flare.IQ

Generation 2
Operation and Maintenance Manual

panametrics.com

BH013C11 EN B

flare.IQ
Generation 2

Operation and Maintenance Manual
BH013C11 Rev. B
May 2024

panametrics.com
Copyright 2024 Baker Hughes company.
This material contains one or more registered trademarks of Baker Hughes Company and its subsidiaries
in one or more countries. All third-party product and company names are trademarks of their respective
holders.

[no content intended for this page]ii

Preface

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

Typographical Conventions
Note:

These paragraphs provide information that provides a deeper understanding of the situation, but is notessential to the proper completion of the instructions.

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

CAUTION!

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

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

Safety Issues
WARNING! It is the responsibility of the user to make sure all local, county, state and national

codes, regulations, rules and laws related to safety and safe operating conditions aremet for each installation.

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

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

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

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

iii

Preface

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

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

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

Environmental Compliance
Waste Electrical and Electronic Equipment (WEEE) Directive
Panametrics is an active participant in Europe’s Waste Electrical and Electronic Equipment (WEEE) take-backinitiative, directive 2012/19/EU.

The equipment that you bought has required the extraction and use of natural resources for its production. It may
contain hazardous substances that could impact health and the environment.
In order to avoid the dissemination of those substances in our environment and to diminish the pressure on thenatural resources, we encourage you to use the appropriate take-back systems. Those systems will reuse or recycle
most of the materials of your end of life equipment in a sound way.
The crossed-out wheeled bin symbol invites you to use those systems.
If you need more information on the collection, reuse and recycling systems, please contact your local or regional
waste administration.
Please visit www.bakerhughesds.com/health-safety-and-environment-hse for take-back instructions and more
information about this initiative.

iv

Contents

Chapter 1. General Information
1.1
1.2
1.3
1.4
1.5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Equipment Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1

Main Processor (DPU) – Advantech UNO-2271G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Network Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 2. Hardware

2.2
2.3

Chapter 3. Software
3.1
3.2

3.3

3.4

Overall Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.1 Flare Control (FC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.2 Flare Meter Digital Validation (DV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.2.3 Combustion Efficiency and Predictive Emissions Monitoring (CE/PEMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3.1 User Roles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.2 Network Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.3.3 Flare Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.4 Fuel Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.5 Control Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.6 Data Status Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3.7 Modbus Connection Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3.8 Control Override. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3.9 Flare Meter Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.10 Emissions (CE/PEMS) - Normal and Override modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3.11 Modbus status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Modbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.1 Modbus Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.2 Modbus Address List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.3 flare.IQ units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Chapter 4. Installation & Maintenance
4.1

4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9

Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1.1 Input (1, Figure 34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1.2 Output (2, Figure 34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1.3 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Communication Network Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.2.1
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
19" Rack Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.3.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Replacing a DPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
4.4.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.5.1 Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Technical Regulations & Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cyber Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.9.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.9.2 Exposed Ports and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

flare.IQ Operation and Maintenance Manualv

Contents

Appendix A. Modbus map for legacy flare.IQ Gen 1 installations
A.1

Scaling Modbus Data (for legacy Gen 1 systems only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Appendix B. flare.IQ Secure Operations Guide

Appendix C. Glossary of Terms and Abbreviationsvi

flare.IQ Operation and Maintenance ManualChapter 1. General Information

Chapter 1.
1.1

General Information

Introduction

This manual contains information about the installation, operation, and maintenance of the flare.IQ Gen 2 hardware
and software system. Proprietary flare control and in situ flare flow meter validation software is installed on arack-mounted assembly of industrial embedded automation computers. flare.IQ also implements real-time flare
combustion efficiency (CE) and destruction and removal efficiency (DRE) monitoring based on a parametric model
derived from empirical data and computational fluid dynamics (CFD) calculations. Hence, the flare.IQ Gen 2 is acomplete turnkey hardware and software flare control solution that enables regulatory compliance along withincreased efficiency and reduced operating costs. The flare.IQ system offers three major features to monitor andcontrol both assisted (downstream) and un-assisted (upstream) flaring - flare control (FC), digital verification (DV)and predictive emissions monitoring (PEMS).

1.2

Application

flare.IQ is an online control computer that receives inputs and sends outputs to the flare operator's Distributed
Control System (DCS) via Modbus TCP to control an assisted flare's fuel gas and steam/air assist supply valves (seeFigure 1). The software algorithm in flare.IQ uses the sound speed measured by an ultrasonic flow meter to calculate
the molecular weight of the flare gas, and from the molecular weight, the Net Heating Value (NHV) is determined.
Supplemental fuel gas demand and steam/air assist demand are then calculated based on current net heating
values, hydrocarbon molecular weight and flare vent gas flow.

