Flow-X Level 1 Training Manual V15 CL FlowX L1 TM-EN · SPIRITIT FLOW-X | LEVEL 1 | TRAINING MANUAL 3 Introduction Welcome to the exciting world of SpiritIT Flow-X! Using one of our

Authors Eric van Boxtel, Peter van DeurzenVersion 1.5Date February 2019

© Copyright 2019 ABB. All rights reserved.

—ABB MEASUREMENT & ANALY TICS | TR AINING MANUAL

SpiritIT Flow-XLevel 1

2 SPIRITI T FLOW-X | LEVEL 1 | TRAINING MANUAL

Content

Introduction............................................................. 3

SpiritIT Flow-X products ......................................... 4Introduction..............................................................4Flow-X/M...................................................................4Flow-X/S.................................................................... 5Flow-X/K.................................................................... 7Flow-X/R....................................................................8Flow-X/P....................................................................8Flow-X/C.................................................................. 10Tamper switch ....................................................... 10

Set up the SpiritIT Flow-X ......................................11Device setup............................................................11

Network setup - individualFlow-X modules ................................................11Flow-X/P............................................................ 13Communication check.................................... 13

Ways of working with SpiritIT Flow-X................................................................................. 14

SpiritIT Flow-Xpress ...............................................16Basic edition........................................................... 16Professional edition.............................................. 18Reading and writing applications ..................... 19

Master applications ...............................................21Standard SpiritIT Flow-Xapplications ............................................................ 21Standard SpiritIT Flow-Xapplication properties ......................................... 21

Single run applications................................... 22Multiple run applications............................... 22

Gas metric............................................................... 22Application functionality ............................... 22Calculations ...................................................... 23

Liquid metric .......................................................... 23Application functionality ............................... 23Calculations ...................................................... 23Coriolis...............................................................24Mass ...................................................................24

I/O .......................................................................... 25Grounding ...............................................................25Digital connections...............................................25

Digital status inputs .......................................26Pulse inputs ......................................................26Digital status outputs .................................... 27Time period inputs.......................................... 27

Analog signals.........................................................27Analog inputs....................................................27HART inputs...................................................... 29PT100 inputs .................................................... 29Analog outputs................................................ 29

Serial ports ............................................................. 30Connecting I/O...................................................... 30I/O Calibration....................................................... 32

Calibration settings........................................ 32Calibration of analog inputs......................... 32Calibration of PT100 inputs.......................... 35

Configure the SpiritIT Flow-X withweb GUI...................................................................37

SpiritIT Flow-X configuration ...............................37Overall setup ...........................................................37Flow computer type ............................................. 38Flow meter configuration ................................... 39

Pulse meters..................................................... 39Smart & Pulse meters..................................... 39Differential pressure flowdevices...............................................................40

Temperature & PressureTransmitters ..........................................................40Density configuration (Liquid) ...........................41Density configuration (Gas) ................................41Alarms & Events..................................................... 42

Application development withSpiritIT Flow-Xpress .............................................. 44

Parameter editor...................................................44Units & Formats..................................................... 45Debug offline ......................................................... 46Ports & Devices...................................................... 47

Serial Master-Slavecommunication................................................48Modbus TCP/IP ................................................48How to check thecommunication?.............................................. 49

Debug information ................................................51Adding a printer .................................................... 52Report configuration ........................................... 54Security editor ....................................................... 55Versions................................................................... 56Miscellaneous settings ........................................ 57SpiritIT Flow-Xtract ............................................... 57

Document Control .................................................59

SPIRITI T FLOW-X | LEVEL 1 | TRAINING MANUAL 3

IntroductionWelcome to the exciting world of SpiritIT Flow-X!

Using one of our SpiritIT Flow-X products, you are able to create your own flow-measurement solution, fully adapted

to your specific needs.

The SpiritIT Flow-X flow computer is a modular product. It can be used in different enclosures. The advantage is that

one module can be used on different ways while the software determines the functionality.

Using this training manual the details of the different products will be explained and if it gives a lot of possibilities to

train it yourself.

Besides the training manuals (level1, level 2 and level 3) there are three reference manuals:

• Volume I – Installation manual, with the installation instructions.• Volume II – The Operation and Configuration manual.

This manual consists of a general part and one of the following application-specific parts:

– Operation and configuration– Gas metric application

– Liquid metric application– Gas customary units application– Liquid customary units application

• Volume III – The Advanced configuration manual, for solutions that exceed our standard applications.


SpiritIT Flow-X products

IntroductionThe SpiritIT Flow-X product line is a modular setup used within different enclosures with no need for separateboards. The flow computer is usable for (fiscal) oil and gas measurement, both in Metric and USC standards. The

product line consist of:

• Flow-X/M modules

• Flow-X enclosures

– Flow-X/S– Flow-X/K

– Flow-X/R– Flow-X/P

• Flow-X/C

• Flow-Xpress configuration software

– Basic– Professional

– Online

Flow-X/MAll products are based on the same flow module (Flow-X/M)

– Generic flow module to be used in different enclosures (Flow-X/S, Flow-X/K, Flow-X/R and Flow-X/P)

– One Flow-X/M is used for one meter run

– LCD display with 4 lines for local display of measured & calculated data

– Navigation buttons to scroll through the displays

– Extensive I/O capabilities

– No separate boards needed

Figure 1 Flow-X/M

Figure 2 Flow-X/M display and navigation buttons


A single Flow-X/M has the following I/O possibilities

Table 1 Flow-X/M in- and outputs

Signal type Nr Description

Analog input 6 Analog transmitter input, 0.008% accuracy full range4-20mA, 0-20mA, 0-5V, 1-5V. Inputs are fully floating (optically isolated)

HART input 4 Independent HART loop inputs, on top of the analog inputs 1 through 4Support for multi-drop HART communication

4-wire PRT inputs 2 High accuracy PT-100 inputs (DIN and American)

Digital I/O 16 Each channel can be one of the following:

Pulse input 1(1)/4(2) Single or dual pulse input - Frequency range 0-10 kHz

Densitometer inputs 4 Periodic time input, 100�s - 5000�s

Status inputs 16 Digital status inputs

Prove detector inputs 4 For pipe and piston provers. Detect time resolution 0.5 microseconds

Pulse outputs 4 Open collector, max. 100 Hz

Status outputs 16 Digital status outputs, open collector

Prover outputs 1 Pulse output for proving systems with separate prover flow computers

Analog outputs 4 Analog outputs for flow control, pressure control. 4-20mA, outputs floating.

