Fluenta FGM 160 Manuale utente

Document number:

72.120.601

Document title:

FGM 160 Operating Instructions

Scope: ISO 9001:2015 §8.6 Release of products and services

Additional Information (when applicable):

2018.09.17 Updated Abbreviations and removed O&SC

AK NB MR MM MB

D 2014.01.20 Proofread and updated JB AP CT MB MW

C 2013.01.30

Removed from User Manual, updated:

changes in text formatting; modifying

graphics in Appendix II and Electronic

modules

MKJ KH - MW MW

B 2009.06.02 Updated information AAJ RT N/A N/A AAJ

A2007.11.30

Issued for Fluenta release; moved to User

Manual

MS RT - N/A AAJ

Rev.

index

Issue date Reason for issue Author Review Review

Review

by QA

Approved

Replacement for:

n/a

Total pages:

Fluenta source doc.

(for translations): n/a

FGM 160 Operating Instructions

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TABLE OF CONTENTS

1. Purpose........................................................................................................................................... 3

2. Abbreviations/Definitions ............................................................................................................. 3

2.1 Abbreviations......................................................................................................................... 3

2.2 Definitions.............................................................................................................................. 3

3. General Information....................................................................................................................... 3

3.1 Hardware Description............................................................................................................ 3

3.1.1Electrical Connections .............................................................................................. 4

3.1.2 Power Supply............................................................................................................ 4

3.1.3 Input Signals............................................................................................................. 4

3.1.3.1 Ultrasonic Transducers ............................................................................. 4

3.1.3.2 Pressure and Temperature Transmitters.................................................. 5

3.1.4 Output Signals .......................................................................................................... 5

3.1.4.1 Modbus Communication (RS-485)............................................................ 5

3.1.4.2 Foundation Fieldbus Output...................................................................... 5

3.1.4.3 Current Loop Outputs................................................................................ 5

3.1.4.4 HART Output............................................................................................. 5

3.1.4.5 Pulse/Frequency Output............................................................................ 5

3.1.5 Electronic Modules in FGM 160................................................................................ 6

3.1.5.1 Digital Signal Processing (DSP) Module................................................... 6

3.1.5.2 Analog Front End (AFE) Module............................................................... 6

3.1.5.3 Pressure & Temperature (P&T) Module.................................................... 6

3.1.5.4 Input/Output (I/O) Module.......................................................................... 6

3.1.5.5 Intrinsic Safety Barrier (IS Barrier) Module ............................................... 6

3.1.5.6 Surge Protection Module........................................................................... 6

3.1.5.7 Local Display Module ................................................................................ 6

3.1.6 Non-Resettable Counter Function............................................................................ 7

3.2 Firmware Description............................................................................................................. 7

3.2.1 DSP Module.............................................................................................................. 7

3.2.2 P&T Module.............................................................................................................. 8

3.2.3 I/O Module ................................................................................................................ 8

3.3 Device Integrity...................................................................................................................... 8

3.3.1 Self-Checking ........................................................................................................... 8

3.3.2 Watchdog Timer ....................................................................................................... 8

3.3.3 Flash Memory........................................................................................................... 8

3.4 Configuration and Operating Software.................................................................................. 9

4. Operating Procedure................................................................................................................... 10

4.1 Introduction.......................................................................................................................... 10

4.2 Power-Up Sequence ........................................................................................................... 10

4.3 Field Computer Configuration.............................................................................................. 10

4.4 Local Display Functions....................................................................................................... 11

4.5 Error Check and Troubleshooting ....................................................................................... 12

4.5.1 Error Check with Local Display............................................................................... 12

4.5.2 Error Check with UFM Manager............................................................................. 13

5. References.................................................................................................................................... 13

6. Appendix I – System Configuration File.................................................................................... 14

7. Appendix II – Inserting settings from Client parameter list .................................................... 18

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1. PURPOSE

This document describes the Fluenta Flare Gas Meter, FGM 160 hardware and software, and

the device integrity.

