Flare - industrial€¦ · the flare gas is determined. Fuel gas demand and steam demand are then set based on current net heating values; hydrocarbon molecular weight and flare vent

Flow

Flare.IQNexus Control System

Operation and Maintenance Manual

GECS10028 Rev. BMarch 2019

bhge.com

http://www.bhge.com

Flare.IQNexus Control System

Operation and Maintenance Manual

GECS10028 Rev. BMarch 2019

bhge.com

© 2018 Baker Hughes, a GE company – All rights reserved.

Baker Hughes reserves the right to make changes in specifications and features shown herein, or discontinue the product described at any time without notice or obligation. Contact your BHGE representative for the most current information. The Baker Hughes logo is a trade mark of Baker Hughes, a GE company. The GE Monogram is a trademark of the General Electric Company.

http://bhge.com

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Preface

Product Registration

Thank you for purchasing your Flare.IQ from Baker Hughes, a GE Company. Please register your product at http://info.geoilandgas.com/productRegistration.html for product support such as the latest software/firmware upgrades, product information and special promotions.

Services

BHGE provides customers with an experienced staff of customer support personnel ready to respond to technical inquiries, as well as other remote and on-site support needs. To complement our broad portfolio of industry-leading solutions, we offer several types of flexible and scalable support services including: Training, Product Repairs, Extended Warranties, Service Agreements and more. Please visit www.gemeasurement.com/services for more details.

Terms and Conditions

Sales Terms and Conditions for your recent purchase of a BHGE product, including the applicable product Warranty, can be found on our website at the following link: www.gemeasurement.com/sales-terms-and-conditions

Typographical Conventions

Note: These paragraphs provide information that provides a deeper understanding of the situation, but is not essential to the proper completion of the instructions.

IMPORTANT: These paragraphs provide information that emphasizes instructions that are essential to proper setup of the equipment. Failure to follow these instructions carefully may cause unreliable performance.

Safety Issues

CAUTION! This symbol indicates a risk of potential minor personal injury and/or severe damage to the equipment, unless these instructions are followed carefully.

WARNING! This symbol indicates a risk of potential serious personal injury, unless these instructions are followed carefully.

WARNING! It is the responsibility of the user to make sure all local, county, state and national codes, regulations, rules and laws related to safety and safe operating conditions are met for each installation.

Attention European Customers! To meet CE Marking requirements for all units intended for use in the EU, all electrical cables must be installed as described in this manual.

Flare.IQ Operation and Maintenance Manual iii

Preface

Auxiliary Equipment

Local Safety Standards

The user must make sure that he operates all auxiliary equipment in accordance with local codes, standards, regulations, or laws applicable to safety.

Working Area

Qualification of Personnel

Make sure that all personnel have manufacturer-approved training applicable to the auxiliary equipment.

Personal Safety Equipment

Make sure that operators and maintenance personnel have all safety equipment applicable to the auxiliary equipment. Examples include safety glasses, protective headgear, safety shoes, etc.

Unauthorized Operation

Make sure that unauthorized personnel cannot gain access to the operation of the equipment.

WARNING! Auxiliary equipment may have both manual and automatic modes of operation. As equipment can move suddenly and without warning, do not enter the work cell of this equipment during automatic operation, and do not enter the work envelope of this equipment during manual operation. If you do, serious injury can result.

WARNING! Make sure that power to the auxiliary equipment is turned OFF and locked out before you perform maintenance procedures on this equipment.

iv Flare.IQ Operation and Maintenance Manual

Preface

Environmental Compliance

RoHS

The Flare.IQ fully complies with RoHS regulations (Directive 2011/65/EU).

Waste Electrical and Electronic Equipment (WEEE) Directive

BHGE is an active participant in Europe’s Waste Electrical and Electronic Equipment (WEEE) take-back initiative (Directive 2012/19/EU).

The equipment that you bought has required the extraction and use of natural resources for its production. It may contain hazardous substances that could impact health and the environment.

In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the natural resources, we encourage you to use the appropriate take-back systems. Those systems will reuse or recycle most of the materials of your end life equipment in a sound way.

The crossed-out wheeled bin symbol invites you to use those systems.

If you need more information on the collection, reuse and recycling systems, please contact your local or regional waste administration.

Please visit http://www.gemeasurement.com/environmental-health-safety-ehs for take-back instructions and more information about this initiative.

Flare.IQ Operation and Maintenance Manual v

Preface

vi Flare.IQ Operation and Maintenance Manual

Contents

Chapter 1. General Information

1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 Equipment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Chapter 2. Hardware

2.1 Main Processor, MPU50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.1.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.1.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.1.3 Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.1.4 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.2 Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3 Network Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.3.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.3.2 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Chapter 3. Software

3.1 Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.1.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.2.1 Flare Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.2.2 Configurable Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.3 Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.3.1 Modbus Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.3.2 Modbus Address List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.3.3 Scaling Modbus Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4 DCS Fuel and Steam Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193.4.1 PID Valve Control Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Chapter 4. Installation & Maintenance

4.1 Power Distribution Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214.1.1 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.2 Communication Network Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.2.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.3 19” Rack Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.3.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.3.2 Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.4 Replacing a MPU50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244.4.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244.4.2 IP Address Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244.4.3 Specifying a Gateway Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.5 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Flare.IQ Operation and Maintenance Manual vii

Contents

4.5.1 Mounting Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.6 Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.7 Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.8 Technical Regulations & Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.9 Cyber Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.9.1 Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294.9.2 Root Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294.9.3 Exposed Ports and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Chapter 5. Glossary of Terms and Abbreviations

viii Flare.IQ Operation and Maintenance Manual



1.1 Introduction

This manual contains information about the installation, maintenance, and operation of the Flare.IQ control system. The proprietary flare control software is embedded in a GE Nexus controller.