Serial 2 RS485/RS232 serial inputs up to 115kb

Ethernet 2 RJ45 Ethernet interface, TCP/IP

Power supply 2 External, 20-32 VDC, nominal 24 VDC, with redundant connections

(1) Version 1 hardware; (2) Version 2 hardware

Flow-X/SThe single enclosure is called Flow-X/S and can be used for single stream functionality,

proving functionality, station functionality or a combination of these. This enclosure has

screw terminals, an 8-pins power supply connector and two separate network terminals.

Characteristics:• DIN rail enclosure with direct screw terminals for field connections• Interfaces include dual Ethernet with built-in web-server via RJ45 connectors

• Graphical LCD display with 4 lines for local display of measured & calculated data• The Flow-X/S may be mounted in 3 ways:

– Horizontally on DIN-rail

– Vertically on DIN-rail

– Wall mounted


Figure 3 Ways of mounting a Flow-X/S

Figure 4 Flow-X/S connection terminals

Pin Function Pin Function Pin Function Pin Function

1 24 V DC out 21 Dig 9 1 PRT 1 pwr+ 21 A-in 6

2 0 V 22 0 V 2 PRT 1 22 A-in common

3 Dig 1 23 Dig 10 3 PRT 1 23 A-out 1

4 0 V 24 0 V 4 PRT 1 24 A-out common

5 Dig 2 25 Dig 11 5 A-in common 25 A-out 2


7 Dig 3 27 Dig 12 7 PRT 2 27 A-out 3


9 Dig 4 29 Dig 13 9 PRT 2 29 A-out 4

10 0 V 30 0 V 10 A-in common 30 A-out common

11 Dig 5 31 Dig 14 11 A-in 1 31 0 V

12 0 V 32 0 V 12 A-in common 32 COM 1 – | Sig+ | Tx+*

13 Dig 6 33 Dig 15 13 A-in 2 33 COM 1 Tx | Sig- | Tx- *

14 0 V 34 0 V 14 A-in common 34 COM 1 Rx | – | Rx- *

15 Dig 7 35 Dig 16 15 A-in 3 35 COM 1 – | – | Rx+ *

16 0 V 36 0 V 16 A-in common 36 COM 2 – | Sig+ | Tx+*

17 Dig 8 37 24 V DC out 17 A-in 4 37 COM 2 Tx | Sig- | Tx- *

18 0 V 38 0 V 18 A-in common 38 COM 2 Rx | – | Rx- *

19 24 V DC out 39 24 V DC 19 A-in 5 39 COM 2 – | – | Rx+ *

20 0 V 20 A-in common

Figure 5 Flow-X/S connections

Pin Description

1 / 2 24 V DC – Primary

3 / 4 24 V DC – Secondary

X1A X1B

X1A: terminal A (39 pins)X1B: terminal B (39 pins)

Power 24 V: Power terminal (8 pins)LanA: TCP/IP connectorLanB: TCP/IP connector


5 - 8 0 V

Figure 6 Power connections Flow-X/S and Flow-X/P

Flow-X/KThe small rack enclosure is called Flow-X/K and can hold one module. It be used for single streamfunctionality, proving functionality, station functionality or a combination of these. This enclosurehas two connector terminals, one 4-pins power supply connector and two separate network termi-

nals for each module.

Characteristics:

• Efficient use of cabinet space• 37-pin D-Sub type connectors for I/O• 2 Ethernet connections individually per flow module.

For the I/O connections see Figure 7 Flow-X/[K][R][P][C] connections.

Connector A Connector B

Pin Function Pin Function Pin Function Pin Function

1 COM1 – | Sig+ | Tx+* 21 0V, Dig common 1 COM2 – | Sig+ | Tx+* 21 0V, Dig common

2 COM1 Tx | Sig– | Tx–* 22 Dig 5 2 COM2 Tx | Sig– | Tx–* 22 Dig 13

3 COM1 – | – | Rx–* 23 0V, Dig common 3 COM2 – | – | Rx–* 23 0V, Dig common

4 COM1 Rx | – | Rx+* 24 Dig 6 4 COM2 Rx | – | Rx+* 24 Dig 14

5 24V out 25 0V, Dig common 5 24V out 25 0V, Dig common

6 Dig 1 26 Dig 7 6 Dig 9 26 Dig 15

7 0V, Dig common 27 0V, Dig common 7 0V, Dig common 27 0V, Dig common

8 Dig 2 28 Dig 8 8 Dig 10 28 Dig 16

9 0V, Dig common 29 0V, Dig common 9 0V, Dig common 29 0V, Dig common

10 Dig 3 30 A-out 2 10 Dig 11 30 A-out 4

11 0V, Dig common 31 A-out common 11 0V, Dig common 31 A-out common

12 A-out 1 32 A-in 1 12 A-out 3 32 A-in 4

13 A-out common 33 A-in common 13 A-out common 33 A-in common

14 A-in common 34 A-in 2 14 A-in common 34 A-in 5

15 PRT 1 power + 35 A-in common 15 PRT 2 power + 35 A-in common

16 PRT 1 signal + 36 A-in 3 16 PRT 2 signal + 36 A-in 6

17 PRT 1 signal – 37 A-in common 17 PRT 2 signal – 37 A-in common

18 PRT 1 power – 18 PRT 2 power –

19 A-in common 19 A-in common

20 Dig 4 20 Dig 12

Figure 7 Flow-X/[K][R][P][C] connections

201

1937


Pin Description

1 24 V DC – Primary

2 24 V DC – Secondary

3 0 V

4 0 V

Figure 8 Power connections of Flow-X/K, Flow-X/R, Flow-X/C

Flow-X/RThe rack enclosure is called Flow-X/R and can hold a maximum

eight modules. Each module can be used for single stream func-tionality, proving functionality, station functionality or a combina-tion of these This Flow-X/R has connector terminals, 4-pins

power supply connectors and two separate network terminals for

each module.

