GE DigitalFlow GF868 Startup Manual
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GE DigitalFlow GF868 Startup Manual

Ultrasonic flowmeter for flare gas
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GE
Measurement & Control
Gas Analysis
DigitalFlow™ GF868
Ultrasonic Flowmeter for Flare Gas
Startup Guide (1 and 2-Channel)
910-194U Rev. F
February 2015
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Summary of Contents for GE DigitalFlow GF868

  • Page 1 Measurement & Control Gas Analysis DigitalFlow™ GF868 Ultrasonic Flowmeter for Flare Gas Startup Guide (1 and 2-Channel) 910-194U Rev. F February 2015...
  • Page 3 DigitalFlow™ GF868 Ultrasonic Flowmeter for Flare Gas Startup Guide (1 and 2-Channel) 910-194U Rev. F February 2015 www.ge-mcs.com ©2015 General Electric Company. All rights reserved. Technical content subject to change without notice.
  • Page 4 [no content intended for this page]...
  • Page 5 Preface Information Paragraphs Note: These paragraphs provide information that provides a deeper understanding of the situation, but is not essential to the proper completion of the instructions. These paragraphs provide information emphasizing instructions which are essential to proper setup of IMPORTANT: the equipment.
  • Page 6 Environmental Compliance Waste Electrical and Electronic Equipment (WEEE) Directive GE Measurement & Control 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.

  • Page 7: Table Of Contents

    Contents Chapter 1. Installation 1.1 Introduction ................... .1 1.2 Unpacking .
  • Page 8 Contents Chapter 2. Initial Setup 2.1 Introduction...................21 2.2 Navigating Through the User Program .
  • Page 9 Contents Chapter 4. Specifications 4.1 General Specifications ................41 4.1.1 Hardware Configuration .
  • Page 10 Contents Appendix C. Optional Enclosures C.1 Introduction...................53 C.2 Rack Mount Enclosure .

  • Page 11: Chapter 1. Installation

    To ensure safe and reliable operation of the Model GF868 flowmeter for flare gas, the system must be installed in accordance with the guidelines established by GE’s engineers. This section explains how to install the Model GF868 electronics console and make wiring connections. It covers: •...

  • Page 12: Site Considerations

    Chapter 1. Installation 1.3 Site Considerations Since the relative physical locations of the flowcell(s) and the GF868 electronics are important, use the guidelines given in this section when planning your GF868 system installation. 1.3.1 Electronics Console Location Normally, the GF868 electronics enclosure is a Type-4X weather-resistant, dust-tight, indoor/outdoor type. (Other enclosure options are described in Appendix C.) Typically, the electronics console is mounted in a meter shed.

  • Page 13: Temperature And Pressure Transmitters

    Note: If you are using your own cabling to connect the transducers to the electronics console, the cabling must have electrical characteristics identical to the cable supplied by GE. Cable must be type RG 62 A/U coaxial cable (93 ) and each cable must be the same length (within ± 4 in.).
  • Page 14 Chapter 1. Installation Installing a Flowcell (cont.) Temperature Transmitter Pressure Transmitter Preamp Transducer FLOW Flowcell Transducer Electronics Console Figure 1: Model GF868 Flowmeter System DigitalFlow™ GF868 Startup Guide (1 and 2-Channel)

  • Page 15: Installing Temperature And Pressure Transmitters

    Chapter 1. Installation 1.5 Installing Temperature and Pressure Transmitters Temperature and pressure transmitters may be installed as part of the flowcell, near the ultrasonic transducer ports. (Be sure to observe the siting requirements mentioned earlier.) These transmitters must use a 0/4 to 20-mA signal to transmit temperature and pressure values to the GF868 console.

