Sick FLOWSIC100 Flare-XT Transmitter - Ultrasonic Mass Flow Measuring Device Operating instructions
Below you will find brief information for FLOWSIC100 Flare-XT, FLSE100-XT. This document covers installation, operation, and maintenance of the FLOWSIC100 Flare-XT Transmitter, an ultrasonic mass flow measuring device using FLSE100-XT sender/receiver units for accurate gas flow measurement. It details safety precautions and troubleshooting tips for reliable operation. For advanced settings and diagnostics, refer to the Service Manual.
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FLOWSIC100 Flare-XT Transmitter
Ultrasonic Mass Flow Measuring Device
Installation
Operation
Maintenance
O P E R A T I N G I N S T R U C T I O N S
Document information
Described product
Product name: FLOWSIC100 Flare-XT Transmitter
Document identification
Title: Operating Instructions FLOWSIC100 Flare-XT
Transmitter
Part No.:
Version:
Release:
8027358/1FPZ
1-1
2022-05
Manufacturer
SICK Engineering GmbH
Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany
Phone:
Fax:
E-Mail:
+49 35205 52410
+49 35205 52450 [email protected]
Original document
The English version 8027358/1FPZ of this document is an original document from SICK Engineering GmbH.
SICK Engineering GmbH assumes no liability for the correctness of an unauthorized translation.
Please contact SICK Engineering GmbH or your local representa tive in case of doubt.
Legal information
Subject to change without notice.
© SICK Engineering GmbH. All rights reserved.
Warning symbols
IMMEDIATE HAZARD of severe injuries or death
Hazard (general)
Voltage hazard
Hazard in potentially explosive atmospheres
Hazard through explosive substances/substance mix tures
Hazard by noxious substances
Hazard by toxic substances
Warning levels/signal words
DANGER
Risk or hazardous situation which will result in severe personal injury or death.
WARNING
Risk or hazardous situation which could result in severe personal injury or death.
CAUTION
Hazard or unsafe practice which could result in less severe or minor injuries.
NOTICE
Hazard which could result in property damage.
Information symbols
Important technical information for this product
Supplementary information
Link referring to information at another place
2 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Contents Contents
1
2
5
4
3
About this document
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Function of this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Scope of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Target groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Data integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Further information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
For your safety
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Basic safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hazards due to hot, cold (cryogenic) or aggressive gases, or high pressure . . . . . 13
Hazard through electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hazards through explosive or ignitable gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hazards through electrostatic discharges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Retraction mechanism of the sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operation in potentially explosive atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Specific conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Use of FLSE100-XT, depending on the temperature code and process temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Permissible gas temperature, depending on the temperature code of the sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Warning information on device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Requirements on the personnel's qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Restrictions on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Product description
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Material for wetted parts (parts with process gas contact) . . . . . . . . . . . . . . . . . . . . . . . 32
Spool piece option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ASC technology (patented) – active sound correlation technology . . . . . . . . . . . . . . . . 35
Project planning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Determining the measuring and installation location for FLSE100-XT . . . . . . . . . . . . . 39
General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Additional requirements for optional spool piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Installation location for external pressure and temperature transmitters (option) 40
Applications with wet gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Clearance for fitting and removing the sender/receiver units . . . . . . . . . . . . . . . . . . 41
Transport and storage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Transport protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Special notes for handling the spool piece option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 3
Contents
7
8
6
Mounting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fitting the spool piece (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installation sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Geometry calculator in FLOWgate TM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installation accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Nozzles, blind flanges and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Ball valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Nozzle installation tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fitting the nozzles on the pipeline (measuring system without spool piece option) . 55
General preparation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Determining the nozzle position for cross-duct versions . . . . . . . . . . . . . . . . . . . . . . 56
Determining the nozzle position for the probe version . . . . . . . . . . . . . . . . . . . . . . . . 58
Welding the nozzle on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Fitting the sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Calculating wetted part length wL with the geometry calculator in FLOWgate TM . 67
Tightening the self-cutting ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fitting the venting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Installing sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Leak tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Pulling the sender/receiver units back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Fitting the weatherproof cover for the sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . 78
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Fitting the weatherproof cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Electrical installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Cable specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Cable glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Requirements for installation in the Ex zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Connection overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Pressure and temperature values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Commissioning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Commissioning with the FLOWgate TM operating software . . . . . . . . . . . . . . . . . . . . . . . 90
Auxiliary means and accessories required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Connecting to the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Establishing a connection with FLOWgate TM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Contents
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9
Commissioning wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Mass flow (calculations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Volume flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Mass flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Algorithm for calculating the molar mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Density calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Finalize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Functionality and plausibility checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Check of device status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Overview of most important measured and calculated values . . . . . . . . . . . . . . . . . 99
Measured values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Calculated values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Maintenance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Routine checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Checking the device status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Comparing theoretical and measured speed of sound (SOS) . . . . . . . . . . . . . . . . .103
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Troubleshooting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Detecting malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Contacting Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Starting a diagnostic session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Decommissioning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Returning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Disposal information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Technical data
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Technical data FLOWSIC100 Flare-XT Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
F1F-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
F1F-M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
F1F-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
F1F-P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Application Evaluation Datasheet (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Applications of FLOWSIC100 Flare-XT Transmitter in a regulated environment . . . .118
Application limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Derating pressure resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Dimension drawings of FLSE100-XT sender/receiver units . . . . . . . . . . . . . . . . . . .122
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 5
Contents
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Spare parts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Recommended spare parts for FLSE100-XT sender/receiver units . . . . . . . . . . . . . . 126
Accessories (optional)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Accessories for FLSE100-XT sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Annex
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Compliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Compliances of FLSE100-XT sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . 130
CE declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Standards compatibility and type approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Type code, FLSE-XT, sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Gasket installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
6 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
About this document
FLOWSIC100 Flare-XT Transmitter
1 About this document
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 7
1.1
1.2
1.3
1.4
About this document
Function of this document
These Operating Instructions describe for the FLOWSIC100 Flare-XT Transmitter with
FLSE100-XT sender/receiver units:
● Device components
● Installation
● Operation
● Maintenance work required for reliable operation
For detailed information on functional checks/device settings, data backup, software update, malfunction and error handling and possible repairs, see the Service Manual.
Retention of documents
▸ Keep these Operating Instructions and all associated documents available for reference.
▸ Pass the documents on to a new owner.
Scope of application
These Operating Instructions apply exclusively to the FLOWSIC100 Flare-XT Transmitter with the described system components.
They are not applicable to other SICK measuring devices.
These Operating Instructions cover standard applications which conform with the technical data specified. Additional information and assistance for special applications are available from your SICK representative.
It is generally recommended to take advantage of qualified consulting services provided by
SICK experts for your specific application.
Target groups
This Manual is intended for persons installing, operating and maintaining the device.
Operation
The device may only be operated by authorized persons who, based on their training on, and knowledge of the specific device, as well as knowledge of the relevant regulations can assess the tasks given and recognize the hazards involved.
Installing and maintaining
Skilled persons are required for installation and maintenance.
Please observe the information at the beginning of the respective Sections.
Data integrity
SICK Engineering GmbH uses standardized data interfaces such as standard IP technology, in its products. The focus here is on the availability of the products and their properties.
SICK Engineering GmbH always assumes that the customer is responsible for the integrity and confidentiality of data and rights involved in connection with using the products.
In all cases, the customer is responsible for the implementation of safety measures suitable for the respective situation, e.g., network separation, firewalls, virus protection and patch management.
8 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
About this document
1.5
Further information
NOTICE:
Observe all supplied documents.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 9
About this document
10 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
For your safety
FLOWSIC100 Flare-XT Transmitter
2 For your safety
Operation in potentially explosive atmospheres
Requirements on the personnel's qualification
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 11
2.1
For your safety
Basic safety information
Observe the safety information here and the warning information in the following Sections of these Operating Instructions to reduce health risks and avoid dangerous situations.
In the case of warning symbols on the devices, the Operating Instructions must be consulted to determine the nature of the potential hazard and the actions required to avoid the hazard.
▸ Only put the FLOWSIC100 Flare-XT Transmitter into operation after reading the
Operating Instructions.
▸ Observe all safety information.
▸ If there is something you do not understand: Contact SICK Customer Service.
▸ Only use the FLOWSIC100 Flare-XT Transmitter as described in these Operating
Instructions. The manufacturer bears no responsibility for any other use.
▸ Do not attempt any work on or repairs to the FLOWSIC100 Flare-XT Transmitter unless described in this Manual.
▸ Do not modify the FLOWSIC100 Flare-XT Transmitter in any way unless specifically instructed and permitted to do so by the manufacturer.
▸ Only use accessories approved by the manufacturer.
▸ Do not use damaged components or parts.
▸ If you do not follow these guidelines, the following applies:
– Any warranty by the manufacturer becomes void,
– The FLOWSIC100 Flare-XT Transmitter can become dangerous
– The approval for use in potentially explosive atmospheres is no longer valid.
Special local requirements
Follow all local laws, regulations and company policies applicable at the respective installation location.
12 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
For your safety
2.1.1
2.1.2
2.1.3
Hazards due to hot, cold (cryogenic) or aggressive gases, or high pressure
The FLSE100-XT sender/receiver units are mounted directly on the gas-carrying pipeline.
On equipment with low hazard potential, e.g., non-toxic, aggressive or explosive gases, gases not hazardous to health, uncritical pressure, moderate gas temperature (not hot, very low/cryogenic), the installation or removal can be performed while the equipment is in operation, however only as far as the valid regulations and equipment safety notices are observed and suitable protective measures are taken. Special regulations that apply to the plant must be observed.
WARNING: Gas hazard
▸ Activities on equipment with increased hazard potential, e.g. by toxic, aggressive, explosive gases, health endangering, higher pressure, high temperatures, low temperature (cryogenic), have to follow legitimate regulations, general standards and guidelines as well as plant operator instructions. Only authorized personnel with special qualification for fitting using the ”Hot Tapping” method may install the devices when the plant is in operation (requirements on the qualification of the personnel, see
). Otherwise, serious injuries might occur, e.g. poisoning, burns etc.
These persons must be trained and technically adept in ”hot tapping” installation work and must know and implement legal as well as generally applicable regulations and in-house regulations.
▸
The express approval of the plant operator in written form is required for installations on running equipment at all times. The plant operator carries the responsibility for professional implementation alone. All safety requirements relevant for the equipment must be observed as well as essential and suitable protective measures taken. All regulations/special regulations that can be applicable for the plant must be observed.
Hazard through electrical equipment
WARNING: Danger through main voltage
▸
Disconnect power supply lines before working on power connections or parts carrying main voltage.
▸ Refit any contact protection removed before switching the main voltage back on again.
Hazards through explosive or ignitable gases
FLSE100-XT sender/receiver units may be used in potentially explosive atmospheres only according to the respective specifications.
WARNING: Hazards through explosive or ignitable gases
▸ In potentially explosive atmospheres, only use the version of the
FLSE100-XT sender/receiver units specified for such use (
▸ Observe the information on
running equipment (”hot tapping” method).
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 13
2.1.4
2.1.5
For your safety
Hazards through electrostatic discharges
The electronic housing of the sender/receiver units and the optionally available spool piece are painted by the manufacturer with a layer thickness of max. 0.2 mm as standard.
WARNING: Ignition hazard through electrostatic discharge
Ignition hazards through electrostatic discharges exist when FLSE100-XT sender/receiver units with special paintwork and a layer thickness > 0.2 mm are used in applications with ignition group IIC according to ATEX and IECEx.
▸ For installation, the risk of electrostatic charging of the surface must be reduced to a minimum.
▸
Use appropriate caution when performing maintenance and cleaning work.
For example, the surfaces should only be cleaned with a damp cloth. The respective devices will be identified by the manufacturer with a warning sign.
Retraction mechanism of the sender/receiver units
The retraction mechanism serves to remove and fit complete sender/receiver units of the
FLSE100-XT for maintenance or replacement without relieving pressure in the pipeline in which the measuring system is fitted. Sender/receiver units with ball valve must be installed to use the retraction mechanism.
This allows maintenance work without having to interrupt the process.
WARNING: Hazard through incorrect use of the retraction mechanism
The retraction mechanism may only be used when the sender/receiver unit is fitted with a ball valve. The retraction mechanism must not be used when a ball valve is not installed.
Only operate the retraction mechanism within the following pressure ranges:
● Maximum operating pressure
– For use of the retraction mechanism: 0.5 bar (g)
– With additional fitting tool (SICK Service only): 8 bar (g)
● Temperature range:
For health and safety reasons (high/low temperatures), SICK recommends only operating the retraction mechanism in the temperature range 0 °C ...
70 °C.
WARNING: Hazardous gas (possibly explosive or toxic)
Small gas quantities escape during the removal and installation of the transducer assemblies. When used correctly, the gas amount enclosed in the retraction nozzle is max. 0.81 dm 3 with F1F-P and max. 0.27 dm 3 with F1F-S,
F1F-M and F1F-H.
▸ In order to prevent damage to health, it is therefore essential that suitable protective equipment is used by the personnel carrying out work on systems containing toxic gases or gases otherwise hazardous to health.
WARNING: Hazardous gas (possibly explosive or toxic)
The retraction nozzle of the sender/receiver units has a connection for optional venting.
▸
This connection is closed with a dummy plug at the factory.
▸ The dummy plug may only be removed when a venting valve is installed,
.
14 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
For your safety
2.2
Intended use
Use the components of the FLOWSIC100 Flare-XT Transmitter only as described in this document.
FLSE100-XT sender/receiver units may only be used to measure the gas velocity, gas volume, mass flow and molecular weight in pipelines.
Do not exceed the maximum permissible pressure and temperature values shown on the type plates of the FLSE100-XT sender/receiver units in operation.
Using the device for purposes other than those intended can lead to safety-critical conditions. The manufacturer bears no responsibility for any other use.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 15
For your safety
F1F-S
2.3
Table 1
Version
Operation in potentially explosive atmospheres
Depending on the respective device version, the FLSE100-XT sender/receiver units are designed for use in potentially explosive atmospheres:
Device versions
IECEx
Ex db [ia Ga] IIA T4 Ga/Gb
Ex db [la Ga] IIB T4 Ga/Gb
Ex db [ia Ga] IIC T6/T4 Ga/Gb
Ex ia IIC T6/T4 Ga
Approval
ATEX
II 1/2G Ex db [ia Ga] IIA T4 Ga/Gb
II 1/2G Ex db [la Ga] IIB T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIC T6/T4 Ga/Gb
II 1G Ex ia IIC T6/T4 Ga
NEC/CEC (USA/CA)
Class I, Division 1, Group D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIA, T4;
Class I, Division 2, Group D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIA, T4
F1F-M
F1F-H
F1F-P
Class I, Division 1, Groups C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB, T4;
Class I, Division 2, Groups C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIB, T4
Ex db [ia Ga] IIA T4 Ga/Gb
Ex db [la Ga] IIB T4 Ga/Gb
Ex db [ia Ga] IIC T6/T4 Ga/Gb
Ex ia IIC T6/T4 Ga
II 1/2G Ex db [ia Ga] IIA T4 Ga/Gb
II 1/2G Ex db [la Ga] IIB T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIC T6/T4 Ga/Gb
II 1G Ex ia IIC T6/T4 Ga
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIC, T4
Class I, Division 1, Group D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIA, T4;
Class I, Division 2, Group D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIA, T4
Ex db IIC T6/T4 Gb
Ex db [ia Ga] IIA T4 Ga/Gb
Ex db [ia Ga] IIB T4 Ga/Gb
Ex db [ia Ga] IIC T6/T4 Ga/Gb
II 2G Ex db IIC T6/T4 Gb
II 1/2G Ex db [ia Ga] IIA T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIB T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIC T6/T4 Ga/Gb
Class I, Division 1, Groups C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB, T4;
Class I, Division 2, Groups C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIB, T4
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIC, T4
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA IIC, T4
Class I, Division 1, Group D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIA, T4;
Class I, Division 2, Group D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIA, T4
Class I, Division 1, Groups C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB, T4;
Class I, Division 2, Groups C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIB, T4
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIC, T4
16 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
For your safety
2.3.1
2.3.2
Specific conditions
Specific conditions of use denoted by X after the certificate number.
