FLOWSIC100 FLARE

FLOWSIC100 FLARE 90° RETROFIT

PRODUCT DESCRIPTION
AVAILABLE DEVICE DOCUMENTATION

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PRODUCT DESCRIPTION
SYSTEM BASIC INFORMATION
FUNCTION PRINCIPLE
PRINCIPLE OF ULTRASONIC RUNTIME DIFFERENCE

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FUNCTION PRINCIPLE
PRINCIPLE OF ULTRASONIC RUNTIME DIFFERENCE

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FUNCTION PRINCIPLE
EX, EXS, EXRE, EXPR VERSION
HILBERT ALGORITHM CROSS-CORRELATION-ALGORITHM

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FUNCTION PRINCIPLE
EXS-90°
HILBERT ALGORITHM LONG SINGLE BURST WITH EDGE ALGORITHM

- Change of the algorithm for the "high-speed

range" of cross-correlation on long single burst
with FL100 edge algorithm:
- Firmware for sender and receiver unit:
21.21.05
 Not compatible to others

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FUNCTION PRINCIPLE
SIGNAL PROCESSING

▪ The main task of the signal processing is to determine the signal runtime and
the runtime difference.

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FUNCTION PRINCIPLE
DETERINATION OF THE GAS VELOCITY (PATH)

▪ Direction of the gas flow:

▪ Against the gas flow:

▪ Resolving for v results in:

▪ Sound velocity:

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DIAGNOSTIC VALUES
SIGNAL TO NOISE RATIO

▪ Signal-to-noise ratio (abbreviated SNR or S/N) is a measure used in science

and engineering that compares the level of a desired signal to the level of
background noise. SNR is defined as the ratio of signal power to the noise
power, often expressed in decibels. A ratio higher than 1:1 (greater than 0 dB)
indicates more signal than noise.

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DIAGNOSTIC VALUES
CAUSES OF NOISE INTERFERENCES

▪ Noise interference by Structure-borne sound

▸ Structure-borne sound is a sound that propagates within a solid.
▸ The excitation for this is done via a fixed connection at the neck of the transducer or at
the transmitting membrane itself to the meterbody or pipeline.
▸ Also too strong vibrations can be the cause of structure-borne noise.
▸ The frequency response of the structure-borne sound signal remains unchanged.

▪ High velocoites
▸ As the speed increases, the noise level around the probe increases.

▪ Pressure control valves

▪ Gas Injection tubes

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DIAGNOSTIC VALUES
GAIN

▪ In electronics, gain is a measure of the ability of a two-port circuit (often an

amplifier) to increase the power or amplitude of a signal from the input to the
output port by adding energy converted from some power supply to the signal. It
is usually defined as the mean ratio of the signal amplitude or power at the
output port to the amplitude or power at the input port. It is often expressed
using the logarithmic decibel (dB) units ("dB gain"). A gain greater than one
(greater than zero dB), that is amplification, is the defining property of an active
component or circuit, while a passive circuit will have a gain of less than one

DAC Amplifier Amplifier DAC

ADC AGC AGC ADC

DSP

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DIAGNOSTIC VALUE
SPEED OF SOUND

▪ The speed of sound is the distance travelled per unit time by a sound wave as it
propagates through an elastic medium. At 20 °C (68 °F), the speed of sound in
air is about 343 meters per second (1,234.8 km/h; 1,125 ft/s; 767 mph; 667
kn), or a kilometre in 2.9 s or a mile in 4.7 s.

▪ It depends strongly on temperature, but also varies by several meters per

second, depending on which gases exist in the medium through which a
soundwave is propagating.

▪ The speed of sound in an ideal gas depends only on its temperature and
composition. The speed has a weak dependence on frequency and pressure in
ordinary air, deviating slightly from ideal behavior

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DIAGNOSTIC VALUES
ACOUSTIC TEMPERATURE

▪ The acoustic gas temperature measurement, also called sound pyrometry, is a

non-contact measuring method based on the temperature dependence of the
speed of sound.

▪ The acoustic temperature measurement of the FLOWSIC100 FLARE has the

most significance if the gas composition is demonstrably constant.

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SYSTEM CONFIGURATION

System Configuration Path layout Remarks

One Path Measurement Two sender / receiver units are mounted on the
pipeline.

Special application conditiones can require a

path positioning outside the center of the
pipeline.

Instead of 2 sender /receiver units also a probe

version can be used (type EX-PR)
Two Path Measurement Two pairs of sender/receiver units are
installed at the same measuring location
and are connected to the same control unit.

Both measurement path should be positioned

outside the center of the pipeline.

