Steam Flow Measurement RELIABLE STEAM FLOW MEASUREMENT FOR THE MOST CHALLENGING APPLICATIONS. Flexible ultrasonic flow measurement solutions

Transcription

1 SPECIAL INFORMATION Stea Flow Measureent RELIABLE STEAM FLOW MEASUREMENT FOR THE MOST CHALLENGING APPLICATIONS Flexible ultrasonic flow easureent solutions

2 FLOWSIC STEAM FLOW MEASUREMENT Stea flow easureent often requires coproise, but it doesn t have to With an ever increasing focus on stea producers and users to increase revenues, reduce costs and iniize waste, traditional floweter technologies soeties struggle to eet the challenge. Measureent point design, procureent, installation and coissioning costs are only the start of the story. Whilst vortex, differential pressure based flow easureent and turbine eters are adequate in any situations, ore deanding applications often see rapid payback and ongoing savings using SICK Ultrasonic stea easureent technology. 2 STEAM FLOW MEASUREMENT SICK /

3 STEAM FLOW MEASUREMENT FLOWSIC High flow turn-down >100:1 High accuracy & repeatability FLOWSIC Virtually no pressure drop Resistant to pulsations and condensate slugs Stea is generated and used in all industries for a wide variety of purposes, including heating, drying, optiizing cobustion and otive power to pups and copressors. While DP flow and vortex eters are a good fit in any cases, there are applications where a ore capable eter is needed; these are the applications where a FLOWSIC ay be the optiu solution and can provide a fast payback: Where widely varying stea deand (flow rate) results in loss of easureent at low flowrates Where the lowest pressure loss is critical Where large stea lines liit the selection of suitable technologies Where poor accuracy results in lost revenue FLOWSIC600 and FLOWSIC100 eters operate around the world on challenging, high-value stea flow installations. These include challenging applications and stea injection into flares, where the challenges of low uncertainty over a wide flow turndown cannot be et by traditional stea flow easureent technologies such as vortex and differential pressure (DP) based eters. With a axiu process teperature of 280 C (536 F) FLOWSIC solutions are suitable for a wide range of saturated and superheated stea applications. VORTEX METER ORIFICE PLATE AVERAGING PITOT Stea flow applications requiring great perforance over a wide flow range and the lowest pressure loss? TURBINE FLOWSIC! ULTRASONIC / STEAM FLOW MEASUREMENT SICK 3

4 FLOWSIC600 STEAM FLOW MEASUREMENT FLOWSIC600 Stea Flow Measureent The FLOWSIC600 ultrasonic flow eter is ideal for high accuracy and greenfield installations where an in-line eter ust eet the challenges of low uncertainty: Greater than 100:1 flow turndown Virtually no pressure loss In-situ validation No wear No routine aintenance Maxiu Reliability The FLOWSIC600 ultrasonic flow eter has no oving parts and does not rely on intrusions into the vapor strea, aking it highly resistant to containation and wear. Self-diagnostics cobine to ensure years of reliable easureent. High Measureent Accuracy The FLOWSIC600 easures saturated and superheated stea flow using ultrasonic technology. SICK ultrasonic sensors offer excellent easureent perforance even at low flow rates and varying line pressures and provide outstanding long ter perforance. Installed cost DP + orifice plate Vortex SICK FLOWSIC600 Cost of aintenance Cost of stea loss due to technology turndown Cost of stea loss due to technology % uncertainty Cost of Peranent Pressure Loss (energy) Second Year $- $20,000 $40,000 $60,000 4 STEAM FLOW MEASUREMENT SICK /

5 STEAM FLOW MEASUREMENT FLOWSIC600 Technical Data Meter characteristics Noinal size Flow rate Max. Velocity Length Weight Order code 4) [³/h] [ft³/h] [³/h] [ft/s] [] [in] [kg] [lbs] Min. Max. Min. Max. DN 50/ , FL6ST-02CL600-* DN80/3 8 1, , FL6ST-03CL600-* DN100/4 13 1, , FL6ST-04CL600-* DN150/6 20 3, , FL6ST-06CL600-* DN200/8 32 4,500 1, , FL6ST-08CL600-* DN250/ ,000 1, , FL6ST-10CL600-* DN300/ ,000 2, , FL6ST-12CL600-* DN350/ ,000 2, , , FL6ST-14CL600-* DN400/ ,000 4, , FL6ST-16CL600-* Materials Meter body: Low teperature carbon steel Transducers: Titaniu Electronics: Aluinu Flange type ASME B16.5, Raised face 2) Meter body finish Meter body: nickel plated, covers: RAL7012 Measuring paraeters Fluid Stea up to 280 C (536 F) Process value Voluetric flow, volue totals at actual conditions velocity of gas, speed of sound Measureent principle Ultrasonic transit tie difference easureent Typical accuracy 1) DN50 / 2 DN80 / 3 or larger 10% Q ax Q ax ±1.5% of rate ±1% of rate 3) Repeatability < 0.1 % Process teperature - 46 C C (-50 F F) Pressure rating PN100 / CL600 2) Approvals Conforities ISO Ex approvals CSA, ATEX, IECEx, zone 1 and zone 2 IIC T4 rating, transducers intrinsically safe Electrical Safety CE IP classification IP 67 Abient conditions Teperature -40 C + 60 C (-40 F F) Huidity 95% Power supply, Outputs and Interfaces Voltage V DC, 1 W Analog output A (@ 200 Ω), Active/passive ode, isolated Digital outputs 1x pulse, 2x status, isolated, OC or NAMUR, Q ax = 2 khz Digital interfaces RS485, Modbus ASCII/RTU, HART rev. 5 Display 2-line LCD 1) With good piping conditions (developed flow profile). Typical uncertainty below Qt is ±3.0% for DN50 (2 ) and ±2.0% for DN80 (3 ) or larger 2) Other pressure ratings or flange types available on request 3) Accuracy ±0.5% available on request 4) Order of ATEX/IECex version replace * with A, Order of CSA version - replace * with C / STEAM FLOW MEASUREMENT SICK 5