Characteristics:

• Efficient use of cabinet space• Holds up to 8 X/M modules

• Used as separate meter runs or as combinations• 37-pin D-Sub type connectors for I/O• 2 Ethernet connections individually per flow module.

• Separate power connection for each module

The I/O connections are exactly the same as the connections of the Flow-X/R, see Figure 7 Flow-X/[K][R][P][C] con-

nections.

Flow-X/PThe panel enclosure is called Flow-X/P and can be used for maximum 4 runs and sta-tion functionality. This Flow-X/P has connector terminals, a 8-pins power supply con-

nector and two separate network terminals for the panel.

Characteristics:

• Panel mounted flow computer• Horizontal or vertical position• Up to 4 flow modules

Additional station module with:

• 7” multi-lingual color touch-screen• 3 additional serial ports

• 2 Ethernet ports


Figure 9 Flow-X/P mounting kit

The following connections are available:

• Power supply (24 VDC)

8-pins and similar as the Flow-X/S power connector, seeFigure 6 Power connections Flow-X/S and Flow-X/P

• Flow module connectors (8 x 37-pin D-sub)

These are the same as the connections of the Flow-X/R,see Figure 7 Flow-X/[K][R][P][C] connections

• 3 additional COM ports (3 x 9-pin D-sub)

The pin layout of the additional com-ports is listed below• 2 Ethernet ports (2 x RJ45)

Pin COM 1(RS-232 only)

COM 2 / COM 3RS-232

COM 2 / COM 3RS-485 (2-wire)

COM 2 / COM 3RS-485 (4-wire)

1 Rx –

2 Rx Rx Rx +

3 Tx Tx Sig – Tx –

4 Sig + Tx +

5 0 V 0 V O V

6

7 RTS

8 CTS

9

Figure 11 Flow-X/P serial connections

Figure 10 Flow-X/P connection terminals


Flow-X/CThis is a Compact panel mounted flow computer with one integrated Flow-X/M mod-

ule with a 7” multi-lingual color touch screen and one additional serial port.

Characteristics:

• Panel mounted flow computer• Horizontal or vertical position• 1 integrated flow module

• 7” multi-lingual color touch-screen• 3 serial ports• 2 Ethernet ports

Tamper switchThe Flow-X/C flow computer as well as each Flow-X/M module have a mechanical tamper switch to prevent changing

of the application and vital parameters within that application. All enclosures have the option of locking the flow

computer with a lead seal by an authorized body, to prevent access to the tamper switch of the individual modules

Figure 12 Tamper switch


Set up the SpiritIT Flow-X

Device setupBefore a SpiritIT Flow-X can be put in operation, the device has to be set-up correctly. The following settings need to

be set locally on each Flow-X/M module and on the Flow-X/P panel display:

• Device name• Bus set-up

– Stand alone– Flow-X/C– Flow-X/P1 - Flow-X/P4

– Flow-X/R (DO NOT USE)

• Network IP address

After making changes in the bus set-up, the flow computer needs to reboot to in order for the changes to take ef-

fect.

After setting up the IP address in the Flow-X it is possible to reach the module using a web browser by typing the IP

address on the top.

Network setup - individual Flow-X modules

For all Flow-X module, the network set-up for the two Ethernet ports has to be such that these are in a different net-

work segment. A subnetwork, or subnet, is a logically visible subdivision of an IP network.

Figure 13 Example of setting up the IP address of a Flow-X/S

It is not allowed to use the same subnet for ETH1 and ETH2. When the network IP addresses are in the same seg-

ment, the Flow-X will show an “Unknown error”.

ETH 2IP-address 2e.g. 192.168.2.100

Subnet 1e.g. 255.255.255.0

ETH 1IP-address 1e.g. 192.168.1.100

Subnet 1e.g. 255.255.255.0


This is a valid combination:

Subnet mask: 255.255.255.000

ETH1 IP address: 192.168.001.001

ETH2 IP address: 192.168.002.001

Figure 14 Network configuration error

ETH1

IP address:Subnet mask:

010.001.001.001255.255.000.000

ETH2


010.001.100.023255.255.000.000

UNKNOWN ERROR

Solution 1ETH1


010.001.001.001255.255.000.000

ETH2


010.002.100.023255.255.000.000

Solution 2ETH1IP address:Subnet mask:

010.001.001.001255.255.255.000

ETH2IP address:Subnet mask:

010.001.100.023255.255.255.000


Flow-X/P

The IP address of the first module must be the IP address of the panel + 1, the IP address of the second module must

be the IP address of the panel + 2, etc. For a Flow-X/P it is very important that the device type is set correctly.

Figure 15 Example of setting the IP address of a Flow-X/P

Communication check

When you want to check the Ethernet setup connection, connect a compter or laptop to the Flow-X and set-up thenetwork configuration of the computer to be in the same segment of the Flow-X. Thenyou open a command window

and type in:

PING 192.168.1.100The Flow-X/P will respond with a good response.

When you want to check the connection with module 1 of the panel you type in:

PING 192.168.1.101Module 1 of the panel will now respond with a good response.

Module 2 can be checked as follows:

PING 192.168.1.102Module 2 of the panel will now respond with a good response.


Figure 16 Connect a pc directly to the Flow-X/P

Ways of working with SpiritIT Flow-X– Display

• Check I/O signals and values

• Change settings

– Web browser:

• Check I/O signals and values

• Change settings

– SpiritIT Flow-Xpress Basic:

• Configuring standard Flow-X applications

• Read application from Flow-X• Write application to Flow-X

– SpiritIT Flow-Xpress Professional:

• Flow-Xpress Basic• Extend / adapt standard Flow-X applications• Create your own applications from scratch

The web display looks as follows:


Figure 17 Web display

EXERCISE – Device setup1. Set the Flow-X to be ‘Standalone’

2. Set the IP-address of the Flow-X to be in the same range (but not the same) as your laptop (use PIN 111111 or

123321)

3. Make an Ethernet connection between the Flow-X and your laptop

4. Start a web browser on your laptop (like Chrome or Internet Explorer)

5. Type the IP-address of the Flow-X into the address bar of your browser

6. Look around what’s there

7. Log in with user name ‘administrator’ and password ‘admin’ or log in with user ‘a’ and no password


SpiritIT Flow-XpressSpiritIT Flow-Xpress is the software for the configuration of the SpiritIT Flow-X. When connected with an Ethernet in-

terface you can read, configure and write the flow computer application.

