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Summary of Contents for Baker Panametrics flare.IQ
- Page 1 flare.IQ Generation 2 Operation and Maintenance Manual BH013C11 EN B panametrics.com...
- Page 3 May 2024 panametrics.com Copyright 2024 Baker Hughes company. This material contains one or more registered trademarks of Baker Hughes Company and its subsidiaries in one or more countries. All third-party product and company names are trademarks of their respective holders.
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- Page 5 Preface 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, Service Agreements and more.
- Page 6 Preface 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.
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Page 7: Table Of Contents
Contents Chapter 1. General Information Introduction ..................... .1 Application . - Page 8 Contents Appendix A. Modbus map for legacy flare.IQ Gen 1 installations Scaling Modbus Data (for legacy Gen 1 systems only) ............52 Appendix B.
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Page 9: Chapter 1. General Information
Chapter 1. General Information Chapter 1. General Information Introduction This manual contains information about the installation, operation, and maintenance of the flare.IQ Gen 2 hardware and software system. Proprietary flare control and in situ flare flow meter validation software is installed on a rack-mounted assembly of industrial embedded automation computers. -
Page 10: Equipment Overview
Chapter 1. General Information The third and most recent feature of the flare.IQ system is in situ flare CE and DRE monitoring based on a parametric model derived from flare CE experimental data and CFD calculations. This PEMS feature can be deployed on both un-assisted upstream flares and assisted downstream flares to achieve maintenance-free, real-time monitoring of CE/DRE based on process and environmental conditions derived from flare flow and wind speed measurement. - Page 11 Chapter 1. General Information detail how to set up and connect the flare.IQ to the DCS. If you have questions about the installation procedures, contact our technical support department. See the rear cover of this manual for contact information. Installation shall be in an enclosed rack that requires tool access. You should discuss environmental and installation factors with a BH applications engineer or field service by the time you receive the hardware.
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Page 12: System Specifications
Chapter 1. General Information Figure 5: Description of warning symbol labels applied to the top module Figure 5 provides a detailed explanation of all the warning symbols and labels applied to the flare.IQ Gen 2 hardware. In addition to following all installation and operation instructions in this User Manual, be sure to follow all applicable safety codes and regulations for installing electrical equipment in your area. - Page 13 Chapter 1. General Information Size / Dimensions • Top module: 19.02" (483 mm) Width x 6.93" (176 mm) Height X 4.94" (126 mm) Depth • Weight = 8.65 lbs. (3.92 kg) • Bottom Module: 19.02" (483 mm) Width x 5.22" (133 mm) Height X 8.05" (204.5 mm) Depth •...
- Page 14 Chapter 1. General Information [no content intended for this page] flare.IQ Operation and Maintenance Manual...
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Page 15: Chapter 2. Hardware
Chapter 2. Hardware Chapter 2. Hardware This section describes the three major components of the flare.IQ Gen 2 system hardware – the Digital Processing Unit (DPU), the network switch and the redundant 24 VDC power supply. Main Processor (DPU) – Advantech UNO-2271G 2.1.1 Functional Description The flare.IQ Gen 2 DPU is based on a highly ruggedized, fan-less, and modular industrial embedded computer. -
Page 16: Power Supply
Chapter 2. Hardware USB Connector A USB 3.0 type A connector that supports plug-and-play functionality is provided to enable service personnel to plug in a keyboard if required. The USB interface can be enabled/disabled in the system BIOS. A silicone rubber dust plug is provided to increase protection of the DPU during regular operation. -
Page 17: Network Switch
Chapter 2. Hardware Network Switch 2.3.1 Functional Description Panametrics' industrial Ethernet 10/100 switches are designed specifically to meet the needs of real-time industrial control solutions. The Ethernet switch model used in this application is an 8-port 10/100 base T copper cables only, IS420ESWAH2A. - Page 18 Chapter 2. Hardware [no content intended for this page] flare.IQ Operation and Maintenance Manual...