1.2 Application

Flare.IQ receives inputs and sends outputs to the customer’s Distributed Control System (DCS) via TCP/IP Modbus to control a flare’s fuel gas and steam supply valves (see Figure 1). The software algorithm uses GE’s flow meter sound speed to calculate molecular weight, and from molecular weight, the net heating value of the flare gas is determined. Fuel gas demand and steam demand are then set based on current net heating values; hydrocarbon molecular weight and flare vent gas flow.

Figure 1: Flare’s fuel gas and steam supply valves

1.3 Equipment Overview

The system hardware includes 19” rack mounting sheet metal, a Digital Processing Unit (DPU), redundant power supplies, an Ethernet switch and other power distribution equipment and cables. See Figure 2 below for an overview of the control equipment. The power distribution and network module is shared with up to six MPU50 modules. A single MPU50 module can only control a single flare stack with a second DPU with identical firmware provided for redundancy. For example, if a customer site has two flare stacks, one power

Flare.IQ Operation and Maintenance Manual 1


distribution and network module and four MPU50 modules would be required. The power distribution and network module weighs approximately 7.40 lbs (3.36 kg) and the MPU50 module weighs approximately 5.20 lbs (2.36 kg).

Figure 2: Control equipment

The power connections and power supplies are accessible from the backside of the rack mount panel as shown in Figure 3.

Figure 3: Power connections and power supplies

4U high power distribution and network module. One power distribution and network module can support up to six MPU50 DPU modules.

2U high MPU50 DPU module

flare.IQ

Redundant 3.8A 24 VDC uni-versal input power supplies, mini-breaker distibution, and input source grounding.

2 Flare.IQ Operation and Maintenance Manual

Chapter 2. Hardware

Chapter 2. Hardware

2.1 Main Processor, MPU50

2.1.1 Functional Description

The Nexus MPU50 controller is an integrated stand-alone computer that runs the flare control application software. The function block based programming language complies with IEC1131-3.

The controller communicates with the Nexus I/O modules or third-party devices through on-board Ethernet and DB-9 serial communication ports. The controller operating system (OS) is QNX® Neutrino®, a real-time multi-tasking OS designed for high-speed, and high-reliability industrial applications.

The MPU50 provides the following communication interfaces with the I/O bus, third-party devices, Human Machine Interface (HMI), and engineering interfaces (see Figure 4):

• ENET1-ENET2: Two RJ45 Ethernet connections for the Unit Data Highway (UDH) for bi-directional real-time communication with HMIs and other control equipment within the control system (controllers, communication modules, etc.).

• ENET3-ENET4: Two RJ45 Ethernet connections for communication with third-party devices (i.e. Modbus to customer DCS).

• ENET5: One RJ45 Ethernet connection for redundant controller tracking, only used on the general control module.

• DB-9 serial communication ports; each port drives two RS-485 serial communication buses, which can interface with third-party devices and systems using Modbus protocol. Four serial communication interfaces can be provided by this module.

The MPU50 offers the following features:

• Integrated design, single-board architecture, industrial-strength protective shell

• No jumper settings required

• No battery

• Fan-free operation

• On-board non-volatile flash memory; no loss of program settings with loss of power or reboot

• Redundant 24V DC power inputs

• 60°C max operating environment temperature.


Chapter 2. Hardware

Figure 4: MPU50 Front View

ENET 1

ENET 2

Speed

Link/Act

Speed

Link/Act

Config

Power

Master

Diag

Online

Boot

ENET 3

ENET 4

ENET 5

Speed

Link/Act

Speed

Link/Act

Speed

Link/Act

USB

COM

Status LEDsConfig: Configuration mode indicationPower: Power status indicationMaster: Master control indicationBoot: Boot progress indicationDiag: Diagnostic indicationOnline: Running status of controller software

UDH Ethernet 1

UDH Ethernet 2

Ethernet Port for interface with other control devices

Ethernet Port for interface with other control devices

Ethernet Port for redundant controller’s tracking

USB Port

RS-232 Serial Port

Serial Communication Port(Bottom, Link1 ~ 4)


Chapter 2. Hardware

2.1.2 Connections

Each MPU50 controller has four DB-9 communication ports (Link 1~4), which are used to communicate with third-party devices via Modbus serial. The connector’s pin definition is shown below:

For Modbus communication, the physical ports Link 1~4 map to its COM ports #2/#3, #4/#5, #6/#7 and #8/#9.

Table 1: Pin Definition of Serial Communication PortSerial Communication Port Pin No. Name Description

1 iLinkR+ iLink R net (communication Port1) data+

2 Null Null

3 Null Null

4 iLinkS+ iLink S net (communication Port2) data+

5 GND Ground (communication Port2)

6 iLinkR- iLink R net (communication Port1) data-

7 Null Null

8 GND Ground (communication Port1)

9 iLinkS- iLink S net (communication Port2) data-

1 2 3 4 5

6 7 8 9

Link 1 ~ Link 4

Connector’s pin


Chapter 2. Hardware

2.1.3 Specification

ItemSpecification

MPU50

Processor Intel® ATOM™ N450, 1.66 GHz, 512 KB (L2 Cache)

Memory 1GB DDR2 RAM

2GB Flash

Operating System QNX®

Programming Control block language with analog and discrete blocks and complies with IEC1131-3 standards

Control frame rate 40ms

Control algorithm Supports basic control algorithms

Primary Ethernet interface (2) Twisted pair 10Base T/100Base T/1000Base T, RJ-45 connectors;

TCP/IP protocol used for communication between controller and HMI/NTP server/other control equipment;

TCP/IP protocol used for communication between controllers

Auxiliary Ethernet interface (3)

Twisted pair 10Base T/100Base T/1000Base T, RJ-45 connectors;

ENET 3-ENET4 can be used to connect other control equipment, or communicate with third-party devices or systems;

ENET 5 is used for redundant controller tracking in the general or advanced control modules.