Figure 1: Schematic of flare.IQ-based control of flare assist (Steam/Air) and supplemental fuel
The flare.IQ is also capable of Digital Validation of an ultrasonic flow meter installed on the vent gas line either on apre-determined schedule or on demand. This Digital Validation algorithm uses measured vs. calculated speed ofsound based on an independent vent gas BTU and/or composition analyzer such as a Gas Chromatograph or Mass
spectrometer. It also utilizes a variety of meter diagnostics such as signal strength, transit times, path length, anddifference in channel velocities to validate the accuracy of the ultrasonic flow measurement.

flare.IQ Operation and Maintenance Manual1Chapter 1. General Information

The third and most recent feature of the flare.IQ system is in situ flare CE and DRE monitoring based on a parametricmodel derived from flare CE experimental data and CFD calculations. This PEMS feature can be deployed on bothun-assisted upstream flares and assisted downstream flares to achieve maintenance-free, real-time monitoring of
CE/DRE based on process and environmental conditions derived from flare flow and wind speed measurement.

1.3

Equipment Overview

The system hardware includes two 19" rack mounting sheet metal modules that house compact fanless Digital
Processing Units (DPU), redundant power supplies, a pair of Ethernet switches and other power distribution
equipment and cables. The top power distribution and networking module is shared with up to six DPU modules
installed in the bottom module (Figure 2). A single DPU module is configured to control a single flare stack while asecond DPU module loaded with identical firmware and settings provided for redundancy. However, a single DPU isadequate for digital verification of a single flare flow meter given the relatively low frequency of this procedure.
Similarly, a single DPU is also adequate for CE/DRE monitoring of a single flare, assisted or non-assisted. The
redundancy option might become necessary for flare PEMS as well in case flare.IQ becomes part of a fiscal
measurement, custody transfer or carbon tax monitoring system in the future. For example, if a customer site has twoflare stacks that need to be controlled, one power distribution and network (top) module and a bottom module withfour (4) DPUs installed would be required. The power distribution and networking module weighs 8.65 lbs. (3.92 kg)
and the bottom DPU module with the maximum number (6) of DPU's installed weighs 8.55 lbs. (3.88 kg).

Figure 2: Front view of Rack mounted Control equipment

WARNING!

A disconnect power switch is required to be installed within 30" (2.5 feet) of the
rack-mounted panels.

WARNING! To ensure the safe operation of this unit, you must install and operate the flare.IQ as

described in this user's manual. In addition, be sure to follow all applicable safety codes
and regulations for installing electrical equipment in your area.

1.4

Equipment Installation

Users typically install the flare.IQ Gen 2 inside an industrial control room that may include a plant distributed control
system (DCS), which controls multiple flare system components such as flare, purge and assist (steam/air) flow
meters, valves, online BTU analyzers (e.g. gas chromatographs, calorimeters) and temperature and pressure
regulators. It is intended for use in an office environment with adequate temperature and RH controls.
This section contains information and instructions for installing the flare.IQ Gen 2 in a plant (DCS) control room, whileconsidering all the above factors. The flare.IQ Gen 2 system can also be installed on unassisted upstream flares with
an ultrasonic flare flow meter and minimal additional control and measurement hardware. Chapter 4 describes in2

flare.IQ Operation and Maintenance ManualChapter 1. General Information

detail how to set up and connect the flare.IQ to the DCS. If you have questions about the installation procedures,contact our technical support department. See the rear cover of this manual for contact information.

Installation shall be in an enclosed rack that requires tool access.
You should discuss environmental and installation factors with a BH applications engineer or field service by the time
you receive the hardware. The equipment provided should be suited to your application and installation site. The
flare.IQ Gen 2 is available only in a 19" rack-mount version suitable for most indoor installations.
The power connections and power supplies are accessible from the backside of the rack mount panel as shown in
Figure 3. The end user brings in a non-detachable power cord per the detailed specifications provided in Section 4.1.

Figure 3: Rear view showing input power connections and power supplies

Figure 4: Rear view close-up of top module showing protective earth grounding

flare.IQ Operation and Maintenance Manual3Chapter 1. General Information

Figure 5: Description of warning symbol labels applied to the top module
Figure 5 provides a detailed explanation of all the warning symbols and labels applied to the flare.IQ Gen 2 hardware.
In addition to following all installation and operation instructions in this User Manual, be sure to follow all applicablesafety codes and regulations for installing electrical equipment in your area.

1.5

System Specifications

Installation•

19" rack mountable (enclosed with tool access), 2 interconnected modules - top (4U) and bottom (3U).

•

Flare Control software always comes with redundant DPUs (i.e., 2 DPUs/flare); Digital Verification or PEMS softwareby itself do not come with redundant DPUs unless combined with Flare Control.

Processor•

Intel Atom® E3815 Single Core 1.46GHz.

Memory•Onboard 4GB DDR3L 1066 MHz.

•

Onboard 32GB eMMC storage.

Connectivity•

One 10/100/1000 Mbps IEEE 802.3u (Ethernet) connection for Modbus TCP/IP.

•

One 10/100/1000 Mbps IEEE 802.3u (Ethernet) connection for DPU configuration/monitoring.

Power
•

AC configuration: Universal power supply adjusts automatically from 100 to 240 VAC, 50/60 Hz.

•

Max power consumption 45 W.