  • Page 16: Making Electrical Connections

    Chapter 1. Installation 1.7 Making Electrical Connections ATTENTION EUROPEAN CUSTOMERS! In order to meet CE Mark requirements, all wiring connections must be made in accordance with the instructions in Appendix A, CE Mark Compliance. This section contains instructions for making all the necessary electrical connections to the Model GF868 flowmeter. See Figure 9 on page 18 for a complete wiring diagram.
  • Page 17 Chapter 1. Installation 1.7.1 Wiring the Line Power (cont.) Refer to Figure 3 on page 7 or Figure 9 on page 18 to locate terminal block TB1 and connect the line power as follows: WARNING! Improper connection of the line power leads, or connecting the meter to the incorrect line voltage, will damage the unit.

  • Page 18: Wiring The Transducers

    Chapter 1. Installation 1.7.2 Wiring the Transducers ATTENTION EUROPEAN CUSTOMERS! In order to meet CE Mark requirements, all wiring connections must be made in accordance with the instructions in Appendix A, CE Mark Compliance. Wiring the GF868 ultrasonic flare gas flowmeter system requires interconnection of the following components: •...
  • Page 19 Chapter 1. Installation 1.7.4a Wiring the RS232 Interface The RS232 communications port provides a serial interface in order to connect the GF868 to a printer, an ANSI terminal or a personal computer. The RS232 serial interface is wired as Data Terminal Equipment (DTE), and the signals available at the GF868 RS232 terminal block are shown in Table 1 below.
  • Page 20 Chapter 1. Installation 1.7.4b Wiring the RS485 Interface Use the optional RS485 serial port to network multiple GF868 flowmeters to a single computer terminal. Upon request, the standard RS232 port on the GF868 may be configured as a two-wire, half-duplex RS485 interface, through a device such as the INMAC Model 800052 RS232-RS422/RS485 converter.
  • Page 21 Chapter 1. Installation 1.7.4c Wiring the Ethernet Interface A modified GF868 can use the Ethernet interface to communicate to an internal network. An optional Ethernet card with a unique MAC (IP) address (installed only in slots 5 or 6) includes an RJ45 connector. To connect the Ethernet-enabled GF868 to the network, insert the jack of an RJ45 cable into the RJ45 connector, route the cable through the bottom of the GF868, and wire the other end of the cable to the Ethernet network according to the manufacturer’s instructions.
  • Page 22 Chapter 1. Installation 1.7.4e Wiring the Foundation Fieldbus Network Fieldbus network connections are made at J8/J9, pins 1 and 2 (see Figure 5). Optionally, a shield can be connected to J8/J9 pin 3, depending on the network wiring. Connector J8 or J9 will be installed depending on the option ordered by the customer.

  • Page 23: Wiring An Alarms Option Card

    Chapter 1. Installation 1.7.5 Wiring an Alarms Option Card The GF868 can accommodate 1 to 6 alarm option card(s). Each alarm option card provides three Form C relays (A, B and C). The alarm relays on the option card are available in two types: •...

  • Page 24: Wiring A 0/4-20 Ma Analog Inputs Option Card

    Chapter 1. Installation 1.7.6 Wiring a 0/4-20 mA Analog Inputs Option Card To calculate standard volumetric flow and mass flow of Flare Gas, the GF868 must have temperature and pressure data from the measurement site. Transmitters installed in the flowcell send this information to the analog input card. This card provides two isolated 4-20 mA inputs (A and B) with 24 VDC supply for loop-powered transmitters.