2. ABBREVIATIONS/DEFINITIONS

2.1 Abbreviations

TFS Transducer Full Size

FGM Flare Gas Meter

2.2 Definitions

Module PC-board with a local controller and a processor

TFS Series Transducers based on the TFS. See document 72.050.001 for details on this

range

3. GENERAL INFORMATION

3.1 Hardware Description

The FGM 160 Field Computer, illustrated in Figure 1, is designed as a distributed system. The

FGM 160 consists of five or six modules, the Digital Signal Processing (DSP) module, the

Analog Front End (AFE) module, the Pressure & Temperature (P&T) module, Input/Output

(I/O) module, Intrinsic Safe Barrier (IS Barrier) module, Surge Protection module and the Local

Display. A distributed system gives several advantages. This design will be more flexible with

respect to future expansions and modifications, as the total processing load for the system can

be divided in several modules. Thus, the danger of overloading a single CPU unit is reduced.

Figure 1: FGM 160 Field Computer.

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The FGM 160 is certified for operation in Hazardous Area.

For detailed information regarding Hazardous Area installation and operation, please refer to

Fluenta Doc. no. 62.120.006 (Hazardous Area Installation Guidelines [1]) and 75.120.215

(FGM 160 Hazardous Area Certificates [2]).

Figure 2: FGM 160 Hook-Up, with the Field Computer, Ultrasonic Transducers, Pressure and Temperature

Transmitters, and connections to Safe Area equipment.

3.1.1 Electrical Connections

For detailed information regarding all electrical connections, please refer to Installation & Hook-

Up Instructions [3].

3.1.2 Power Supply

The FGM 160 requires 24 VDC power supply (nominal). If 24 VDC is not available, an optional

110-230 VAC/24 VDC converter can be supplied by Fluenta.

For detailed equipment information and equipment ratings, please refer to Hazardous Area

Installation Guidelines [1].

3.1.3 Input Signals

3.1.3.1 Ultrasonic Transducers

FGM 160 ultrasonic transducers are connected to the FGM 160 Field Computer by means of

prefabricated signal cables included.

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3.1.3.2 Pressure and Temperature Transmitters

The FGM 160 can be configured to accept analog 4-20 mA transmitters or HART compatible

transmitters. The pressure and temperature transmitters may be omitted if the system is

configured to get the pressure and temperature data from the DCS system (Modbus

communication link).

3.1.4 Output Signals

3.1.4.1 Modbus Communication (RS-485)

The FGM 160 has two separate Modbus communication ports.

One is dedicated for communication with a DCS system. The second is a service port for

configuration and monitoring of the FGM 160 system.

In the FGM 160 Foundation Fieldbus configuration, DCS Output is disabled.

3.1.4.2 Foundation Fieldbus Output

A maximum of four (4) parameters can be predefined according to customer requirements.

The list of parameters available for the customer can be found in Fluenta AS doc. No.

72.120.305 (all parameters available by using Modbus Serial Interface are accessible using

Foundation Fieldbus output).

3.1.4.3 Current Loop Outputs

Up to six (6) current loop outputs are available for output of selectable parameter values, where

three (3) analog outputs are configured as the default. The 4-20 mA current loop output

channels can be configured as active or passive outputs.

4-20 mA Outputs are replaced by FF Outputs in FGM 160 Foundation Fieldbus Configuration.

3.1.4.4 HART Output

One of the current loop outputs can be also configured for HART output communication. Refer

to HART Output Interface Specification [5] for details.

3.1.4.5 Pulse/Frequency Output

The FGM 160 can be also configured to provide a pulse or frequency output signal. The pulse

output will represent an incrementation of the totalizer (of e.g. volume or mass), whereas the

frequency output will represent a process parameter (e.g. volume flow rate, mass flow rate

etc.)