Configuration Serial port Access through RJ45 connector on front panel, connect with computer’s RS-232 serial port to set up the controller

USB port For base software load and firmware installation and setup

Serial communication port (4) DB-9 connectors, each one contains two pair of isolated RS-485 interfaces

RS-485 serial communication 8 serial buses, Modbus protocol

Optional, 8 serial buses, Modbus protocol

Third-party comm. (Applies to comm. control module only)

Modbus protocol, with data refresh rate once per second:

Power supply & consumption Dual redundant 24V DC (±10%), 15W

Physical

Size 213mm x 40mm x 180mm (High x Width x Depth)

Weight 1600g

Operating temperature 0 – 60°C (32 – 140°F)

Storage temperature -40 – 85°C (-40 – 185°F)

Operating relative humidity 5 – 95% (non-condensing)

Communication speed (bps) Analog points Digital points

38400

19200

14400

9600

1536

768

576

384

12288

6144

4608

3072


Chapter 2. Hardware

2.1.4 Diagnostics

LED Indication

LEDs are provided on the MPU50 front panel for the controller’s operation status. Also, each RJ45 Ethernet interface provides 2 LEDs for network connection status.

Alarms

When the following abnormalities exist, the controller’s Diagnostic LED will illuminate to indicate the fault:

• Any alarm existing in the controller’s associated I/O module

• Controller’s CPU temperature is higher than the set point

• Controller’s load rate is higher than the set point

• Controller’s memory usage is greater than the set point

• UDH failure

• Any iLink failure

• Controller NTP loss of synchronization.

LED Flashing Pattern Description

Config Flashing, Green Controller is updating configuration

LED Out No configuration in process

Master Solid on, Green Controller is running in Primary Master mode

LED Out Controller is not running in Master mode

Boot Solid on, Green Controller is initiating

LED Out Controller is not in initiating mode

Diag Solid on, Red Alarm condition within the controller

LED Out No Alarm condition present

Power Solid on, Green Controller power is present

LED Out No power supply or power supply failure

Online Flashing, Green Controller is online, application software is running

LED Out Controller is offline

Speed Solid on, Orange Ethernet link speed is 100 Mbps

LED Out Ethernet link speed is 10 Mbps, or has not connected to network

Link/Act Solid on, Green Connection has been established between controller & switch

Flashing, Green Connection is active

LED Out No network connection


Chapter 2. Hardware

2.2 Power Supplies


The MINI POWER is a 24 VDC, 3.8 A supply, with a wide input power range (100 – 240 VAC). Two internal DC/DC converters convert supply power into an adjustable and regulated 24 V output voltage. Two MINI POWERs can be connected in parallel (load sharing) to create a high reliability (redundant) supply. Reliable startup of heavy loads is ensured by a power reserve of up to 100%.

MINI POWER also operates in applications where the static voltage dips or in transient power supply failures. Powerful capacitors ensure mains buffering of more than 20 ms at full load.


Chapter 2. Hardware

2.3 Network Switch


GE’s industrial Ethernet 10/100 switches are designed specifically to meet the needs of real-time industrial control solutions. The Ethernet switch model used in this application is an 8-port 10/100 base T copper with two 100Mbps 100 base FX fiber-optic uplinks and LC-type connections, IS420ESWAH2A. To meet the requirements for speed and functionality, the following features are provided:

• 802.3, 802.3u, and 802.3x compatibility

• 10/100 base T copper with auto negotiation

• Full/half duplex auto-negotiation

• Two 100 base FX uplink ports

• HP-MDIX auto sensing

• LEDs for Link Presence, Activity and Duplex, and Speed per port (each LED has two colors)

• LED for Power

• Minimum 256 KB buffer with 4K media access control (MAC) addresses.

Flow Control (Pause)

The switch supports flow control between switches. It uses IEEE defined pause packets to receive and honor pause packets. The switch only sends the pause packets if it needs flow control on a port.

Reliability and Performance

Because high reliability is critical to any controls solutions business, the switch meets or exceeds 500,000 hours Mean Time Between Failures (MTBF) at 35°C (95 °F) ambient temperature, ground fixed controlled environment.

Connectors

The RJ-45 connectors support multiple insertions and removals with an estimated service life expectancy of 200 insertion/removal cycles.

Mounting

The switch enclosure can be panel mounted (switch mounts to rear of panel rear with bracket). Physical dimensions (width x depth x height) for the ESWA = 138 x 86 x 56 mm (5.45 x 3.40 x 2.20 in.).

Power

Supports two redundant diode-OR’d power supply inputs of 18 to 36 V DC, < 0.5A (total).

Environment

Convection cooled when mounted vertically or horizontally. Coating is corrosion resistant with provisions made for grounding per IEC 60721-3-3 Class 3C2.

The ambient air operating temperature is between -30 to 65°C (-22 to 149°F), with a storage temperature between -40 to 85°C (-40 to 185 °F).


Chapter 2. Hardware

It can operate in a 5 to 95% relative humidity non-condensing environment.

Meets Universal Building Code (UBC) - Seismic Code section 2312 Zone 4 for seismic vibration. For shipping vibration, the switch can survive 72 hours at 0.3 G rms between frequencies of 4 to 16 Hz. Three shocks of 15G, 2-millisecond impulse each repeated for all three axes as mounted on panel base. Operating vibration specification is 1.0 G Horizontal, 0.5 G vertical at 15 to 120 Hz.