•

DC configuration: Not available.

4

flare.IQ Operation and Maintenance ManualChapter 1. General Information

Size / Dimensions•

Top module: 19.02" (483 mm) Width x 6.93" (176 mm) Height X 4.94" (126 mm) Depth• Weight = 8.65 lbs. (3.92 kg)•

Bottom Module: 19.02" (483 mm) Width x 5.22" (133 mm) Height X 8.05" (204.5 mm) Depth• Weight = 8.55 lbs. (3.88 kg) - with maximum number of DPU's (6) installed

Operating Temperature•

0°C to +40°C (32°F to +140°F).

Storage Temperature•-40°C to +70°C (-40°F to +158°F).

Relative Humidity•

10% - 95% RH @ 25°C, non-condensing.

Maximum Operating Altitude•2000 m (6562 ft).

Overvoltage (Installation) Category•

II.

Pollution Degree•

2.

Ingress Protection•

IP 10 (Protected from touch by hands greater than 50 mm; not protected from liquids).

Warm-up Time•

Meets specified accuracy within 5 minutes of turn-on.

flare.IQ Operation and Maintenance Manual

5Chapter 1. General Information[no content intended for this page]6

flare.IQ Operation and Maintenance ManualChapter 2. Hardware

Chapter 2. Hardware
This section describes the three major components of the flare.IQ Gen 2 system hardware – the Digital Processing
Unit (DPU), the network switch and the redundant 24 VDC power supply.

2.1

Main Processor (DPU) – Advantech UNO-2271G

2.1.1

Functional Description

The flare.IQ Gen 2 DPU is based on a highly ruggedized, fan-less, and modular industrial embedded computer. The
Advantech UNO-2271G edge gateway shown in Figure 6 supports HDMI display, 2 x GbE LAN and 1 x USB 3.0 interfaces.
It is equipped with an Intel® Atom™ processor, 4GB of DDR3L RAM and 32 GB of eMMC solid-state storage.

Figure 6: Advantech DPU Front View
The DPU offers the following features:•

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

•

Intel® Atom™ E3815/E3825 processor with 4GB DDR3L onboard memory.

•

2 x GbE, 1 x USB 3.0, 1 x HDMI.

•

Compact fanless design.

•

Rubber stopper design with internal reserved screws for 2nd layer assembly.

•

32GB eMMC non-volatile flash memory storage onboard.

2.1.2

Connections

LAN: Ethernet Connector
The DPU is equipped with two Gigabit LAN controllers that are fully compliant with IEEE 802.3u 10/100/1000 Base-T. The
two Ethernet ports have standard RJ-45 jacks labeled LAN A and LAN B as shown in Figure 6.
Power Connector
The DPU features a Phoenix Contact connector that is compatible with 10–30 VDC input power shown in Figure 7 on
page 7. The added inclusion of reversed wiring protection means reversing wiring of the ground and power lines will
not damage the system. Following a forced shutdown, wait 4 seconds before powering on the system. The power
connector must then be reconnected.

Figure 7: Phoenix Contact input power connector

flare.IQ Operation and Maintenance Manual

7

Chapter 2. Hardware

USB Connector
A USB 3.0 type A connector that supports plug-and-play functionality is provided to enable service personnel to plugin a keyboard if required. The USB interface can be enabled/disabled in the system BIOS. A silicone rubber dust plug
is provided to increase protection of the DPU during regular operation.
HDMI Connector
An HDMI type A connector is provided for the attachment of a monitor display for use by service personnel if required.
A silicone rubber dust plug is provided for this port as well to protect the DPU during regular operation.
RTC Battery Specification
The DPU is equipped with a real-time clock (RTC) Battery to ensure that the BIOS and system clock settings are
retained even when the power is disconnected.
•

Type: Panasonic BR2032•

Output Voltage: 3 V, 195mA

Power Button/Power Management
The UNO-2271G system has been configured to automatically power on when DC power is applied. Pressing andholding the power button down for 10 seconds will power off the controller, if required.
Reset Button
If the DPU becomes unresponsive, gently press the "Reset" button with a paper clip to activate the hardware resetfunction.
LED Indication
A Power status LED is provided on the DPU front panel right above the Power connector. Also, each RJ45 Ethernet
interface provides 2 LEDs for network connection status, i.e., the system's Link (green) and Active (green) status.
While designed for long-term availability, BH reserves the right to change the DPU hardware provided on flare.IQ Gen
2 with a suitable replacement as required.

