Flowsic100 Full

FLOWSIC100.
The ultrasonic gas flow measurement system.

Introduction
FLOWSIC100
TÜV certified acc. to 13., 17., 27. BImSchV

and TA-Luft
: SICK : NEP 2009 FLOWSIC100

Introduction
SICK - German technology leader in ultrasonics
FLOWSIC100
FLOWSIC100
Continuous Process
FLOWSIC600
Emission
Monitoring FLOWSIC100 FLOWSIC150
Flare Natural gas + Carflow FLOWSIC200
Process
industry Exhaust gas
Process control measurement Air velocity
Automotive measurement
industry Traffic tunnels

Content
Training course objectives
: Getting an overview of FLOWSIC100

- different device types and specification
- measuring task
- functional principle
: Advising customers for his application

- introduce the FLOWSIC100, features + benefits
- analyse the application conditions
- give recommendations for installation + use of the device
: Make device configurations and quotations

- choose the suitable device type configuration
- use price list FLOWSIC100

Basics of FLOWSIC100
Measuring task
Measurement of gas velocity in ducts, chimneys and pipes

Measured value in m/s [ft/sec] and calculation of volume flow in
m³/h [ascf/min] in actual conditions
Major applications:
: CEMS (continuous emission monitoring)
: Process control
- Flare Gas
- Hydrocarbon processing
- Blast furnace gas
- and many more

Application ranges of FLOWSIC100
Inner channel diameter min. - max.: 0,15 ...13 m
Medium temperature: -40 ... + 450 °C
Inner channel pressure max.: -0,5 ... +0,3 barg (+16 barg)
Dust concentration (load) max.: 100 g/m³ s. c.
Ambient Temperature min. ... max.: -40 ... +60 °C
Cable length between control unit

and sender/receiver unit max: 1.000 m

Measurement principle
Detection of transit time

L
t AB =
c + v p cos( )
Transit times:
L
tBA =
c − v p cos( )
L  1 1 
vp =  - 
2 cos( )  t AB t BA 
vp - average velocity on measuring path

tAB,tBA - transit times
L - length of measuring path
a - installation angle to flow axis
c - speed of sound

Calculation of volume flow in actual conditions
L 1 1 
c=  + 
Qia =v A(C ) Speed of sound
2  t AB t BA 
Qi.a.= volume flow [m³/h i.a.] or [aft³/min]

Ultrasonic „add” value for:
v = velocity [m/s] or [ft/s]
Calculation of gas temperature
A = duct area [m²] or [ft²]
Calculation of mass flow
C = calibration- (or profile)-factor
Calculation of molecular weight
Diagnostics

Calibration Probe measuring point Measurement

axis Cross-Stack
stack
35
30
25
flow velocity [ m/s]
20
Profile measurement
axis
15
Practical profile with

unsymmetrical inlet 10
0
-3, 5 -3 -2, 5 -2 -1, 5 -1 -0, 5 0 0,5 1 1,5 2 2,5 3 3,5
distance relative to the stack centre [m]

Calibration
: Profile measurements,
: net point measurement according
VDI2066
e.g. with Gravimat SHC500
Rectangular ducts Circular ducts

Calibration
▪ Calculation of calibration
coefficients by using a regression
analysis
v A = Cv 2  v 2 + Cv1  v + Cv 0
Flowsic measurement v [m/sec]

Check Cycle
Zero point check (send & receive via internal loop)

: A sender signal is internally sent back and picked up as a receiver signal
and is amplified, demodulated and evaluated.
: This check covers the entire system, including the transducers. If everything is
working correctly, the zero point of the system is obtained.
: Deviations over 0.25 m/s (0.8 ft/s) cause a warning message. In this case
transducer and electronics have to be checked separately.

Check Cycle
Span test (send & receive with internal time delay)

: send & receive via internal loop
: A time difference, corresponding to 70 % of full scale is added to the
measurement.
: If all system components are functional, the result of the measurement equals
the calculated time delay.
: In case of deviations, a malfunction message occurs.