Figure 18 SpiritIT Flow-Xpress overview

SpiritIT Flow-Xpress can be installed running the setup. The license determines if you have a basic version or profes-

sional version. The license usually is a software key. To obtain a licnese:

• Start the License Manager

• Export the license information or copy the text marked as “Machine Identification Code”• Send this information to [email protected]• You will get a file with an Authorization Key and a License Number

• Enter the Authorization Key and License Number into the appropriate fields and click “Install”• At the top of the dialog, you should now see the word “Authorized” in green.

Basic editionWith SpiritIT Flow-Xpress Basic it is possible to read configuration applications from hard disk and send them to alltypes of SpiritIT Flow-X devices. With SpiritIT Flow-Xpress Basic it is also possible to read the configuration from the

SpiritIT Flow-X device and write it to hard disk.

– Device setup

• Flow-X/S (Single)• Flow-X/P (Panel)

– Set up communication protocols (Modbus / HART / Ethernet)

– Modify or add display pages

– Define additional languages

– Add user names and passwords

– Add user definable calculations

– Modify or add reports

The following menu items are available:

mailto:[email protected]


File menuThe File menu is used for reading an application from file or device. After the configuration is finished it can be saved

on hard disc or can be sent to the device.

Figure 19 Flow-Xpress File menu

View menuThe View menu makes it possible to select the individual setup settings, like device settings, port settings, displays,

parameters.

Figure 20 Flow-Xpress View menu

Build menuThe purpose of the Build menu is to compile the application and check on errors.

Figure 21 Flow-Xpress Build menu


Debug menuFrom the Debug menu, Debug offline can be started to do an offline check.

Figure 22 Flow-Xpress Debug menu

Tools menuThrough the Tools menu some options can be set and it is possible to read the debug info from a device.

Figure 23 Flow-Xpress Tools menu

Help menuThrough the Help menu the manuals can be reached.

Figure 24 Flow-Xpress Help menu

Online modeIn the online mode it is possible to connect to one of the modules to check and edit the parameters or users online.

Figure 25 Online mode

Professional editionBesides the Basic functionality you also have additional functionality with SpiritIT Flow-Xpress Professional. WithSpiritIT Flow-Xpress Professional it is f.e. possible to change the configurations or add your own functionality and

drivers.


Reading and writing applicationsWhen reading/writing an application with SpiritIT Flow-Xpress:

• Only flow computers that comply with the device setup can be selected for writing• Write with or without parameters• Write with or without users

• Write with or without COM-port settings

Figure 26 Device selection

Figure 27 Write to selected device

EXERCISE - Flow-Xpress installation1. Install Flow-Xpress software on your laptop

2. Run the Flow-Xpress_(<version>).exe installation file

3. Provide user name, company name and computer name

4. Obtain and install the license for Flow-Xpress Basic

Figure 28 Flow-Xpress Basic


EXERCISE - Read and write application1. Start Flow-Xpress Start -> Programs -> Flow-Xpress

2. Read the application from the Flow-X

3. Look up the files that have been saved to your harddisk

(My Documents -> Flow-Xpress -> Received)

4. Write the application to the Flow-X

Use the default user name: ‘a’ and no password (leave empty)


Master applications

Standard SpiritIT Flow-X applicationsThe following standard SpiritIT Flow-X applications are available:

• Gas Metric• Liquid Metric• Gas US Customary

• Liquid US Customary

Standard SpiritIT Flow-X application properties– Supports both single meter runs and metering stations consisting of several meter runs.

– Supports any type of ‘smart’ meters with flow rate / total output through analog, HART or Modbus signal

– Automatic use of backup signal for smart meters with an additional pulse output

– Analog, HART and Modbus options for live inputs

– Last good, keypad and fallback option for failing input signals.

– Automatic switching from HART to analog signal in case of HART failure

– Data valid input (in combination with a pulse input)

– Support of turbine, PD, ultrasonic, coriolis, orifice, venturi and V-cone flow meters

– Built-in support for Micro Motion and Endress & Hauser coriolis flow meters

– Orifice, venturi and V-cone standards:

• ISO-5167, AGA-3

– One, two or three dP cells

• 1 cell full range• 2 cells Low/High range• 2 cells full range

• 3 cells Low/Mid/High range• 3 cells Low/High/High range• 3 cells full range

– User definable HART and Modbus interface to flow meters and other devices (such as gas chromatographs)

– One or two densitometers on run and station levels

– Meter body correction for pressure and temperature

– Selectable meter factor and meter K-factor interpolation curves (12 points each)

– Master meter proving

– Period totals and averages of in-use and input data

– Maintenance totalizers

– Generating of period- and manually generated reports

– Indication of total rollover on reports

– Indication of input override / failure on reports

– Diagnostic displays for smart meters

– Station functionality

– Valve control

– (Re)printing of reports directly to a printer


Single run applications

Single run r applications are applications running in a single Flow-X/M module. It provides the full functionality, in-

cluding:

– Bi-directional (forward/reverse)


– 4 periods totals and averages (hourly , daily & 2 user configurable)

– Batch totals and averages (liquid only)

– Station and proving functionality with remote station / remote run

– Station sampler & Run Sampler

Multiple run applications

For Version 1 hardware, multiple run applications are applications running in a Flow-X/P with multiple Flow-X/M

modules. It provides the abridged functionality to save memory consumption, including:

– Uni-directional (forward)


– 2 periods totals and averages (daily & 1 user configurable)

– Station and proving functionality

– Station sampler only

– Cross-module I/O sharing

For Version 2 hardware, multiple run applications are applications running in a Flow-X/P with multiple Flow-X/M

modules or running on a Flow-X/C or on a single Flow-X/M. It provides the full functionality, including:

– Bi-directional (forward/reverse)


– 4 periods totals and averages (daily, hourly & 2 user configurable)

– Station and proving functionality

– Station sampler & Run Samplers

– Cross-module I/O sharing

Gas metric

Application functionality

The gas metric application supports the following in addition to the standard application functionality:

• One or two specific gravity transducers on run and station levels• One or two gas chromatographs on run and station levels• Remote gas composition through Modbus on run and station levels

• Process inputs for density, base density and specific gravity• Several compressibility algorithms for line and base conditions:

AGA-8, ISO-6976, SGERG, NX-19, GPA-2172 and GERG-2008

• Built-in support for Sick, Elster-Instromet, Daniel, RMG, Krohne and General Electric (GE) ultrasonic flow me-ters

• Built-in support for Micro Motion Coriolis flow meters

• Built-in support for ABB, Siemens, Elster-Instromet, Yokogawa and Daniel gas chromatographs• AGA-10 for speed of sound verification


Calculations

Liquid metric

Application functionality

The liquid metric application supports the following in addition to the standard application functionality:

• Process inputs for density, standard density, viscosity and BS&W

• Viscosity correction• Batch totals and averages of in-use and input data• Built-in support for Daniel, Caldon, General Electric (GE) and Krohne ultrasonic flow meters

• Built-in support for ABB, Micro Motion and Endress+Hauser Coriolis flow meters• Several standards for standard density calculation:

API-2540, API MPMS 11.1:2004, API MPMS 11.2, GPA-TP27

• Valve sequencing• PID control with cascading feature• Sampler control

• Support of bi-directional and unidirectional ball provers• Support of Brooks compact prover, Calibron, and Flow MD piston provers• Up to 4 prove detector switch inputs

Calculations


Coriolis

Mass

EXERCISE - Write new application1. Create new application from Master ->

“Gas_Metric Master.fxm” or “Liquid_Metric Master.fxm”

2. Set device to be Flow-X/S

3. Write the application to the Flow-X

a) Use the default user name: ‘a’ and no password (leave empty)

b) Wait until the flow computer has rebooted

EXERCISE - Flow-X menu structure1. Log in as operator (user name: operator, password: operator)

2. Investigate the display menu structure of the application

a) Look up how to set alarm limits for temperature, pressure and flow rateb) Look up how to set and activate override values for temperature and pressure

c) Look up how to acknowledge alarms

d) Look up the event log / audit trail

3. Log in as engineer (user name: engineer, password: engineer)

a) Investigate the display menu structure of the applicationb) Look up the configuration settings

c) Look up the IO configuration settings and calibration displays


I/O

GroundingFlow-X uses the following separate ground earth connections:

• Chassis ground: through the chassis grounding screw• 0 V: common ground for main power supply, digital inputs and digital outputs• Ain common: isolated common ground for the analog inputs

• Aout common: isolated common ground for the analog outputs• No isolated common available then connect Ain common/Aout common to 0 V

Figure 29 Ground wiring

Digital connections– 16 general-purpose digital channels

– Sampled at 10 MHz

– Digital signals

• Digital status input• Digital status output

• Pulse input• Time period input (e.g. densitometers)• Pulse output (e.g. counters)

• Detector inputs (proving)• Prover bus output (to prover flow computer)

Figure 30 Digital channel circuit


Digital status inputs

– Each digital channel can be configured as digital status input

– Max 16 digital inputs on each Flow-X/M

– Sampled at 10 MHz

– Each input is sampled:

• Unfiltered

• Filtered with 8ms debounce period (shorter periods are ignored)

– Powered:

• Internally

• Externally

– Selectable threshold level:

• Channel 1 to 8: 1.25 or 12 V

• Channel 9 to 16: 3.75 or 12 V

Figure 31 Digital inputs

Pulse inputs

– Each digital channel can be configured as pulse input

– Max. 1(1) / 4(2) single/dual pulse inputs per Flow-X/M module

– Threshold levels:

• Channel 1 to 8: 1.25 or 12 V

• Channel 9 to 16: 3.75 or 12 V

– Pulse integrity checking (dual pulse only)

– Max. frequency 10 kHz

(1) Version 1 hardware; (2) Version 2 hardware

Figure 32 Pulse inputs


Digital status outputs

– Each digital channel can be configured as digital status output

– Acts as an open collector

– Internally powered digital output

– Externally powered digital output

– Connecting a digital output to a digital input

Figure 33 Digital outputs

Time period inputs

– Digital channels 1-4 can be configured as time period input

– Used for densitometers and specific gravity transducers

– Max. 4 time period inputs per Flow-X/M module

Analog signals

Analog inputs

Each Flow-X/M flow module provides 6 analog inputs, configurable as:

• 4 – 20 mA (internal resistor of 250� is activated)

• 0 – 20 mA (internal resistor of 250� is activated)• 1 - 5 Volt• 0 – 5 Volt

Figure 34 Analog current inputs


Figure 35 Splitting up analog voltage inputs (analog inputs configured as 1-5V)

Figure 36 Analog current input with barrier

Figure 37 Analog voltage input


HART inputs

– Analog inputs 1-4 of each Flow-X/M module can be configured as HART inputs

– The flow computer supports both a single HART transmitter and multiple HART transmitters per loop

Figure 38 HART inputs

PT100 inputs

Each Flow-X/M flow module provides two PT100 inputs

Figure 39 PT100 inputs

Analog outputs

The Flow-X modules provide 4 analog outputs. These outputs are:

– 4-20 mA

– Output circuits are floating in relation to the other type of I/O

– Each analog output can drive a load up to 650 Ohm

Figure 40 Analog outputs


Serial portsFlow-X/M

• 2 serial ports• RS-232 or RS-485

Flow-X/P

• 3 additional serial ports

• COM 1: RS-232• COM 2, COM 3: RS-232 or RS-485

RS-485: 2-wire (half duplex) or 4-wire (full duplex)

Figure 41 Serial ports

Connecting I/OEXERCISE - Digital input1. Connect a switch to Digital Channel 8

a) Look up connection diagram and pin lay-out in installation manual

b) Use a pull-up resistor between digital input and 24 V out

c) Configure digital 8 signal type as ‘Digital Input’