2.2

Power Supply

2.2.1

Functional Description

The MINI POWER is a 24 VDC, 3.8 A supply, with a wide input voltage range (100 - 240 VAC). Two internal DC/DC
converters convert supply power into an adjustable and regulated 24 V output voltage. Two MINI POWERs areconnected in parallel (load sharing) to create a high reliability (redundant) supply. Reliable startup of heavy loads isensured by a power reserve of up to 100%. MINI POWER also operates in applications where the static voltage dips orin transient power supply failures. Powerful capacitors ensure mains buffering of more than 20 ms at full load.
The mechanical structure and the housing of this Power Supply are largely determined by its compliance with safety
regulations, and thus the possible installation location of the power supply unit. According to EN 60529, particularattention must be paid to shock protection, foreign body protection and water protection. These degrees ofprotection are listed in the IP (Ingress Protection) code. Generally, IP 20 protection is adequate for dry rooms andcontrol cabinets.
This degree of protection ensures reliable protection from touching live components and prevents penetration offoreign particles with a diameter of more than 12.5 mm (0.5 in.). Protection against water is not provided. In thisapplication, the power supply is installed in a rack-mounted control cabinet, which itself ensures the desired degreeof protection.
For this power supply with class of protection I, protection against electric shock is not only based on the insulation
rating. In addition, parts are connected to the protective conductor of the permanent installation in such a way thatno voltage can remain even if the basic insulation fails. Hence, the system is always provided with a protective earth(PE) ground connection. These units are usually grounded using the PE connection on the AC input terminal. The
power supply unit is electrically connected to the mounting DIN rail via the mounting rail adapter. PE connection via
the terminal point is not required if the mounting rail is grounded.

8

flare.IQ Operation and Maintenance ManualChapter 2. Hardware

2.3

Network Switch

2.3.1

Functional Description

Panametrics' industrial Ethernet 10/100 switches are designed specifically to meet the needs of real-time industrial
control solutions. The Ethernet switch model used in this application is an 8-port 10/100 base T copper cables only,
IS420ESWAH2A. To meet the requirements for speed and functionality, the following features are provided:•

802.3, 802.3u, and 802.3x compatibility•

10/100 base T copper with auto negotiation•

Full/half duplex auto-negotiation•

Two 100 base FX uplink ports•

HP-MDIX auto sensing•

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

LED for Power•

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

Flow Control (Pause)
The switch supports flow control between switches. It uses IEEE defined pause packets to receive and honor pause
packets. The switch only sends the pause packets if it needs flow control on a port.
Connectors
The RJ-45 connectors support multiple insertions and removals with an estimated service life expectancy of 200
insertion/removal cycles.
Mounting
The two Ethernet switches labeled Ethernet #1 (Configure/Monitor) and Ethernet #2 (Flare control/to DCS) are
mounted in the 4U top power distribution and networking module.
Power
Supports two redundant diode-OR'd power supply inputs of 18 to 36 V DC, < 0.5A (total).
Environment
Convection cooled when mounted vertically or horizontally. Coating is corrosion resistant with provisions made forgrounding per IEC 60721-3-3 Class 3C2.
Diagnostics
The two status LED's indicate diagnostic information as show in Table 1 below.

LED oneTable 1: Network Switch Diagnostic Indicators
Flashes Green for activity at Full Duplex
Flashes Yellow for activity at Half Duplex
Green = Link and 100 Mb

LED twoflare.IQ Operation and Maintenance Manual

Yellow = Link and 10 Mb
No led lit = no link

9

Chapter 2. Hardware[no content intended for this page]10

flare.IQ Operation and Maintenance ManualChapter 3. Software

Chapter 3. Software
3.1

Overall Architecture

All flare.IQ software applications run on a real-time operating system (RTOS) for embedded devices. As described in
the following section, all analog inputs from the flare flow meter, steam/air flow meter, and online analyzer are
received from the DCS via Modbus/TCP. On startup, the RTOS automatically starts the flare.IQ core software, theembedded web server, and the Web Console application. The flare.IQ core is a component architecture of separate
processes that perform the data acquisition and processing for flare control, meter validation, and emissions
monitoring. It includes a dedicated Modbus/TCP server and components for verifying license status and user
permissions.
The Web Console application is a browser-hosted interface that can be opened by a single authorized user
connected to the flare.IQ via LAN A (Ethernet 1). It is used for configuring the flare.IQ during initial set-up andcommissioning. As described below, it can be used to monitor the functionality of flare.IQ during operation, to upload
software updates and license files, as well as to download meter validation reports and data logs.

3.2

Functional Description

3.2.1

Flare Control (FC)As described in Section 1.2, flare.IQ can be used to calculate in real time the steam/air assist and supplemental fuelrequirements for the efficient operation of downstream flares. The flare control software algorithm uses the speed ofsound measured by BH’s ultrasonic flare flow meter to estimate the molecular weight of the vent gas between
updates from an optional online analyzer such as a Gas Chromatograph, Mass Spectrometer or Calorimeter. The
calculated molecular weight, vent gas flow, and fuel flow are then used to estimate the net heating value of the ventgas (NHVvg). The net heating value is used to control the supplemental fuel gas flow (i.e., fuel gas valve demand to
the DCS). The steam/air assist demand is a function of the molecular weight of the hydrocarbons in the vent gas
and the flare flow. The system also calculates the NHV in the combustion zone. The high-level process logic flow
diagram is shown in Figure 8 below.