Specific conditions relating to all FLSE models
● As an option, offshore painting is used, where the layer thickness exceeds the limit of
0.2 mm for Gas group IIC (see Table 8 in IEC 60079-0:2011). In this case, the device is marked with a warning label according to IEC 60079-1, Table 16.
Under certain extreme circumstances, the device may generate an ignition-capable level of electrostatic charge. Therefore, the device shall not be installed in a location where the external conditions are conducive to the build-up of electrostatic charge on such surfaces. In addition, the device shall only be cleaned with a damp cloth (see clause
7.4.2 of IEC 60079-0:2011).
● The ultrasonic transducers are manufactured from titanium. In rare cases, ignition sources could arise due to impact or friction sparks. The user must ensure the enclosure and ultrasonic transducers are adequately protected against danger arising from impacts or friction (see Section 8.3 of IEC 60079-0:2011).
● The lengths of the flameproof joints are sometimes longer and the widths of the flameproof joints are sometimes shorter than required in Table 2 or 3 of IEC 60079-1:
2014. Flameproof joints are not intended to be repaired. Contact the manufacturer when dimensional information of flameproof joints is needed.
Specific conditions relating to the FLSE100-XT with intrinsically safe transducers
● The device contains a shunt zener diode, which requires connection to a barrier ground in accordance with IEC 60079-14. The protective ground conductor terminals of the device are to be connected to the potential equalization system of the installation area.
● The maximum permitted voltage in the safe area (Um) must not exceed the rated
125 V AC. Connect the device only to device which does not carry voltage higher than
125 V AC. Use SELV power supplies and device that meet the requirements of IEC/
EN 60950 or IEC/EN 61010-1.
● The maximum piezo-electric energy released by an impact on the ultrasonic transducers exceeds the limit for Gas Group IIC specified in Clause 10.7 of
IEC 60079-11:2011. The user must ensure that the ultrasonic transducers are suitably protected against danger from impact.
● The sender/receiver units with the intrinsically safe transducers may be installed into a duct wall separating Zone 0 from another area, e. g. Zone 1. The user must ensure that the material of the ultrasonic transducers shall not be subject to environmental conditions, e.g. chemical exposure or abrasion, which might adversely affect their enclosure and in particular their membrane.
Use of FLSE100-XT, depending on the temperature code and process temperature
Installation and use of sender/receiver units - electronics and transducers parts in the same area
This area is a hazardous area, i.e. Zone 1 or Zone 2 in which an explosive atmosphere exists under normal atmospheric conditions of:
– Specified ambient temperature -40 ... +70 °C for T4 or -40 ... +55 °C for T6,
Optionally minimum ambient temperature -50 °C
– Ambient pressure 80 kPa (0.8 bar) to 110 kPa (1.1 bar)
– Air with normal oxygen content, typically 21 percent by volume.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 17
For your safety
2.3.3
Permissible gas temperature, depending on the temperature code of the sender/ receiver units
Case 1 (see
):
Under normal atmospheric conditions, an explosive atmosphere categorized as Zone 1 or
Zone 2 exists outside the pipeline. Process conditions in the pipeline can differ from the atmospheric conditions. Process conditions can be in the range specified on the type plate of the sender/receiver units. In this case the gas or gas mixture can be combustible but must not be explosive.
Case 2 and 3 (see → Table 2 ):
On both sides of the pipeline an explosive atmosphere exists under normal atmospheric conditions. The pipe wall separates different zones, i.e. Zone 1 exists inside the pipe and
Zone 2 outside. This means gas temperature and line pressure may not exceed the specified ambient values.
NOTICE:
The pipe wall can separate different hazardous areas (zones).
Table 2
Classified tempera ture code in the hazard ous area
Permitted gas temperature for temperature code
Case 1
● Ultrasonic sensor outside explosive atmosphere Zone
1 or 2
● Electronics in explosive atmosphere Zone 1 or 2
● Gas pressure and gas temperature according to specification on device label
Case 2
● Ultrasonic sensor in explosive atmosphere Zone 1 or 2
● Electronics in explosive atmosphere Zone 1 or 2
● Gas pressure and gas temperature according to ambient specification of device
Case 3
● Ultrasonic sensor in explosive atmosphere Zone 0
● Electronics in explosive atmosphere Zone 1 or 2
● Gas pressure atmospheric, gas temperature max +60 °C
● Not for F1F-H
Zone 1 or 2 Non-Ex atmosphere
Zone 1 or 2 Zone 1 or 2 Zone 1 or 2 Zone 0
The sender/receiver units can be used with the following gas temperatures:
T6 -196 1) … +80 °C -196 1) … +55 °C
T4
T3
-196
-196
1)
1)
… +130 °C
… +195 °C
-196
-196
1)
1)
… +70 °C
… +70 °C
T2 -196 1) … +280 °C -196 1) … +70 °C
1) For F1F-H: -70 °C
-50 … +55 °C
-50 … +70 °C
-50 … +70 °C
-50 … +70 °C
18 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
For your safety
2.4
NOTICE: Observe the ambient temperature
Be aware that the ambient air around the pipeline might heat up.
● The ambient temperature around the electronic housing may not exceed
+70 °C for the sender/receiver unit marked with T4.
● The ambient temperature around the electronic housing may not exceed
+55 °C for the sender/receiver unit marked with T6.
The compliance with these requirements is the sole responsibility of the user.
A temperature fuse protects the sender/receiver unit electronics against impermissible high temperatures. The temperature fuse interrupts the function of the electronics should such high temperatures occur. The switch-off reaction of the temperature fuse is permanent and can only be reset by the manufacturer through repair.
Warning information on device
WARNING: Danger identification on device
The following symbol draws attention to important dangers directly on the device:
2.5
▸ Consult the Operating Instructions in all cases where the symbol is attached to the device or shown on the display.
Requirements on the personnel's qualification
Designated users
The FLSE100-XT sender/receiver units may only be installed and operated by skilled technicians who, based on their technical training and knowledge as well as knowledge of the relevant regulations, can assess the tasks given and recognize the hazards involved.
Skilled persons are persons according to DIN VDE 0105, DIN VDE 1000-10 or
IEC 60050-826 or directly comparable standards.
The named persons must have exact knowledge of operational hazards caused, e.g., by low voltage, hot, toxic, explosive gases or gases under pressure, gas-liquid mixtures or other media as well as adequate knowledge of the measuring system gained through training.
Specific requirements for use of devices in hazardous areas
▸ Cabling/installation, device setup, maintenance and testing may only be carried out by experienced persons familiar with the rules and regulations for hazardous areas, in particular:
– Degree of protection
– Fitting instructions
– Area definition
▸ Regulations to be applied:
– IEC 60079-14
– IEC 60079-17 or comparable national regulations.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 19
2.6
For your safety
Restrictions on use
WARNING: Hazard through pressure/temperature
▸
Use the FLSE100-XT sender/receiver units only within the pressure and temperature limits as specified in these Operating Instructions and on the device type plate.
▸
The selected materials must be resistant to the process gases. It is the responsibility of the plant operator to ensure this.
WARNING: Dangerous voltage
● The rated voltage U
M
may not exceed 125 V in the safe area for use of the sender/receiver units F1F-S, F1F-M and F1F-P for Zone 1. Higher voltages can jeopardize intrinsic safety of the ultrasonic transducer circuit when errors occur.
▸
Ensure the rated voltage U
M
used in the safe area does not exceed
125 V.
● The FLSE100-XT sender/receiver units are not equipped with a main power switch for switching off the operating voltage.
▸ Plan and install a suitable switching off device.
The sender/receiver units are intended for installation in gas-carrying pipelines. It is not absolutely necessary that atmospheric conditions prevail within the pipeline. The pipe wall is then a zone-separating wall, i.e. no Ex zone is defined within the pipeline, at least temporarily (
, Case 1).
WARNING: Leakage hazard
Operation with leakage is not permitted.
● The metallic and hermetically sealed, fully welded enclosure and the seal must comply with all safety requirements which must also be fulfilled by the pipeline itself with respect to design pressure and temperature and compatibility of the material with the medium.
● The ultrasonic transducers with their gas-tight and pressure-proof enclosures must be installed in the pipeline gas-tight and pressure-tight.
The FLSE100-XT is fitted with standardized sealing flanges for this purpose.
● The sealing itself must consist of material which is compatible with the medium and is suitable for the application conditions.
▸ Check the sealing surfaces and elements for intactness before installa tion.
▸ Check the sealing effect with suitable methods after installation.
▸
Leak tightness is to be checked regularly during operation and the seal replaced, as required.
● Before every re-installation new seals have to be used in the required design.
20 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
For your safety
Application limitations for use in Ex zone 1
▸ Ultrasonic probes made of titanium may be used in Zone 1 only when risks of ignition arising from impacts or friction on the sensor enclosure can be ruled out.
▸ When ultrasonic probes are installed in pipelines with a defined hazardous area, solid parts, e.g. dust or other particles may not cause an ignition hazard.
Application limitations for use in hazardous area classification Ex zone 0 in the pipeline
Use in applications of Zone 0 is generally only possible for device types F1F-S, F1F-M and
F1F-P under consideration of the application limitations described in these Operating
Instructions.
● Ultrasonic probes can also be operated in Zone 0 under atmospheric conditions (ambient temperature -40°C to +70°C and ambient pressure
0.8 bar to 1.1 bar absolute). The devices must be labeled at least with the information Ex ia.
● Ultrasonic probes made of titanium may be used in Zone 0 only when no rigid components transported through the medium (e.g. dust and other particles) are present and the ultrasonic probes are fitted in Zone 0 in a way (e.g. inside a pipeline) that risks of ignition arising from impacts or friction can be ruled out. The intrinsically safe ultrasonic transducers with their gas-tight and pressure-proof enclosures must be installed gas-tight and pressure-tight in the zone-separating wall to Zone 0. The wall must be thicker than 3 mm. The requirements in EN 60079-26 Section 4.6 must be adhered to.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 21
For your safety
22 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Product description
FLOWSIC100 Flare-XT Transmitter
3 Product description
ASC technology (patented) – active sound correlation technology
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 23
3.1
Fig. 1
Product description
Product identification
Product name:
Manufacturer
FLSE100-XT
SICK Engineering GmbH
Bergener Ring 27
01458 Ottendorf-Okrilla
Germany
Type plate
Type plate example FLSE100-XT-S
Example of marking plate FLSE100-XT-S (ATEX/IECEx)
Fig. 2 Type plate example FLSE100-XT-M
3
Example of marking plate passive (SLAVE)
FLSE100-XT-S (ATEX/IECEx)
Example of marking plate FLSE100-XT-M (ATEX/IECEx)
Example of marking plate passive (SLAVE)
FLSE100-XT-M (ATEX/IECEx)
24 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Product description
Fig. 3 Type plate example FLSE100-XT-H
Example of marking plate FLSE100-XT-H (ATEX/IECEx)
Fig. 4 Type plate example FLSE100-XT-P
3
Example of marking plate FLSE100-XT3 (ATEX/IECEx)
Example of marking plate passive (SLAVE)
FLSE100-XT-H (ATEX/IECEx)
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 25
3.2
Fig. 5
Product description
Functional principle
The FLOWSIC100 Flare-XT Transmitter gas flow rate measuring devices operate according to the principle of ultrasonic transit time difference measurement. Sender/receiver units
are mounted on both sides of a pipeline at a certain angle of inclination to the gas flow (Fig.
5). These sender/receiver units contain piezoelectric ultrasonic transducers that function
alternately as senders and receivers. The sound pulses are emitted at an angle to the flow direction of the gas. Depending on angle α and gas flow rate v, the transit time of the respective sound direction varies as a result of certain ”acceleration and braking effects”.
The higher the gas velocity and the smaller the angle to the flow direction, the more the transit times of the sound pulses differ.
Gas flow rate v is calculated from the difference between both transit times, independent of the sound velocity value. With this measuring method, changes of the sound velocity due to pressure or temperature variations therefore have no influence on the gas velocity determined.
Functional principle FLOWSIC100 Flare-XT Transmitter
Sender/ receiver unit,
(probe A) v
t
AB t
BA
L
Higher level
POWER t t v = velocity of gas in m/s
L = measuring path in m
= angle of inclination in °
AB
BA
= sound transit time
in flow direction
= sound transit time
against flow direction
Sender/receiver unit,
(probe B)
Determination of gas velocity
Measuring path L is equivalent to the active measuring path, i.e. the free flow path. For measuring path L, sound velocity c and path angle between sound and flow directions, the following is valid for the transit time of the sound for sound propagation in direction of the gas flow (forward direction): t
AB
=
L c + v · cos
(2.1)
Valid against the flow is: t
BA
=
L c - v · cos
(2.2)
Resolving for v results in: v =
L
2 · cos
·
( 1 1 t
AB t
BA
)
(2.3) i.e. a relation in which only the path length and the path angle exist as constants.
26 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Product description
Determination of sound velocity
The sound velocity can be determined by resolving formulas 2.1 and 2.2 for c.
c =
L
2
·
( t t
AB
+ t
AB
· t
BA
BA
)
(2.4)
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 27
3.3
Fig. 6
Product description
System overview
The FLOWSIC100 Flare-XT Transmitter comprises the components:
● FLSE100-XT sender/receiver unit
For transmitting and receiving ultrasonic pulses, signal processing and controlling the system functions, evaluation and output of data connected via an RS485 interface
● Installation accessories (e.g., nozzle, nozzle installation tool, ball valve)
● Connection cable between sender/receiver units
● Connection cable between sender/receiver units and higher level control system
(optionally available)
● Spool piece option
Spool piece ready for installation in an existing pipeline (flange connection or welded connection) including assembly means for fitting the sender/receiver units
System overview FLOWSIC100 Flare-XT Transmitter
Top view
1 2
Draufsicht
To higher level control system
Zur Interface unit
4
1 Sender/receiver unit, FLSE-XT active sensor
2 Connection cable
3 Sender/receiver unit, FLSE-XT passive sensor
4 Optional spool piece
3
28 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Product description
3.4
Fig. 7
Sender/receiver units
Cross-duct
F1F-S (active and passive sensor shown as examples)
2 3 5 6
1 4
Sensor length
7
10 5 6 7
1 Pressure compensation element
2 Electronics unit
3 T-connector
4 TNC connector (connection for passive sensor)
5 Self-cutting ring
6 Retraction nozzle
7 Duct probe
8 Sensor contour
9 Transducer
10 TNC connector (connection for active sensor)
9
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 29
Fig. 8 F1F-M (only active sensor shown)
2 3 5
Product description
6 8 9
Fig. 9
1 4
Sensor length
1 Pressure compensation element
2 Electronics unit
3 T-connector
4 TNC connector (connection for passive sensor)
5 Self-cutting ring
6 Retraction nozzle
7 Duct probe
8 Sensor contour
9 Transducer
F1F-H (only active sensor shown)
2 4
5 6
7
7 8
1 3
1 Pressure compensation element
2 Electronics unit
3 Cable gland (connection for passive sensor)
4 Self-cutting ring
Sensor length
5 Retraction nozzle
6 Duct probe
7 Sensor contour
8 Transducer
30 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Product description
Fig. 10
2
Probe version
F1F-P
3 5 6 8
1
4
1 Pressure compensation element
2 Electronics unit
3 T-connector
4 Pressure compensation element
5 Self-cutting ring
6 Retraction nozzle
7 Duct probe
8 Transducer
9 Sensor contour
7 9
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 31
Product description
3.5
Fig. 11
Material for wetted parts (parts with process gas contact)
Parts with process gas contact
Cross-duct versions F1F-S / -M / -H
1 2 12 11 10 9
Probe version F1F-P
1 12
2 3 4 5
18 17
6 7
16
11
3 4 5
10 15
6 7
13
8
14
32
17
1 Pipe screw fitting
2 Threaded ring
3 Spring
4 Sealing disc
5 Sealing profile
6 Retraction nozzle
7 Retraction flange
8 Transducer
9 Sensor contour
8
10 Duct probe
11 Connection for optional venting
12 Centering
13 Sensor contour probe version F1F-P
14 Adjusting ring
15 Thrust ring
16 Probe tube
17 Transducer pipe screw fitting
18 Transducer and contour holder
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Product description
Table 3 Overview of parts with process gas contact
Material
Stainless steel
1.4404
Component
Retraction flange (7), threaded ring (2)
Connection for optional venting (11), retraction nozzle (6)
Duct probe (10), sensor contour (13), transducer and contour holder
(18), transducer pipe screw fitting (17)
Titanium
PTFE
Adjusting ring (14), pipe screw fitting (1), sealing disc (4)
Duct probe (10), transducer assembly (8)
Transducer assembly (8), probe tube (16)
Centering (12)
Sensor contour (9)
Thrust ring (15)
PTFE/graphite Sealing profile (5)
Stainless steel
1.4568
Spring (3)
Type FLSE100-XT
F1F-S F1F-M F1F-H F1F-P x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
3.6
Fig. 12
Spool piece option
The FLOWSIC100 Flare-XT Transmitter can also be fitted with an optional spool piece to simplify assembly. The exact design (nominal diameter, connection, material) always depends on the customer specifications.