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3.1.5 Electronic Modules in FGM 160

3.1.5.1 Digital Signal Processing (DSP) Module

The Digital Signal Processing module is the processing module in the system. The DSP

Module generates the ultrasound measurement signals and controls the measurement

sequences. It collects data from the other module registers and performs flow calculations

based on this data. All calculated parameters are stored in defined registers. All of these

registers are available for UFM Manager software through the Modbus service port at the I/O

Module. A selection of these registers is also available for the DCS system (through the DCS

port at the I/O Module).

3.1.5.2 Analog Front End (AFE) Module

The Analog Front End Module is the interface between the DSP Module and the ultrasonic

transducers via the IS-Barrier unit. At the AFE Module, measurement signals are multiplexed

and switched between upstream and downstream direction.

3.1.5.3 Pressure & Temperature (P&T) Module

The Pressure & Temperature Module collects pressure and temperature information from

external sensors via 4-20 mA current loop or HART Interface. All pressure and temperature

data are stored in predefined registers available for the DSP Module. Accordingly, the DSP

unit can retrieve P&T parameters in a minimum amount of time.

3.1.5.4 Input/Output (I/O) Module

The Input/Output Module is the interface between the FGM 160 in hazardous areas and

equipment in safe areas. At the I/O Module, 24 VDC (nom.) supply voltage is converted to the

required operational voltages for the other modules. Furthermore, all signals and

communications to and from the DCS system and UFM Manager are handled by this unit.

3.1.5.5 Intrinsic Safety Barrier (IS Barrier) Module

The Intrinsic Safety Barrier Module ensures the intrinsic safety for operation of the ultrasonic

sensors mounted in hazardous area. In addition, the IS-Barrier Module includes safety barriers

for the P&T transmitters. Therefore, the P&T transmitters with “Ex i” certification can be

interfaced directly to the FGM 160. For specifications regarding the P&T transmitter barriers,

please refer to Hazardous Area Installation Guidelines [1].

3.1.5.6 Surge Protection Module

The Surge protection Module protects the power input and the signal output lines from

externally generated spikes, surges and overvoltage.

3.1.5.7 Local Display Module

The Local Display (LD) Module is the front unit, visible through the Ex-d safety glass. At the

LD, a set of predefined metering process parameters can be viewed. In addition, four LEDs

give the status of Power, Alarms, Measurement and Communication.

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3.1.6 Non-Resettable Counter Function

The non-resettable counter function will record and keep the totalized volume and mass. The

totalized values are accessible through the DCS Modbus interface or through UFM Manager.

Figure 3 Electronic modules

3.2 Firmware Description

In the following sections a general description of the firmware for the different modules is

outlined.

3.2.1 DSP Module

•The DSP Module initializes the system at start-up. Tasks are set to initial states and

the system is ready for operation.

•The signals transmitted by the ultrasound transducers are generated by the DSP

Module. The sequencing is controlled by this module, and, depending on the velocity

of the medium in the pipe, either both Chirp and CW signals or just Chirp signals are

used for the flow measurements. One ultrasonic transit time measurement is always

succeeded by an ultrasonic transit time measurement in the opposite direction.

•Data sampling and signal processing are carried out after a specified number of

sequences. Then, the DSP module calculates the difference in transit time

measurements and calculates the parameters available in the FGM system.

•Flow velocity and volume flow rate calculations run continuously, calculating new

values based on data from the P&T module and transit time measurements from the

ultrasonic transducers.

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•Gas density and mass flow calculations are calculated based on calculated velocity of

sound and measured pressure and temperature.

•Volume and mass totalising calculations are continuously updated based on volumetric

and mass flow rate calculations.

•All system configuration parameters are stored in the Flash memory (non-volatile

memory) at the DSP Module.

•The DSP Module carries out self-checking and evaluation of input and calculated

parameters.

3.2.2 P&T Module

•The P&T Module continuously collects pressure and temperature values from the

external pressure and temperature transmitters mounted downstream of the FGM 160.