  • Page 25: Wiring The Totalizer/ Frequency Outputs

    Chapter 1. Installation 1.7.7 Wiring the Totalizer/ Frequency Outputs The GF868 can accommodate 1 to 6 totalizer/frequency outputs option cards. Each totalizer/frequency outputs option card provides four outputs (A, B, C, and D) that can be used as either totalizer or frequency outputs. Each totalizer/frequency output requires two wires.
  • Page 26 Chapter 1. Installation [no content intended for this page] DigitalFlow™ GF868 Startup Guide (1 and 2-Channel)
  • Page 27 Chapter 1. Installation Ø0.38 (10), 4 Places 1.40 (36) 0.75 (19) 8.00 (203) 2.87 (73) 14.24 13.00 13.49 7.00 (362) (330) (343) (178) Ø0.13 (3), 4 Places 2.69 (68) 5.10 (129) 11.37 (289) 3/4" Conduit Plate 10.74 (273) Ø1.10 (28), 6 Places 1/2"...
  • Page 28 Chapter 1. Installation Directive, this unit requires an external Model GF868. – G N/L2 L1 Directive , a transparent plastic shroud protects DigitalFlow™ GF868 Startup Guide (1 and 2-Channel)
  • Page 29 FLYING LEAD TO BNC COAX CABLES (REFERENCE ONLY) PRESSURE INPUT (UP TO 1000 FEET) GF868 FLOW SUPPLIED BY GE COAXIAL CABLES, BNC TO BNC PIN # (SUPPLIED BY GE) 10 FOOT 24V+ SENSOR +IN1 -OUT TRANSDUCER (REF ONLY) PIPE (REF ONLY) -IN1 24V-...
  • Page 30 Chapter 1. Installation DigitalFlow™ GF868 Startup Guide (1 and 2-Channel)

  • Page 31: Chapter 2. Initial Setup

    Chapter 2. Initial Setup Chapter 2. Initial Setup 2.1 Introduction This chapter provides instructions for entering the minimum amount of programming data required to place the GF868 flowmeter into operation. Before your GF868 can begin taking measurements, you must enter the necessary information into the submenus.

  • Page 32: Accessing The User Program

    Chapter 2. Initial Setup 2.3 Accessing the User Program To enter the Program Menu, press the key on the keypad. [PROG] Note: Note: If the security feature is active, the GF868 will prompt you for a password. Enter the password and press See the submenu section in Chapter 1, Programming Site Data, of the Programming Manual for [ENT].

  • Page 33: Activating A Channel

    Chapter 2. Initial Setup 2.4 Activating a Channel submenu permits selection of the desired measurement method. In addition, it is used to activate/deactivate ACTIV one or both of the channels in a 2-Channel Model GF868. 2.4.1 1-Channel Meter 1. Enter the submenu by pressing at the prompt.

  • Page 34: Entering System Data For A Channel

    Chapter 2. Initial Setup 2.5 Entering System Data for a Channel Begin programming the S submenu in either the 1-Channel or 2-Channel section below. YSTM 2.5.1 A 1-Channel Meter For the 1-Channel Model GF868, the information entered in the SYSTM submenu pertains to the global operation of the flowmeter.

  • Page 35: A 2-Channel Meter

    Chapter 2. Initial Setup 2.5.2 A 2-Channel Meter For the 2-Channel Model GF868, the information entered in the SYSTM submenu pertains only to the currently selected channel. 1. At the User Program screen shown, press the function key to program the submenu.
  • Page 36 Chapter 2. Initial Setup 2.5.3 1- and 2-Channel Meters (cont.) 4. Use the [F1]-[F4] and [] keys to select the Totalizer Units. The abbreviations and definitions of all the available volumetric and totalizer units are shown in Table 2-2 on the previous page.

  • Page 37: Entering Pipe Data

    Chapter 2. Initial Setup 2.6 Entering Pipe Data submenu permits entry of the transducer and pipe specifications. To program this menu, complete the PIPE following steps: 1. At the User (or Channel) Program screen, press to program the submenu. [F3] PIPE 2.6.1 Transducer Number 2.

  • Page 38: Pipe Wall

    Chapter 2. Initial Setup 2.6.3 Pipe Wall 4. Use the numeric keys to enter the known thickness of the Pipe Wall. Press [ENT]. If the pipe wall thickness is not available, look up the value in a table of standard pipe size data or use the Model GF868’s on-line Help Menu (see the Programming Manual for details).
  • Page 39 Chapter 2. Initial Setup 2.6.6a Further Options After completing the above steps, the meter returns to the User (or Channel) PROGRAM prompt. Continue as follows: • To continue programming the meter, refer to the menu maps in Appendix A of the Programming Manual and navigate to the desired menu.
  • Page 40 Chapter 2. Initial Setup [no content intended for this page] DigitalFlow™ GF868 Startup Guide (1 and 2-Channel)
  • Page 41 Chapter 2. Initial Setup PROG (2-Channel)) (1-Channel) NOTE: Plain text represents prompt area messages and boxed text represents option bar choices. Fx represent function keys to select option bar choices. GLOBL SAVE PROGRAM status Channel PROGRAM status ACTIV SYSTM PIPE (2-Channel) (1-Channel) (2-Channel) (1-Channel)