The installation length of the spool piece depends on the nominal diameter of the pipe:
– Installation length 800 mm for pipe diameter up to 28”
– Installation length 1100 mm for pipe diameter 30” ... 60”
– Installation length for pipe diameter >60”...72” on request
All system solutions (FLOWSIC100 Flare-XT Transmitter + spool piece) are optionally available with pressure and temperature sensors. For the positioning of pressure and temperature transmitters the following configurations are available:
– Spool piece with standard installation length with integrated pressure tapping, temperature sensor 10 cm ... 50 cm in the outflow area
– Spool piece, extended length with integrated pressure and temperature tapping.
Spool piece option (example)
800 mm
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 33
34
Product description
3.7
System configuration
The FLOWSIC100 Flare-XT Transmitter is a basic flare gas measurement system based on ultrasonic technology without additional field electronics. It supports the most important measurement tasks, like volume and mass flow calculation which are needed to meet regulatory compliance. It is mounted into nozzles which are welded to the existing pipeline.
Optionally available as a variant with separately supplied spool piece for easier fitting of the sensors without welding. Here, the sensors are first integrated in the spool piece at the measuring point.
SICK offers further flare gas measuring technology with advanced diagnostics, additional
IO (e.g. analog out, HART®, Foundation Fieldbus, etc.), a local display as well as counters, logbooks and data archives. Therefore an additional field electronics – the Interface Unit is required. See overview for details.
Fig. 13 Flare Transmitter, Flare Instrument and Flare Meter comparison
3URGXFWFRQÀJXUDWLRQV
)ODUH7UDQVPLWWHU )ODUH,QVWUXPHQW )ODUH0HWHU
Blue parts: 6,&.VFRSHRIGHOLYHU\
Orange parts: Additional set of matching sensors (2 nd path)
Gray parts: Optional parts
Reference meter
Standard delivery scope
Optional delivery scope
I/O
Display
Counter / logbook / data archives i-diagnostics TM
Voltage supply
Advantages
Number of possible measuring paths
Measurement uncertainty
Sensors incl. interconnection cable
-
-
-
Interface unit
3URGXFWDQGPDWHULDOFHUWLÀFDWLRQ
Flare meter fully assembled in
PHDVXUHG6,&.VSRROSLHFH
Performance capability evaluation
Performance capability evaluation FLOW calibration
Customized documentation
Customer service training
Accessory spool piece for installation without welding
Modbus® RTU Modbus® RTU/TCP
-
Foundation Fieldbus
Analog incl. HART / digital / frequency
-
-
x x
24 V DC
Lean measurement solution for basic requirements x
9'&99$&
Extended functionality
Extended functionality and lowest measurement uncertainty
1-path 1-path / 2-path
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Product description
3.8
Fig. 14
ASC technology (patented) – active sound correlation technology
If the ultrasonic signal is scattered due to extreme gas velocity, the ASC technology (active sound correlation technology) takes over.
The ultrasonic transducer works like a microphone and correlates the strong noises at high flow rates to gas velocity.
This ensures measurement is still available even for extreme flare gas behavior.
Measurement uncertainty is higher as compared to ultrasonic transit time difference
measurement, see technical data, p. 111, §12
.
ASC technology
Fig. 15
Normal conditions,
Ultrasonic transit time difference measurement
Increased gas velocity,
Ultrasonic transit time difference measurement
Scattered ultrasonic signal,
ASC technology active
When ASC technology is active, the FLOWgate TM operating software signals “Extended VOG
Range”.
Signaling “Extended VOG Range”
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 35
Product description
36 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Project planning
FLOWSIC100 Flare-XT Transmitter
4 Project planning
Determining the measuring and installation location for FLSE100-XT
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 37
Project planning
4.1
Overview
The following Table provides an overview of the project planning work necessary as prerequisite for trouble-free assembly and subsequent device functionality.
Task
Determine measuring and installation locations
Select device components
Plan power supply
Requirements
Flow distribution, inlet and outlet paths
Access, accident prevention
Installation free of vibrations
Lowest possible influence on the measurement accuracy
Easy and safe
Maximum allowable vibration velocity
7 mm/s (rms)
Ambient conditions
Limit values in accordance with Technical
Data
Internal pipe diameter Sender/receiver unit type
Gas temperature Sender/receiver unit type
Gas composition
Fitting locations
Material of duct probe and transducer
Cable lengths
Operating voltage, power requirements According to Technical Data
Work step
Follow specifications for new equipment; select best possible location for existing equipment
Provide platforms or pedestals as required.
Avoid/reduce vibrations through adequate measures.
If necessary:
Provide weatherproof covers / sun protection, enclose or lag device components.
Select components according to the
Configuration Table and information as from
p. 51, §6.6 as well as the Application
Evaluation Sheet.
Plan adequate cable cross-sections and fuses
38 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Project planning
4.2
Determining the measuring and installation location for FLSE100-XT
Measurement accuracy is influenced, among other things, by flow behavior and the position of the measuring axis. Large cross-section variations, curved pipes, fittings, air flaps or inlets can cause profile deformations or turbulences with a negative effect on the accuracy of the measuring result.
Select the FLSE-XT installation location at a position with as little interference as possible to ensure best possible device performance.
Criteria
4.2.1
General requirements
Flow behavior
Pipeline design
Requirements
Position with swirl-free as well as rotationally symmetrical flow profile
Balanced, uniform profiles are most likely to be expected for long inlet and outlet paths
Whenever possible, no deflections, cross-section variations, curves, feed and drain lines, flaps or fittings in the area of the inlet and outlet paths
Isometric conditions at the measuring point are most important for determining the required inlet and outlet piping and should be investigated carefully. The conditions depend on the specific application and the device configuration. Typically, an upstream 20 D straight pipe section and a downstream 5 D straight pipe section are required.
Measuring location
Wall and insulation thickness
Inlet and out let path lengths
● Uncritical flow inlet conditions require straight inlet piping.
● More complex inlet disturbances require longer inlet and outlet piping.
● If the 2-path configuration is used, the needed minimum inlet and outlet sections can be further reduced compared to 1-path measurement with the same measurement uncertainty.
● SICK offers expertise support for optimal adjustment of the meter for the given inlet and outlet piping conditions.
Pipelines with vertical, horizontal or inclined direction
Installation location
Working platform
Pipelines with horizontal or vertical direction
● Horizontal installation:
Align the spool piece so that the planes formed by the measuring paths are horizontal. This minimizes the problem of dirt in the pipeline entering the transducer ports.
● Vertical installation:
Only possible if the measuring system is used for dry, non-condensing gases.
Almost free of vibrations, maximum allowable vibration velocity 7 mm/s (rms)
Largest possible distance to control valves or other noisy fixtures
With electrical connections and lighting
Easy and safe access for installation and maintenance work of the sender/receiver units
Platform secured by a railing to prevent possible accidents
Sufficient clearance to fit/remove the sender/receiver units
● Maximum wall thickness 15 mm
Larger wall thicknesses require customer-specific solutions (available on request only).
● Minimum wall thickness depends on pressure, temperature, pipe size and static/dynamic load at the measurement location (contact SICK for support).
Nozzles may only be isolated when the gas temperature is < 100 °C.
Ball valve, venting valve and electronics must not be insulated.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 39
Project planning
4.2.2
Additional requirements for optional spool piece
Criteria
Pipeline design
Gas flow
Seals between spool piece and pipeline
Pressure sensor
Temperature sensor
Fastening and sealing material
Requirements
● Same nominal size of adjacent pipes and spool piece.
● Differences of internal diameters of inlet pipe and spool piece < 1%.
● No welding beads and burs on the flanges of the inlet pipe
Free from any foreign material, dust and liquids. Otherwise, filters and traps shall be used.
Must not protrude into the pipeline. Any protrusion into the flowing gas stream may change the flow profile and thus may adversely affect measuring accuracy.
Pressure tapping over the measuring path
Spool piece with standard installation length with integrated pressure tapping, temperature sensor
10 cm ... 50 cm in the outflow area
Bolts, nuts and flange seals used must be suitable for the operational conditions and comply with legal regulations and relevant standards.
4.2.3
Fig. 16
Installation location for external pressure and temperature transmitters (option)
Pressure and temperature transmitters can not be directly connected to the
FLOWSIC100 Flare-XT Transmitter, see
.
Pressure tappings and thermowells for external transmitters have to be installed in the following way:
● Pressure tapping connection: Directly at the measuring point, centrally above the measuring path, on the top of the pipeline
● Temperature sleeve: Outlet section with distance 10 cm ... 50 cm, measured from the middle of the measuring path, on the top of the pipeline
Installation location
Top view
1
10 cm ... 50 cm
40
4
3 2
1 Sender/receiver unit FLSE-XT, active sensor
2 Temperature sensor
3 Pressure sensor
4 Sender/receiver unit FLSE-XT, passive sensor
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Project planning
4.2.4
4.2.5
Applications with wet gas
Condensate can accumulate in the nozzle pipes. The following solutions can help to prevent measurement problems (malfunctions caused by solid-borne noise, see Service Manual), or damage when removing the sender/receiver unit (condensate runs out).
● Use a nozzle position which prevents accumulations of condensates in nozzle pipes.
● Use a closed continuous or periodical condensate drain with backflow to the pipeline.
● Isolate the nozzle pipe to reduce dew point underruns (only for low gas temperatures <
100 °C).
Clearance for fitting and removing the sender/receiver units
NOTICE:
Observe the dimension drawings in
.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 41
Project planning
42 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Transport and storage
FLOWSIC100 Flare-XT Transmitter
5 Transport and storage
Special notes for handling the spool piece option
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 43
5.1
Fig. 17
Transport and storage
Transport protection
To prevent transport damage, the FLSE100-XT sender/receiver units must be secured
according to Fig. 17 before each transport.
▸ Retract the transducer fully into the retraction nozzle.
▸ Ensure in a suitable manner that the transducer cannot slip out of the retraction nozzle during transport.
NOTICE:
No additional loads may act on the electronics unit and on the cable outlet of the sender/receiver units. Especially in the retracted position, no additional force (except in the direction of the duct probe) may act on the electronics unit.
Transport protection
1
5.2
1 Retraction nozzle
Storage
Comply with permissible storage conditions (
44 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Transport and storage
5.3
Fig. 18
Special notes for handling the spool piece option
Transport and storage
▸ During all transport and storage work, ensure:
– The spool piece is well secured at all times
– Measures are taken to avoid mechanical damage
▸ Protect sealing surfaces of the flanges and the interior of the spool piece if it must be stored outside for more than one day, e.g. with Anticorit spray (not required for spool pieces made of stainless steel). Do the same if the meter must be stored in dry conditions, but for more than a week.
Lifting requirements
WARNING: Danger due to size and mass of the spool piece
▸ Only use lifting gear and load handling equipment (e.g. lifting straps) which are suitable for the weight to be lifted. Max. load information can be found on the type plate of the lifting gear.
▸ Only use the eye bolts when lifting the spool piece.
▸
Do not lift the spool piece using these eye bolts when additional loads (e.g. blind flanges, filling for pressure tests or tubes) are attached.
▸ During transport, the spool piece must not be turned over or start to swing.
Lifting requirements (installed sender/receiver units are not shown)
Max. 60°
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 45
Transport and storage
46 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
FLOWSIC100 Flare-XT Transmitter
6 Mounting
Fitting the spool piece (option)
Geometry calculator in FLOWgate TM
Fitting the nozzles on the pipeline (measuring system without spool piece option)
Fitting the sender/receiver units
Pulling the sender/receiver units back
Fitting the weatherproof cover for the sender/receiver unit
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 47
6.1
Fig. 19
Mounting
Safety
WARNING: Risks during installation
▸
Observe the relevant safety regulations as well as the safety notices on
p. 11, §2 during all installation work.
▸ Carry out assembly work on equipment with hazard potential (hot or aggressive gases, higher internal pipeline pressure) only when the equipment is at a standstill.
Fitting when the equipment is running is only possible using the ”hot tapping method”. Such work may only be carried out by a specialized contractor authorized by the plant operator.
▸ Take suitable protection measures against possible local hazards or hazards arising from the equipment.
WARNING: Mechanical burden
The static load moment of all parts to be installed on the pipeline can be up to approx. 600 Nm. Strong pipe vibrations can cause damage and can lead to dangerous situations.
▸ Use a mechanical support for the nozzles welded to the pipeline, e.g.
”gusset plates”.
NOTICE:
The plant operator is responsible for the safety of the system under mechanical load.
Option mechanical support for nozzle ”gusset plates”
6.2
Scope of delivery
▸ Check that delivery includes all ordered parts.
▸ Check parts for possible transport damage. Pay particular attention to transducer surfaces, sealing surfaces on the flanges and, if delivered, the interior of the spool piece.
▸ Immediately document and report damage to the manufacturer.
NOTICE:
To ensure safe and reliable operation of the measuring devices, it must be ensured the current operating conditions on the plant side match the specification on the type plates of the sender/receiver units.
48 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
6.3
Fitting the spool piece (option)
The spool piece must be mounted in the pipeline so that the arrow marking on it corresponds to the flow direction.
The flow is output by the measuring system as a positive value when the active sensor and passive sensor of the sender/receiver units for the cross-duct versions are installed
.
WARNING: Danger due to size and mass of the spool piece
▸
Observe the transport information in p. 45, §5.3
Required fitting work
▸ Position the spool piece at the desired section of the pipeline using the hoist.
▸ After attaching the flange bolts, but before tightening, check the correct seating and alignment of the flange seal.
▸ Align the spool piece so that the offset between inlet pipe, spool piece and outlet pipe is minimized.
▸ Insert the remaining fixing screws and tighten the nuts crosswise. The applied torque must not be lower than specified in the project planning.
▸ Install the pressure measurement line between the pressure tapping point (option) and the pressure sensor (option).
Perform a leak tightness check with suitable means after completion of the installation work,
NOTICE:
If the sender/receiver units of a measuring system configured as a Flare Meter
(
) are removed for transport, the spool piece is provided at the factory with markings for fitting.