Computation of both measuring path to one

measuring result is performed by the MCUP.
2x1 Path Measurement The MCUP serves two independent
1-path measurement systems.

Seperate processing and output of the

measuring results for both measuring points
is performed by the MCUP.

3x1 Path Measurement Three individual measuring paths from different

measuring points can be connected to one
control unit.

Seperate processing and output of the measuring

points are performed by the MCUP.

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COMMUNICATION BETWEEN S/R UNITS AND MCUP

Configuration Layout Description

1-path measurement - connection of one Two sender/receiver units (type EX-S, EX und EX-
measuring point to the MCUP RE) are connected to the MCUP and work as
master and slave.
The FLSE master has a second interface in the
terminal box to enable unique separation of the
communication to the FLSE slave and to the MCUP.
The master triggers the slave and takes over the
measuring regime. The MCUP can independently
query the measured values from the master units
(asynchronous to the measuring cycle).
2-path and The master-slave communication is realized using
2x1-path measurement - connection and the same principle as for the single path
computation of two measuring paths of a measurement. The connection of both measuring
measuring point to the MCUP paths is usually carried out with bus cabling.

An approved explosion-protected junction box (SICK

option) is to be used for cabling in Ex zone 2.
Cabling in hazardous areas Ex zone 1 may be
carried out only with an approved "Exe" junction box
or "Ex-d" junction box (not included in SICK scope of
delivery).
3x1-path measurement - connection of three The master-slave communication is realized using
measuring paths of different measuring points to the same principle as for the single path
the MCUP measurement. The connection of all measuring
paths have to be carried out with bus cabling.
An approved explosion-protected junction box (SICK
option) is to be used for cabling in Ex zone 2.
Cabling in hazardous areas Ex zone 1 may be
carried out only with an approved "Exe" junction box
or "Ex-d" junction box (not included in SICK scope of
delivery).

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SYSTEM OVERVIEW
SYSTEM COMPONENTS

The measuring system consists of the following components:

▸ FLSE100 sender/receiver unit (details → pg. 31, § 2.2.1)For sending and receiving
ultrasonic pulses, for signal processing and control of system functions
▸ Nozzle (details → pg. 55, § 2.2.2.1)For mounting the sender/receiver units on the
pipeline
▸ Nozzle installation tool for precise positioning and alignment of nozzles
▸ Ball valve (details → pg. 57, § 2.2.2.2)
For mounting retractable sender/receiver units on the pipeline
▸ MCUP control unit (details → pg. 59, § 2.2.4)For control, evaluation and output of the
sensor data connected via the RS485 interface
▸ Connection cable between the sender/receiver units
▸ Connection cable between sender/receiver units and MCUP
▸ Meter body option (spool piece) Spool piece ready for mounting in an existing pipeline
(flange connection or welded connection); including installation materials to fit the
sender/receiver units.
▸ External temperature and pressure transmitters available on request

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SYSTEM COMPONENTS
SENDER AND RECEIVER UNITS
MEASUREMEMT TASKS

The sender and receiver unit has the following measurement tasks:
▸ Determination of the path velocity
▸ Determination of the sound velocity
▸ Determination of the acoustic temperature
▸ Determination of the transducer temperature
▸ Volume counter

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SENDER AND RECEIVER UNITS
EXS VERSION PREFERABLY WITH 80 KHZ, ALSO 135 KHZ
FLOWSIC100 EX-S
ATEX II ½ G Ex de [ia] IIC T4
Optional:T6, zone 0 for transducers

FLOWSIC100 EX-S
ATEX II 3 G Ex nA II T4 X

FLOWSIC100 EX-S
ATEX II ½ G Ex de [ia] IIC T4
CSA CI I, Div1/Div2 group BCD T4

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SENDER AND RECEIVER UNITS
EXS 90°VERSION PREFERABLY WITH 135 KHZ

Paramter Code Design / Description

Nominal length L 924 For pipelines up to 24“ FLSE100-EXS 90°, retractable
948 For pipelines up to 48“ FLSE100-EXS 90°, retractable
972 For pipelines up to 72“ FLSE100-EXS 90°, retractable
Sealing material in M Metal
retraction mechanism

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SENDER AND RECEIVER UNITS
EX AND EXRE VERSION PREFERABLY WITH 42 KHZ

FLOWSIC100 EX, EXRE

ATEX II ½ G Ex de [ia] IIC T4
Optional:T6, zone 0 for transducers

FLOWSIC100 EX, EXRE

ATEX II 3 G Ex nA II T4 X

FLOWSIC100 EX, EXRE

ATEX II ½ G Ex de [ia] IIC T4
CSA CI I, Div1/Div2 group BCD T4

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SENDER AND RECEIVER UNITS
PROBE VERSION PREFERABLY WITH 135 KHZ

FLOWSIC100 EX-PR
ATEX II ½ G Ex de [ia] IIC T4
Optional:T6, zone 0 for transducers