6 FLOWSIC100 STEAM FLOW MEASUREMENT FLOWSIC100 Stea Flow Measureent The FLOWSIC100 ultrasonic gas and stea flow eter faily delivers an optiu cobination of perforance and installation flexibility, especially in brown-field and large pipe installations. 400:1 flow turndown Virtually no pressure loss In-situ validation No wear No routine aintenance Maxiu Reliability The FLOWSIC100 ultrasonic flow eter has no oving parts and offers outstanding perforance and durability. Containated stea carrying corrosive coponents has no ipact on the easureent. Highly corrosion resistant aterials (such as titaniu) are selected for critical transducer wetted parts. Material suitability is assessed for each application. High Installation Flexibility The FLOWSIC100 offers high flexibility enabling optiized solutions for even the ost challenging saturated and superheated applications. Cross-duct type for easy installation on an existing pipeline using welding nozzles. Single-probe type for siple and cost-saving installation on one side of the stea line. Retraction echanis for quick and siple replacing of sensor during plant operation. Installed cost DP + Orifice Plate Vortex SICK FLOWSIC100 Cost of aintenance Cost of stea loss due to technology % uncertainly Cost of stea loss due to technology turndown Cost of Peranent Pressure Loss (energy) Second Year $- $25,000 $50,000 $75,000 $100,000 Illustration based on 6" line 6 STEAM FLOW MEASUREMENT SICK /

7 STEAM FLOW MEASUREMENT FLOWSIC100 Technical Data 1) Meter characteristics Measureent configuration Measuring paraeters Measured values FLOWSIC100 EX-S Cross-duct 1-path or 2-path Flow velocity, voluetric flow FLOWSIC100 EX-PR Probe version 1-path or 2-path Measuring range /s ( ft/s) /s ( ft/s) Repeatability Uncertainty of easureent 2) Voluetric flow a. c. (1-path easureent): Voluetric flow a. c. (2-path easureent): Noinal pipe size 1-path easureent 2-path easureent Process teperature Standard: High-teperature: Operating pressure Approvals Ex approvals Outputs and interfaces Analog outputs 3) Analog inputs 3) Digital outputs 3) Digital inputs Interfaces S/R units Control unit Bus protocol (via optional interface odule) 0.2 % at 10 /s (33 ft/s) ± 5 % ± 3 % in the range 0.3 /s (1 ft/s) up to the upper range value C C (-94 F F) Zone 1: 70 C C (-94 F F) Zone 2: 70 C C (-94 F F) 0.5 bar (g) bar (g), optional up to 20 bar (g) ATEX zone 1 and 2, IECEx, CSA CI I, Div 1 ATEX zone 1 and 2, IECEx, CSA CI I, Div 1; CI I Div 2 1) No standard solution, available separately only. For full specification see product data sheet. 2) For fully developed flow profiles. 3) Optional extendable by using I/O odules active output: 0/2/ A, ax. load 500 W, according to NAMUR NE43 2 inputs: /10 V or A Pulse/frequency output (opt. odule); 5 outputs: 48 V d.c./1a, 30 V d.c./1a (MCUP zone 2); floating status signals: operation/alfunction, aintenance, check cycle, liit value, aint. request 2 inputs for connection of floating contacts USB 1.1 (virtual COM, service interface) RS-232 (service interface) RS-485 (only Ex-versions) Digital transitter interface (via optional interface odule) Interface odule (option) Pulse, Ethernet + pulse, Ethernet triplex + pulse, MODBUS TCP + pulse, MODBUS RS485 + pulse, HARTBUS AO + pulse, PROFIBUS RS485 + pulse, Foundation Fieldbus + pulse / STEAM FLOW MEASUREMENT SICK 7