These readings are used in calculations performed by the DSP module.

•In addition to the external temperature reading, the P&T also reads the internal

temperature value. This value is used to monitor the internal temperature in the Ex-d

enclosure.

3.2.3 I/O Module

•The I/O Module handles all signals and communication with systems in Safe Area.

•Data requests and commands from UFM Manager are processed by the I/O Module. A

predefined number of accessible parameters are available from the FGM. Accessible

parameters depend on whether 4-20 mA, HART or Modbus is utilized.

•Software downloads to the DSP-, P&T- and I/O Module are carried out by the I/O-

module.

•All data requests from DCS system are handled by the I/O Module; either through

Modbus or HART interfaces.

3.3 Device Integrity

3.3.1 Self-Checking

The FGM 160 performs a self-checking sequence, where it checks that inputs from the

transducers and Temperature and Pressure transmitters are within a valid range, and that

other functions are operating as intended.

3.3.2 Watchdog Timer

The Watchdog Timer is initialized at start-up, and cannot be disabled, ensuring that in the

unlikely situation of system hang-up occurring, the Watchdog Timer will reset the system

forcing a complete reboot and start-up.

3.3.3 Flash Memory

System configuration is stored in Flash Memory (non-volatile memory). In case of a power

break, all system configurations are reloaded from the Flash memory

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3.4 Configuration and Operating Software

Through the FGM 160 Ultrsonic Flare Meter Manager (UFM Manager), the operator can

monitor process data, configure the meter and specify process data to be saved to a data log

file for later analysis. UFM Manager further enables the operator to operate the meter remotely,

by using e.g. a RS 485/TCP/IP converter and remote control software.

It should be noted, UFM Manager is required to replace the default settings with actual

applicable settings provided by customer. Fluenta service engineers and partners will always

set up the FGM 160 according to the latest submitted parameters from the Client when

installing and commissioning the FGM 160. Fluenta service engineers and partners always

have the UFM Manager with them.

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4. OPERATING PROCEDURE

4.1 Introduction

This section provides information about how to operate the FGM 160 field computer. The FGM

160 is a field mounted stand-alone ultrasonic gas flow measurement system, and does not

require any safe area communication device in order to operate. However, in order to

continuously monitor data and the meter performance, it is recommended to use the UFM

Manager software package. This program will provide hands-on process and status data

continuously with possible remote access to the FGM 160 system from any remote system

with the appropriate remote control software installed.

4.2 Power-Up Sequence

The power-up sequence describes the necessary handling of the FGM 160 in order to ensure

correct operation. The power-up sequence is as follows:

1. Connect all power, input and output signals and communication cables according to

the project specification and all relevant procedures and instructions.

2. Make sure that the power cable is connected to a suitable power source, either directly

to a 24 VDC supply or through a 110-240 VAC/24 VDC converter.

3. Turn on the power to the FGM 160. There is no power switch on the FGM 160 Field

Computer, so the power must be switched by an external switch or similar, preferably

in safe area.

4. On startup, the FGM 160 will go through a boot and an initialization sequence before

entering the standard operational (measurement) mode.

5. When the FGM 160 has entered the standard operational (measurement) mode, the

meter will, according to the system configuration, carry out transit time measurements,

retrieve pressure and temperature data, calculate volumetric and mass flow rates and

either actively output a set of predefined parameters at the analog 4-20mA outputs, or

make a set of process parameters available for DCS HART or Modbus communication.

4.3 Field Computer Configuration

The FGM 160 can be configured by using UFM Manager. During manufacturing, default

configuration is entered into the Field Computer. The system configuration will be modified by

Fluenta service engineers or partners when installing and commissioning the meter. This

configuration can be changed at any time by using The UFM Manager software. All system

configuration parameters are stored in a non-volatile memory, ensuring that no configuration

parameters are lost in case of power loss. Appendix II explains how to insert or modify system

configuration according to a Client parameter list.

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