Check Cycle

Product family FLOWSIC100
FLOWSIC100 standard types
: Titanium transducers as standard
: Medium gas temperature -40 ... +260 °C
: Medium and high power version
: Single probe version
: No purge air

FLOWSIC100 standard types
FLOWSIC100 PR
FLOWSIC100 M
FLOWSIC100 S
FLOWSIC100 H
FLOWSIC100 AC-types (internal air-cooled types)
: Patented internal air-cooling
: Medium power and high power version,
single probe version (on request)
: No intake of cool air in the duct

Outlet of
cooling air
Transducer
Inlet of
cooling air

MCU Control unit

with integrated blower unit

FLOWSIC100 M-AC
FLOWSIC100 H-AC

FLOWSIC100 purged types
: Medium power and high power version
: For applications with wet and sticky dust only
FLOWSIC100 PM
FLOWSIC100 PH
FLOWSIC100 PH-S

Modular concept - the CEMS decision tree

More than 260 °C (500
°F)?
Y N
D > 10 ft ?
Internal cooled versions
Y N
One-sided inst. only ? One-sided

inst. only ?
Y N
Y N
FS100 PR
FS100 PR FS100 PR FS100 M
FS100 H FS100 S*
FS100 PR
*) D < 1,7 m, no certification needed

System components FLOWSIC100

System components FLOWSIC100
Sender/Receiver unit
: Calculation of measured values (gas velocity, gas volume flow) in electronics of

sender/receiver units
: No transfer of run-time data to evaluation unit (exception: data for signal diagnosis)
: “Master-Slave“ concept (master sensor triggers slave-sensor)

System components
Sender/Receiver units - Standard type
Electronic unit Connection M Duct probe Transducer
NL = 200, 350, 550

Connection for cable
Example FLSE100-M (Medium Power)

System components
Sender/Receiver units - Standard type
Electronic unit Connection PR/PR-AC Duct probe
Transducer
NL = 350, 550, 750

Connection for cable
Example FLSE100-PR (Probe version)

System components
Sender/Receiver units - Ultrasonic transducers
Transducer frequency Low frequency Medium frequency High frequency
Power High Power Medium Power Small size transducer
Material Stainless steel Stainless steel Stainless steel

Titanium Titanium Titanium
Hastelloy Hastelloy
Suitable for Large duct diameter, Medium duct Short measuring
High dust load diameters, medium distance, low dust
applications dust
Stainless steel: Use for dry and non-aggressive gas

Titanium: Use for moisture gas with aggressive components
Hastelloy: Use for moisture gas with high aggressive components (HF, HCL)

System components
Sender/Receiver units - Configuration
Example: FLSE100-MAC 35SSTI
: Medium Power Transducer
: Air-Cooled (internal)
: Nominal probe length 350 mm
: Probe material Stainless Steel
: Transducer material Titanium

System components
Flange with tube / Connecting cables
: Different nominal lengths

: Different materials
- carbon steel
- stainless steel
: Connection cable Master 5m / 10m / 50m

: Connection cable Slave 5m / 10m / 50 m

System components
Connection box
: for connection of “Master” and “Slave” connection cable

: for single-probe version optionally

System components
Multi Control Unit (MCU)
: Main function is I/O - flexible + modular expandable
acc. to customer requirements
: Robust design
: Display (uniform for SICK MAIHAK sensors)
: 19” version available

System components
Multi Control Unit (MCU)- details of function
: I/O (Base configuration)

- 1 x analog output
- 2 x analog input
- 5 x digital output (relay contacts)
- 4 x digital input
- Interface USB 1.1, RS232
(for service and parameterization)
- RS485 for data communication with s/r units

System components
Multi Control Unit (MCU)- I/O options
: Analog and digital modules (each with 2 in- or outputs)

- analog output modules (up to 4)
- analog input modules (up to 4)
- digital output module (2 x changeover contacts)
: Interface options
- Ethernet TCP/IP
- Profibus DP
- Modbus RS485

System components
: Display module
- display of measured values
- status information
- configuration settings for commissioning of device