▸ Fit the sender/receiver units according to the markings on the spool piece to ensure measuring accuracy.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 49
6.4
6.5
Mounting
Installation sequence
Carry out all assembly work on-site.
This includes:
▸ Determining the nozzle position
▸ Welding the nozzle on
The nozzles are manufactured precisely at the factory according to customer specifications for fitting on the pipeline.
▸ For retractable installation:
Fitting the ball valves (measuring system without optional spool piece)
▸ Fitting the sender/receiver units
NOTICE:
To ensure measurement accuracy, the geometry parameters must be determined as exactly as possible. Maximum tolerances:
– Nozzle positions and fitting angle of the nozzles: ±1 mm / ±1°
– Measurement of nozzle length: ±1 mm
– Measurement of ball valves: ±1 mm
NOTICE:
The exact wall thickness must be determined for precise calculation of the pipeline inner diameter. “Schedule” information from the applicable standards is less accurate than an exact measurement.
The wall thickness must be determined accurately to 0.1 mm. SICK recommends using a suitable ultrasonic measuring instrument to determine the wall thickness.
Geometry calculator in FLOWgate
TM
Certain geometry parameters must be determined and calculated for installation of
FLSE100-XT sender/receiver units.
The following dimensions can be calculated using the geometry calculator integrated in
FLOWgate TM :
● Probe offset a (nozzle offset), p. 56, §6.7.2
.
The following parameters must be determined during installation for calculation of the probe offset:
– Circumference, wall thickness and nominal nozzle angle
● Wetted part length wL,
For installation of the sender/receiver units, the wetted part length is calculated from:
– Circumference
– Wall thickness
– Gasket thickness
– Nozzle length
– For retractable installation: Ball valve length
– Nozzle angle
– Additionally for cross-duct versions: Probe offset a
● Geometry installation parameters for commissioning the measuring system,
.
50 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
6.6
Fig. 20
Installation accessories
Sender/receiver units are fitted to the pipeline using the following material:
Installation accessories (using ANSI CL150 (as example)
7
6
1 2 3 4 5
1 Blind flange
2 Ball valve (only when sender/receiver units are to be retracted in operation)
3 Seal
4 Nozzle
5 Marking
6 Welding bevel
7 Pipeline
Connection ANSI CL150 2"
NOTICE:
Use of installation accessories for temperature range according to type plate:
● The ball valve must not be insulated for media temperatures below -40 °C or higher than +160°C.
● For gas temperatures higher than +180°C or below -40 °C , the tempera ture at the nozzle flange must be checked after through-heating during ini tial start-up. If required, the nozzle insulation must be removed as required to stay in the specified temperature limit.
● Do not exceed temperature and pressure ranges listed in
It must be ensured that the temperature of the nozzle and ball valve is not so high that the material strength is no longer guaranteed when derating the pressure over the temperature,
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 51
6.6.1
Fig. 21
Mounting
Nozzles, blind flanges and seals
Nozzles are delivered with factory adaption to the nominal pipe diameter, welding bevel and marking for nozzle alignment according to the gas flow.
Nozzle
Table 4
Table 5
2
1
1 Welding bevel
2 Marking
Nozzles and blind flanges
NOTICE:
Observe the diagrams on p. 120, §12.5
.
Available nozzles and blind flanges
Flange connection Material
CL150
CL300
PN25 DN50
LTCS P355 QH1 / A350 LF2
SS 1.4401, 1.4404, ASTM A182 Gr. 316, 316L
LTCS P355 QH1 / A350 LF2
SS 1.4401, 1.4404, ASTM A182 Gr. 316, 316L
LTCS P355 QH1 / A350 LF2
SS 1.4401, 1.4404, ASTM A182 Gr. 316, 316L
Temperature ranges
-46 … +280°C
-196 … +280°C
-46 … +280°C
-196 … +280°C
-46 … +280°C
-196 … +280°C
NOTICE:
Observe the diagrams on p. 120, §12.5
.
To prevent galvanic corrosion between LTCS nozzles and stainless steel ball valves, a nozzle insulation set (sealing material set with polymer seals and sleeves) is available as an accessory,
Seals
NOTICE:
Observe the diagrams on p. 120, §12.5
.
Flat seals are required for the flange connection between nozzle and ball valve and between the ball valve and the sender/receiver unit. These seals are included in the standard scope of delivery of the ball valve and/or sender/receiver unit.
Available seals
Material
Serrated gasket B9A 1.4571
Temperature range
-196 … +280°C
52 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
6.6.2
Table 6
Table 7
Ball valve
The ball valve serves for safe separation of the sender/receiver units from the process and is required when the sender/receiver units are to be dismounted during the process. SICK recommends using a ball valve.
Ball valves for various flange connections (Cl150, CL300, PN25 DN50) and temperature ranges) are available.
NOTICE:
Observe the diagrams on
Ball valve according to ANSI
Component
Standard temperature
Ball valve CL150 2" SS
Ball valve CL300 2" SS
Connection Material (ASTM)
CL150 2"
CL300 2"
Stainless steel 1.4408
(CF08M)
Stainless steel 1.4408
(CF08M)
Low temperature
Ball valve CL150 2" SS CL150 2"
Ball valve CL300 2" SS
High temperature
Ball valve CL150 2" SS
Ball valve CL300 2" SS
CL300 2"
CL150 2"
CL300 2"
Stainless steel 1.4408
(CF08M)
Stainless steel 1.4408
(CF08M)
Stainless steel 1.4408
(CF08M)
Stainless steel 1.4408
(CF08M)
Ball valve according to DIN
Component
Standard temperature
Ball valve PN16 DN50 SS
Connection Material (ASTM)
PN16 DN50 Stainless steel 1.4408
(CF08M)
Low temperature
Ball valve Stainless steel 1.4408
(CF08M)
High temperature
Ball valve PN40 DN50 PN40 DN50 Stainless steel 1.4408
(CF08M)
Gas temperature range
-46...+200°C
(-50...+392°F)
-46...+200°C
(-50...+392°F)
-196...+200°C
(-320...+392°F)
-196...+200°C
(-320...+392°F)
-50...+400°C
(-58...+752°F)
-50...+400°C
(-58...+752°F)
Gas temperature range
-46...+200°C
(-50...+392°F)
-196...+200°C
(-320...+392°F)
-50...+400°C
(-58...+752°F)
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 53
6.6.3
Fig. 22
Mounting
Nozzle installation tool
The installation tool serves to align and weld the nozzle on the pipeline. SICK offers various nozzle installation tools depending on the nominal pipe diameter and path configuration.
The nozzle installation tool contains, per nozzle
● Welding aid M16 75°(1),
● Centering plate 2” (2),
● Threaded rod M16 length 290 mm (3),
● Centering 2” (4),
● Assembly material
● Installation paper strip as tool to determine the exact nozzle position on the pipeline.
Nozzle installation tool
4 3 2
1
54 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
6.7
6.7.1
Fitting the nozzles on the pipeline (measuring system without spool piece option)
General preparation work
The installation tool (
) contains a foil strip (length approx. 4 times the pipe diameter, width approx. 0.75 of the pipe diameter) as a resource to determine the exact position of the nozzle on the pipeline. The foil strip is prepared with nozzle markings for different pipe diameters.
Fig. 23 General preparation work
1) Wind the strip around the pipeline at the selected measuring point (ensure exact right-angled alignment) and secure (e.g. with adhesive strips).
2) Mark the strip where overlapping starts.
3) Loosen the fastening, take the strip off and lay it out on a level surface.
Overlap line
U
For 1-path measurements, fold the strip to the overlap line so that the part matching pipe circumference (U) is halved.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 55
6.7.2
Fig. 24
Mounting
Determining the nozzle position for cross-duct versions
NOTICE:
Note probe offset a, the wall thickness and circumference U; these values are required for calculating the path angle and path length with FLOWgate TM during commissioning.
Calculate probe offset a with the geometry calculator in FLOWgate TM
1 Start FLOWgate TM operating software.
2 Create a FL100 Flare-XT Trans offline device.
3 Open the “Geometry calculator” tile in the “Change parameters” menu.
4 Select the “Cross-duct” device type.
5 Enter circumference U and the wall thickness w in the “Dimensions of components” section.
6 Click “Calculate probe offset”.
Probe offset a is calculated.
Geometry calculator in FLOWgate TM
Fig. 25
Marking the nozzle positions on the pipeline
Determining the nozzle positions on the strip
1-path measurement
4a) Roll the strip out again and mark the kink line.
Overlap line U/2 Kink line
90° 90°
5) Draw guide lines (1) for the nozzle positions with the previously calculated nozzle offset a, mark crossing points (2) and draw marking points (3) in distance 60 mm (x) from the crossing points.
56 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
U / 2 x
x x x
2 3 a
Fig. 26 Marking the nozzle positions on the pipeline for cross-duct versions
1-path measurement
6) Roll the strip back around the pipeline and mark the nozzle positions with crossing and marking points by using a metal center punch.
Crossing point (marking for the center of the nozzle)
Marking point (aid for aligning the nozzle)
7) Take the strip off again and join the additional markings with a line.
Marking lines
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 57
6.7.3
Fig. 27
Mounting
Determining the nozzle position for the probe version
Determining the nozzle positions on the strip
1-path measurement
1) Start preparation work as shown in p. 55, Fig. 23.
4a) Roll the strip out again and mark the kink line.
Overlap line U/2 Kink line
90° 90°
5) Draw a guide line (1) for the nozzle position(s), mark crossing points (2) and draw marking points (3) in distance 80 mm (x) from the crossing points.
U/2 1
2
3 x x x
x
58 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
Fig. 28 Marking the nozzle position(s) on the pipeline for the probe version
1-path measurement
6) Roll the strip back around the pipeline and mark the nozzle positions with crossing and marking points by using a metal center punch.
Crossing point (marking for the center of the nozzle)
Marking point (aid for aligning the nozzle)
7) Take the strip off again and join the additional markings with a line.
6.7.4
Marking lines
Welding the nozzle on
Use the installation tool that corresponds to the nozzle to be welded on the pipeline to carry out the following work.
WARNING: Hazards through combustible gases or high pressure
If “hot tapping” is not used, depressurize the pipeline and flush free of flammable gases before starting the work.
WARNING: Risk of explosion/health hazard
A faulty welding seam can allow gas to escape from the pipeline. This can immediately lead to a dangerous situation.
▸
Ensure welding seams are gas-tight.
▸ Check strength and durable tightness of the welding seams.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 59
60
Fig. 29
Mounting
WARNING: Qualified personnel required
● Any welding and installation work on pipelines may only be carried out by authorized personnel with a specific qualification.
● Special qualified and approved procedures have to be followed. This procedure requires the written agreement by the plant operator.
● The general safety requirements and all other plant operator instructions have to be followed.
▸
Position the welding aid (1) on the pipeline (2) as shown in → Fig. 29.
NOTICE:
Check the welding aid position after welding. The deviation from the drawn lines must not be more than 0.5 mm. Otherwise reposition the welding aid.
▸ Screw in threaded rod (3) with the sharp tip in the welding aid.
NOTICE:
The threaded rod is fitted by the manufacturer with a clamp ring. This is to aid removal of the centering plate following installation of the nozzles. The clamp ring should therefore not be removed.
Positioning of the welding aid
View B
A
View A
1
2
Marking lines
View B
Flow direction
1
3
2
1
2
3
Welding aid
Pipeline
Threaded rod
Angle Type FLSE100-XT
75 ° F1F-S, F1F-M, F1F-H, F1F-P
▸ Slide centering plate (4) on the cone of the welding aid (1) and fasten with the nut (5).
▸ Slide nozzle (6) over threaded rod and centering plate.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
Fig. 30
▸ Position centering (7) into the nozzle opening so that the marking on the centering corresponds to the nozzle type (ANSI or DIN, size).
▸ Screw counternuts (8), (9) onto the threaded rod, position and secure the nozzle with suitable auxiliary materials so that the required weld gap is achieved (e.g. use an uncoated wire).
Align the nozzle so that the marking lines on nozzle and pipe wall are flush.
Especially for two-path installations, the additional nozzle identifications "Left" and
"Right" must be observed! On a horizontally running pipe, the nozzle with identification
"Left" must be aligned above and with identification "Right" below the pipe, with the marking lines in the direction of flow.
▸ Then fasten the nozzle.
Fitting the nozzle
10
4 5 6 7 8 9
1
5
6
1
4
Welding aid
Centering plate
Nut
Nozzle
7 Centering
8, 9 Counter nuts
10 Clamp ring
Marking lines
▸ Unscrew the threaded rod as a whole from the welding aid. To do this, place a wrench on the counternuts. The centering plate will be removed by the clamp ring.
▸ Finish off the weld seam piece by piece and allow sufficient time for cooling down to avoid unnecessary strain or distortion on the nozzle and pipe wall.
In order to ensure the promised measurement uncertainty according to p. 111, §12
“Technical data”, a sinking of the nozzles into the pipe wall or a distortion of the nozzles
must be avoided.
▸ For cross-duct versions of FLOWSIC100 Flare-XT Transmitter (F1F-S, F1F-M, F1F-H):
– Determine the distance D1 between outer pipe wall and centering after a sufficient time for cooling down.
– On cross-duct versions, weld the nozzle on the opposite pipeline side in the same manner and then determine distance D2.
– Note measures D1 and D2; these measures are required for the geometry calcula tion during commissioning .
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 61
Fig. 31 Determining the effective nozzle length
Mounting
(Nozzle)
Centering
D1
▸ Ball valves have to be installed when using retractable sender/receiver units. The ball valves are installed after finishing nozzle welding.
▸ Check and ensure gas tightness of ball valve installation before you continue.
WARNING: Hazard through leakage
▸ Operation in leaky condition is not allowed and potentially dangerous.
▸
Hazard through explosive, toxic and hot gas!
Drilling holes into the pipeline if plant is out of operation
The pipe wall must be drilled out at the nozzle position so that the sender/receiver unit can be inserted into the pipeline (
).
▸ Only once on each nozzle.
▸ Have this work done by skilled persons specially qualified for this work.
62 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
Drilling holes into the pipeline if plant is in operation (“hot tapping”)
WARNING: Hazards during “hot tapping”
When sender/receiver units are installed on the pipeline when the system is in operation (“hot tapping”):
▸ Only have this work done by skilled persons qualified for “hot tapping”.
▸ Comply with all legal, general and company-internal regulations.
▸ Only start installation work when all planned measures have been checked and approved by the plant operator.
▸ Only once on each nozzle.
▸ The hole cutter diameter must be 46 ... 48 mm for 2“ nozzles.
▸ Mount the drilling tool on the ball valve.
▸ Open the ball valve and drill out the holes in the pipeline in the center of the nozzle position.
▸ Retract the drilling tool.
▸ Close the ball valve again. Then, remove the drilling tool.
▸ Mount a blind flange on the ball valve as long as no sender/receiver unit is installed.
WARNING: Accident risk
When the hole has been drilled and no sender/receiver unit has been installed:
Gas flows through the pipeline when the ball valve is opened.
▸ Keep the ball valve closed and fitted until a sender/receiver unit has been fitted.
▸ Secure the ball valve against unintentional activation.
▸ Instruct other persons accordingly.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 63
6.8
Fig. 32
1
Mounting
Fitting the sender/receiver units
WARNING: General risks during installation
▸
Observe and follow the valid regulations and safety regulations as well as
the safety notices in p. 11, §2 .
▸ Take special precautions for plants with increased hazard potential (toxic/ aggressive/explosive gases, higher pressure, higher temperature).
Otherwise serious injuries are possible.
▸ Take suitable protection measures against possible local hazards or hazards arising from the equipment.
▸ Observe the allowable operating parameters during all work.
