injury and/or severe damage
to the equipment, unless these instructions
are followed carefully.
WARNING!
This symbol indicates a risk of potential
serious personal injury, unless these
instructions are followed carefully.
Safety issues
WARNING!
It is the responsibility of the user to make sure
all local, county, state and national codes,
regulations, rules and laws related to safety
and safe operating conditions are met for
each installation.
Attention European customers!
To meet CE marking requirements for all units
intended for use in the EU, all electrical cables
must be installed as described in this manual.
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Auxiliary equipment
Local safety standards
The user must make sure that he operates all auxiliary
equipment in accordance with local codes, standards,
regulations, or laws applicable to safety.
Working area
WARNING!
Auxiliary equipment may have both
manual and automatic modes of operation.
As equipment can move suddenly and
without warning, do not enter the work cell of
this equipment during automatic operation,
and do not enter the work envelope of this
equipment during manual operation. If you
do, serious injury can result.
WARNING!
Make sure that power to the auxiliary
equipment is turned OFF and locked out
before you perform maintenance procedures
on this equipment.
Qualification of personnel
Make sure that all personnel have manufacturer-approved
training applicable to the auxiliary equipment.
Personal safety equipment
Make sure that operators and maintenance personnel have
all safety equipment applicable to the auxiliary equipment.
Examples include safety glasses, protective headgear,
safety shoes, etc.
Unauthorized operation
Make sure that unauthorized personnel cannot gain access
to the operation of the equipment.
Environmental compliance
RoHS
The flare.IQ fully complies with RoHS regulations (directive
2011/65/EU).
Waste Electrical and Electronic Equipment (WEEE) directive
Panametrics is an active participant in Europe’s Waste
Electrical and Electronic Equipment (WEEE) take-back
initiative (Directive 2012/19/EU).
The equipment that you bought has required the extraction
and use of natural resources for its production. It may
contain hazardous substances that could impact health
and the environment.
In order to avoid the dissemination of those substances
in our environment and to diminish the pressure on the
natural resources, we encourage you to use the appropriate
take-back systems. Those systems will reuse or recycle most
of the materials of your end life equipment in a sound way.
The crossed-out wheeled bin symbol invites you to use
those systems.
If you need more information on the collection, reuse and
recycling systems, please contact your local or regional
waste administration.
Please visit https://www.bakerhughesds.com/health-safety-
and-environment-hse for take-back instructions and more
information about this initiative.
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Contents
Chapter 1. General information .........................................................9
1.1 Introduction .....................................................................................9
1.2 Application ......................................................................................9
1.3 Equipment overview ............................................................................ 10
1.4 Equipment installation...........................................................................11
1.5 System specifications............................................................................12
Chapter 2: Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Main processor (DPU) – Advantech UNO-2271G...................................................13
2.1.1 Functional description ...................................................................................13
2.1.2 Connections .............................................................................................13
2.2 Power supply ................................................................................... 14
2.2.1 Functional description ...................................................................................14
2.3 Network switch ................................................................................. 14
2.3.1 Functional description ...................................................................................14
Chapter 3. Software ................................................................... 15
3.1 Overall architecture............................................................................. 15
3.2 Functional description .......................................................................... 15
3.2.1 Flare control..............................................................................................15
3.2.2 Flare meter validation....................................................................................16
3.3 Configuration ....................................................................................17
3.3.1 User roles ................................................................................................19
3.3.2 Network setup............................................................................................19
3.3.3 Flare configuration.......................................................................................21
3.3.4 Fuel configuration....................................................................................... 23
3.3.5 Monitor overview........................................................................................ 23
3.3.6 Data status color........................................................................................24
3.3.7 Modbus connection status..............................................................................24
3.3.8 Monitor override.........................................................................................26
3.3.9 Flare meter validation....................................................................................27
3.4 Modbus.........................................................................................29
3.4.1 Modbus configuration .................................................................................. 29