  • Page 43: Chapter 3. Operation

    Chapter 3. Operation Chapter 3. Operation 3.1 Introduction See Chapter 1, Installation, and Chapter 2, Initial Setup, to prepare the system for operation. When the meter is ready to take measurements, proceed with this chapter. The following specific topics are discussed: •...

  • Page 44: Powering Up

    Immediately upon power up, the Model GF868 displays “GE” and the software version in the left pane of the display window. The Model GF868 performs a series of internal checks and display the results in the right pane of the display window.

  • Page 45: Using The Display

    Chapter 3. Operation 3.3 Using the Display The Model GF868 display is divided into a left pane and a right pane. The two screen panes can be set independently to display any of the available measurement or diagnostic parameters. The components of a typical measurement mode screen are shown in Figure 13.
  • Page 46 Chapter 3. Operation Using the Display (cont.) At various times, one or more of the following four symbols may be displayed on the far right of the locator bar: •  : This symbol, which is called the pointer, indicates that additional option bar entries are available. These options can be accessed by using the [...

  • Page 47: Taking Measurements

    Chapter 3. Operation 3.4 Taking Measurements The Model GF868 is capable of displaying several different variables in a variety of formats. However, this manual will only discuss the basic measurement displays in the default screen format. Refer to the Programming Manual for instructions on setting up alternate screen displays and see the Service Manual for a discussion of the diagnostic parameters listed under the option.

  • Page 48: Foundation Fieldbus Communications

    Chapter 3. Operation Taking Measurements (cont.) Table 8: Measurement Parameter Options Option Bar Choice Description Flow Velocity [F1] Volumetric Flow [F2] VOLUM Forward Totalized Volume Flow [F3] +TOTL Reverse Totalized Volume Flow [F4] -TOTL [ Total Flow Measurement Time + [F1] TIME [...
  • Page 49 Chapter 3. Operation 3.4.1 Foundation Fieldbus Communications (cont.) Table 9: Measurement Parameter Options Using a Foundation Fieldbus Device Channel 1 Units Channel 2 Units Average Units Ch1 Velocity ft/s or m/s* Ch2 Velocity ft/s or m/s* Avg Velocity ft/s or m/s* VOL_U VOL_U VOL_U...
  • Page 50 Chapter 3. Operation [no content intended for this page] DigitalFlow™ GF868 Startup Guide (1 and 2-Channel)

  • Page 51: Chapter 4. Specifications

    Chapter 4. Specifications Chapter 4. Specifications 4.1 General Specifications The general specifications for the Model GF868 flowmeter are divided into the following categories: 4.1.1 Hardware Configuration Package Options: Epoxy-coated aluminum (standard) Stainless steel (optional) Fiberglass (optional) Explosion-proof (optional) Flameproof (optional) Physical: (Epoxy-coated aluminum package) Size: 14.24 ...

  • Page 52: Molecular Weight And Mass Flow Accuracy (% Of Reading)

    Chapter 4. Specifications 4.1.5 Molecular Weight and Mass Flow Accuracy (% of Reading) Molecular Weight (hydrocarbon mixtures): MW 2 to 120 g/mol. 1.8%, optimizable for other gas composition Mass Flow (hydrocarbon mixtures, typical): 1-path: 3 to 7% 2-path: 2.4 to 5% Note: Dependent on accuracy of temperature and pressure inputs.