▸
Ball valve and sender/receiver unit do not function correctly following incorrect installation. Both parts can be damaged. Serious injuries are possible.
Tools required
● 2 jaw wrenches, size 27and jaw wrench, size 30
● Length gauge: tolerance 1 mm
● Torque wrench, size 41, tightening torque: 150 Nm
Overview
2 4 5
6 7 8
1
3
2 4
1 Electronics unit
2 Duct probe
3 Cutting ring screw connection
4 Retraction nozzle
3 6 7 8
5 Mounting kit (gasket, fastening screws, nuts, washers, centering sleeves)
6 Ball valve
7 Nozzle
8 Pipeline
64 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
Fig. 33
Using the centering sleeves
The mounting kit for the sender/receiver units includes centering sleeves.
The centering sleeves serve to ensure the centering of the process flanges of the sender/ receiver units.
Using the centering sleeves
4
3
4
5
Fig. 34
2
1
1 Centering sleeve
2 Washer
3 Nut
2
6
4 Flange
5 Fastening screw
6 Seal
Using the nozzle insulation set (accessory)
A nozzle insulation set is available as an option (Part No. 2057569) to prevent galvanic corrosion of the LTCS nozzles and stainless steel ball valves. The insulation sleeves included in the nozzle insulation set replace the standard centering sleeves. In this case, dispose of the centering sleeves and use the longer insulation sleeves instead.
Using the nozzle insulation set
5
4
2
3
1
1 Insulation sleeve
2 Washer
3 Insulating disc
4 Nut
5
6
2
3
7
5 Flange
6 Fastening screw
7 Seal
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 65
Mounting
Check the following points before installation
● Sender/receiver units to be fitted for a particular measuring point must belong to the same system to ensure the maximum measurement accuracy possible. Exchanging structurally identical sender/receiver units from different measuring systems is not allowed.
● Sender/receiver unit pairs are matched and can only be exchanged in pairs for identical units.
● Sender/receiver units from one system are marked with sequential serial numbers
(printed on the device label).
The FLSE100-XT active sensor always has the lower number and the FLSE100-XT pas sive sensor has the higher number.
● The flange connections of the sender/receiver units and nozzles must be compatible.
● The flange connections of the nozzles must be free of welding beads on the inside.
NOTICE:
The deformation characteristic of the flange gasket has an influence on the geometry of the installation and therefore on the uncertainty of the measurement. SICK recommends:
● Only use the same gasket type as the original delivery.
● Apply a tightening torque according to the installed gasket,
.
66 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
6.8.1
Fig. 35
Calculating wetted part length wL with the geometry calculator in FLOWgate
TM
Before installation, calculate how deep the sender/receiver units will be pushed into the pipeline.
The wetted part length depends on:
● Nozzle length
● Gasket thickness
● Ball valve length
● Wall thickness
NOTICE:
The wall thickness must be determined accurately to 0.1 mm. SICK recommends using a suitable ultrasonic measuring instrument to determine the wall thickness.
1 Start operating software FLOWgate TM .
2 Create a FL100 Flare-XT Trans offline device.
1 Open the “Geometry calculator” tile in the “Change parameters” menu.
2 Select the “Cross-duct” or “probe” device type.
3 For installations with ball valve, move the “Path is changeable” slider to “Yes”, for installations without ball valve, move it to “No”.
4 For cross-duct versions, enter the “Probe offset” as determined during nozzle
installation, p. 56, §6.7.2
.
5 Enter the required dimensions:
– Circumference U
– Wall thickness w
– Gasket thickness S
– Gasket thicknesses D1 and D2
– For installation with ball valve: Length of ball valve VL
– Angle β: For cross-duct versions, enter the nominal nozzle angle (e.g. 75°, 60°,
45°). For the probe version, measure the installation angle and enter the exact value (maximum tolerance for measuring the installation angle: ±0.3°).
6 Click “Calculate parameter values” in “Parameter values”.
The wetted part length wL is calculated .
7 Click “Create Report” to generate a protocol of the geometry data.
NOTICE:
The Geometry Data report is required when commissioning with FLOWgate TM , see
Creating a protocol
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 67
Fig. 36 Installation of F1F-S, F1F-M, F1F-H (cross-duct versions)
Mounting
68 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
Fig. 37 Installation of F1F-P (probe version)
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 69
6.8.2
Fig. 38
Mounting
Tightening the self-cutting ring
SICK recommends that the correct setting of the wetted part length and tightening the cutting ring be carried out in a workshop before installation in the pipeline.
Tightening the self-cutting ring in the correct position ensures the correct wetted part length for installation in the pipeline.
WARNING: Risk of leakage due to damage to the duct probe
If the duct probe is displaced when the pipe screw fitting is tightened, the duct probe may be damaged so that no tightness can be achieved after tightening the cutting ring.
▸ Only move the duct probe when the pipe screw fitting is loosened.
▸ Tighten the pipe screw fitting with a torque of 150 Nm after positioning the duct probe.
Otherwise there a risk of leakage.
NOTICE: Damage due to incorrect position of the self-cutting ring
The position of the self-cutting ring cannot be changed after tightening! If the self-cutting ring is tightened in the wrong position, the sender/receiver unit must be replaced; for cross-duct versions both sender/receiver units must be replaced.
Before tightening the self-cutting ring, make sure that the wetted part length has been calculated correctly:
▸
Check the measured values.
▸ Check that the wetted part length is plausible compared with nozzle length and ball valve length.
Positioning of self-cutting ring (overview)
2
1 3
4
Wetted part length wL
1 Cap nut (self-cutting ring fitting)
2 Self-cutting ring marking
3 Pipe screw fitting
4 Duct probe
70 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
Fig. 39
Proceed as follows to set the wetted part length and to tighten the self-cutting ring:
1 Loosen the pipe screw fitting.
The pipe screw fitting is screwed hand-tight at the factory. Loosen the pipe screw fitting completely to set the wetted part length.
2 Set the calculated wetted part length wL and check with a length gauge (maximum tol -
3 Screw in the pipe screw fitting and tighten with a torque of 150 Nm. Secure the sender/ receiver unit in a suitable manner, e.g.
– Screw the retraction nozzle to a suitable flange connection that provides the space required inside for the duct probe (diameter and length of the set wetted part length wL).
– Alternatively, install threaded bolts/screws in the through-holes of the retraction nozzle to prevent slipping. Position a suitable rigid rod between the threaded bolts/ screws for countering. Ensure that the duct probe and the flange sealing surface are not damaged.
Securing the sender/receiver unit (example)
4 First tighten the self-cutting ring fitting hand-tight.
NOTICE: Damage due to incorrect position of the self-cutting ring
The position of the self-cutting ring cannot be changed after tightening! If the self-cutting ring is tightened in the wrong position, the sender/receiver unit must be replaced; for cross-duct versions both sender/receiver units must be replaced.
Before tightening the self-cutting ring, make sure that the wetted part length has been calculated correctly:
▸
Check the measured values.
▸ Check that the wetted part length is plausible compared with nozzle length and ball valve length.
5 Now tighten the self-cutting ring fitting tight 1.25 turns.
Counter with a jaw wrench at the pipe screw fitting.
6
Mark the self-cutting ring fitting position, → Fig. 38.
7 Completely loosen the pipe screw fitting again.
8 Loosen the cap nut again and fully retract the sender/receiver unit for transport and installation in the pipeline.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 71
6.8.3
Fig. 40
Mounting
9 The self-cutting ring remains in the fixed position on the duct probe.
10 Then tighten the pipe screw fitting again hand-tight.
WARNING: Leakage hazard
Repeated use may damage the gasket of the pipe screw fitting.
▸
Before reuse, i.e. whenever the pipe screw fitting is to be tightened again, check the gasket of the pipe screw fitting:
▸ Replace the gasket if it has visible deformations, indentations or damage. In this case contact SICK Service.
Otherwise there a risk of leakage.
Fitting the venting valve
A venting valve is available as an option from SICK (Part No. 2108210).
Use a suitable valve with 1/8" NPT thread when the valve available from SICK is not used.
WARNING: Hazard through gas in the pipeline
▸ Install the venting valve only when the sender/receiver unit is not yet installed in the pipeline or when the pipeline is free from pressure and dangerous gas.
▸ During installation and operation, adjust the position of the vent so that personnel do not come into direct contact with the medium.
▸
Open the vent slowly.
▸ Small quantities of medium can escape via the spindle in the open position. Take appropriate protective measures for the operating personnel.
1
Remove the dummy plug on the sender/receiver unit, → Fig. 40.
2 Wrap the sealing tape (PTFE) 2.5 layers around the external thread of the venting valve in thread direction.
3 Screw the venting valve in.
Pay attention to the alignment of the key surfaces: The valve must not hit the ball valve; align the wrench surfaces as parallel as possible to the flange sealing surface.
4 Tighten the screw plug of the valve so that no gas escapes there.
5 Then carry out a leak tightness check with suitable means.
Venting valve connection
1 Dummy plug; venting valve connection
1
72 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
6.8.4
Installing sender/receiver units
WARNING: Hazard through incorrect use of the retraction mechanism
▸
Observe the information on activating the retraction mechanism, p. 14,
1 Make sure the ball valves are closed.
– If applicable, close ball valves.
– If applicable, remove blind flanges.
2 Position the flange gasket.
3 Position the sender/receiver unit on the ball valve.
Make sure the seal does not move during positioning.
For cross-duct versions, make sure to install the passive sensor (→ Fig. 7) on the nozzle
on the downstream side so that the sender/receiver unit points against the flow direc tion.
4
Insert the 4 bolts with the centering sleeves (→ Fig. 33) and screw the sender/receiver
unit on the ball valve.
Apply a tightening torque according to the installed gasket, p. 138, §15.4
.
5 Completely loosen the pipe screw fitting.
6 Open the ball valve.
WARNING: Danger due to gas leaks
When gas escapes, close the ball valve again and contact SICK Service.
7 Push the sender/receiver unit into the pipeline.
8 Check the gasket of the pipe screw fitting for damage.
WARNING: Leakage hazard
Repeated use may damage the gasket of the pipe screw fitting.
▸ Before reuse, i.e. whenever the pipe screw fitting is to be tightened again, check the gasket of the pipe screw fitting:
▸
Replace the gasket if it has visible deformations, indentations or damage. In this case contact SICK Service.
Otherwise there a risk of leakage.
9 Screw in the pipe screw fitting and tighten with a torque of 150 Nm.
10 Push the sender/receiver unit to the stop.
11 On probe version F1F-P, now align the measuring path correctly before securing the selfcutting ring fitting.
Align the probe version as described in the following section, "Observe when aligning the probe version" .
For cross-duct versions, proceed with the next step.
12 Tighten the self-cutting ring fitting tight 1.25 turns.
Make sure the markings for the self-cutting ring fitting are next to each other again,
13 For cross-duct versions, install the active sensor on the nozzle on the upstream side so that the sender/receiver unit points in the flow direction.
14 Connect potential equalization of the sender/receiver units FLSE-XT.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 73
Fig. 41
Mounting
Observe when aligning the probe version
Before securing the self-cutting ring fitting again, align probe version F1F-P correctly:
The measuring path must be aligned in flow direction, i.e. the arrow shown must point in flow direction.
Marking on probe version F1F-P
Flow direction
▸
Align the measuring path of probe version F1F-P as shown, see → Fig. 41. The
maximum deviation of the rotation angle of the probe to the flow direction may be ±3°.
To ensure this, use a laser to align probe version F1F-P:
74 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
Fig. 42
Alignment of the device to the flow direction using a laser
WARNING: Risk of explosion
The laser may only be used if no Ex atmosphere is present. Use of the laser is not permitted under Ex conditions.
1 Mark the pipe center one meter before and after probe version F1F-P, e.g. with chalk or
2 Place a laser on the side of the electronics housing and let the laser beam hit the pipe at the level of the end of the first marking.
3 Measure the distance between the point of impact of the laser and the marking on the pipeline.
4 Repeat the procedure for the second marking.
5 Align the electronics housing so that distance a corresponds approximately to distance b.
The maximum permissible difference between value a and value b is 10 mm.
6 After alignment, tighten the self-cutting ring fitting 1.25 turns.
Make sure the markings for the self-cutting ring fitting are next to each other again,
Alignment of probe version F1F-P
2
1
2 a b
Marking: 1 m Marking: 1 m
1 Laser
2 Laser beam
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 75
6.8.5
Mounting
Leak tightness check
NOTICE:
▸ Perform a leak tightness check with suitable means after completion of the installation work.
▸ Also perform a leak tightness check with suitable means after completion of the installation work with spool piece. No leakage check has been made at the factory.
▸
NOTICE:
Proceed as follows when leak tightness is not established:
Pull the sender/receiver units back and disconnect them from the process
by closing the ball valve, p. 77, §6.9
Contact SICK Service.
76 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
6.9
Fig. 43
Pulling the sender/receiver units back
WARNING: Hazard through incorrect use of the retraction mechanism
▸
Observe the information on activating the retraction mechanism, p. 14,
1
Completely loosen the cap nut of the self-cutting ring fitting, → Fig. 43.
2
Completely loosen the pipe screw fitting, → Fig. 43.
3 Pull the sender/receiver unit back completely to the stop.
4 Close the ball valve.
NOTICE:
The ball valve must close without resistance.
If this is not possible:
▸ Make sure the sender/receiver unit has been pulled back completely.
NOTICE:
Do not use force when the sender/receiver unit cannot be pulled back.
▸ Tighten the pipe screw fitting again with a torque of 150 Nm.
▸ Contact SICK Service.
NOTICE:
No additional loads may act on the electronics unit and on the cable outlet of the sender/receiver units. Especially in the retracted position, no additional force (except in the direction of the duct probe) may act on the electronics unit.
Cap nut
2
1
1 Cap nut (self-cutting ring fitting)
2 Pipe screw fitting
WARNING: Hazardous gas (possibly explosive or toxic)
Consider the gas trapped in the retraction nozzle,
.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 77
6.10
6.10.1
Fig. 44
Mounting
Fitting the weatherproof cover for the sender/receiver unit
The weatherproof cover (Part No. 2105581) serves to shield the electronics of the sender/ receiver unit from sunlight and weather influences.
NOTICE:
Apart from the SICK weatherproof cover, no other loads may be mounted on the devices.
Overview
Weatherproof cover overview
3
2
1
2
1 Holder
2 Safety splints
3 Weatherproof cover
4 Hexagon head screws
5 Pipe clip
6 Washers
7 Hexagon nuts
4
5
6
7
6
7
78 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Mounting
Fig. 45 Dimensions [mm]
188 271
6.10.2
Fitting the weatherproof cover
1 Fasten the holder on the sender/receiver unit:
Fasten the holder with the pipe clip to the probe neck of the sender/ receiver unit using hexagon head screws with nuts and washers.
Apply a tightening torque of 18 Nm.
Make sure the holder is correctly aligned and the probe is not damaged. See the adjacent Figure.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 79
2 Push the weatherproof cover into the holder.
Mounting
3 Fix the weatherproof cover with the four safety splints.
80 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Electrical installation
FLOWSIC100 Flare-XT Transmitter
7 Electrical installation
Requirements for installation in the Ex zone
Pressure and temperature values
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 81
7.1
7.2
7.3
Electrical installation
Safety
WARNING: Electrical hazard
Incorrect cabling can cause serious injuries, device malfunctions or failure of the measurement system.
▸ Observe the relevant safety regulations as well as the safety notices in
p. 11, §2 during all installation work.
▸
Take suitable protection measures against possible local hazards or hazards arising from the equipment.
Prerequisites
All assembly work previously described must be completed (as far as applicable) before starting installation work. Unless otherwise agreed with SICK or an authorized representative, all of the installation work must be carried out by the plant operator. This includes laying and connecting the power supply and signal cables and installing switches and power fuses.