Diagnostics

2.3.2 Specifications

LED one Flashes Green for activity at Full Duplex

Flashes Yellow for activity at Half Duplex

LED two Green = Link and 100 Mb

Yellow = Link and 10 Mb

No led lit = no link

Table 2: SpecificationsItem Description

Mounting The switch enclosure can be panel mounted (switch mounts to rear of panel rear with bracket) or DIN-rail mounted. DIN-rail mounting meets vibration and shock specifications. User connections are freely accessible with both mounting types.

Physical dimensions (width x depth x height)

ESWA = 138 x 86 x 56 mm (5.45 x 3.40 x 2.20 in.)

ESWB = 188 x 86 x 56 mm (7.40 x 3.40 x 2.20 in.)

Incoming power connection

Supports two redundant diode-OR'd power supply inputs of 18 to 36V DC

Cooling Convection cooled when mounted vertically or horizontally

Coating Resistant to corrosion with provisions made for grounding per IEC 60721-3-3 Class 3C2

Operating temperature

The ambient air to the standard enclosure for operation will be between -30 to 65°C (-22 to 149°F)

Shipping, storage temperature

Range is between -40 to 85°C (-40 to 185°F)

Humidity Operates in a 5 to 95% relative humidity non-condensing environment without any external temperature or humidity excursions

Seismic Vibration Meets Universal Building Code (UBC) - Seismic Code section 2312 Zone 4

Shipping vibration, shock

The switch can survive 72 hours at 0.3 G rms between frequencies of 4 to 16 Hz. Three shocks of 15G, 2-millisecond impulse each repeated for all three axes as mounted on panel base

Operating vibration

Can survive 1.0 G Horizontal, 0.5 G vertical at 15 to 120 Hz


Chapter 3. Software

Chapter 3. Software

3.1 Logic


The software algorithm uses GE’s flow meter sound speed to estimate molecular weight in between updates from the Gas Chromatograph or Calorimeter. Molecular weight, vent gas flow, and fuel flow is then used to estimate the net heating value of the vent gas in between updates from the Gas Chromatograph. The net heating value is used to control the fuel gas flow (fuel gas valve demand to the DCS). The steam flow demand is a function of the molecular weight of the hydrocarbons and the flare vent gas flow. The high-level process logic flow diagram is shown in Figure 5 below.

Figure 5: High-level process logic flow

Flare InputsFlowPressureTemperatureSound Speed

Fuel InputsFlow

Steam InputsFlowPressureTemperature

GC/MS InputsXH2, XN2, XCO2, XCO, XAr, XH2O, NHVVG, MW

Estimate the Molecular Weight

Estimate the vent gas net heating value

Calculate Fuel Flow Demand

Calculate Steam Flow Demand

OutputsSteam DemandFuel DemandTip VelocityNHVCZ


Chapter 3. Software

3.2 Configuration

3.2.1 Flare Configuration

The Flare.IQ is capable of operating with a wide variation of flare installations, such as steam vs. air assist, gas chromatograph vs. calorimeter, and multi-flare, single-stack installations. Some Modbus parameters may not be applicable depending on the installation. This is indicated by Configuration Codes in the table below. Refer to Table 3 to find the code applicable to your installation.

Table 3: Configuration CodesSingle Flare Installation Type

Assist BTU MeasureFuel Flow Measure Air Speed Part Number Order String

Steam GC/MS GF n/a FIQ-S-S1 FLARE-n-1-1-1-1-0-0

Steam GC/MS Bypass n/a FIQ-S-S2 FLARE-n-1-1-1-2-0-0

Steam Calorimeter GF n/a FIQ-S-S3 FLARE-n-1-1-2-1-0-0

Steam Calorimeter Bypass n/a FIQ-S-S4 FLARE-n-1-1-2-2-0-0

Perimeter Air GC/MS GF CV FIQ-S-A1 FLARE-n-1-2-1-1-1-0

Perimeter Air GC/MS Bypass CV FIQ-S-A2 FLARE-n-1-2-1-2-1-0

Perimeter Air Calorimeter GF CV FIQ-S-A3 FLARE-n-1-2-2-1-1-0

Perimeter Air Calorimeter Bypass CV FIQ-S-A4 FLARE-n-1-2-2-2-1-0

Perimeter Air GC/MS GF 3-speed FIQ-S-A5 FLARE-n-1-2-1-1-2-0

Perimeter Air GC/MS Bypass 3-speed FIQ-S-A6 FLARE-n-1-2-1-2-2-0

Perimeter Air Calorimeter GF 3-speed FIQ-S-A7 FLARE-n-1-2-2-1-2-0

Perimeter Air Calorimeter Bypass 3-speed FIQ-S-A8 FLARE-n-1-2-2-2-2-0

Pre-mix Air GC/MS GF CV FIQ-S-M1 FLARE-n-1-3-1-1-1-0

Pre-mix Air GC/MS Bypass CV FIQ-S-M2 FLARE-n-1-3-1-2-1-0

Pre-mix Air Calorimeter GF CV FIQ-S-M3 FLARE-n-1-3-2-1-1-0

Pre-mix Air Calorimeter Bypass CV FIQ-S-M4 FLARE-n-1-3-2-2-1-0

Pre-mix Air GC/MS GF 3-speed FIQ-S-M5 FLARE-n-1-3-1-1-2-0

Pre-mix Air GC/MS Bypass 3-speed FIQ-S-M6 FLARE-n-1-3-1-2-2-0

Pre-mix Air Calorimeter GF 3-speed FIQ-S-M7 FLARE-n-1-3-2-1-2-0

Pre-mix Air Calorimeter Bypass 3-speed FIQ-S-M8 FLARE-n-1-3-2-2-2-0


Chapter 3. Software

3.2.2 Configurable Parameters

The following configurable settings are used to set the site-specific conditions used by the control software.