3.4.2 Modbus address list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.4.3 flare.IQ units.............................................................................................36
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Chapter 4. Installation and maintenance ..............................................37
4.1 Power distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1.1 Input (1, figure 29) ........................................................................................37
4.1.2 Output (2, figure 29)......................................................................................37
4.1.3 Wiring diagram ..........................................................................................37
4.2 Communication network diagram ..............................................................39
4.2.1 Functional description ..................................................................................39
4.3 19” Rack mounting ..............................................................................40
4.3.1 Functional description ..................................................................................40
4.3.2 Module installation......................................................................................40
4.4 Replacing a DPU ................................................................................ 41
4.4.1 Installation ...............................................................................................41
4.5 Environment .................................................................................... 41
4.5.1 Mounting location........................................................................................41
4.6 Spare parts list.................................................................................. 41
4.7 Reliability ....................................................................................... 41
4.8 Technical regulations and standards ........................................................... 41
4.9 Cyber security ..................................................................................42
4.9.1 Precautions ............................................................................................. 42
4.9.2 Exposed ports and services............................................................................. 42
APPENDIX A:
Modbus map for legacy flare.IQ Gen 1 installations.....................................43
A.1. Scaling Modbus data (for legacy Gen 1 systems only) ...........................................46
APPENDIX B:
Glossary of terms and abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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Chapter 1. General information
1.1 Introduction
This manual contains information about the installation,
operation, and maintenance of the flare.IQ Gen 2 control
system. Proprietary flare control and flare flow meter
validation software is installed on a rack mounted
assembly of industrial embedded automation computers.
The flare.IQ Gen 2 is a complete turnkey hardware and
software flare control solution that enables regulatory
compliance along with increased efficiency and reduced
operating costs.
1.2 Application
flare.IQ is a control computer that receives inputs and sends
outputs to the customer’s distributed control system (DCS)
via TCP/IP Modbus to control a flare’s fuel gas and steam
supply valves (see figure 1). The software algorithm in
flare.IQ uses the sound speed measured by Panametrics’
ultrasonic flow meter to calculate the molecular weight
of the flare gas, and from the molecular weight, the net
heating value (NHV) is determined. Supplemental fuel gas
demand and steam/air demand are then calculated based
on current net heating values, hydrocarbon molecular
weight and flare vent gas flow. The flare.IQ is also capable
of digital validation of an ultrasonic flow meter installed on
the vent gas line either on a pre-determined schedule or
on demand. This digital validation algorithm uses measured
vs. calculated speed of sound based on an independent
online vent gas BTU and/or composition analyzer such as
a gas chromatograph. It also utilizes a variety of meter
diagnostics such as signal strength, transit times, path
length, and difference in channel velocities.
DCS
Modbus/TCP
flare.IQ
DPU
BTU
measurement
Control
valve
Control
valve
Flow
Flow
Flow Flare gas
Steam/air
Fuel gas
Figure 1: Schematic of flare.IQ-based control of flare assist (steam/air) and supplemental fuel
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1.3 Equipment overview
The system hardware includes two 19” rack mounting
sheet metal modules that house compact fanless digital
processing units (DPU), redundant power supplies, a pair of
ethernet switches and other power distribution equipment
and cables. The top power distribution and networking
module is shared with up to six DPU modules installed in the
bottom module (figure 2). A single DPU module is configured
to control a single flare stack while a second DPU module
loaded with identical firmware and settings provided for
redundancy. However, a single DPU is adequate for digital
verification of a single flare flow meter given the relatively
low frequency of this procedure. For example, if a customer
site has two flare stacks that need to be controlled, one
power distribution and network (top) module and a bottom
module with four (4) DPUs installed would be required. The
power distribution and networking module weighs 8.65 lbs.
(3.92 kg) and the bottom DPU module with the maximum
number (6) of DPU’s installed weighs 8.55 lbs. (3.88 kg).
4U high power
distribution and
network module (top).
One power distribution
and network module
can support up to
six DPUs
3U high DPU module
(bottom)
Figure 2: Front view of rack mounted control equipment
WARNING!
A disconnect power switch is required
to be installed within 30” (2.5 feet) of the
rack-mounted panels.
WARNING!
To ensure the safe operation of this unit,
you must install and operate the flare.IQ as
described in this user’s manual. In addition,
be sure to follow all applicable safety codes
and regulations for installing electrical
equipment in your area.
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