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Page 19: Chapter 3. Software
Chapter 3. Software Chapter 3. Software Overall Architecture All flare.IQ software applications run on a real-time operating system (RTOS) for embedded devices. As described in the following section, all analog inputs from the flare flow meter, steam/air flow meter, and online analyzer are received from the DCS via Modbus/TCP. -
Page 20: Flare Meter Digital Validation (Dv)
Chapter 3. Software 3.2.2 Flare Meter Digital Validation (DV) Ultrasonic flare flow meters are widely used on oil & gas production assets, pipelines, and in refineries and petrochemical plants for flare operation and emission control. Regulatory compliance requires these flare flow meters to be validated periodically to meet their expected performance per the manufacturer's specifications. - Page 21 Chapter 3. Software Figure 10: Flare flow meter validation logic The high-level logic for the Panametrics flare flow meter performance validation is illustrated in Figure 10. flare.IQ uses a FIFO buffer to track meter performance and diagnostics data over the last 8 hours. This buffer's capacity is set to expect flare flow and diagnostic data no faster than once every 5 seconds.
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Page 22: Combustion Efficiency And Predictive Emissions Monitoring (Ce/Pems)
Chapter 3. Software 3.2.3 Combustion Efficiency and Predictive Emissions Monitoring (CE/PEMS) A new feature that has been recently added to the flare.IQ Gen 2 software is the online calculation of flare combustion efficiency (CE), destruction and removal efficiency (DRE) and various gas emission values. This Predictive Emissions Monitoring System (PEMS) feature can be utilized for monitoring both unassisted (upstream) flares and steam/air assisted (downstream) flares independently of the Flare Control and Digital Validation features described above. - Page 23 Chapter 3. Software Figure 12: Log in screen of the Web Console application The Web Console is designed to work with Chrome and Firefox browsers and is optimized for a screen resolution of 1280 x 1024. Upon initial log in with the default admin password, the user is led to the Service tab from where they can navigate to the Features tab shown in Figure 13 to upload appropriate software licenses.
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Page 24: User Roles
Chapter 3. Software Figure 14: Web Console Features page after uploading software license information. To update software, clicking the "Choose Software file" button opens up a file browser allowing the user to select a new Software Image file. Only a single file with ".tar.gz" or ".tgz" file extensions can be selected. A software update will reboot the DPU and will require the user to log back into the Web Console. -
Page 25: Network Setup
Chapter 3. Software Figure 15: Web Console Accounts page showing procedure of setting up new accounts with different access levels. 3.3.2 Network Setup There are two Ethernet switches on the top flare.IQ module, labeled Configure/Monitor (Ethernet 1) and LAN B Flare Control/DCS (Ethernet 2). - Page 26 Chapter 3. Software Figure 16: Network set-up page including IP address and Modbus Word/Byte order configuration. This page also includes options for changing the Modbus/TCP configuration: • Modbus/TCP server listen port (502 is the default) • Modbus Node/Device address (1 is the default). Please note that the flare.IQ does not support address 0 (accept any address).
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Page 27: Flare Configuration
Chapter 3. Software Figure 17: Service configuration page that enables uploading installation specific site files 3.3.3 Flare Configuration The flare.IQ Gen 2 is capable of operating with a wide variety of flare installations such as steam or air assist, online gas chromatograph, mass spectrometer or calorimeter for BTU measurement, and multi-flare, single-stack installations. - Page 28 Chapter 3. Software All fields in the flare and fuel configuration pages utilize tooltips. Tooltips will indicate appropriate information about the item being hovered over. Some of the installation-specific parameters that apply to all types of flare installations available on the left side of flare configuration page are: •...
- Page 29 Chapter 3. Software Figure 20: Flare settings for Air assist (continuous) Figure 20 shows the Web Console settings for an Air assist flare configuration where the air flow can be varied continuously. While majority of these parameters are like those under the Steam assist settings, the only differences are the following: •...