* These values are determined after a site survey by your GE applications engineer.

Parameter Tag Description Default Units

QSTEAM_MIN Minimum allowed steam flow demand * PPH

QSTEAM_MAX Maximum allowed steam flow demand * PPH

QFUEL_MIN Minimum allowed fuel demand * SCFH

QFUEL_MAX Maximum allowed fuel flow demand * SCFH

ACTTHD Action Threshold for changes in steam or fuel demand

15 %

NHVFUEL Nominal fuel Net Heating Value (natural gas)

920 BTU/SCF

D Flare Tip Diameter * inches

STEAM_RATIO_CF Flare-to-steam ratio correction factor 1.0 ---

MW_LOW_CF Low Molecular Weight Correction Factor 1.0 ---

MW_NORM_CF Normal Molecular Weight Correction Factor

1.0 ---

MW_HIGH_CF High Molecular Weight Correction Factor 1.0 ---

GC_UPDATE_RATE Time interval between readings from GC/MS

* seconds

N2_CONSTANT_VOLUME_ENABLE HC calculation assumes N2 volume proportional to total flare flow

0/False True/False

H2_BTU_CORRECTION_ENABLE NHV calculation assumes GC/MS applies EPA ‘1212’ rule for H2 content

0/False True/False


Chapter 3. Software

3.3 Modbus

3.3.1 Modbus Configuration

The Modbus/TCP configuration is as follows:

ModbusAddress = 1

LinkType = Tcp_Link

Protocol = TCP_RTU

ByteOrder = Most Significant First

WordOrder = Least Significant First

AxType = WORD

TCP Port = 502

3.3.2 Modbus Address List

All analog values sent and received must be integers. The “Scaling” column in the table below shows the scaling factor to multiple or divide a value by before sending or after receiving (/ = divide, * = multiply) on DCS master.

A signal is considered bad quality when its link to Modbus is broken, the signal value is unchanging or the signal is out of range. In these cases, the signal value is held at the last known good value. Additionally, the Flare.IQ will validate that inputs are reasonable; for example, if the total concentration of all specified composition gases exceeds 100%, the signal values of all gases will be set to bad quality until the composition is corrected.

The Modbus addresses are as follows:

Cmd: Address

Signal Name Description CfgScalin

gUnits

Boolean Write to Flare.IQ (Modbus Force Single Coil Command 05)

5:0001 HEARTBEAT_FB Heartbeat (from DCS) All n/a T/F

Boolean Read from Flare.IQ (Modbus Read Input Status Command 02)

2:0001 HEARTBEAT Heartbeat (from Flare.IQ) All n/a T/F

2:0002 MB_COMM_FAIL Modbus Communications Failed All n/a T/F

2:0003 FUEL_DEMAND_BQ Supplemental Fuel Demand Exceeds Capacity

All n/a T/F

2:0004 STEAM_DEMAND_BQ

Steam Demand Exceeds Capacity Sx n/a T/F

2:0005 AIR_DEMAND_BQ Air Demand Exceeds Capacity Ax n/a T/F


Chapter 3. Software

2:0006 AR_BQ Argon Content Signal Bad All n/a T/F

2:0007 CO2_BQ Carbon Dioxide Content Signal Bad All n/a T/F

2:0008 CO_BQ Carbon Monoxide Content Signal Bad All n/a T/F

2:0009 H2_BQ Hydrogen Content Signal Bad All n/a T/F

2:0010 N2_BQ Nitrogen Content Signal Bad All n/a T/F

2:0011 O2_BQ Oxygen Content Signal Bad All n/a T/F

2:0012 H20_BQ Water Vapor Content Signal Bad All n/a T/F

2:0013 MW_BQ Molecular Weight Signal Bad All n/a T/F

2:0014 NVHVG_BQ Net Heating Value (Vent Gas) Signal Bad All n/a T/F

2:0015 RESERVED Reserved for Future Use – Will always return FALSE

All n/a T/F


All n/a T/F

2:0017 QFUEL_BQ Fuel Gas Flow Signal Bad All n/a T/F


All n/a T/F

2:0019 QFLARE_BQ Flare Flow Signal Bad All n/a T/F

2:0020 TFLARE_BQ Flare Temperature Signal Bad All n/a T/F

2:0021 PFLARE_BQ Flare Pressure Signal Bad All n/a T/F

2:0022 CFLARE_BQ Flare Sound Speed Signal Bad All n/a T/F


All n/a T/F

2:0024 QSTEAM_BQ Steam Flow Signal Bad All n/a T/F

2:0025 TSTEAM_BQ Steam Temperature Signal Bad All n/a T/F


All n/a T/F

2:0027 QAIR_BQ Air Flow Signal Bad Ax n/a T/F

2:0028 TAIR_BQ Air Temperature Signal Bad Ax n/a T/F

2:0029 PAIR_BQ Air Pressure Signal Bad Ax n/a T/F


All n/a T/F

2:0031 CALC_SS_BQ Calculated Sound Speed Invalid All n/a T/F


All n/a T/F

Analog InputsWrite to Flare.IQ: Modbus Preset Single Register Command 06*Read from Flare.IQ: Modbus Read Holding Register Command 04