System components
: Multifunctional use for flow- and dust measurement technology

- optional 2-path measurement or connection of dust sensor possible
FLSE100 FLSE100 FLSE100 FLSE100

Master Slave Master Slave
MCU

System components
Purge air unit (for external purged types only)
: Not for standard types !
: Selection of type depends on inner

channel pressure
: Two different types

- 2BH13 up to +30 mbar (g)
- 2BH14 >+30 mbar ... +100 mbar (g)

System components
User software SOPAS Engineeringtool (SOPAS ET)
: Same user interface for all sensors of Division 03 / harmonization of
SICK MAIHAK CEMS technology on a shared software platform
: Extended and improved functionality compared with previous
MEPAFLOW

System components
SOPAS ET - Main configurations for commissioning

Certifications
Certifications for CEMS
: TÜV certified acc. to european regulations

- EU directive 2001/80/EC
- EU directive 2000/76/EC for waste incineration plants
- 27. BImSchV, TA-Luft
- 6 months maintenance interval proofed by a 12 months field test
: Compliant to requirements of US regulation US EPA 40 CFR pt.60 and 75
: MCERTS and GOST certification pending

Mounting and installation
Flow profile
Important: Allow for long undisturbed inlet!

Large duct diameters / platform construction
Recommendation: Installation at 60 ° saves costs

Large duct diameters / platform construction
: Application for probe version

FLOWSIC100 PR
: Where a platform is available

from one side only

Single probe version

FLOWSIC100 PR

: Why is the single-probe version good as well?

- For it doesn’t matter that much
- if there is just one probe.
Minimum distance to stack wall were
the local velocity is representative for
- As long as you don’t measure the flow profile
too close to the wall.
Close to stack wall the

gas velocity goes to
zero

Installation of flange with pipe


Flange with pipe mounted on brick or concrete duct

Installation of purged S/R units

Applications
Target Industries
: Power Generation
: Iron and steel manufacturing
: Cement industry
: Pulp and paper
: Waste incinerators

Applications
CEMS application requirements
: Large duct diameters = long measuring distances
: Expected measuring accuracy appr. ± 2-5 %
: Gases with low dust load
: Saturated and dry gases

Applications
Power Plant - CEMS stack measurement
Device: FLOWSIC100 H
Measuring task:
: Measurement of flow rate
Application details:
: Stack diameter inside: 8,5m (28 ft.)
: Flue gas temperature: 182°C (360°F)
: Dust concentration: <10mg/m³ (<0,3 mg/ft³)
: Gas velocity: 10m/s (33 ft/s)

Applications
Power Plant - CEMS stack measurement

Applications where access from one
side is possible only
Device: FLOWSIC100 PR
Measuring task:
: Stack diameter inside: 7,8m (26 ft)
: Flue gas temperature: 165°C (330 °F)
: Dust concentration: <50mg/m³ (<1.4 mg/ft³)

Applications
Waste incineration plant - CEMS stack measurement

Device: FLOWSIC100 H
Measuring task:
: Stack diameter inside: 3.2m (10.5 ft)
: Flue gas temperature: 70°C (158 °F) wet gas

Applications
Process application - controlling of water injection

Device: FLOWSIC100 PH-S
Measuring task:
: Controlling of the volume flow after the last
cyclone filter for the controlling of the water
injection of flow rate
: Channel diameter: 3,5 m (11,5 ft)
: Channel material: carbon steel
: Temperature: up to 400°C (750 °F)
: Flow velocity: ~20 m/s (65 ft/s)
: Dust concentration: ~100 g/m³ (43.7 gr/ft³)

Applications
Process application - combustion air

Device: FLOWSIC100 M-AC
Measuring task:
Controlling of primary air to reduce the nitrogen
oxides. This application requires a reliable result
of measurement for the controlling of the primary
air flap
: channel diameter: 0,7 m (2,3 ft)
: channel material: carbon steel
: temperature: 313 °C (595 °F) The dust was collected from the
: flow velocity: ~25 m/s (82 ft/s) FLOWSIC housing after 12 month
: over pressure: 34 mbar (0.5 psi) without maintenance (here type PMD).