2. Configure polarity so that pressing the switch = ON

3. Verify input signal on Diagnostics display page

4. Verify working of digital input force

EXERCISE - Pulse input1. Connect a (single) pulse to Digital Channel 1

a) Pulse generator with voltage outputb) Look up connection diagram and pin lay-out in Installation manual

c) Configure digital 1 signal type as ‘Pulse input A’

2. Verify input signal through Diagnostics display page

3. Verify working of pulse input force

4. Dual pulse: See what is happening if you configure a second digital channel as ‘Pulse input B’

EXERCISE - Analog input1. Connect a ‘transmitter’ to analog input 1

a) Look up connection diagram and pin lay-out in Installation manual

b) Don’t forget to connect common ground to analog input groundc) Configure input type as 4-20mA


d) Configure scaling as -50 to 200 EU

2. Verify input signal via Diagnostics display page

a) Try several input values

b) Verify working of transmitter low failure at lowest current

3. Configure analog input 2

a) Input type 4-20 mA

b) Scaling 0 to 100 EU

4. Force analog input 2 at 50%

EXERCISE - Pulse output1. Use the web display to configure digital channel 7 as pulse output 1

2. Force the pulse output in the ‘Force IO’ display

3. Check the pulse using a LED or lamp with resistor between 24V output and digital channel 7

4. Investigate the function of parameters ‘max frequency’ and ‘pulse width’

5. Read the application file to your laptop and save it


I/O CalibrationThe following signals can be calibrated:

• Analog input signals• PT100 inputs

Calibration settings

– Configure 1–5 calibration points for analog inputs

– Configure 1–5 calibration points for PT100 inputs

– Inactivity timeout limit for automatic disabling the calibration if not disabled manually

Figure 42 I/O Calibration settings

Example to calibrate analog inputs (4-20mA) with 5 points:

Point Current % span

1 4 mA 0

2 8 mA 25

3 12 mA 50

4 16 mA 75

5 20 mA 100

Calibration of analog inputs

The first thing to calibrate an analog input is to select the analog input.


Figure 43 Analog input calibration I

After selecting an analog input, the first calibration point is shown.

Figure 44 Analog input calibration II

Now the calibration points can be checked one by one by clicking on the ‘Next Calibration Step’ button.

Be sure a 4-20mA loop calibrator is connected to the right analog input. When point 1 (4mA) is checked be sure 4 mA

is set on the loop calibrator.


Figure 45 4-20mA loop calibrator

After pressing the Recalibrate this point button, the current value is set to the reference value. In this case 4mA. This

way al the other points can be checked and recalibrated if necessary.

Figure 46 Analog input calibration III

At the end of the calibration don’t forget to set the Selected analog input to none to switch off the calibration mode.


Calibration of PT100 inputs

When calibrating a PT100 select the PT100 input first.

Figure 47 PT100 input calibration I

After selecting a PT100 input, the first calibration point is shown.

Figure 48 PT100 input calibration II

Now the calibration points can be checked one by one by clicking on the ‘Next Calibration Step’ button. After clickingthe ‘Recalibrate this point’ button, the current value is set to the reference value. At the end of the calibration don’t

forget to set the Selected PT100 input to none to switch off the calibration mode.


EXERCISE - Analog input calibration1. Set up the following analog input calibration points:

0%, 25%, 50%, 75%, 100%

2. Connect an analog simulator to the analog input

3. Select the analog input for calibration

4. Check the different calibration steps from 0% to 100%

5. Deselect the analog input


Configure the SpiritIT Flow-X with web GUI

SpiritIT Flow-X configuration1. Set up SpiritIT Flow-Xpress configuration (before writing to the Flow-X)

• Device setup• Ports & Devices• Displays

• Languages• Reports• User names and passwords

• Custom calculations

2. Set up configuration parameters:

• before writing the application:

– Flow-Xpress

• after writing the applications:

– Flow-X display

– Web interface– Flow-Xpress online mode

First configure the following parameters:

• Overall setup• Run setup

– Configuration screens are shown or hidden based on these parameters

– Next you can do the detailed configuration

Overall setup– Run functionality

Figure 49 Run functionality

– Station functionality


Figure 50 Station functionality

Flow computer typeThe following flow computer types are available:

• Standalone run• Station only• Proving only

• Station / Run• Proving / Run• Station / Proving

• Station / Proving / Run• Prover IO server

Table 2 Flow computer types

Local run(s) Stationfunctionality

Provingfunctionality

Communicateto remote

run(s)

X/P panelacts asstation

X/P panelacts asprover

Standalone run P

Station only P P

Proving only P P

Station / Run P P *) P

Proving / Run P P *) P

Station / Proving P P P

Station / Proving /Run

P P P *) P P

Prover IO server P P P

*) optional


Flow meter configurationSelect meter dedevice type:

• Pulse• Smart meters• Smart meters with pulses, either Pulse primary or Serial primary

• Differential pressure meters

– Orifice– Venturi

– V-Cone– Nozzle

Pulse meters

K-factor– Only for pulse meters

– Converts number of pulses into amount

• Volume pulses/m3 (Metric) | pulses/bbl (USC)

• Mass pulses/ton (Liquid Metric) | pulses/kg (Gas Metric) | pulses/lbm (USC)

– Fixed value or curve depending on pulse frequency

Indicated flow rate = Meter frequency / K-Factor

The meter is considered inactive if the measured value is below the Low flow cut-off frequency

Smart & Pulse meters

Meter factor– For pulse meters and smart meters

– Correction factor based on calibration / proving

– Fixed value or curve depending on flow rate

– Represented as Meter Factor (~1.000) or Meter error (~0.000%)

Meter factor = 100 / (100 + Meter Error)

Gross flow rate = Indicated flow rate x Meter factor

Meter body correction– Correction factor to compensate for the pressure / temperature effect on the meter body

– Smart flow meter OR Flow-X

Gross flow rate = Indicated flow rate x Meter factor x Meter body correction

The following picture shows how the K-factor and meter factor are applied by the Flow-X:

Figure 51 K-factor and meter factor

The meter is considered inactive if the measured value is below the Low flow cut-off flow rate