X:0010 XAR_INPUT Argon Content (from GC/MS) *10 %

X:0011 XCO2_INPUT CO2 Content (from GC/MS) *10 %


Chapter 3. Software

X:0012 XCO_INPUT CO Content (from GC meter) *10 %

X:0013 XH2_INPUT Hydrogen Content (from GC/MS) *10 %

X:0014 XN2_INPUT Nitrogen Content (from GC/MS) *10 %

X:0015 XO2_INPUT Oxygen Content (from GC/MS) *10 %

X:0016 XH2O_INPUT Water Vapor Content (from GC/MS) *10 %

X:0020 MW_INPUT Molecular Weight (from GC/MS) *100 g/mol

X:0021 NHVVG_INPUT Net Heating Value (Vent Gas) (from GC/MS)

*10 BTU/SCF

X:0030 QFUEL_TC Fuel Gas Flow /10 SCFH

X:0040 QFLARE_TC Flare Flow /100 SCFH

X:0041 TFLARE_TC Flare Temperature *10 °F

X:0042 PFLARE_TC Flare Pressure *100 PSIA

X:0043 CFLARE_TC Flare Sound Speed *10 ft/s

X:0050 QSTEAM_TC Steam Flow /10 PPH

X:0051 TSTEAM_TC Steam Temperature *10 °F

X:0060 QAIR Air Flow /10 CFM

X:0080 STEAM_RATIO_CF Steam Ratio Correction Factor *100

X:0081 MW_LOW_CF Low Molecular Weight Correction Factor *100

X:0082 MW_NORM_CF Normal Molecular Weight Correction Factor

*100

X:0083 MW_HIGH_CF High Molecular Weight Correction Factor

*100

X:0090 GC_UPDATE_RATE Expected GC/MS Update Interval *1 seconds

X:0130 QFUEL_MIN_MB Minimum Fuel Flow Parameter *1 SCFH

X:0131 QFUEL_MAX_MB Maximum Fuel Flow Parameter /10 SCFH

X:0140 FLARE_DIAM Flare Tip Diameter *100 In.

X:0150 QSTEAM_MIN_MB Minimum Steam Flow Parameter Sx *1 PPH

X:0151 QSTEAM_MAX_MB Maximum Steam Flow Parameter Sx /10 PPH


Chapter 3. Software

*Modbus Command 16 (Preset Multiple Registers) may be used if Command 06 (Preset Single Register) is not available.

3.3.3 Scaling Modbus Data

All analog data is transferred to/from the Flare.IQ as 16-bit, unsigned integers. Each input parameter and output value occupy a single 16-bit Modbus register. To maintain the desired dynamic range or turndown, data may be scaled by multiplying or dividing by a multiple of ten.

Example 1:

XH2_INPUT is a value written to the Flare.IQ containing the percentage of Hydrogen in the flare gas, expressed in the Modbus Address List as:

X:0160 QAIR_LOW Low Air Flow Ax *1 CFM

X:0161 QAIR_MID Mid Air Flow Ax /10 CFM

X:0162 QAIR_HIGH High Air Flow Ax /100 CFM

Analog OutputsRead from Flare.IQ: Modbus Read Input Register Command 04

4:0001 QFUEL_DEMAND Fuel Gas Demand *10 SCFH

4:0002 QSTEAM_DEMAND Steam Demand *10 PPH

4:0003 NHVCZ_ACTUAL Net Heating Value in CZ Calculated (corrected)

*1 BTU/SCF

4:0004 VTIP_ACTUAL Flare Tip Velocity Calculated /100 ft/s

4:0005 VTIP_MAX Maximum Allowable Flare Tip Velocity /100 ft/s

4:0006 MW_CALC Molecular Weight Calculated /100 g/g-mol

4:0007 NHVCZ_MEASURED Net Heating Value in CZ from GCMS/ Calorimeter (corrected)

*1 BTU/SCF

4:0008 NHVCZ_CURRENT Net Heating Value in CZ at Current Fuel and Steam (corrected)

*1 BTU/SCF

4:0009 NHVCZ_MEASURED_TC

Net Heating Value CZ from GC at Current Fuel and Steam (corrected for reporting)

*1 BTU/SCF

4:0010 NHVCZ_UNCORRECTED-TC

Net Heating Value CZ from GC with calculated fuel and steam (not corrected)

*1 BTU/SCF

4:0011 NHVCZ_UNCORRECTED-ACTUAL

Net Heating Value CZ from GC at Current Fuel and Steam (not corrected)

*1 BTU/SCF


Chapter 3. Software

The GC/MS data indicates that the H2 content is 27.5%.

Applying the Scaling factor (*10): 27.5 * 10 = 275

275 is the integer value that should be written to Modbus register 0013 with Command 06 (Preset Single Register).

Example 2:

QFUEL_DEMAND is a value read from the Flare.IQ containing the amount of supplemental fuel in Standard Cubic Feet per Hour (SCFH) required for compliance. It is expressed in the Modbus Address List as:

Reading Modbus register 0001 with Command 04 (Read Input Register) returns the integer value 3125.

Applying the Scaling factor (*10): 3125 * 10 = 31,250

31,250 SCFH is the amount of supplemental fuel required for compliance.

Example 3:

VTIP_ACTUAL is a value read from the Flare.IQ containing the velocity of the flare gas through the flare tip in feet per second (ft/s). It is expressed in the Modbus Address List as:

Reading Modbus register 0004 with Command 04 (Read Input Register) returns the integer value 4833.

Applying the Scaling factor (/100): 4833 / 100 = 48.33

48.33 ft/s is the calculated flare gas velocity.