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Page 30: Fuel Configuration
Chapter 3. Software 3.3.4 Fuel Configuration As shown in Figure 22 this page enables setting the following flare (supplemental) fuel specific parameters: • Choice of Flare Energy Content from - GC/Calorimeter. • Analyzer Update Rate Minimum allowed fuel flow. • Maximum allowed fuel flow. •... -
Page 31: Data Status Color
Chapter 3. Software • The Flare pane displays the critical flare measurements as captured by the DCS and sent to the flare.IQ. Use this to verify that the data obtained from the flare flowmeter, temperature, and pressure sensors is being reliably transferred from the DCS to the flare.IQ. -
Page 32: Modbus Connection Status
Chapter 3. Software • Data displayed in gray is determined to be 'stale'. The result is valid, but it is marked as stale because the parameter has not been recalculated or is the result of a calculation using another parameter that has not been updated by the DCS in a specified time period. -
Page 33: Control Override
Chapter 3. Software Figure 25: Control page under timeout conditions 3.3.8 Control Override When logged in as an Administrator or Operator, an Override switch is displayed on the upper right of the Control page. Override mode is a troubleshooting and diagnostic tool for flare.IQ calculations page, overriding the data from the DCS. -
Page 34: Flare Meter Validation
Chapter 3. Software Be sure to turn Override off to resume normal operation when testing is completed. Figure 26: Control Page with Override Enabled. 3.3.9 Flare Meter Validation The flare.IQ Gen 2 system is designed to operate at any GF868/XGF868i installation that employs a Modbus RTU or Modbus TCP connection between the Panametrics flare flow meter and the DCS. - Page 35 Chapter 3. Software Figure 27: Validation page showing system is ready for on-demand digital verification. As shown in Figure 10 on page 13, running digital verification requires a minimum amount of meter diagnostic data collected over an 8-hour time window. This ensures verification occurs only when stability criteria for all flow meter diagnostics are adequately satisfied.
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Page 36: 3.3.10 Emissions (Ce/Pems) - Normal And Override Modes
Chapter 3. Software There are two other possible outcomes of the digital verification process as described in Section 3.2.2 See “Flare Meter Digital Validation (DV)” on page 12. The former result is to be expected when either the Sound speed or the Diagnostics validation fail their installation-specific pass/fail criteria. - Page 37 Chapter 3. Software Figure 30: Emissions page without Modbus connection • The Flare Inputs pane in the top center displays the critical flare measurements such as flare flow, assist flow, flare temp, pressure, etc. collected by the DCS and sent to the flare.IQ as Modbus inputs. This pane should be used to verify that the data obtained from the flare flowmeter, temperature, and pressure sensors are being reliably transferred from the DCS to the flare.IQ.
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Page 38: Modbus Status
Chapter 3. Software • Flare sound (box has to be clicked to initiate a new calculation) • Flare flow • Flare temperature • Flare pressure • Steam/Air assist flow • Downstream N2 purge • Wind speed • C:H ratio in vent gas •... - Page 39 Chapter 3. Software Figure 32 shows the Modbus map for flare control while Figure 33 displays the Modbus map for Digital Validation. There is a slider bar in the top right that lets the Operator switch between the two pages. Figure 32: Modbus page showing Digital Validation As shown in the figures above, these parameters for each of the two features are grouped into Holding (analog input), Input (analog output) and Boolean status and coil registers (where relevant).
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Page 40: Modbus
Chapter 3. Software Modbus 3.4.1 Modbus Configuration The default Modbus TCP configuration is as follows: Modbus Device Address = 1 TCP Port = 502 Byte Order = Most Significant Byte First. Word Order = Most Significant Word First. This configuration can be changed as required on the Network page of the Web Console. 3.4.2 Modbus Address List flare.IQ Gen 2 uses 32-bit IEEE-754 Floating point representation for all analog inputs (Modbus holding registers) and... - Page 41 Chapter 3. Software Table 3: Modbus Address List - Holding Registers for Flare Control (analog inputs) (cont.) Register Number of Register Tag Name Description Address Registers 1056 Flare Sound Speed CFLARE_TC 1060 Steam Flow Rate QSTEAM_TC 1062 Steam Temperature (future use) TSTEAM_TC 1064 Steam Pressure (future use)
- Page 42 Chapter 3. Software Table 4: Modbus Address List - Holding registers for Digital Validation (analog inputs) (cont.) Register Number of Register Tag Name Description Address Registers Water Vapor Concentration 1022 Flare Temperature TFLARE_TC 1052 Flare Pressure PFLARE_TC 1054 Flare Sound Speed CFLARE_TC 1056 Chanel Configuration of the Flare meter...