Applications
Process application - Copper industry

Device: FLOWSIC100 PH-S
Measuring task:
: Measuring of exhaust gas from copper smelting
process for the sulphuric acid production.
: Channel diameter: 3,4 m (11,2 ft)
: Dust content: ~ 1.000mg/m³
: Temperature: ~ 400 °C (752 °F)
: Flow velocity: ~ 25 m/s (82 ft/s)
: Overpressure: 100 mbar (1.45 psi)
: Acid dew point : 180°C (356 °F)
: SO2 content: 10 ... 15 g/m³

Applications
Process application - Copper industry
What problems do we had to solve ?

: Acid dew point at 180 °C (356 °F)
: High aggressive gas composition
: High dust load
: The cold air purge drop down the the
flue gas temperature below the
acid dew point at the point of intersection.
Our solution:
: The transducer and probe tube made in Hastelloy.

: Use of purge air heaters

Content
: 1. Introduction / training course objectives

: 2. Basics
: 3. Product family FLOWSIC100
: 4. System components
: 5. Certifications
: 6. Mounting and installation
: 7. Applications
: 8. Special solutions
: 9. Advantages of FLOWSIC100
: 10. Features and highlights
: 11. Competitive comparison
: 12. Conclusion
: 13. Short training

Special Features of FLOWSIC100
1. No purge air required
FLOWSIC100 operates at gas temperatures up to 260 °C without purge air and
above with a innovative internal cooling up to 450 °C.
Advantages
: Lower costs for installation, maintenance, consumables !
: No dew point underruns - no corrosion problems !
: No intake of cooling air in the measured medium

2. Probe version available
Probe version FLOWSIC100 PR allows installation from one side only if
access isn‘t possible from two sides.
Advantage
: Probe version can save costs at large stack diameters because a
expensive 2nd platform constructions isn’t needed !

3. High performance titanium transducers as a standard
All CEMS devices are equipped with long lasting titanium transducers. For
extrem aggressive conditions Hastelloy solutions are available.
SICK technology allows the exchange of a single transducer in case of
failure.
Advantage
: High durability also in wet gas conditions
: Single transducer exchange means lower cost and shorter repair time !

4. High application safety and flexibility
FLOWSIC100 technique is based on SICK‘s experience in ultrasonic
technology for more than 25 years.
Advantage
: Multiple choice for individual application conditions possible
: Ultrasonic technology on highest level of development for long life
measurement and high application safety

5. Easy exchange of Teledyne installations in the US market
FLOWSIC100 is delivered acc. to US standards:
: Flange connection with bolting circle acc. to ANSI CL150 for installation in
existing flanges
: Mounting material 5/8“ screws + nuts
: 19“ version of MCU available
Advantage
: Easy exchange of existing installations
: Plug and play

Features and highlights
Technology features
No Moved parts
: Differential measurement
: Results are independent of gas temperature,

pressure, density and contamination of transducers
: High measuring accuracy even at gas velocity

near zero
No loss of pressure
: No loss of pressure
p2
: No mechanical moving parts

p1
: Easy installation : p1> p2
: Low maintenance effort

Why is ultrasound the best technology ?
Marginal contact to the measured medium

: That means:
- no contamination
- always highest measuring precision !
Reliable and accurate measurement even under extremely difficult conditions

- stack diameters above 3 m,
- wet gas,
- low gas velocity (even close to point zero),
- turbulences

Special features of FLOWSIC100
: Long lasting titanium transducers as a standard
: No purge air
: Easy installation and commissioning
: Single probe version for one-side installation available
: 2-path solution available

: Modular concept allows optimal solutions for individual

application conditions
: FLOWSIC100 - well established products with all

advantages of advanced ultrasonic technology
: SICK MAIHAK - the german technology leader with more than 25 years
of experience in ultrasonic technology