Cmd: Address

Signal Name Description Cfg Scaling Units

X:0013 XH2_INPUT Hydrogen Content (from GC/MS) *10 %

Cmd: Address


4:0001 QFUEL_DEMAND Fuel Gas Demand *10 SCFH

Cmd: Address


4:0004 VTIP_ACTUAL Flare Tip Velocity Calculated /100 ft/s


Chapter 3. Software

3.4 DCS Fuel and Steam Valve Control

3.4.1 PID Valve Control Example

The following is an example (Figure 6) of DCS control logic to accept the Flare.IQ demand setpoints when in automatic control. The below example is for the fuel valve, but the steam valve logic would be similar. If the valve control loops already exist in the DCS, it is simply a matter of using the demand signal from Flare.IQ (via. Modbus) as the automatic control setpoint of a PID controller. The fuel and steam flow signals already exist in the DCS. If either the feedback signal or the demand signal is of bad quality, the automatic control should be disabled.

Figure 6: Example of DCS control logic


Chapter 3. Software





4.1 Power Distribution Wiring Diagram

4.1.1 Wiring Diagram

The control requires a single or redundant power source(s) and safety ground connection. See Wiring Diagram below for more details (Figure 7).

CAUTION! Make sure all electrical connections are correct and secure.

Figure 7: Wiring Diagram



4.2 Communication Network Diagram


The Flare.IQ communication network connections are shown in Figure 8. Any available Ethernet port may be used for the customer’s Modbus Ethernet connection.

Figure 8: Communication network connections

4.3 19” Rack Mounting


The Flare.IQ system is designed to be mounted in a standard 19” rack mount cabinet. The power distribution and network module has 4 mounting points, and the MPU50 module has 2 mounting points. Recommended mounting hardware is #10-32 X 0.75” long machine screws in conjunction with #10-32 snap-in cage nuts. It is recommended that all mounting hardware be either steel with zinc plating or stainless steel. Note that required mounting hardware may vary with 19” rack design. Figure 9 below shows the recommended mounting method.



Figure 9: Recommended mounting method

4.3.2 Module Installation

The modules will be labelled with section labels in the order they are recommended to be installed in the rack. For example, a system with 6 flares will have 7 modules, 1 power distribution and network module and 6 MPU50 DPU modules. The power distribution and network module will be section 1 of X, where X is the total number of modules. The MPU50 DPU module for Flare 1 will be section 2 of X, the MPU50 DPU module for Flare 2 will be section 3 of X, and so on. The section labels will correspond with the DPU IP addresses for flare numbers as shown below in Table 4, “Factory set IP addresses,” on page 26. The section labels are located on the back of the modules, in the upper right corners. Figure 10 below shows recommended module placement for an example system with 3 flares.

Figure 10: Recommended module placement

#10-32 snap-in cage nut

#10-32 X 0.75” long machine screw

4X power distribution and network module

2X MPU50 DPU module

flare.IQ

FRONT BACK

POWER DISTRIBUTION AND NETWORK

SECTION 1 OF 7

DPU1

SECTION 2 OF 7

DPU2

SECTION 3 OF 7

DPU3

SECTION 4 OF 7

DPU4

SECTION 5 OF 7

DPU5

SECTION 6 OF 7

DPU6

SECTION 7 OF 7

SECTION LABELS

flare.IQ



4.4 Replacing a MPU50

4.4.1 Installation

The MPU50 mounts directly to the panel sheet metal.

To remove the controller

1. Unplug the 24V dc power cable from DPU.

2. Remove the Ethernet cables from the controller.

3. Loosen the upper and lower setscrews mounted on the controller. Slightly lift the module and take out the controller.

To install the controller

1. Mount an upper screw on the panel. Hang the controller on the screw and align it with the panel’s lower screw hole. Mount a lower screw and tighten both screws to secure the controller.

2. Connect the corresponding communication interface cables.

3. Plug the system network cables into the UDH ports (ENET1 & ENET2) of the controller.

4. Plug the dual-24V dc power cable into the power input socket on the top of the controller.

CAUTION! Electronic controls contain static-sensitive parts. Observe the following precautions to prevent damage to these parts:

• Discharge body static before handling the control equipment.

• Do not touch the components or connectors on electronic equipment with your hands.

4.4.2 IP Address Setup

The controller must be configured with an IP address prior to connecting to the UDH. The factory set default IP address is 192.168.101.1.

Note: Controller’s platform software installation and initialization parameter settings have been set in the factory. For control system security, the USB port will be disabled before system delivery.

The controller node number is equivalent to the IP address (node 1 equals IP address 191.168.101.1).

To change the MPU50 IP address:

1. Connect Engineering computer to ENET1 port of MPU50 directly or via switch.

2. Open OptimumC’s “SystCFG”.

3. Right click “UDH” and then left click “Insert New …” to create new device with a node number matching the current IP of the MPU50 (i.e. if MPU50 IP address is 192.168.101.1 set node to 1).



4. Configure the device type option to be “Standard controller” with redundancy option “Simplex”.

5. Select the device you just created and click “Link to controller”.

6. Fill in the password (default is the same as the user name), then click “Connect”.

7. Right click on the controller, and then select “Properties” to change the MPU50 node number and IP address.

8. For example, to change the MPU50’s current IP address from 1 to 2, set the node number to be “2”, DPU name to be “DPU2”, redundancy to simplex and redundancy role to be “R”.



9. Click “OK” button, and a “Warning” popup will appear. Click “Reboot” to accept the configuration change and reboot the DPU.

10. After MPU50 reboots, it will have a node number of 2 and IP address 192.168.101.2.

Table 4 shows the factory set IP addresses for a system with multiple Flare.IQs.