Differential pressure flow devices

Device types– Orifice plates

– Nozzles

– Venturi tubes

– V-Cone

Calculation standards– AGA-3

– ISO-5167

– GOST8-586 (2005) (not configured in Master Applications)

The meter is considered inactive if the measured value is below the Low flow cut-off dP

Temperature & Pressure TransmittersTransmitter input type– Always override value

– Analog / PT100 input

– HART

– Fallback to analog

– Custom input (Modbus)

– Smart Meter

Run setup– Single transmitter

– Dual transmitter

Dual transmitter mode– Auto A

– Auto B

– Average

– Deviation limit


Density configuration (Liquid)Run setup:

• Meter device type• Observed density input type• Standard density input type

• Meter density calculation method

Here an overview is shown of the determination of the density for liquids:

Figure 52 Density determination for liquid

Density configuration (Gas)Run setup:

• Meter device type• Observed density input type• Base density input type

• Meter density calculation method• SG input type• Gas composition input type

Here an overview is shown of the determination of the density for gas:

Figure 53 Density determination for gas


Alarms & EventsThe SpiritIT Flow-X contains two pages for Alarms & Events:

• Active & Unacknowledged alarms• Historical Events

Figure 54 Alarm display

Figure 55 Events display


EXERCISE - Single run flow computer1. Use the web display to set up the Flow-X for the following configuration:

Standalone run

Pulse meterAnalog pressure transmitterAnalog temperature transmitter

Fixed product / densityGas : Always use override composition

Liquid : Always use override standard density (from product table) / Always use override BS&W

2. Force the inputs (only if no live inputs available)

3. Check if the flow rates are <> 0 and if the totalizers are counting

EXERCISE - Meter factor curve1. Enable meter factor curve interpolation

2. Use the web display to configure the following meter factor curve:Flow rate Meter factor10 m3/h 1.01

150 m3/h 0.98500 m3/h 0.97

1000 m3/h 1.02

3. Modify the meter frequency and see how the in-use meter factor changes

EXERCISE - Bidirectional flow1. Use the web display to configure digital channel 8 as a flow direction digital input:

a) Verify that the reverse totalizers are enabled (Configuration � Overall setup � Common settings)

b) Enable flow direction input (Configuration � Run � Flow meter � Flow direction)c) Select digital input channel 8d) Fill in the reverse meter factor curve

Flow rate Meter factor10 m3/h 1.05

500 m3/h 1.04

2. Press the switch or force the input and see how the forward and reverse totalizers behave

EXERCISE - Analog outputs1. Use the web display to configure:

A gross volume flow rate output (0-1000 m3/hr) on analog output 1A temperature output (-50 - +200 °C) on analog output 2

A pressure output (0 - 100 barg) on analog output 3

2. Check on the IO Diagnostics displays if the outputs are working

3. Check the current of the analog outputs using a multimeter

EXERCISE - Pulse output1. Use the web display to configure a gross volume pulse output on digital channel 7

a) Configure the quantity per pulse such that one pulse is given at each 10 m3

2. Check the pulse using a lamp or LED on digital channel 7

a) Be sure the pulse output is not forced!


Application development with SpiritIT Flow-Xpress

Parameter editorWith the parameter editor it is possible to:

• Configure SpiritIT Flow-X offline

• Load parameter set from file• Save parameter set to file• Print parameter set

Figure 56 Parameter editor

EXERCISE – Parameter editor1. Read the application from the Flow-X and load it in Flow-Xpress

a) Open the parameter editor and browse through the settings

b) Notice that all the parameters that you have modified are shown BOLD

2. Modify a number of parameters in the parameter editor

a) Write the application to the Flow-X

b) Select the parameters check box to ensure that parameters are written as well

c) Check if the parameters have been implemented in the Flow-X


Units & FormatsWith Flow-Xpress you can select and change the units and formatting of numbers being shown on the displays.

When selecting the Units & Formats section from the Navigation section, you will see in the main section the where

you can set-up the units and numerical formats for the displays. It contains 2 tabs:

– Display Units & Formats

This allows you to select / change the default display units and default display format. Per unit group (e.g. pres-sure, temperature, mass per time, etc.) you can select the units from the available units applicable for that groupand enter the numerical format (decimal places) to show on displays. The sete-up in this section will be default

for all displays. It only applies for displays, not for calculations, communication or reports.

– Configuration

This tab shows a list with all the display units grouped per unit (pressure, temperature, mass per time, etc.). It ispossibility to add your own engineering units. Per unit you can set the

• Text to show on displays

• Conversion factor (from base unit)• Offset (from base unit)

Figure 57 Units & Formats

EXERCISE – Units & Formats1. Configure the following global display format & units:

pressure #.## kPa

absolute pressure #.## kPa(a)gauge pressure #.## kPa(g)

Mass per time #.### kg/min

2. Write the application to the flow computer and check the units on the displays

3. Add a new unit to convert pressure to tonne/ft2 with conversion factor: 95760.52

4. Configure the pressure to show in this new unit

5. Write the application to the flow computer and check the units on the displays


Debug offline“Debug Offline” can be used for:

• Full flow computer simulation• No Flow-X hardware needed to test Flow-X application• Flow-X software running on laptop

• Update parameters offline, save into file and write to Flow-X later

After activating Debug Offline the following dialog is shown:

Figure 58 Debug Offline

EXERCISE - Flow-X/P11. Use Flow-Xpress and ‘Debug offline’ to set up the Flow-X for the following configuration:

Flow-X/P with one runStandalone runTurbine meter with digital input 1 as pulse A

Pressure transmitter on analog input 2

Temperature transmitter on PT100 input 1

2. Force the inputs and check if the flow rates are <> 0 and the totalizers are counting

EXERCISE - Flow-X/P21. Use Flow-Xpress and ‘Debug offline’ to add a second run:

a) Change the configuration to Flow-X/P2 with two runs

b) Add a second turbine meter with digital input 1 as pulse A on module 2

c) Add a pressure and temperature transmitter as analog inputs on module 2

2. Force the inputs and check if the flow rates are <> 0 and the totalizers are counting


Ports & DevicesIn this window you can:

• Configure serial ports• Configure HART communication devices• Configure serial Modbus devices

• Configure Modbus TCP/IP devices• Configure printers

Figure 59 ports & devices

Through Ports and devices it is possible to activate communication drivers for communication to devices through

serial, HART or Ethernet ports.