Figure 8: High-level flare control process logic flow

flare.IQ Operation and Maintenance Manual11

Chapter 3. Software

3.2.2

Flare Meter Digital Validation (DV)Ultrasonic flare flow meters are widely used on oil & gas production assets, pipelines, and in refineries andpetrochemical plants for flare operation and emission control. Regulatory compliance requires these flare flow
meters to be validated periodically to meet their expected performance per the manufacturer's specifications.
Typically, this requires a service engineer to travel to the meter installation site, conduct a visual and/or physicalinspection of the meter hardware and components, access the electronics and/or transducers to collectperformance/diagnostic data for a prescribed period. The service engineer then generates a Pass/Fail evaluation
report for the meter after performing certain on-site tests and reviewing the diagnostic data.
A key new feature of the flare.IQ Gen 2 is digital verification, a new Software as a Service offering to realize thisperiodic meter validation in situ. This feature obviates the logistical complications of a service visit and plant/processinterruption that may be required to access the meter. This feature has been implemented by building in theintelligence required to conduct digital verification of a flare meter in situ into the flare.IQ Gen 2 system without
human intervention. The flare meter verification algorithm relies on a "reference" measurement of the vent gas
composition, which could be done with an online analyzer such as a Gas Chromatograph or Mass Spectrometer
where available. It also uses as input the flare pressure and temperature, flow meter data and diagnostics. The
overall logic of the flow meter validation scheme is shown in Figure 9.

Figure 9: Digital Flare flow meter validation scheme
In case there is no online flare gas analyzer, a time-stamped sample can be analyzed off-line and used as areference for vent gas composition. The main objective of the Digital Validation is to verify that the flare meter isfunctioning as designed without having to physically access its hardware. In order to efficiently collect and digitally
analyze all relevant diagnostics, this DV feature requires a Modbus/TCP or RS485 connection between the flare flow
meter and flare.IQ. Since the flare monitoring application is inherently noisy and variable, flow validation requires astable flare process, which usually happens when there is no/low flaring event. In this case, vent gas flow rate isnormally low, and flare gas compositions are relatively simple and constant.

12

flare.IQ Operation and Maintenance ManualChapter 3. Software

Figure 10: Flare flow meter validation logic
The high-level logic for the Panametrics flare flow meter performance validation is illustrated in Figure 10. flare.IQ
uses a FIFO buffer to track meter performance and diagnostics data over the last 8 hours. This buffer's capacity is set
to expect flare flow and diagnostic data no faster than once every 5 seconds. If an on-demand validation is initiatedby the end user, flare.IQ will analyze the last 8-hour data and report a result as one of the following:
a.

Pass

c.

Process unstable for validation

b.

Fail

If the validation is initiated on a pre-determined schedule, this validation will operate on an automated fashion on
the last batch of 8-hour data available. At the end of each digital verification cycle, a summary meter validation
report and the raw data (over the entire 8-hour block) used for generating the report are saved to the flash memoryof the DPU in CSV format.

flare.IQ Operation and Maintenance Manual13

Chapter 3. Software

3.2.3

Combustion Efficiency and Predictive Emissions Monitoring (CE/PEMS)

A new feature that has been recently added to the flare.IQ Gen 2 software is the online calculation of flare
combustion efficiency (CE), destruction and removal efficiency (DRE) and various gas emission values. This
Predictive Emissions Monitoring System (PEMS) feature can be utilized for monitoring both unassisted (upstream)
flares and steam/air assisted (downstream) flares independently of the Flare Control and Digital Validation featuresdescribed above. As shown in Figure 11, a parametric model can utilize the vent gas NHV and flare operating
conditions to calculate CO2, CO and VOC emissions.

Figure 11: High-level schematic of flare CE, DRE and emissions calculations
flare.IQ implements in situ flare CE and DRE monitoring based on a parametric model derived from flare CE
experimental data and computational fluid dynamics (CFD) calculations. At its core, it utilizes the calculation ofmolecular weight and Net Heating Value of the flare gas from the flare temperature, pressure and sound speed
derived from the ultrasonic flow meter. This PEMS calculation can be customized for upstream and downstream
flares to achieve real-time monitoring of CE/DRE based on process and environmental conditions derived fromultrasonic flare flow, assist/fuel flow and wind speed measurement.

3.3

Configuration

The Web Console application can be used to configure the flare.IQ during initial commissioning as well as to monitor
performance of various components of the software such as flare control, digital verification and PEMS. This secure
Web Console can be launched from a supported web browser running on a host PC connected to the Configure /Monitor (Ethernet 1) switch on the top module (see Figure 36 on page 44). From your web browser enter https://<ip
address>/fiqWeb to launch the web console. If you leave off /fiqWeb, a default page will load that has a link to the
Web Console page. The login screen of the Web Console application is shown in Figure 12 below.

14

flare.IQ Operation and Maintenance ManualChapter 3. Software

Figure 12: Log in screen of the Web Console application
The Web Console is designed to work with Chrome and Firefox browsers and is optimized for a screen resolution of1280 x 1024. Upon initial log in with the default admin password, the user is led to the Service tab from where they cannavigate to the Features tab shown in Figure 13 to upload appropriate software licenses.