  • Page 53: Input/Output Specifications

    Chapter 4. Specifications 4.2.5 Input/Output Specifications Keypad: 39-key membrane keypad with tactile feedback Display: Two independent software-configurable 64 x 128-pixel LCD graphic displays Printer/Terminal Communications: One RS-232 port for printer, terminal, PC, SCADA, etc. Standard Inputs: Two isolated 4 to 20 mA inputs (121 load) with integral 24 VDC power supply Note: These inputs are required for temperature and pressure inputs.

  • Page 54: Operational Specifications

    Chapter 4. Specifications 4.2.5 Input/Output Specifications (cont.) Totalizer/Frequency Output Options: Select up to 3 Totalizer/Frequency Output Boards, each with four outputs per board, 10 kHz max. All boards allow software-selectable functioning in two modes: Totalizer Mode: one pulse per defined unit of parameter (e.g., 1 pulse/SCF). Frequency Mode: 5-volt frequency proportional to magnitude of parameter (e.g., 10 Hz = 1 SCFM).

  • Page 55: Transducer/Flowcell Specifications

    Chapter 4. Specifications 4.4 Transducer/Flowcell Specifications 4.4.1 Transducer Type Standard GE type T5 (welded assembly of Ti transducer). For agency certifications, contact the factory. 4.4.2 Temperature Range Standard: –94° to +300°F (–70° to 150°C) Optional high temperature: –94° to +536°F (–70° to +280°C) Optional low temperature: –364°...

  • Page 56: Flowcell Specifications

    Chapter 4. Specifications 4.5 Flowcell Specifications 4.5.1 Spoolpiece Prefabricated spools complete with transducer/mechanism port: Pipe sizes: 3 to 120 in. Process Connections: Plain end; 150, 300, or 600 lb. RF flanged. Materials: carbon steel, low-carbon steel, stainless steel, or other. 4.5.2 Hot/Cold Tap Mechanisms installed via hot or cold tap.

  • Page 57: Appendix A. Ce Mark Compliance

    Appendix A. CE Mark Compliance Appendix A. CE Mark Compliance A.1 Introduction For CE Mark compliance, the Model GF868 flowmeter must be wired in accordance with the instructions in this appendix. CE Mark compliance is required only for units intended for use in EC countries. IMPORTANT: A.2 Wiring The Model GF868 must be wired with the recommended cable, and all connections must be properly shielded and...
  • Page 58 [no content intended for this page] DigitalFlow™ GF868 Startup Guide (1 and 2-Channel)

  • Page 59: Appendix B. Data Records

    Appendix B. Data Records Appendix B. Data Records B.1 Option Cards Installed Whenever an option card is installed in one of the Model GF868’s expansion slots, record the type of card and any additional setup information in the appropriate row of Table 11. Table 11: Option Cards Installed Slot # Type of Option Card...

  • Page 60: Initial Setup Data

    Appendix B. Data Records B.2 Initial Setup Data After the Model GF868 flowmeter has been installed, some initial setup data must be entered via the User Program, prior to operation. Record that information in Table 12. Table 12: Data Information Sheet General Information Model # Reference...
  • Page 61 Appendix B. Data Records Table 12: Data Information Sheet (cont.) Pipe/Transducer Parameters - PIPE Channel 1 Channel 2 (if applicable) Std. Trans. # Std. Trans. # Spec. Trans. # Spec. Trans. # Spec. Trans. Hz Spec. Trans. Hz Spec. Trans. Tw Spec.
  • Page 62 [no content intended for this page] DigitalFlow™ GF868 Startup Guide (1 and 2-Channel)

  • Page 63: Appendix C. Optional Enclosures

    Appendix C. Optional Enclosures Appendix C. Optional Enclosures C.1 Introduction Upon request the Model GF868 flowmeter may be supplied in an enclosure other than the standard Type-4X enclosure described in Chapter 1, Installation, of this manual. Although the standard installation and wiring instructions still apply in general terms, some of the details may vary for different enclosure types.