To activate a device on a COM, Ethernet or HART port, right click on the port. This brings up the list of available de-

vices:

Figure 60 Device selection on COM1

Now activate one of the devices. When a device is selected, the right part of the screen shows the applicable device

settings.


Figure 61 Device settings

Serial Master-Slave communication

Using Modbus/HART there is normally one master and one or more slave devices. The master sends request (com-

mands) to one or more slave device(s) and the slave device(s) will respond.

Figure 62 Serial Master-Slave communication

The Flow-X also supports a ‘Listen mode’, making it possible to connect one slave device (transmitter, gas chromato-graph, etc.) to two or more flow computers. One (active) master sends requests to a slave device and another (pas-

sive) master is picking up data by listening to the communication between the active master and the slave device.When the active master stops communicating, the passive master will start sending requests and becomes the ac-

tive master. This way multiple masters can use one and the same slave device.

Figure 63 Serial Master-Slave communication with listen mode

Modbus TCP/IP

With Modbus TCP/IP there can be multiple client and multiple server systems on the network as shown here:


Figure 64 Client/server configuration

How to check the communication?

To check the communication between the Flow-X and a gas chromatograph it is possible using your web browser on

your laptop.

– Connect your laptop to the flow-X by the Ethernet

– Start the web browser, e.g. Chrome or Internet Explorer

– Go to the flow computer web GUI

– Browse to System -> Diagnostics -> Communications

Figure 65 Check communication via the web browser

The following dialog is shown:


Figure 66 Communication ports in the web browser

Select one or more ports for debugging.

After pressing “Start Logging” you can check the communication as follows:

Figure 67 Communication messages

In red you can see the requests sent by the Flow-X and in blue you can see the responses from the device.


Debug informationYou can view debug logs with the web browser:

• Enable debug logging:

– (Standalone) System / Diagnostics / Debug Logs– (Panel) System / Modules / Panel / Diagnostics / Debug Logs

• View logs:

– (Standalone) System / Diagnostics– (Panel) System / Modules / Panel / Diagnostics

Figure 68 Read debug info from device

Using SpiritIT Flow-Xpress it is possible to download information log files.

• Start SpiritIT Flow-Xpress and select “Read debug info from device” from the Tools menu.• Then select the IP address from the list on the dialog, login and store the file on hard disc.

• The stored file is a zip file and contains the debug information.


Figure 69 Read debug info from device

EXERCISE – Download debug info1. Download the debug information of your flow computer and store it on your hard disc.

2. Investigate what kind of files have been downloaded.

Adding a printerThe following picture shows how to connect a network text printer to the flow computer:

Figure 70 Add network printer

The printer is added to the list and the printer properties can be filled in:


Figure 71 Network printer properties

The printer name is to be filled in in SpiritIT Flow-Xpress. The IP address is to be configured later on the flow com-

puter display, after writing the application:

Figure 72 Define the IP address of the printer

The printer settings can be found at the display System -> Printers.


Report configuration– Configure for each report on which printer it shall be printed

– Configure the number of copies that are printed when the report is generated

– Configure the number of printed copies at a reprint command

Figure 73 Number of (re-)printed reports

The number of generated copies and reprinted copies are set to 0 by default. If a report needs to be printed auto-matically “Generate copies” needs to be set to 1 or more. To enable manual report reprinting, “Reprint copies” has to

be set to 1 or more.


Security editorFeatures:

• Add or remove user names• Assign user levels to users• Change passwords and PIN codes

• Assign tasks to security levels• Define the minimum security level of tags that are blocked by the hardware security switch

Figure 74 Security editor

The security settings can also be changed in online mode.

Figure 75 Online mode


EXERCISE - Online mode1. Use the online mode to add a username, security level 2000, with password and PIN code

2. Select ‘Write all changes to device’

3. Log on to the flow computer through the web browser using the new username and password

4. Log on to the flow computer through the flow computer LCD using the new PIN code

Versions– It’s good practice to add a revision after you’ve done some modifications to the application

– Include a description of the modifications

– At each revision the 4th digit of the version number is augmented

Figure 76 Application revisions

EXERCISE – Applications revisions1. Add a revision

a) Enter your name, a status indication and a description

b) Click ‘Add Revision’

2. Verify that your revision has been appended to the Revision History

3. Verify that the version number has been augmented


Miscellaneous settingsThe following settings are available:

• Date and time settings• Home display settings• Security settings

Figure 77 General settings of the Flow-X

SpiritIT Flow-XtractA new tool has been developed which enables you to easily and quickly extract archived data and reports from your

SpiritIT Flow-X flow computer. The tool comes as a lightweight Excel add-in and provides a simple user interface from

which you can select the desired data. To install the add-in:

1. Open Excel

2. Open the add-in

3. Enable macros when prompted

Once loaded, the interface can be accessed via a dedicated Flow-Xtract ribbon in the Excel interface.

Figure 78 Flow-Xtract excel add-in


Via the ‘Settings’ option, you can set the ip-address, the folder where reports will be stored, the file format in which

reports are stored and whether you want to overwrite previously stored reports.


Before report and archive data can be extracted, you will be prompted to supply login details. Once logged in, theavailable report or archive types will be listed. You can select one or more items from this list and extract the data.

You can filter the returned data by applying a filter on the period for which you want the data to be extracted.



Document ControlVersion 1.0Author: Eric van BoxtelDate: February 2016

First release of level 1 manual

Version 1.1Author: Eric van Boxtel

Date: March 2016

Updated release of level 1 manual

Version 1.2Author: Eric van BoxtelDate: June 2016


Version 1.3Author: Louis Joosten

Date: Februari 2017


Version 1.4Author: Peter van DeurzenDate: November 2017

Version 1.5Author: Peter van DeurzenDate: February 2019

Updated for V2 hardware and related single/multi-run applications.Minor changes on Flow-X menu structure and IO channel numbers.