FLOWSIC100 EX-PR
ATEX II 3 G Ex nA II T4 X

FLOWSIC100 EX-PR
ATEX II ½ G Ex de [ia] IIC T4
CSA CI I, Div1/Div2 group BCD T4

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SENDER AND RECEIVER UNITS
APPLICATION AREA, CONFIGURATIONS

Type of sender/
receiver unit Gas temperature [°C] Pressure Active measuring Pipe diameter NL
standard range high temperature [barg] path [mm] [mm]
range [mm]

FLSE100-EXS -70 ... +280°C 16 105 ... 620 100 ... 600 148 / 176
-70 ... +260°C
(4" ... 24")
FLSE100-EXS for zone 2 330
retractable
-70 ... +180
FLSE100-EX -70 ... +280°C 205 ... 1850 200 ... 1800 198 / 226
-70 ... +260°C
(8" ... 72")
FLSE100-EXRE for zone 2 380

FLSE100-EXPR -70 ... +280°C 16 300 ... 1800 220 3) / 350 4)

-70 ... +260°C 150 (fixed)
(12" ... 72")
FLSE100-EXPR 16 1) 400 3) / 530 4)
for zone 2
retractable 0,5 2)

1): in measuring operation

2): when retraction mechanism is being used
3): for pipe diameter 300 mm ... 1200 mm (12” ... 48”)
4): for pipe diameter >1200 mm ... 1800 mm (> 48” ... 72”)

Versions for low-temperature range -196 ... +100°C on request

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CONTROL UNIT MCUP
TASKS AND FUNCTIONS

The control unit has the calculation tasks:

▸ Calculation of the area velocity
▸ Calculation of the volume flow ac
▸ Calculation of the volume flow sc
▸ Caclulation of the Mass flow and MW
▸ Volume counter

The control unit has the following functions:

▸ Control of the data transfer and processing of the sender/receiver unit data connected
via the RS485 interface.
▸ Signal output via analog output (measured value) and relay outputs (device status)
▸ Signal input via analog and digital inputs
▸ Voltage supply of the connected sender/receiver units
▸ Communication with higher level control systems via optional modules

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CONTROL UNIT MCUP
VERSIONS

MCUP compact MCUP medium MCUP Ex-d MCUP 19“- Racket

Measuring points:1 Measuring points:1…3 Measuring points:1…3
No Ex protection Ex zone 2 ATEX II 3G Ex nA II T4 ATEX II 2G Ex de IIC T6
CSA CI I, Div2, CI I, zone 2 Flameproof housing
Non EX

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CONNECTION CABLES AND CABLE GLANDS

▪ Connection cables serve communication between sender/receiver units

FLSE100 and between sender/receiver units and control unit MCUP. SICK offers
standard cables and cable glands:
▸ a) Connection between sender/receiver units
― cable glands metric M20, NPT ½", material brass and stainless steel
― cable UNITRONIC® Li2YCYv (TP) with reinforced black outer sheath, fixed cable length
▸ b) Connection between sender/receiver unit master and MCUP:
― cable UNITRONIC® Li2YCYv (TP) with reinforced black outer sheath, meter good with free
selectable lengths in steps of 5 m
― cable glands metric M20, M25, NPT ½", NPT ¾", material brass and stainless steel

▪ Other connection cables for MCUP (power supply, outputs MCUP etc.) are not in
the SICK scope of delivery.

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MOUNTING ACCESSOIRES
BALL VALVE

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MOUNTING ACCESSOIRES
NOZZLES, BLIND FLANGES AND SEALS

▪ The nozzles are an integrated part of the measurement system depending on

the type:
▸ For FLOWSIC100 EX-S/EX/EX-RE: Nozzles of type "Long Welding Neck"
▸ For FLOWSIC100 EX-PR: Nozzles of type "Long Welding Neck"
▪ Other nozzle types (latro, heavy barrel) are available as an option.
▪ Nozzles are delivered with factory adaption to the nominal pipe diameter, bevel
for welding and marking for nozzle alignment according to the gas flow.

Additional information's and an overview please see the operating instructions.