- Page 43 Chapter 3. Software Table 4: Modbus Address List - Holding registers for Digital Validation (analog inputs) (cont.) Register Number of Register Tag Name Description Address Registers Ch 2 Sound speed from Flare meter SOUNDSPEED_CH2 2204 Ch 2 Upstream Signal Strength from Flare meter SIG_STRENGTH_CH2_UP 2206 Ch 2 Downstream Signal Strength from Flare meter...
- Page 44 Chapter 3. Software Table 6: Modbus Address List - Input Registers for Flare Control (analog outputs (cont.)) Register Number of Register Tag Name Description Address Registers NHVCZ_MEASURED Net Heating Value in the Combustion Zone derived from GC/Calorimeter at Fuel and Steam set-points calculated by flare.IQ NHVCZ_CURRENT Net Heating Value in the Combustion Zone derived...
- Page 45 Chapter 3. Software Table 8: Modbus Address List - Input registers for CE/PEMS (analog outputs) Register Number of Description Register Tag Name Address Registers EM_CO Carbon Monoxide emissions EM_CO2 Carbon Dioxide emissions CO2-equivalent emissions based on Global Warming EM_CO2_EQUIVALENT Potentials EM_VOC Volatile Organic Compound emissions EM_DRE...
- Page 46 Chapter 3. Software Table 9: Modbus Address List - Boolean status registers (read only) (cont.) Register Tag Name Register Number of Description Address Registers QSTEAM_BQ Steam Flow Measurement Bad TSTEAM_BQ Steam Temperature Measurement Bad RESERVED_26 Reserved, returns 0 QAIR_BQ Air Flow Measurement Bad TAIR_BQ Air Temperature Measurement Bad PAIR_BQ...
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Page 47: Flare.iq Units
Chapter 3. Software Table 11: English and Metric (SI) units used in flare.IQ Gen2 Parameter English Flare Page Flare Diameter Flare Low Cut-off ft/s Steam Rate Limit MTPH/min PPH/min Steam Min MTPH Steam Max MTPH Air Min /sec Air Max /sec Volumetric Flow of N2 SCFH... - Page 48 Chapter 3. Software [no content intended for this page] flare.IQ Operation and Maintenance Manual...
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Page 49: Chapter 4. Installation & Maintenance
Chapter 4. Installation & Maintenance Chapter 4. Installation & Maintenance Power Distribution Installation and startup must only be carried out by qualified personnel. The relevant country-specific electrical safety codes and regulations (e.g., VDE, DIN) must be observed. Before startup it is important to ensure that: •... -
Page 50: Output (2, Figure 34)
Chapter 4. Installation & Maintenance 4.1.2 Output (2, Figure 34) The power supply unit meets the requirements of NEC Class 2. The 24 V DC connection is made using the "+" and "-" screw connections on the screw connection 2. The output voltage set upon delivery is 24 VDC and can be adjusted from 22.5 to 26 V DC on the potentiometer 4. - Page 51 Chapter 4. Installation & Maintenance Figure 35: System Wiring Diagram flare.IQ Operation and Maintenance Manual...