Cable specification
The following cable specifications correspond to the standard SICK cables. Special requirements on cabling in the Ex zone are not considered here. The plant operator is responsible that all cables used comply with valid regulations and guidelines for cabling in hazardous areas at the plant.
Standard connection cables between sender/receiver units
The standard connection cables between sender/receiver units are included in the scope of delivery.
● Connection cable between sender/receiver units of device types F1F-M, F1F-S
Cable type:
Exi, coaxial, RG62, connection TNC with safeguard against pulling off, length
3 m
● Connection cable between sender/receiver units of device type F1F-H
Cable type:
Armored cable with certified flameproof cable glands including separating seal, completely mounted, length 5 m
Connection cable between sender/receiver units and higher level control system
The connection cable between sender/receiver units and the higher level control system must comply with the following standard and can optionally be ordered from SICK:
Cable type: Li2YCYv(TP) 2x2x0.5 mm², with reinforced outer sheath, from Lappkabel
The cable must fulfill the following requirements for function of the device:
– Operating capacity < 150 pF/m
– Wire cross-sectional area at least 0.5 mm² (AWG20 to AWG16 max.)
– Screen with Cu wire mesh
The maximum cable length for the RS485 interface is defined as 1000 m total length.
When designing the cable cross-section for the power supply of the sender/receiver units, the voltage drop across the cable due to the line resistance must be taken into account.
The supply voltage on the sender/receiver unit must be at least 20 V.
82 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Electrical installation
7.4
With a supply voltage of 24 V and a current consumption of 40 mA for a sender/receiver unit, the following maximum line resistance results:
24 V
40
– 20 mA
V
= 100 in total for the plus and minus lines
For 1000 m and a cable cross-section of 0.5 mm 2 , the following calculation results:
35 km m 2 = 70
This value is thus below the limit value of 100 Ω.
With smaller cable cross-sections or a lesser lower supply voltage limit, there may therefore be restrictions on the maximum cable length.
Cable glands
The enclosure inputs are closed with certified sealing plugs. Cable glands are not included in the scope of delivery, except for the completely installed connection cables between the sender/receiver units type F1F-H.
Only use installation material approved for the applied hazard zone.
The user is responsible for correct selection.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 83
84
7.5
Electrical installation
Requirements for installation in the Ex zone
WARNING: Risk of explosion
▸ Do not open the enclosures while energized.
▸
Do not connect or disconnect the circuits unless the voltage has been turned off or the area is safe.
▸ When using alternative connection of devices not belonging to the system, especially external power supply devices, power supply units, etc., ensure that the maximum voltage at the connections does not exceed 125 V even if a fault occurs.
▸
Do not use the device when cables or terminals are damaged.
General information
● The documentation for zone classification according to EN 60079-10 must be available.
● The devices to be used must be checked for suitability for the application area.
● After installation, an initial test of the device and the plant according to EN/IEC 60079-17 must be performed.
Cables
● Cables must fulfill the requirements according to EN 60079-14.
● Protect cables especially endangered by thermal, mechanical or chemical stress, e.g. by laying in protective tubes.
● Cables must be flame-retardant according to DIN VDE 0472 Part 804. The fire behavior according to B / IEC 60332-1 must be approved.
● Observe the clamping range of the cable glands for cable selection.
● Ex-d cable gland must be suitable for the intended cable type (e.g. cables with or without armoring).
● Cables and lines for Ex-d cable glands must comply with the requirements in
EN 60079-14.
● Protect the wire ends with connector sleeves against fraying.
● Replace unused cable glands with certified Ex-d sealing plugs.
● Connect or safeguard unused wires to ground so that a short circuit with other conductive parts is excluded.
● Carry out potential equalization in accordance with EN 60079-14 (see also the following
Section).
● “Conduit” systems must comply with the requirements in EN 60079-14 9.4 and 9.6. In addition, compliance with national and other relevant standards is required.
● “Conduits” according to IEC 60614-2-1 or IEC 60614-2-5 are not suitable.
● “Conduit” systems must be protected against vibration.
● Use thread sealant according to EN/IEC 60079-14, Section for threads with ½" NPT.
The following applies additionally for intrinsically safe cable connection with intrinsically safe ultrasonic transducers/probes for the F1F-M, F1F-P, F1F-S sender/receiver units:
● The device marking must at least include the information Ex ia.
● Use only cables delivered by SICK.
The connections of the intrinsically safe ultrasonic probes are designed so that the individ ual circuits are safely separated from other intrinsically safe and non-intrinsically safe cir cuits.
If the transducer circuits are disconnected while energizing, it still must be observed that the safe separation from other intrinsically safe and non-intrinsically safe circuits is not overrid den and thus intrinsic safety endangered. For this reason, the associated connection cable
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Electrical installation should be disconnected at both ends, i.e. unplugged individually and successively, first from the electronics and then, if required, from the ultrasonic probes, or suitably attached to pre vent uncontrolled movement of the cable with the unprotected, open cable connector. The cables for the intrinsically safe components are marked either with “Exi” or a blue cable cov ering or with blue shrink sleeves on the cable ends or with the SICK item number, at least on the associated packaging. The technical safety data are shown in the Type Examination Cer tificate.
● Operation of the sender/receiver units type F1F-M, F1F-P, F1F-S with sensors and components not belonging to the system and sensors from other manufacturers is not permitted. See the Type Examination Certificate for the technical safety data.
Specific requirements for installation in the USA and Canada
● Installations in USA must be carried out according to NEC (ANSI/NFPA70).
● Installations in Canada must be carried out according to CEC part 1.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 85
7.6
Fig. 46
Electrical installation
Connection overview
Pin assignment in the terminal compartment of the sender/receiver units
Terminal compartment FLSE100-XT sender/receiver with electronics (active sensor)
2
1
Table 8
1 Terminal compartment open
2 Grounding terminals
Connection of the sender/receiver units
Terminals
Designation in
Terminal box
B
Active sensor
Description
A +24 V DC GND
External connection ** yellow green white brown
Assignment IF1 IF1 +24 V DC GND
Passive sensor
MCX connector
**: Applicable only for cables with wire color code according to DIN 47100
IF1: MODBUS communication between FLSE active sensor and a higher level control system
(Interface 1)
MCX: Signal for FLSE passive sensor
NOTICE:
Self-locking terminals for wire sizes 0.5 .. 1.5 mm² (AWG20 ... AWG16).
Interconnection of sender/receiver units
▸ For the F1F-H device, use a coax plug-on aid to connect the passive sensor to the active sensor.
▸ Support and fix the connection cables accordingly so that no significant additional forces can act on the duct probe ends.
86 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Electrical installation
7.7
Fig. 47
Connection diagrams
Cabling of the sender/receiver units gnd B A
Service
RS485**
Display connection
Higher level
MCUP processor board
control system
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
A B C D E
On-site cabling in explosion protected version according to
br ws gn ge gnd
+24 V DC
RS485a
RS485b
Terminals
RS485b
RS485a
+24 V DC gnd ge gn ws br gnd
+24 V DC
RS485a
RS485b
FLSE100-XT (passive ultrasonic transducer) *
*: Not for FLSE100-XT-P
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 87
7.8
Electrical installation
Pressure and temperature values
Fixed values for pressure and temperature are written to the device when the device is powered-up. Since pressure and temperature values have a significant influence on the correct calculation of mass flow rate, molecular weight, gas density and Reynolds number, best accuracy is achieved with actual values. Therefore those values can optionally also be input by a MODBUS master.
See additional MODBUS specification for more information.
The MODBUS specification is available on the product CD delivered with the
FLOWSIC100 Flare-XT Transmitter.
When the pressure and temperature transmitters are connected to a DCS / SCADA system and then written via MODBUS into the FLOWSIC100 Flare-XT Transmitter electronics, the initialized fixed values are overwritten and the live values are used.
88 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Commissioning
FLOWSIC100 Flare-XT Transmitter
8 Commissioning
Commissioning with the FLOWgate TM operating software
Functionality and plausibility checks
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 89
8.1
8.2
8.2.1
Commissioning
General information
● Before commissioning, the sender/receiver units must be installed and electrically connected.
● The field setup wizard in the FLOWgate™ operating software supports commissioning,
.
Commissioning with the FLOWgate
TM
operating software
Auxiliary means and accessories required
Description
MEPA interface set RS485/USB
(adapter, USB cable, plug)
Part No.
6030669
FLOWgate TM , as from version 1.20, available on the product
CD delivered with the FLOWSIC100 Flare-XT Transmitter
The current FLOWgate TM version is available via the following link: https://www.sick.com
Enter “Flowgate” in the search mask.
NOTICE:
A suitable voltage supply of 24 V DC is required for commissioning of the
FLSE-XT sender and receiver units.
90 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Commissioning
8.3
Fig. 48
Connecting to the device
If commissioning is performed directly on the sender and receiver unit, a mobile power supply is required and the correct pin assignment must be observed.
WARNING: Electrical hazard
Incorrect cabling can cause serious injuries, device malfunctions or failure of the measurement system.
▸ Observe the relevant safety regulations as well as the safety notices in
during all installation work.
▸
Take suitable protection measures against possible local hazards or hazards arising from the equipment.
▸ Open the cover of the electronics and connect the RS485/USB adapter according to the connection diagram:
– USB-485: A → Sensor RS-485: A
– USB-485: B → Sensor RS-485: B
Connection diagram
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 91
8.4
Fig. 49
Commissioning
Establishing a connection with FLOWgate
TM
1 Install the FLOWgate TM operating software.
2 Click on the FLOWgate TM icon to start FLOWgate TM :
3 Add the FL100 Flare-XT Trans to the Device Manager of the FLOWgate TM operating soft ware and create a connection to the device.
Factory setting of the RS485 interface:
● Protocol: MODBUS RTU
● Transfer rate: 57600 baud
● MODBUS address: 1
● Data format: 8 data bits, N (no parity), 1 stop bit
4 Login to the device with the default user “Authorized user (Operator)”.
Standard password for the “Authorized user (Operator)”: flaregas
5 To start the field setup, open the "Commissioning" menu and follow the step-by-step instructions.
Commissioning with FLOWgate TM I
92 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Commissioning
8.5
Fig. 50
Commissioning wizard
The commissioning wizard leads step by step through the necessary parameterization of the FLOWSIC100 Flare-XT Transmitter and ensures no important settings are forgotten.
The respective parameters are written to the FLSE-XT sender/receiver unit after every step.
▸ Switch to Configuration mode to start commissioning.
Starting configuration mode
8.5.1
8.5.2
Fig. 51
Identification
The connected device is automatically recognized.
▸ Compare the serial numbers with the type plates.
▸ Enter a device name: The device name is freely selectable.
Application
User warnings
▸ Configure the " Performance warn limit" as desired for the particular application:
If the error rate of the measurements is higher than the set warning limit, a warning is issued. Do not change the default value, if you are unsure which warning threshold is suitable for your application.
Serial communication
▸ If required, configure the settings for serial communication.
Settings for serial communication (default)
A MODBUS response will be delayed by the minimum timespan defined in
"Response delay". This parameter can be used to limit the communication speed in case of communication issues.
Unit System
▸ Select the unit system for the display in FLOWgate TM .
For the output values in metric or imperial units there are different register ranges in the MODBUS specification.
See additional MODBUS specification for more information.
The MODBUS specification is available on the product CD delivered with the
FLOWSIC100 Flare-XT Transmitter.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 93
Fig. 52
Commissioning
Flow control
▸ Configure the flow parameters as desired for the particular application:
– Low flow cutoff: If the measured value is less than the value of the low flow cutoff, the output of the gas velocity is zero. Accordingly, the output for the volume flow will also be zero.
– Suppress negative velocity: If the slider ist set to "Yes", a negative velocity is sup pressed and not taken into account.
Base conditions
The volume flow at base conditions is calculated according to p. 94, §8.5.3.1
.
▸ To activate the the calculation of the volume flow at base conditions, set the slider to
"Yes".
▸ The reference conditions for the conversion can be configured.
Calculation of volume flow at base conditions
94
8.5.3
8.5.3.1
NOTICE:
The calculation for the volume flow at base conditions does not consider the device status.The volume is always converted, even if the device is in error status.
Mass flow (calculations)
Volume flow
Volume flow rate at operating conditions
In general, volume flow rate Q ac
is defined by representative cross-sectional area A and mean gas velocity v
A with respect to the cross-section (area velocity):
Path velocity v , the mean value of the flow velocity on the sound path between the two sender and receiver units is determined with the FLOWSIC100 Flare-XT Transmitter.
Especially with small pipe diameters, this is not identical with the area velocity. The correction is done with a polynomial relation k = ( ,
0
CC
4
) under consideration of the flow profile in dependence on Reynolds number Re and a set of
5 coefficients ( CC
0
… CC
4
). The coefficients of this function were determined using numerical flow simulation and regression analysis.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Commissioning
The volume flow results from :
Fig. 53
8.5.3.2
Fig. 54
The Reynolds number used in the correction is calculated device-internal:
Re = v D
In addition to measured variable path velocity v and inner pipe diameter D , the process parameters density of medium ρ and viscosity η are used. The density can either be
predefined or calculated using a molar mass algorithm, p. 96, §8.5.3.3
.
The viscosity can be configured as fixed value. Pressure and temperature have a significant influence on accuracy. The best accuracy is achieved when externally installed pressure and temperature sensors are connected to a DCS / SCADA system and then written via
MODBUS into the FLOWSIC100 Flare-XT Transmitter electronics.
In addition to the calculation of the Reynolds number, process values are required to calculate the flow rate at base conditions and the mass flow rate.
NOTICE:
The correct evaluation of the Reynolds number is decisive for the determination of the correct calibration function. The Reynolds number must be determined with an accuracy of 20 % in order to achieve the device accuracy offered by
SICK.
Volume flow rate at base conditions
The volume flow rate is converted from operating conditions to base or standard conditions based on the gas equation
Calculation of the volume flow at base conditions
Tsc
Tac with the parameters pressure in operating conditions temperature in operating conditions T standard conditions K = Z ac
/Z sc
.
ac p ac
and base conditions p
and base condition T sc sc
, the
, as well as compressibility
K . Compressibility is the relationship of the compressibility factors in operating and
For applications < 5 bar, compressibility can always be approximated sufficiently well with value 1. In applications with higher process pressures, constant values for the compressibility factors can be configured.
Mass flow rate
The mass flow rate ṁ is calculated from the measured volume flow rate under operating conditions Q ac
and the determined density ρ ac
according to equation:
Calculation of the mass flow rate
= Qac ac
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 95
8.5.3.3
Fig. 55
Fig. 56
Commissioning
Algorithm for calculating the molar mass
▸ Select the desired algorithm for the use of the molar mass:
– Fixed value
– Basic
– Hydro Carbon
If no algorithm is selected and the selection is set to "disabled", no molar mass is calculated and the output molar mass is zero.
Fixed value
If "fixed value" is selected, a fixed value for the density can be specified.
Basic algorithm
The basic algorithm is suitable for basically flammable gases with a constant composition and low hydrocarbons content. The basic algorithm is based on the following equation, which can be used to determine the molar mass for ideal gases
Basic algorithm formula
Mm = -------------------
VOS
2
Mm= molar mass
κ = adiabatic coefficient
R = universal gas constant
T = temperature
VOS = velocity of sound
The algorithm requires the adiabatic coefficient κ (mean value) as input value.
Velocity of sound can be measured by FLOWSIC100 Flare-XT Transmitter.
The algorithm is suitable for all ideal gases with pressures < 5 bar with constant gas composition.
Hydrocarbon algorithm
The hydrocarbon algorithm is suitable for typical hydrocarbon mixtures with inert gases proportion < 10%. On the basis of the velocity of sound, the molar mass is calculated with the assumption of a typical hydrocarbon mixture. Changes in the composition of the hydrocarbon fractions can be taken into account.