Figure 13: Web Console Service page upon initial login prior to installation of any valid licenses
Software license files that provide access to one or more of the three features listed on this page for a
pre-determined duration can be obtained from your Panametrics Service Engineer. Please note these encrypted
license files are tied to the specific DPU hardware on your flare.IQ Gen 2 system. These license files can be uploaded
from the host PC connected to the flare.IQ by selecting the files using the "Choose Licenses" button and uploadingthem using the "Upload Licenses" button as shown in Figure 13.
When successfully uploaded, all menu items on the left side of the Web Console application will turn blue (live) on the
Features page and the validity of each license will be indicated by showing the number of days each for which
licensable service is valid (Figure 14). The color coding for the number of days remaining depends on the value,
going from green (> 15 days, long duration) to yellow (0 - 14 days) to red (-1 to -30 days). After the 30-day grace
period, the licensed component will stop functioning. Function will resume immediately after a new, valid license isinstalled.

flare.IQ Operation and Maintenance Manual

15

Chapter 3. Software

Figure 14: Web Console Features page after uploading software license information.
To update software, clicking the "Choose Software file" button opens up a file browser allowing the user to select a
new Software Image file. Only a single file with ".tar.gz" or ".tgz" file extensions can be selected. A software update will
reboot the DPU and will require the user to log back into the Web Console. Depending on the agreed terms andconditions, please note these software updates to correct for defects are provided free of charge. Any newly added
product software features have to be purchased.

3.3.1

User Roles

There are 4 different types of User with different access levels as defined below• Administrator: Administrators have full permissions and can access and modify all pages of the Web Console.
Administrators can create new accounts on the system, including other administrators.
• Field Service: Field Service accounts have the highest level of access with the added ability to update software
via the Features page and upload/download configuration files for Meter Validation on the Service page.
Panametrics service personnel will typically create a Field Service account so they can access the system
without requiring an Administrator to be present. They will, however, not be able to add, delete or modify otheruser accounts set up on the system by an Administrator.
• Operator: Operators can access and modify the Control, Flare, Fuel, Emissions, Validation, Features, Modbus
and Service pages, so that they may observe and change the flare.IQ operating parameters as required.
Operators do not have access to the Network configuration page. An Operator may change their own
password on the Accounts page.
• Viewer: Viewers have read-only access to the Control page and may change their own password on the
Accounts page.
Figure 15 shows how new users can be added by creating new accounts for them along with the Username andPassword requirements. During the initial configuration, the Panametrics field service engineer will log in using theircredentials but can help the Administrator set up other accounts as required.

16

flare.IQ Operation and Maintenance ManualChapter 3. Software

Figure 15: Web Console Accounts page showing procedure of setting up new accounts with different access levels.

3.3.2

Network Setup

There are two Ethernet switches on the top flare.IQ module, labeled Configure/Monitor (Ethernet 1) and LAN B FlareControl/DCS (Ethernet 2). The Web Console uses the LAN A (Ethernet 1) jack on each DPU. The Modbus TCP
connection to the DCS is only supported on the LAN B (Ethernet 2) jack. DHCP is disabled. By default, the ports are at
the following addresses:• LAN A: IP address: 192.168.100.100, netmask 255.255.255.0, gateway = 192.168.100.1• LAN B: IP address: 192.168.100.200, netmask 255.255.255.0, gateway = 192.168.100.1

DPU MODULE #Table 2: Factory set default IP addresses
DPU Config IP Address
Modbus IP Address1

192.168.100.100

192.168.100.200

2

192.168.100.101

192.168.100.201

3

192.168.100.102

192.168.100.202

4

192.168.100.103

192.168.100.203

5192.168.100.104

192.168.100.204

6192.168.100.105

192.168.100.205

Figure 16 shows the Network configuration page that can be navigated to after initial login. Any host PC should be set
to a static IP address on the same subnet as the LAN A connections on all DPUs. As shown in Table 2, the DPU modules
are addressed according to their mounted location (DPU 1 is assigned IP address 192.168.100.100).

flare.IQ Operation and Maintenance Manual

17Chapter 3. Software

Figure 16: Network set-up page including IP address and Modbus Word/Byte order configuration.
This page also includes options for changing the Modbus/TCP configuration:• Modbus/TCP server listen port (502 is the default)• Modbus Node/Device address (1 is the default). Please note that the flare.IQ does not support address 0(accept any address).
• Byte order (Most Significant Byte (MSB) first is the default). Please note that MSB order is per the Modbus
standards.
• Word order (Most Significant Word (MSW) first is the default). Please note that word order is not formallydefined by the Modbus standards.
A detailed description of the Modbus map required to set up the DCS Modbus master is shown in Section 3.4.2.
Figure 17 shows the Service page of the Web Console which enables the following important system settings:• Change Flare Name
• Choice of units of measure - SI (Metric) vs. English (Imperial)• Ability to download installation specific Site File (text) that contains a record of ALL configuration settings
available to the Web Console• Ability to upload the configuration file required to set Pass/Fail criteria for digital meter verification (Field
Service access only).
• Reset Totalizer (for Steam and Fuel totalizer features).
1. When the flare control license is valid, the totalizer will be displaying message stating "Not applicable for units
utilizing Flare Control".
2. If only the DV or DV and PEMS both licenses are valid, the totalizer will show a message indicating a successful reset as "Totalizer has been reset successfully" after reset totalizer button is been clicked.
3. If only the PEMS license is valid, the totalizer will be displaying a message stating "Not applicable for units utilizing Emissions".