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Page 52: Communication Network Diagram
Chapter 4. Installation & Maintenance Communication Network Diagram 4.2.1 Functional Description The flare.IQ Gen 2 has two independent unmanaged 8-port network switches installed on the top module – one labeled Flare Control/DCS (Modbus TCP) and the other labeled Configure/Monitor. As shown in Figure 36 below, each DPU installed in the bottom module has two independent ethernet ports –... -
Page 53: 19" Rack Mounting
Chapter 4. Installation & Maintenance 19" Rack Mounting 4.3.1 Functional Description The flare.IQ Gen 2 system is designed to be mounted in a standard 19" rack mount cabinet. Please note mounting hardware is not included in the shipping box. The top power distribution and network module has 4 mounting points, and the bottom DPU module has 4 mounting points. -
Page 54: Replacing A Dpu
Chapter 4. Installation & Maintenance Figure 38: Recommended module and DPU placement (primary #1 and redundant #2 for each flare) Replacing a DPU 4.4.1 Installation The Advantech DPU mounts directly to the panel sheet metal. To remove the controller Unplug the 24V dc power cable from DPU. Remove the Ethernet cables from the controller. -
Page 55: Environment
Chapter 4. Installation & Maintenance Environment 4.5.1 Mounting Location Consider these requirements when selecting the mounting location: • Adequate ventilation for cooling. • Space for servicing and repair. • Protection from direct exposure to water or to a condensation-prone environment; a cabinet with at least an IP52 rating. - Page 56 Chapter 4. Installation & Maintenance Table 14: Network port assignments on DPU Port Service/Description Web Console (TCP), http Web Console (TCP), https / TLS 502* Modbus/TCP The port used by Modbus/TCP can be reassigned using the Web Console to another value if required by the local network infrastructure The two Ethernet ports provided on each DPU are isolated from each other at both the hardware and software level.
- Page 57 Appendix A. Modbus map for legacy flare.IQ Gen 1 installations Appendix A. Modbus map for legacy flare.IQ Gen 1 installations flare.IQ Gen 2 is designed to be backward compatible with Gen 1 installations for flare control applications (digital meter verification feature is not available in Gen 1). For those customers that wish to continue to use their existing DCS configuration for flare control, the Gen 2 system supports the Modbus Map of unsigned integers shown in Table 11 (analog inputs) and Table 12 (analog outputs).
- Page 58 Appendix A. Modbus map for legacy flare.IQ Gen 1 installations Table 15: Modbus address list for flare.IQ Gen 1 legacy customers (analog inputs) for flare control with scaling factors (cont.) Register Tag Register Number of Units Description Scaling Name Address Registers factor MW_HIGH...
- Page 59 Appendix A. Modbus map for legacy flare.IQ Gen 1 installations Table 16: Modbus address list for flare.IQ Gen 1 legacy customers (analog outputs) for flare control with scaling factors (cont.) Register Tag Name Register Number of Units Description Scaling Address Registers Factor NHVCZ_UNCORRECTED_ACTUA...
- Page 60 Appendix A. Modbus map for legacy flare.IQ Gen 1 installations Scaling Modbus Data (for legacy Gen 1 systems only) All analog data is transferred to/from the flare.IQ as 16-bit, unsigned integers. Each input parameter and output value occupy a single 16-bit Modbus register. To maintain the desired dynamic range or turndown, data may be scaled by multiplying or dividing by a multiple of ten.
- Page 61 IMPORTANT: It is the end user's responsibility to abide by the above cyber security recommendations. Baker Hughes has no control over the flare.IQ usage environment or misuse of this product. The end user assumes all risk and responsibility for proper use of the product.
- Page 62 Appendix B. flare.IQ Secure Operations Guide [no content intended for this page] flare.IQ Operation and Maintenance Manual...
- Page 63 Appendix C. Glossary of Terms and Abbreviations Appendix C. Glossary of Terms and Abbreviations bara Bars absolute (pressure relative to vacuum) BTU/SCF British Thermal Units Per Standard Cubic Foot Cubic Feet Per Minute Distributed Control System Digital Processing Unit ft/s feet per second g/mol grams per mole...
- Page 64 Appendix C. Glossary of Terms and Abbreviations [no content intended for this page] flare.IQ Operation and Maintenance Manual...
- Page 65 Warranty Warranty Each instrument manufactured by Panametrics is warranted to be free from defects in material and workmanship. Liability under this warranty is limited to restoring the instrument to normal operation or replacing the instrument, at the sole discretion of Panametrics. Fuses and batteries are specifically excluded from any liability. This warranty is effective from the date of delivery to the original purchaser.
- Page 66 Warranty [no content intended for this page] flare.IQ Operation and Maintenance Manual...
- Page 68 Copyright 2024 Baker Hughes company. This material contains one or more registered trademarks of Baker Hughes Company and its subsidiaries in one or more countries. All third-party product and company names are trademarks of their respective holders.
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