Hydrocarbon algorithm formula
96 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Commissioning
8.5.3.4
Fig. 57
8.5.4
Fig. 58
Density calculation
If the Basic algorithm or the Hydro carbon algorithm is selected, the density is calculated in a separate step according to the real gas equation:
Calculation of the density
ac
= ----------------------------------
0
Tac
Installation
Geometric dimensions of assembling parts
The dimensions of the components can be taken from the report generated during assembly.
▸
For installations with ball valves, set slider “Path is retractable” to “Yes”.
Installation parameters z
ρ
P ac ac
= Density at flowing conditions
= Pressure at flowing conditions
Mm = Molare Masse
T
R ac
= Compressibility factor at flowing conditions
0 ac
= Universal gas constant
= Temperature at flowing conditions
8.5.5
▸
Enter the dimensions determined during installation:
– Wall thickness w, circumference U
for cross-duct versions and p. 58, §6.7.3
for the probe versions
– Nozzle length D1; and the length of the second nozzle D2 for cross-duct versions,
– Gasket thickness S, length of ball valve VL p. 64, §6.8
▸
Click “Calculate transducer distance”.
The transducer distance is calculated.
▸
Click “Calculate parameter values”.
The parameter values are calculated.
Finalize
Finalize
▸ If desired, reset the event summary.
Generate reports
▸ Create a parameter report and archive the report with the delivery documentation.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 97
8.6
Fig. 59
Commissioning
Functionality and plausibility checks
After commissioning, reconnect the FLOWSIC100 Flare-XT Transmitter to the host system.
WARNING: Electrical hazard
Incorrect cabling can cause serious injuries, device malfunctions or failure of the measurement system.
▸ Observe the relevant safety regulations as well as the safety notices in
p. 11, §2 during all installation work.
▸
Take suitable protection measures against possible local hazards or hazards arising from the equipment.
When commissioning has been completed with the FLOWgate TM operating software, it is advisable to check the functionality and plausibility of the communication with the DCS or
SCADA.
For such a check, it is advisable to use the "Technical Bulletin" MODBUS specification valid for the FLOWSIC100 Flare-XT Transmitter.
See additional MODBUS specification for more information.
The MODBUS specification is available on the product CD delivered with the
FLOWSIC100 Flare-XT Transmitter.
The MODBUS specification specifies the electrical interface and serial communication based on MODBUS protocol of the FLOWSIC100 Flare-XT Transmitter.
A function and plausibility check is always possible via the "Guest" user level.
Example of serial communication to a SCADA or DSC
8.6.1
FLOWSIC100 Flare-XT Transmitter
The FLOWSIC100 Flare-XT Transmitter supports the MODBUS RTU transmission mode.
Factory setting of the RS485 interface:
● Protocol: MODBUS RTU
● Transfer rate: 57600 baud
● MODBUS address: 1
● Data format: 8 data bits, N (no parity), 1 stop bit
Check of device status
Register #1016 contains a variety of information representing the current device status.
The device status of the FLOWSIC100 Flare-XT Transmitter shall have the status
"Measurement valid" after commissioning. This is true when Bit 7 of register #1016 is "1".
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Commissioning
Fig. 60 Register #1016, Bit 7
8.6.2
8.6.2.1
Table 9
8.6.2.2
If the status "Measurement valid" is not reached, it is necessary to determine the possible cause. The Technical Bulletin MODBUS gives detailed explaination of the register #1016 which helps to trouble shooting. A transition to operation is not recommended without the status "Measurement valid".
Overview of most important measured and calculated values
Measured values
The FLOWSIC100 Flare-XT Transmitter delivers the following measured values:
● Gas velocity
● Actual volume
● Speed of sound
During the system check, these measured values can now be evaluated and checked for plausibility about the prevailing process and application conditions. The following registers are important for this.
Register for measured values
Register
Metric
#1000
#1002
#1004
Imperial
#1500
#1502
#1504
Description
Volume flow a.c.
Velocity of gas
Speed of sound
Volume flow a.c.
Velocity of gas
Speed of sound
Unit m m / h m / h ft 3
3 / h
/ h ft / s ft / s
Calculated values
The FLOWSIC100 Flare-XT Transmitter calculates the following values based on the measured values.
● Standard volume with optional p and T live input reading
● Mass flow
● Molar mass
● Density
During the system check, these calculated values can now be evaluated and checked for plausibility about the prevailing process and application conditions. The following registers are important for this.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 99
Commissioning
Table 10
Table 11
Standard volume
Register
Metric
#1121
#1123
#1133
Imperial
#1506
#1508
#1534
Description
Actual used temperature
Actual used pressure
Volume flow s.c.
Actual used temperature
Actual used pressure
Volume flow s.c.
Unit m 3 / h m 3 / h m 3 / h
°F
Psi (a) scfh
Mass flow
Calculation see
Mass flow
Description Register
Metric
#1119
Imperial
#1526
Mass flow
Mass flow
Unit kg / h lb / h
Molar mass
The molar mass is calculated by the algorithm in use, either Basic or Hydrocarbon or as
simple fixed value, p. 96, §8.5.3.3
.
Description Unit Register
Metric
#1065
Imperial
#1528
Molar mass (calculated)
Molar mass (calculated) g / mol lb / lbmol
Density
Calculation see
.
The density in the operating state is necessary for the calculation of the Reynolds number in the linearization and the calculation of the mass flow. This can either be:
● Fixed value
● Calculated value
Register
#1071
Description
Density actual
Unit kg / m 3
100 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Maintenance
FLOWSIC100 Flare-XT Transmitter
9 Maintenance
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 101
9.1
9.2
Maintenance
Safety information
WARNING: Hazard through improper maintenance work
After all maintenance work, make sure the entire measuring system and any accessories installed are in a safe condition.
General information
Maintenance strategy
Just like any other electronic measuring system, the FLOWSIC100 Flare-XT Transmitter requires regular maintenance. By inspecting the system regularly and observing the scheduled maintenance intervals, the service life of the device can be lengthened significantly and ensures measurements are always reliable.
Even though the FLOWSIC100 Flare-XT Transmitter is often deployed in harsh environments, its design and measuring principle are such that the device requires only minimal maintenance.
Maintenance tasks
The tasks to be carried out are limited to routine checks and cleaning the surfaces of sender/receiver units.
Maintenance intervals
The maintenance interval depends on specific system parameters such as operation, gas composition, gas temperature, gas moisture as well as ambient conditions. By default, the manufacturer's requirement is that, if a verification interval of one year is observed, the measurement is ensured within the manufacturer's specifications.
The activities required locally and their completion must be documented by the operator in a Maintenance Manual.
Maintenance agreement
Regular maintenance work can be carried out by the plant operator according to the
Service manual when the plant operator has attended an official FLOWSIC100 Flare-XT
Transmitter service training by SICK. These activities must be carried out by qualified
persons as described in p. 19, §2.5
. If desired, SICK Service or authorized Service support centers can carry out all maintenance work. Any repairs will be made by specialists on-site whenever possible.
102 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Maintenance
9.3
9.3.1
Table 12
Routine checks
The FLOWgate™ operating software provides a user-friendly option for the performance of routine checks.
Checking the device status
▸ Check the device status.
Signaling the device status in FLOWgate TM
Status Description
Normal operation, neither warnings nor errors exist
9.3.2
Fig. 61
Device status warning: At least one warning is pending in the device, the measured value is still valid.
Device status error: At least one error is pending in the device, the mea sured value is invalid.
▸ Click on the symbol in the Status bar when warnings or errors exist.
The current Status overview opens and shows details and information on how to pro ceed.
Comparing theoretical and measured speed of sound (SOS)
One of the main criteria for correct operation of an ultrasonic gas flow meter is conformity between the theoretical sound velocity calculated for the actual gas composition, temperature and pressure, and the sound velocity measured by the ultrasonic gas flow meter.
The Speed of Sound Calculator (SOS Calculator) available in the FLOWgate TM operating software calculates a theoretical SOS for a specific gas composition at a specified temperature and pressure. The calculation of thermodynamic properties is based optionally on the “GERG-2008” or “AGA10” algorithm.
1
Connect the FLOWSIC100 Flare-XT Transmitter and FLOWgate™, p. 91, §8.3
2 Open “SOS Calculator” in the “Diagnostics” menu.
SOS calculator
3 Select the gas composition and confirm with “Apply”. The gas composition can be entered manually or loaded as file.
4 Enter the current process conditions and select “Calculate SOS”.
5 Compare the calculated speed of sound with the measured value.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 103
Fig. 62 Comparing the speed of sound
Maintenance
9.4
Cleaning
Cleaning the FLSE100-XT sender/receiver units
▸ Only clean the surfaces of the FLSE100-XT sender/receiver units with a damp cloth.
▸ Only use materials for cleaning which do not damage the surface of the FLSE100-XT sender/receiver units.
▸ Do not use solvents for cleaning.
104 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Troubleshooting
FLOWSIC100 Flare-XT Transmitter
10 Troubleshooting
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 105
10.1
10.2
10.3
Fig. 63
Troubleshooting
Detecting malfunctions
Any deviations from normal operation must be regarded as a serious indication of a functional impairment. These include:
● Significant drifts in the measuring results.
● Increased power input.
● A rise in system component temperatures.
● Triggering of monitoring devices.
● Smells or smoke emission
● Failure of a measuring path.
NOTICE:
Proceed as follows when a measuring path fails:
Pull the sender/receiver units back and disconnect them from the process
by closing the ball valve, p. 77, §6.9
Contact SICK Service.
Contacting Customer Service
Contact SICK Customer Service for any malfunctions you cannot clear yourself.
To help Customer Service to understand malfunctions that have occurred, the
FLOWgate TM operating software provides the option to create a diagnostics file that can be sent to Customer Service,
Starting a diagnostic session
If you would like to start a diagnostic session with FLOWgate TM , first connect to the device as described in
.
1 Click the icon in the Tool bar to start a diagnostic session.
2 Select the desired data collection duration.
It is recommended to select a data collection duration of at least 5 minutes.
Data collection duration for the diagnostic session
3 Click “Start” to start recording.
The following message with the current storage location of the data collection is shown after successful creation of the diagnostic session.
106 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Troubleshooting
Fig. 64 Diagnostic recording completed
Fig. 65
4 Click “OK” to confirm the message.
5 Select the storage location for the diagnostic session:
– Click “Close” to leave the file at the standard storage location.
– Click “Save as” to select a storage location for the diagnostic recording.
– Click “E-mail” to send the file per e-mail. The file is appended to an e-mail when an e-mail client is available.
Save the diagnostic session
The diagnostic sessions are saved as files with the ending .sfgsession. The files are saved by default under:
C:\Users\Public\Documents\SICK\FLOWgate
The name of the storage folder consists of device type and serial number of the device.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 107
Troubleshooting
108 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Decommissioning
FLOWSIC100 Flare-XT Transmitter
11 Decommissioning
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 109
11.1
11.1.1
11.1.2
11.2
11.2.1
11.2.2
Decommissioning
Returning
Contact
Please contact your SICK representative for assistance.
Packaging
Make sure the FLOWSIC100 Flare-XT Transmitter cannot be damaged during transport.
Disposal information
Materials
● The FLOWSIC100 Flare-XT Transmitter mainly consists of steel, aluminum and plastic materials.
● It does not contain any toxic, radioactive or other environmentally harmful substances.
● Substances from the pipeline can possibly penetrate, or deposit on seals.
Disposal
▸ Dispose of electronic components as electronic waste.
▸ Check which materials having contact with the pipeline must be disposed of as hazardous waste.
110 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Technical data
FLOWSIC100 Flare-XT Transmitter
12 Technical data
Technical data FLOWSIC100 Flare-XT Transmitter
Application Evaluation Datasheet (example)
Applications of FLOWSIC100 Flare-XT Transmitter in a regulated environment
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 111
Technical data
12.1
Technical data FLOWSIC100 Flare-XT Transmitter
NOTICE:
The exact device specifications and performance data of the product may deviate and depend on the respective application and customer specification.
Only the metrological parameters described in the Application Evaluation
Datasheet apply.
If the delivery documentation of your FLOWSIC100 Flare-XT Transmitter does not include an Application Evaluation Datasheet, contact your SICK partner!
Example of an Application Evaluation Datasheet: p. 116, §12.2
Table 13 FLOWSIC100 Flare-XT Transmitter (FLSE100-XT)
Measuring parameters
Measured values
Number of measuring paths
Nominal pipe size
Measuring principle
Measured medium
Measuring ranges
Repeatability
Resolution
1)
Uncertainty of measurement 1, 2) , 3)
Mass flow rate, volumetric flow s. c. (standard condition), volumetric flow a. c. (actual condition), molecular weight, gas velocity, sound velocity
1 path
1-path measurement: 4 ″ ... 72 ″
* Other nominal sizes on request
Ultrasonic transit time difference measurement, ASC technology
Natural gas, typical flare gas
0.03 m/s … 120 m/s
According to ISO 5725-1; JCGM 200:2012): < 0.5% related to the measured value in the range
≥ 1 m/s
(According to JCGM 200:2012): + 0.001 m/s
Flow rate a. c.
1% … 5%
Relative to the measured value with ultrasonic technology.
(in range ≥ 0.3 m/s to upper measuring range value)
Mass flow rate
2% … 5.5%
Relative to the measured value with ultrasonic technology.
(in range ≥ 0.3 m/s to upper measuring range value)
Uncertainty of measurement ASC technology 1),2), 4)
Resolution
Power supply
Power supply
Power
Flow rate a. c.: 1% … 8%
+ 0.001 m/s
20…28 VDC
A higher switch-on current must be expected (500 mA).
1 W
5)
0.04 A (with 24 VDC)
Inputs/outputs
Digital data interfaces
Approvals
Conformities
1 x RS485 (MODBUS RTU), optically isolated
ATEX: 2014/34/EU
EMC: 2014/30/EU
PED: 2014/68/EU
Ambient conditions
Ambient humidity ≤ 95% relative humidity
112 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Technical data
Table 13 FLOWSIC100 Flare-XT Transmitter (FLSE100-XT)
Temperature range
Storage temperature
Degree of protection
Dimensions
Dimensions (W x H x D)
Ignition group IIC T4:
-40 °C ... +70 °C
-50 °C ... +70 °C (optional)
Ignition group IIC T6:
-40 °C ... +55 °C
-50 °C ... +55 °C (optional)
-40 °C ... +70 °C
-50 °C ... +70 °C (optional)
IP 66 / 67
Details, see dimension drawings
2)
3)
1)
4)
5)
Dependent on application conditions such as gas composition, process temperature, device type, pipe diameter, etc.
For mass flow rate, additional selection and configuration of the conversion algorithm as well as uncertainty of the pressure and temperature sensors are required. To be evaluated by SICK.
With fully developed flow profile. Typically, an upstream 20 D straight pipe section and a downstream 5 D straight pipe section are required.
Below a specific limiting Reynolds number, only runtime effects and geometry uncertainties are considered for the specified accuracies, whereby contributions from the flow profile are excluded.
Additional uncertainty of measurement. In the range of 100% ... 130% of the last gas velocity measured with ultrasonic transit time difference measurement .
Ensure sufficient supply voltage on the FLSE100-XT input terminals. Performance of the sender/receiver units is restricted when the value falls below the minimum permissible limit. Consider the total cable length between power supply and FLSE100-XT when dimensioning the power
supply and the cable cross-section, see also p. 82, §7.3
.