8 APPLICATION EXAMPLE STEAM FLOW MEASUREMENT IN A STEEL MILL Challenging flow conditions result in loss of easureent and high aintenance costs A ajor European steel ill needed reliable easureent of stea flow over a wide flow turndown for internal cost etering. A turbine eter was chosen as this proised acceptable flow turndown and accuracy and would therefore avoid easureent losses at lower flow rates. A vortex eter was also considered however its inability to provide a easureent at lower flowing velocities ade this technology unsuitable. The turbine eter was installed and provided easureent over the full stea flow range; however linearity at lower flows was poor. In addition to the disappointing low flow perforance, the turbine eter required costly, regular aintenance. Rapid changes in stea velocity resulted in bearing wear and daaged blades; causing inaccurate easureent and subsequent frequent failure of the eter. The eter was returned to the anufacturer two to three ties each year as a result. The cobination of loss of easureent, de-coissioning, repair costs and re-coissioning was unacceptable and drove the plant to seek a better solution. The solution? Following detailed consultation with SICK, a FLOWSIC100 was installed on the 8 (DN200) saturated stea flow line in The ultrasonic flow eter has provided a reliable and aintenance free easureent ever since. Steel aker replaces turbine eter with SICK Ultrasonic flow eter and sees rapid return on investent 8 STEAM FLOW MEASUREMENT SICK /

9 STEAM FLOW MEASUREMENT IN A STEEL MILL APPLICATION EXAMPLE Ultrasonic flow eter benefits 1. Full bore ultrasonic eter producing virtually no pressure drop and no corresponding energy loss. 2. Very high flow turndown enables reliable easureent over a wider flow range. 3. High accuracy, even at low flow rates, resulting in less lost stea. 4. No oving or daageable parts, enabling further aintenance savings. 5. No risk of daage to equipent downstrea fro failed turbine blades. Magnetic Pick-up Sender/Receiver unit Flow Straightener / Rotor Support FLOW Flow Rotor Shaft Turbine Rotor Gas flow in a typical turbine flow eter Unhindered gas flow using an ultrasonic FLOWSIC100 Rapid return on investent In spite of an initially higher capex cost, the FLOWSIC100 Process flow eter delivered a return on investent of less than one year; considering aintenance savings alone. Cuulative Owenership Cost Exaple Flowsic100 Turbine Meter Cuulative Cost Payback Months / STEAM FLOW MEASUREMENT SICK 9

10 NOTES 10 STEAM FLOW MEASUREMENT SICK /

11 SERVICES REGISTER AT TODAY AND ENJOY ALL THE BENEFITS Select products, accessories, docuentation and software quickly and easily. Create, save and share personalized wish lists. View the net price and date of delivery for every product. Requests for quotation, ordering and delivery tracking ade easy. Overview of all quotations and orders. Direct ordering: subit even very coplex orders in oents. View the status of quotations and orders at any tie. Receive e-ail notifications of status changes. Easily repeat previous orders. Conveniently export quotations and orders to work with your systes. SERVICES FOR MACHINES AND SYSTEMS: SICK LifeTie Services Our coprehensive and versatile LifeTie Services are the perfect addition to the coprehensive range of products fro SICK. The services range fro product-independent consulting to traditional product services. Consulting and design Safe and professional Product and syste support Reliable, fast and on-site Verification and optiization Safe and regularly inspected Upgrade and retrofits Easy, safe and econoical Training and education Practical, focused and professional / STEAM FLOW MEASUREMENT SICK 11

12 / AA Pre USod en47 SICK AT A GLANCE SICK is a leading anufacturer of intelligent sensors and sensor solutions for industrial applications. With ore than 8,000 eployees and over 50 subsidiaries and equity investents as well as nuerous agencies worldwide, we are always close to our custoers. A unique range of products and services creates the perfect basis for controlling processes securely and efficiently, protecting individuals fro accidents and preventing daage to the environent. We have extensive experience in various industries and understand their processes and requireents. With intelligent sensors, we can deliver exactly what our custoers need. In application centers in Europe, Asia and North Aerica, syste solutions are tested and optiized in accordance with custoer specifications. All this akes us a reliable supplier and developent partner. Coprehensive services round out our offering: SICK LifeTie Services provide support throughout the achine life cycle and ensure safety and productivity. For us, that is Sensor Intelligence. Worldwide presence: Australia, Austria, Belgiu/Luxebourg, Brazil, Czech Republic, Canada, China, Denark, Finland, France, Gerany, Great Britain, Hungary, India, Israel, Italy, Japan, Mexico, Netherlands, Norway, Poland, Roania, Russia, Singapore, Slovenia, South Africa, South Korea, Spain, Sweden, Switzerland, Taiwan, Turkey, United Arab Eirates, USA Detailed addresses and additional representatives - SICK AG Waldkirch Gerany