18

flare.IQ Operation and Maintenance ManualChapter 3. Software

Figure 17: Service configuration page that enables uploading installation specific site files

3.3.3

Flare Configuration

The flare.IQ Gen 2 is capable of operating with a wide variety of flare installations such as steam or air assist, online
gas chromatograph, mass spectrometer or calorimeter for BTU measurement, and multi-flare, single-stackinstallations. Depending on the specifics of each installation, the Web Console can be used to configure the flare.IQ
Gen 2 during initial set-up. Figure 18 shows the flare configuration page for the steam assist option. All quantities are
displayed in English units as listed in Table 11 on page 39.

Figure 18: Flare Configuration page showing Tooltip example

flare.IQ Operation and Maintenance Manual

19Chapter 3. Software

All fields in the flare and fuel configuration pages utilize tooltips. Tooltips will indicate appropriate information about
the item being hovered over. Some of the installation-specific parameters that apply to all types of flare installations
available on the left side of flare configuration page are:
• Flare Tip Diameter• Flare-to-steam ratio correction factor• Choice of flare assist: Steam vs. Air• Choice of Continuous velocity vs. 3-speed Air assist

Figure 19: Flare settings for Steam assist
Figure 19 shows a typical Steam assist flare configuration page. Some installation specific parameters that may
need to be fine-tuned for your installation can be set on this page including:• Low Molecular Weight (MW) Correction Factor• Normal MW Correction Factor• High MW Correction Factor• Low MW cut-off• Normal MW cut-off• High MW cut-off• Minimum allowed steam flow
• Maximum allowed steam flowYour Panametrics Field Service Engineer can provide in-depth instructions on the purpose of each configuration
parameter and how to determine the correct values to enter.

20

flare.IQ Operation and Maintenance ManualChapter 3. Software

Figure 20: Flare settings for Air assist (continuous)
Figure 20 shows the Web Console settings for an Air assist flare configuration where the air flow can be varied
continuously. While majority of these parameters are like those under the Steam assist settings, the only differences
are the following:• Minimum Air flow
• Maximum Air flow
This figure also shows as a representative example the state of the Web Console prior to clicking either "CANCEL" or"SAVE & CONTINUE" at the bottom. One of these must be clicked for any of the other tabs to be available. Figure 21
shows the Web Console settings for the discrete (3-speed) Air assist configuration with the following settings:• Low Air flow
• Medium Air flow
• High Air flow

Figure 21: Flare settings for Air assist (discrete)
flare.IQ Operation and Maintenance Manual21

Chapter 3. Software

3.3.4

Fuel Configuration

As shown in Figure 22 this page enables setting the following flare (supplemental) fuel specific parameters:• Choice of Flare Energy Content from - GC/Calorimeter.
• Analyzer Update Rate Minimum allowed fuel flow.
• Maximum allowed fuel flow.
• Lag time between fuel flow change and flare meter response.
• Action Threshold for changes in steam or fuel demand.
• Nominal fuel Net Heating Value (natural gas in this example).
The bottom left of the fuel page has two special configuration parameters:
4.
5.

Choice of NHV for H2 between 275 BTU/SCF and 1212 BTU/SCF (apply EPA 1212 rule).
Choice of constant N2 volumetric flow (i.e., N2 mole fraction inversely proportional to total flare gas flow) or constant N2 mole fraction.

In addition to tooltips, detailed information on the purpose of each of the above settings as they apply to your flareinstallation along with in-depth instructions on how to determine the correct values to enter can be obtained fromyour Panametrics Field Service Engineer.

Figure 22: Fuel settings configuration page

3.3.5

Control Overview

After all configuration steps are complete, the Control Overview is displayed. This screen provides a real-time
readout of essential data being sent to the flare.IQ, and the results the flare.IQ has calculated. Displayed data isorganized in 'panes' as follows:•

The Heading Bar displays the configured flare name or tag, the Modbus connection status, and the user currently
logged in. A running time display indicates updates of the data below.

•

The System Readouts pane shows the Net Heating Value (NHV) actual. This is the calculated energy content at
the flare tip, as determined by the gas composition and energy content derived from the vent/flare gas
flowmeter measurements. NHVcurrent must remain above a critical value of 270 BTU/SCF for EPA complianceunder the MACT rules.

•

This pane also shows the Fuel Demand and Steam or Air demand. These are the quantities of supplemental fueland assist flow calculated by the flare.IQ for optimal operation. It is these values that the controlling DCS should
use as setpoints for the fuel flow, steam flow, or air flow.