12.1.1
F1F-S
Table 14
Gas temperature
Ex approvals
IECEx
Technical data F1F-S
Measuring conditions
Operating pressure: 1) CL150 device flange: 20 bar (g)
PN25 device flange (optional): 20 bar (g)
CL300 device flange (optional). 20 bar (g)
–196 °C ... +280 °C
ATEX
NEC/CEC (US/CA)
Ex db [ia Ga] IIA T4 Ga/Gb
Ex db [la Ga] IIB T4 Ga/Gb
Ex db [ia Ga] IIC T6/T4 Ga/Gb
Ex ia IIC T6/T4 Ga
II 1/2G Ex db [ia Ga] IIA T4 Ga/Gb
II 1/2G Ex db [la Ga] IIB T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIC T6/T4 Ga/Gb
II 1G Ex ia IIC T6/T4 Ga
Class I, Division 1, Group D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIA, T4;
Class I, Division 2, Group D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIA, T4
Class I, Division 1, Groups C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB, T4;
Class I, Division 2, Groups C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIB, T4
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIC, T4
Installation
Weight ≤ 12 kg (sensor pair)
1)
Temperature-dependent, for details see p. 120, §12.5
"Derating pressure resistance"
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 113
114
Technical data
12.1.2
F1F-M
Table 15
Gas temperature
Ex approvals
IECEx
Technical data F1F-M
Measuring conditions
Operating pressure: 1) CL150 device flange: 20 bar (g)
PN25 device flange (optional): 20 bar (g)
CL300 device flange (optional). 20 bar (g)
–196 °C ... +280 °C
ATEX
NEC/CEC (US/CA)
Ex db [ia Ga] IIA T4 Ga/Gb
Ex db [la Ga] IIB T4 Ga/Gb
Ex db [ia Ga] IIC T6/T4 Ga/Gb
Ex ia IIC T6/T4 Ga
II 1/2G Ex db [ia Ga] IIA T4 Ga/Gb
II 1/2G Ex db [la Ga] IIB T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIC T6/T4 Ga/Gb
II 1G Ex ia IIC T6/T4 Ga
Class I, Division 1, Group D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIA, T4;
Class I, Division 2, Group D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIA, T4
Class I, Division 1, Groups C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB, T4;
Class I, Division 2, Groups C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIB, T4
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIC, T4
Installation
Weight ≤ 12 kg (sensor pair)
1) Temperature-dependent, for details see
"Derating pressure resistance"
12.1.3
F1F-H
Table 16 Technical data F1F-H
Measuring conditions
Operating pressure: 1) CL150 device flange:
ATEX/IECEx: 20 bar(g)
CSA: 16 bar(g)
PN25 device flange (optional):
ATEX/IECEx: 20 bar(g)
CSA: 16 bar(g)
CL300 device flange (optional):
ATEX/IECEx: 20 bar(g)
CSA: 16 bar(g)
–70 °C ... +280 °C Gas temperature
Ex approvals
IECEx
ATEX
NEC/CEC (US/CA)
Ex db IIC T6/T4 Gb
II 2G Ex db IIC T6/T4 Gb
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA IIC, T4
Installation
Weight ≤ 14 kg (sensor pair)
1) Temperature-dependent, for details see
"Derating pressure resistance"
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Technical data
12.1.4
F1F-P
Table 17
Gas temperature
Ex approvals
IECEx
Technical data F1F-P
Measuring conditions
Operating pressure: 1) CL150 device flange:
ATEX/IECEx: 20 bar(g)
CSA: 16 bar(g)
PN25 device flange (optional):
ATEX/IECEx: 20 bar(g)
CSA: 16 bar(g)
CL300 device flange (optional):
ATEX/IECEx: 20 bar(g)
CSA: 16 bar(g)
–196 °C ... +280 °C
ATEX
NEC/CEC (US/CA)
Ex db [ia Ga] IIA T4 Ga/Gb
Ex db [ia Ga] IIB T4 Ga/Gb
Ex db [ia Ga] IIC T6/T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIA T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIB T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIC T6/T4 Ga/Gb
Class I, Division 1, Group D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIA, T4;
Class I, Division 2, Group D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIA, T4
Class I, Division 1, Groups C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB, T4;
Class I, Division 2, Groups C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIB, T4
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIC, T4
Installation
Weight ≤ 10 kg
1)
Temperature-dependent, for details see p. 120, §12.5
"Derating pressure resistance"
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 115
12.2
Fig. 66
Technical data
Application Evaluation Datasheet (example)
Application Evaluation Datasheet Page 1 (example)
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FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Technical data
Fig. 67 Application Evaluation Datasheet Page 2 (example)
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FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 117
Technical data
12.3
12.4
Fig. 68
Applications of FLOWSIC100 Flare-XT Transmitter in a regulated envi
-
ronment
The gas flow meter can be used for emission measurements, which may be subject to one or more regulations in some jurisdictions. Compliance with all emission regulations applicable at the site of the installation remains the responsibility of the owner / operator.
When correctly designed and applied, SICK's ultrasonic flow technology meets or exceeds most regulatory performance requirements. Please contact your SICK representative to find out about the right flare measurement solution that meets the currently applicable regulatory requirements.
Application limits
Exemplary V max
of of 1-path solutions dependent on the sound velocity (SOS)
130
120
110
100
90
80
70
60
50
40
0 10 20 30 40 50 60 70 80
2-path sos = 340 m/s 2-path sos = 430 m/s 2-path sos = 650 m/s
118 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Technical data
Fig. 69 V min
with 20% uncertainty of 1-path solutions depending on the speed of sound (SOS)
Welded
0.07
0.06
0.05
0.04
0.03
0.19
0.18
0.17
0.16
0.15
0.14
0.13
0.12
0.11
0.10
0.09
0.08
0 10 20 30 40 50 60 70 80
Fig. 70
2-path sos = 340 m/s 2-path sos = 450 m/s 2-path sos = 650 m/s
Uncertainty of flow rate as function of the velocity of gas (VOG)
Ultrasonic measurement
12
ASC technology
(Additional uncertainty compared to ultra sonic measurement)
12
10
8
6
10
8
6
4
2
0
0.01
0.1
1 10 100 90 100 110 120 130
0
4
2
Dry Calibration Flow Calibration
The exemplary expression of uncertainty according to GUM (Guide to the Expression of Uncertainty in Measurement):
ISO/IEC Guide 98-3:2008-09 shows an F1F-S in 1-path, 16" nominal size and assumes a gas temperature of 20 °C, ambient pressure and a typical molecular weight greater than 27 g/mol.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 119
12.5
Fig. 71
Technical data
Derating pressure resistance
NOTICE:
The diagrams apply to the standard variants of the FLSE100-XT sender/ receiver units. Deviations in other versions are possible.
Observe the maximum permissible design values shown on the type plates of the devices.
F1F-S/-M
21
20
19
18
17
16
15
14
13
12
11
10
-200 -150 -100 -50 0
38 °C
50 100 150 200 250 300
Fig. 72 F1F-H ATEX/CSA
21
20
19
18
17
16
15
14
13
12
11
10
-100 -50 0
0°C 100 °C
50 100 150 200 250 300
120 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Technical data
Fig. 73 F1F-P
21
20
19
18
17
16
15
14
13
12
11
10
-200 -150 -100
38 °C 100 °C
-50 0 50 100
Temperature [°C]
Temperature [°C]
150 200 250 300
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 121
12.6
12.6.1
Fig. 74
Technical data
Dimension drawings
Dimension drawings of FLSE100-XT sender/receiver units
Dimensions for F1F-S/-M/-H CL150, 2"
F1F-S/-M/-H
A
B C C
D
E
Pushed-in position
90 F F
G
150
92
150
92
H
Withdrawn position
Table 18
Table 19
Extended version
FLSE100-XT Dimensions of extended version
A B C D
F1F-S
F1F-M
983
980
583
582
400
398
871
869
F1F-H 846 448 398 919
Compact version
FLSE100-XT Dimensions of compact version
F1F-S
F1F-M
F1F-H
A
883
880
746
B
583
582
448
C
300
298
298
D
771
769
819
E
471
471
518
F
178
178
178
E
471
471
518
F
178
178
178
G
984
851
H
1055.5 944
873
917
G H
955.5
844
884 773
751.5
817
122 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Technical data
Fig. 75
Dimensions for F1F-P, CL150, 2"
F1F-P
150
92
893
1508
90
615
Pushed-in position
1527
Withdrawn position
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 123
Technical data
124 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Spare parts
FLOWSIC100 Flare-XT Transmitter
13 Spare parts
Recommended spare parts for FLSE100-XT sender/receiver units
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 125
13.1
Spare parts
Recommended spare parts for FLSE100-XT sender/receiver units
Part No.
Description
2108048 Assembly kit ANSI150 2Z SS ET
2108049 Assembly kit ANSI300 2Z SS ET
2108050 Assembly kit DN50 PN16 M16 SS ET
2107288
Replacement cover for aluminum EXD M20 housing
Contents: Cover, cover lock, cover insulation, O-ring, spring washer, screws, assembly paste, sealing plugs
2107289
2110151
2110152
Replacement cover for stainless steel EXD M20 housing
Contents: Cover, cover lock, cover insulation, O-ring, spring washer, screws, assembly paste, sealing plugs
Replacement cover for aluminum EXD NPT housing
Contents: Cover, cover lock, cover insulation, O-ring, spring washer, screws, assembly paste, sealing plugs
Replacement cover for stainless steel EXD NPT housing
Contents: Cover, cover lock, cover insulation, O-ring, spring washer, screws, assembly paste, sealing plugs
1)
2)
Recommended spare parts for commissioning
Recommended spare parts for 2 years operation
1 1) 2 2)
X X
X X
X X
X
X
X
X
126 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Accessories (optional)
FLOWSIC100 Flare-XT Transmitter
14 Accessories (optional)
Accessories for FLSE100-XT sender/receiver units
Further accessory parts (cable screw fittings, ball valves, nozzles, etc.) are available on request from SICK
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 127
14.1
Accessories (optional)
Accessories for FLSE100-XT sender/receiver units
Part No.
2105581
Description
Weather/sun protective cover for electronics of the active ultrasonic sensor
2108210 Venting/drain valve for ultrasonic sensor
6030669 MEPA interface set RS485/USB (adapter, USB cable, plug)
128 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Annex
FLOWSIC100 Flare-XT Transmitter
15 Annex
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 129
15.1
15.1.1
15.1.1.1
15.1.1.2
Annex
Compliances
NOTICE:
Applied European standards and harmonized standards are listed in the valid version of the manufacturer‘s CE conformity declaration.
Compliances of FLSE100-XT sender/receiver units
CE declaration
The FLSE100-XT sender/receiver units have been developed, built and tested according to the following EU Directives:
● ATEX Directive 2014/34/EU
● EMC Directive 2014/30/EC
Conformity with the above Directives has been determined and the CE label attached to the device.
Standards compatibility and type approval
The FLSE100-XT sender/receiver units comply with the following Norms, Standards or recommendations:
● IEC 60079-0: 2015, IEC 60079-1: 2014, IEC 60079-7: 2015
● IEC 60079-11: 2011 + Cor. 2012, IEC 60079-15: 2010
● EN 60079-0:2012, EN 60079-1:2014, EN 60079-7:2015, EN 60079-11:2012,
EN60079-15:2010
● EN 61326-1:2013 (Electrical equipment - EMC requirements)
● EN 60529: 1991/A1:2000/A2:2013 (IP)
130 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Annex
15.2
Fig. 76
Connection diagrams
Connection diagrams, FLSE-XT (page 1 of 5)
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 131
Fig. 77 Connection diagrams, FLSE-XT (page 2 of 5)
Annex
132 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Annex
Fig. 78 Connection diagrams, FLSE-XT (page 3 of 5)
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 133
Fig. 79 Connection diagrams, FLSE-XT (page 4 of 5)
Annex
134 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Annex
Fig. 80 Connection diagrams, FLSE-XT (page 5 of 5)
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 135
136
15.3
15.3.1
Fig. 81
Annex
Type code
Type code, FLSE-XT, sender/receiver units
FLSE-XT, sender/receiver units (overview)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
1 Ultrasonic sensor
2 Meter layout
3 Meter length
4 Ex approval
5 Ex classification / temperature class
6 Sensor electronics
7 Material electronics housing
8 Painting electronics housing
9 Cable entries
10 Tropicalizing electronic boards
11 Ultrasonic transducer
12 Transducer and tube material
13 Sensor contour material
14 Sensor retraction
15 Sensor process connection
16 Sensor process connection execution
17 Material process connection S/R unit
18 Gas temperature range
19 Ambient tempurature range
20 PMI Test
21 HVROC Test
22 Tag plate
23 Reserve
24 Reserve
25 Special solution
F1F -
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Annex
Fig. 82 FLSE-XT, sender/receiver units (explanation)
1
2
Ultrasonic sensor
F1F FLSE100-XT
Meter layout
R R90
H Cross-duct H
M Cross-duct M
S Cross-duct S
P Probe
3 Installation length
S Standard
E Extended
2 R90-24
4 R90-48
7 R90-72
4 Ex approval
A ATEX/IECEx
C CSA (NEC/CEC),FM (NEC)
I INMETRO
5 Ex classification / temperature class
DA
DB
DC
DD
II 1/2 G Ex db [ia Ga] IIA T4 Ga/Gb
Cl I, Div1, Grp.D, T4
II 1/2 G Ex db [ia Ga] IIB T4 Ga/Gb
Cl I, Div1, Grps.CD, T4
II 1/2 G Ex db [ia Ga] IIC T6 Ga/Gb
Cl I, Div1, Grps.BCD, T4
II 2 G Ex db IIC T6 Gb
Cl I, Div1, Grps.BCD, T4
IC II 1 G Ex ia IIC T6 Ga
6 Sensor electronics
Y Yes
N No
7 Material electronics housing
8
A Aluminium
B Stainless steel
Painting electronics housing
9
1 SICK standard painting
2 SICK offshore painting
Cable entries
A Metric
B NPT
C Connector
10 Tropicalizing electronic boards
1 Tropicalized - SICK standard
N No
11 Ultrasonic transducer
4I 42 kHz intrinsically safe
4D 42 kHz flameproof
1I 135 kHz intrinsically safe
12 Transducer and tube material
A Titanium
13 Sensor contour material
2 Stainless steel
6 PTFE
14 Sensor retraction
R Retractable
15 Sensor process connection
A ASME B16.5, CL150 2" RF
B ASME B16.5, Cl150 3" RF
C ASME B16.5, CL300 2" RF
D ASME B16.5, CL300 3" RF
E EN 1092-1, PN25 DN50 RF
16 Sensor process connection execution
S Seamless retraction flange
W Welded retraction flange
17 Material process connection S/R unit
B Stainless steel
18 Gas temperature range
E -70 ... +280°C
F -196 ... +280°C
19 Ambient tempurature range
A -40...+70°C
B -50...+70°C
C -40...+55°C T6, -40...+70°C T4
D -50...+55°C T6, -50...+70°C T4
20
PMI Test
P PMI Test
N No
21 HVROC Test
H HVROC Test
N No
22 Tag plate
A Tag plate sticker
B Tag plate stainless steel + sticker
N No
23 Reserve
24
25
N -
Reserve
N -
Special solution
N No
X Special Solution
E EXRE Upgrade
Characteristic value “X” in the type code denotes a customer-specific version.
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 137
15.4
Fig. 83
Gasket installation
Gasket installation (developed by ”pikotek”)
Annex
138 FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH
Annex
Fig. 84 Gasket installation (developed by ”pikotek”), screw tightening torques for comb profile gasket B9A and polymer gasket GYLON
5/8“ A320 gr. L7m (A193 gr. B8m)
FLOWSIC100 Flare-XT Transmitter · Operating Instructions · 8027358/1FPZ/V1-1/2022-05 · © SICK Engineering GmbH 139
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Key features
- Ultrasonic measurement technology
- Suitable for use in potentially explosive atmospheres
- Retraction mechanism for maintenance without pressure relief
- Active sound correlation technology (ASC)
- Various temperature code options for different process temperatures
- FLOWgate™ software integration for commissioning and data analysis