  • Page 64: Rack Mount Front Panel

    Appendix C. Optional Enclosures Rack Mount Wiring (cont.) 3. Wire the 0/4-20 mA analog outputs at the left side of the rear panel in accordance with the instructions in Chapter 1, Installation, of this manual. 4. Wire the RS232 serial port by completing the following steps: a.
  • Page 65 Appendix C. Optional Enclosures 14.83 (377) 4.19 (106) 16.99 (432) 11.82 11.37 (300) (289) 13.13 (333) 15.70 (399) 3.31 (84) 2.25 5.22 (57) (133) 18.25 (464) 19.00 (483) DigitalFlow™ GF868 Startup Guide (1 and 2-Channel)
  • Page 66 Appendix C. Optional Enclosures CH2 TRANSDUCER RS232 SERIAL PORT (DB9) For compliance with the European Union's Low Voltage NOTE: BNC # Description Pin # Description Directive, this unit requires an external power Upstream XDCR No Connection disconnect device such as a switch or circuit breaker. The Downstream XDCR TX - Transmit disconnect device must be marked as such, clearly visible,...
  • Page 67 Appendix C. Optional Enclosures Mounting Holes Mounting Holes Handle Handle HELP EXIT DISP PROG PRNT SCREEN GF868 LCD Display Function Keys Console Keys Main Keypad DigitalFlow™ GF868 Startup Guide (1 and 2-Channel)
  • Page 68 Appendix C. Optional Enclosures DigitalFlow™ GF868 Startup Guide (1 and 2-Channel)

  • Page 69: Appendix D. Measuring P And L Dimensions

    – Standard GE 90° transducers have the face offset from the centerline of the body by 0.6 inches. Thus, a pair of transducers has a total offset of 1.2 inches, as indicated in the second equation. For example, suppose that the transducer installation angle is 30°...
  • Page 70 Appendix D. Measuring P and L Dimensions Pipe Thickness 180° Installation Pipe O.D. Bias 90° Installation Figure 17: Top View of Transducer Installations DigitalFlow™ GF868 Startup Guide (1 and 2-Channel)
  • Page 71 Index ..25 Initial Setup Abbreviations, Volumetric & Totalizer Units ......50 .
  • Page 72 Index Programming Data Terminal Block ....... . 49 ......8 Record Serial Port - RS232 .
  • Page 73 AUTHORIZATION NUMBER (RAN), and shipping instructions for the return of the instrument to a service center will be provided. 2. If GE Sensing instructs you to send your instrument to a service center, it must be shipped prepaid to the authorized repair station indicated in the shipping instructions.
  • Page 74 Warranty [no content intended for this page] DigitalFlow™ GF868 Startup Guide (1 and 2-Channel)
  • Page 75 Cable glands of an approved flameproof design are required for Ex d rated equipment. These must be installed according to the manufacturer’s instructions. Where the cable glands are provided by GE, the manufacturer’s instructions, as supplied to GE, will be included in the documentation.

  • Page 76: Special Conditions For Safe Use

    Certification & Safety Statements for GE Infrastructure Products Used in Hazardous Locations August 2014 Special Conditions for Safe Use Consult the manufacturer if dimensional information on any flameproof joint is necessary. Follow the manufacturer’s instructions to reduce the potential of an electrostatic charging hazard.
  • Page 77 EC DECLARATION Sensing CONFORMITY DOC-0013, Rev. B GE Sensing 1100 Technology Park Drive Billerica, MA 01821 declare under our sole responsibility that the DigitalFlow™ DF8688 Liquid Ultrasonic Flowmeter DigitalFlow™ GC868 Clamp-On Gas Ultrasonic Flowmeter DigitalFlow™ GF868 Flare Gas Mass Ultrasonic Flowmeter DigitalFlow™...
  • Page 80 Customer Support Centers U.S.A. The Boston Center 1100 Technology Park Drive Billerica, MA 01821 U.S.A. Tel: 800 833 9438 (toll-free) 978 437 1000 E-mail: [email protected] Ireland Sensing House Shannon Free Zone East Shannon, County Clare Ireland Tel: +353 (0)61 470200 E-mail: [email protected] An ISO 9001:2008 Certified Company www.ge-mcs.com/en/about_us/quality.html...

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