Table 4: Factory set IP addressesFlare Modbus IP Address DPU Config IP Address DPU MODULE SECTION NUMBER*

1 191.168.101.11 191.168.101.1 2 of X

2 191.168.101.12 191.168.101.2 3 of X

3 191.168.101.13 191.168.101.3 4 of X

4 191.168.101.14 191.168.101.4 5 of X

5 191.168.101.15 191.168.101.5 6 of X

6 191.168.101.16 191.168.101.6 7 of X

*X is the total number of power distribution and network and MPU50 DPU modules for the system



4.4.3 Specifying a Gateway Address

In some circumstances, it may be necessary to specify a gateway address that is outside the subnet the Flare.IQ is assigned to. For example, the Flare.IQ may reside outside a firewall isolating it from the DCS. The SystCFG utility does not provide a means to set a gateway address, but this can be performed via the DPU’s telnet console.

The most straightforward way to configure a gateway address is to create a routing file on the DPU directly.

From a PC, telnet in to the DPU:

telnet 192.168.1.1

Login as user: root

Password: ge

Change to the /etc/system directory:

# cd /etc/system <Enter>

Use the echo command to create the gateway address file. For this example, assume the firewall has a gateway address of 192.168.200.1. Note that the double-quotes are required!

# echo “192.168.200.1” > sysinit.iprouter <Enter>

Restart the DPU with the shutdown command:

# shutdown (note: The Telnet session will be disconnected).

The DPU will automatically restart. Wait 1 minute for it to resume operation.

Login again via telnet.

Use the route show command to verify that the gateway address is now active as the default:

# route show

Internet:

Destination Gateway Flags

Default 192.168.200.1 UG

127.0.0.1 127.0.0.1 UH

<more routes>

Log out of the DPU before resuming operation.



4.5 Environment

4.5.1 Mounting Location

Consider these requirements when selecting the mounting location:

• adequate ventilation for cooling;

• space for servicing and repair;

• protection from direct exposure to water or to a condensation-prone environment; a cabinet with at least an IP52 rating;

• protection from high-voltage or high-current devices, or devices which produce electromagnetic interference;

• avoidance of vibration;

• selection of a location that will provide an operating temperature range of 0 to 60°C (32 to 140°F) with less than 95% humidity (non-condensing).

4.6 Spare Parts List

The following is the recommended spare parts list.

4.7 Reliability

The Flare.IQ failure rates of components are calculated at an ambient temperature of 60° Celsius.

The calculated MTBF for the Flare.IQ system including power, network, and processor is as follows:

515,453 hours or 58.8 years.

4.8 Technical Regulations & Standards

This product carries an ETL Panel Shop Listing for UL 508A type Industrial Control Panels.

4.9 Cyber Security

This product was developed with the guidance of the ISA/IEC 62443 cyber security standard. Even though reasonable efforts to investigate, confirm, and resolve security vulnerabilities in this product have been made, risks still exist.

Part Number Part Name Part Description

369B1860G0026 MPU50 Nexus General Control Module

208D9845P0024 Power Supply 24VDC Power Supply

IS420ESWAH3A Ethernet Switch 8 Port Ethernet Switch

656B3059P0001 Power Harness Flying Lead to Molex Harness

656B3059P0002 Power Harness Dual Power Wiring Harness



4.9.1 Precautions

As such, the Flare.IQ DPU ports ENET1 / ENET2 and Ethernet switch should never connect to a switch or computer that is connected to the internet or business IT infrastructure. The Flare.IQ’s Ethernet switch should only be connected to the DCS’s Modbus communications module (a direct connection if possible). The default passwords should also be changed to a password of length greater than 6 characters.

4.9.2 Root Passwords

The Flare.IQ DPU permits a console login via the Telnet protocol on Port 23. Telnet provides a virtual serial terminal connection over TCP. Telnet does not encrypt any data sent over the connection. A console login may be required to modify the network operating characteristics of the DPU. A login to the DPU root account is required. The root account has a default password of ge. It is imperative that the root password be changed before the Flare.IQ is placed into active service. To change the root password, connect via telnet, log in as root, and enter the passwd command to specify a new password. Keep a copy of the new password in a safe place, it is not possible to recover a lost root password.

4.9.3 Exposed Ports and Services

The Flare.IQ DPU may use or expose the following ports and services to provide network communications:

Port Service/Description

23 Telnet management interface for Nexus MPU (TCP)

502 Modbus/TCP

3xxx 3000 + Node number of DPU – OptimumC Configuration (TCP)

5311 GE Mark VIe System Data Interface (TCP)

7937 GE Ethernet Global Data (EGD) Command Service Port (TCP)

18246-18248 GE EGD Producer/Consumer Service Port (UDP)







DCS Distributed Control System

DPU Digital Processing Unit (See MPU)

MBPS Mega Bits Per Second

MPC The OptimumC Main Programming Control

PPH Pounds Per Hour

SCFH Standard Cubic Feet per Hour

TCP Transmission Control Protocol

UDP User Datagram Protocol





Customer Support Centers

U.S.A.

The Boston Center1100 Technology Park DriveBillerica, MA 01821U.S.A.Tel: 800 833 9438 (toll-free)

978 437 1000E-mail: [email protected]

Ireland

Sensing House ShannonFree Zone EastShannon, County ClareIrelandTel: +353 61 61470200E-mail: [email protected]

bhge.com

© 2018 Baker Hughes, a GE company – All rights reserved.

Baker Hughes reserves the right to make changes in specifications and features shown herein, or discontinue the product described at any time without notice or obligation. Contact your BHGE representative for the most current information. The Baker Hughes logo is a trade mark of Baker Hughes, a GE company. The GE Monogram is a trademark of the General Electric Company.

GECS10028 Rev. B

http://www.bhge.com

Documents

Flare - industrial€¦ · the flare gas is determined. Fuel gas demand and steam demand are then set based on current net heating values; hydrocarbon molecular weight and flare vent