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NOZZLE INSTALLATION TOOL

▪ The installation tool serves to align and weld the nozzle on the pipeline. It
consists of:
▸ welding aid M16 75 °(1) or welding aid M16 90 °(5),
▸ centering plate 2” (2) or centering plate 3” (6),
▸ threaded rod M16 length 290 mm (3),
▸ centering 2”/3” (4),
▸ Installation
▸ paper strip as tool to determine the exact nozzle position on the pipeline.

Design for FLOWSIC100 EX-S Design for FLOWSIC100 EX / EXRE Design for FLOWSIC100 EX PR

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METER BODY OPTION
„SPOOL PIECE“
▪ The FLOWSIC100 Flare can also be fitted with an optional spoolpiece to reduce geometric uncertainty of device
installation and to simplify assembly. The exact design (nominal diameter, connection, material) always depends
on the customer specifications.

▪ The installation length of the spoolpiece 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

▪ System solutions (FLOWSIC100 Flare + spoolpiece) are available as options with pressure and temperature
transmitters. For the positioning of pressure and temperature transmitters the following configurations are
available:
▸ Spoolpiece, standard length with integrated pressure tapping, temperature sensor 3D downstream (customer pipeline)
▸ Spoolpiece, extended length with integrated pressure and temperature tapping.

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COMPUTATIONS
CALCULATIONS
VOLUEM FLOW IN OPERATING STATE

▪ Generally, the devices of the FLOWSIC100 Flare family are used to determine
the volume flow in closed pipelines. The volume flow Qac is defined by the
representative cross-sectional area A and the mean gas velocity vA with respect
to cross-section (area velocity):

▪ Since the average values of path and area velocity are not identical, especially
for small pipe diameters, a functional, systematic relation between the
determined path velocity v and the average area velocity v A was introduced.

▪ This functional relation is implemented by a calibrating function in the

FLOWSIC100 Flare. The coefficients of this function are determined at factory
through comparison measurement on a test bench and regression analysis, and
stored in the MCUP control unit. The coefficients for various nominal pipe
diameters are activated during start-up.

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CALCULATIONS
CALCULATION OF VOLUME FLOW IN STANDARD STATE
▪ The volume flow can be converted as follows to the standard state:

▪ Q ac: Volume flow in actual state

▪ Q sc: Volume flow in standard state
▪ ppipe: Absolute pipeline pressure; usually entered as constant/default value typical for the equipment. If an
optional analog module is used as an analog input for connection of a separate pressure transducer, the
volume flow can be normalized with current plant values.
▪ pnormal: 1013 mbar
▪ Tpipe: Gas temperature (in K): In FLOWSIC100 Flare, a choice can be made here whether to use a substitute
constant temperature determined with ultrasonic measurement or the substitute temperature read in via
the optional analog input (to increase precision).
▪ Tnormal: Standard temperature. In Europe 273 K, in the USA 293 K
▪ κ: Compressibility (=1 for ideal gases); can be configured as a constant

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MASS FLOW AND MOLECULAR WEIGHT
ALGORITHMS IN USE
▪ The mass flow of the gas is computed from flow speed and sound velocity, pressure and further measured
variables.
▪ The molecular weight of the gas is computed from sound velocity and further measured variables.

p ac   R  Tac
M Flow  Q ac    MW   
c2 c2
▪ The operating software uses three different algorithms to calculate mass flow and molecular weight:
▸ Basic algorithm:
― Usage for process gases (not only hydrocarbons) with constant mixture
― Uses a constant value for substance-dependent coefficient κ (adiabatic coefficient).
▸ Hydrocarbon algorithm:
― Most used algorithm for flare applications
― Usage for hydrocarbon gas mixtures with and without H2
― Determination of Kappa and Molecular weight on base of correlative functional relations:
― Molecular weight and speed of sound (SOS)
― Adiabatic coefficient Kappa and speed of sound (SOS)
▸ Algorithm MR-113:
― Determines κ under consideration of the actual gas composition for hydrocarbon mixture.

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MASS FLOW AND MOLECULAR WEIGHT

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MASS FLOW AND MOLECULAR WEIGHT
NECESSITY FOR USING EXTERNAL PRESSURE AND TEMPERATURE

▪ The following table shows what calculations require use of external pressure
and temperature transmitters.
Calculation of External pressure transmitter External temperature transmitter

Volume flow in standard state x x

Mass flow x x

Molecular weight - x

▪ Temperature transmitter:
▸ Pt100, 3- or 4-wires connection, head mounted transmitter, 2-wires Smart transmitter,
explosion protected, output 4 ... 20 mA
▪ Pressure transmitter:
▸ Absolute pressure type, 1 ... 16 bar, 2-wires Smart transmitter, explosion protected,
output 4 ... 20 mA

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MANY THANKS FOR YOUR ATTENTION.