Competitive comparison
Conventional technology - Differential pressure
Principle
: Measurement of total pressure on the front side of
the probe + static pressure on the back of the
probe
: Pressure differences represents a measurement

for the gas velocity

Conventional technology - Differential pressure
Advantages
: Best known technology
: Broad installed base in the field
: Simple construction and manufacturing
Weaknesses
: Difficult to install at large stacks
: Sensitive to contamination and blockages
: High dust concentration means high service expenditures
: No measurement possible close to zero, inaccurate at low gas velocities

Ultrasonic technology - Competitors

DURAG / Model D-FL200
Advantages
: Nothing known in flow
Disadvantages
: Old, heavy technology
: Purged units only
: No titanium transducers
: Not reliable
: No position in the US

Content
: 1. Introduction / training course objectives

: 2. Basics
: 3. Product family FLOWSIC100
: 4. System components
: 5. Certifications
: 6. Mounting and installation
: 7. Applications
: 8. Special solutions
: 9. Advantages of FLOWSIC100
: 10. Features and highlights
: 11. Competitive comparison
: 12. Conclusion
: 13. Short training

Conclusion
Summary - What you should know after the training course
: Measuring task and function of the FLOWSIC100
: Different device types and main specification
: How to advise a customer for a application
: Analyse application conditions and configure the suitable FLOWSIC100
: Prepare quotations of FLOWSIC100

: Thank you for your attention.

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FLOWSIC100.

The ultrasonic gas flow measurement system.

TÜV certified acc. to 13., 17., 27. BImSchV

: SICK : NEP 2009 FLOWSIC100

SICK - German technology leader in ultrasonics

: SICK : NEP 2009 FLOWSIC100

Training course objectives

: Getting an overview of FLOWSIC100

: Advising customers for his application

: Make device configurations and quotations

: SICK : NEP 2009 FLOWSIC100

Measurement of gas velocity in ducts, chimneys and pipes

: SICK : NEP 2009 FLOWSIC100

Application ranges of FLOWSIC100

Inner channel diameter min. - max.: 0,15 ...13 m

Medium temperature: -40 ... + 450 °C

Dust concentration (load) max.: 100 g/m³ s. c.

Ambient Temperature min. ... max.: -40 ... +60 °C

Cable length between control unit

: SICK : NEP 2009 FLOWSIC100

Detection of transit time

vp - average velocity on measuring path

: SICK : NEP 2009 FLOWSIC100

Calculation of volume flow in actual conditions

Qi.a.= volume flow [m³/h i.a.] or [aft³/min]

: SICK : NEP 2009 FLOWSIC100

Calibration Probe measuring point Measurement

Practical profile with

distance relative to the stack centre [m]

: SICK : NEP 2009 FLOWSIC100

e.g. with Gravimat SHC500

Rectangular ducts Circular ducts

: SICK : NEP 2009 FLOWSIC100

Flowsic measurement v [m/sec]

: SICK : NEP 2009 FLOWSIC100

Zero point check (send & receive via internal loop)

: SICK : NEP 2009 FLOWSIC100

Span test (send & receive with internal time delay)

: SICK : NEP 2009 FLOWSIC100

: SICK : NEP 2009 FLOWSIC100

FLOWSIC100 standard types

: Titanium transducers as standard

: Medium gas temperature -40 ... +260 °C

: Medium and high power version

: Single probe version

: SICK : NEP 2009 FLOWSIC100

FLOWSIC100 standard types

FLOWSIC100 AC-types (internal air-cooled types)

: Patented internal air-cooling

: Titanium transducers as standard

: Medium gas temperature -40 ... +450 °C

: Medium power and high power version,

single probe version (on request)

: No intake of cool air in the duct

: SICK : NEP 2009 FLOWSIC100

FLOWSIC100 AC-types (internal air-cooled types)

: SICK : NEP 2009 FLOWSIC100

FLOWSIC100 AC-types (internal air-cooled types)

MCU Control unit

: SICK : NEP 2009 FLOWSIC100

FLOWSIC100 AC-types (internal air-cooled types)

: SICK : NEP 2009 FLOWSIC100

FLOWSIC100 purged types

: Titanium transducers as standard