22

flare.IQ Operation and Maintenance ManualChapter 3. Software•

The Flare pane displays the critical flare measurements as captured by the DCS and sent to the flare.IQ. Use thisto verify that the data obtained from the flare flowmeter, temperature, and pressure sensors is being reliablytransferred from the DCS to the flare.IQ.

•

The Assist pane displays the amount of supplemental fuel, steam, or air being provided to the flare, as measured
by additional flowmeters, or determined from control valve positions by the DCS.

•

The Customer Analyzer Data pane displays the concentration of non-hydrocarbon components in the flare gas
as determined by a Gas Chromatograph (GC), Mass Spectrometer (MS), or Calorimeter. If available, the NHV and
Molecular weight of the vent gas as determined by these instruments is also displayed.

•

The flare.IQ Calculations pane displays results calculated by the flare.IQ consisting of:•

NHV of vent gas (NHVvg) derived from the gas composition and sound speed data•

Molecular Weight (MW) of the vent gas derived from the gas composition and sound speed data•

NHV in the combustion zone (NHVCZ) derived from the gas composition and sound speed data•

Calculation of the flare gas velocity at the tip of the flare stack (Vtip).

Figure 23: Control page with no Modbus connection

3.3.6

Data Status Color

The Control Overview screen uses color to provide additional information about the data displayed. The top of thedisplay presents the following color key:

• Data displayed in green is determined by the flare.IQ to be valid, within programmed limits, and has been
recently updated.

• Data displayed in red is determined to be invalid. This can be caused by the parameter never having been sentby the DCS or is the result of a failed calculation (for example, a divide by zero condition caused by anotherparameter being invalid).

flare.IQ Operation and Maintenance Manual

23Chapter 3. Software• Data displayed in gray is determined to be 'stale'. The result is valid, but it is marked as stale because theparameter has not been recalculated or is the result of a calculation using another parameter that has notbeen updated by the DCS in a specified time period. Most parameters are considered stale if they have notbeen updated for 150 seconds (2.5 minutes). Gas composition data is considered stale if it has not been
updated for the time specified as the GC/MS Update Rate on the Fuel Settings page.

• Data displayed in blue is determined by the flare.IQ to be below the low range limit determined for thatparameter. This is usually an indication of an error in a parameter value supplied by the DCS.

• Data displayed in orange is determined by the flare.IQ to be above the high range limit determined for thatparameter. This is usually an indication of an error in a parameter value supplied by the DCS.

Figure 24: Control page with active Modbus connection

3.3.7

Modbus Connection Status

The status of the Modbus link between the DCS and the flare.IQ is displayed in the Heading Bar. Note that this is the
network connection on LAN B. It is not an indication of communication status between the browser displaying the
Web Console and the flare.IQ. Any issues with the network connection on LAN A will appear as an http error by thebrowser.
There are three Modbus connection states:•

Disconnected - The DCS or other Modbus master has not initiated a TCP session with the flare.IQ or has
disconnected/closed the TCP session. A disconnect is assumed to have occurred if there is no traffic on thedesignated port for 30 seconds (Figure 23).

•

Connected - The DCS has initiated a TCP session with the flare.IQ and is actively sending Modbus requests. Thisis the normal state of system operation (Figure 24).

•

Time Out - The DCS has not disconnected/closed the TCP session with the flare.IQ but has not sent a Modbus
request for more than 15 seconds (Figure 25).

24

flare.IQ Operation and Maintenance ManualChapter 3. Software

Figure 25: Control page under timeout conditions

3.3.8

Control Override

When logged in as an Administrator or Operator, an Override switch is displayed on the upper right of the Control
page. Override mode is a troubleshooting and diagnostic tool for flare.IQ calculations page, overriding the data fromthe DCS.
When placed in Override, the Fuel and Assist setpoint calculations are determined by values entered by
the Operator, NOT by the data Conprovided by the DCS. The DCS flare control must be placed in
MANUAL mode before selecting Override. Automatic or 'cascade' control by the DCS MUST be disabled!
The flare.IQ will then calculate results based on the manual entries. This allows the effect of changing theseparameters to be observed without having to otherwise disturb DCS operations or configuration. The changes incalculated values will continue to be read by the DCS. It is imperative that the DCS be placed in Manual mode before
attempting to override any parameter. Otherwise the DCS would act on the changes in setpoint values, which are nolonger valid. When Override is switched off, the flare.IQ will accept new data from the DCS as soon as it is provided via
Modbus. When the calculated results have stabilized at the new values, the DCS may be returned toautomatic/cascade control.
The parameters that can be manually entered in Override mode (by entering numerical value and pressing ENTER)
are:•

Flare flow•

Flare sound speed•

Flare temperature•

Flare pressure•

Steam/Air assist flow•

Supplemental fuel flow•

Vent gas NHV•

Non-HC gas concentrations

These parameters will hold the last values written by the DCS before Override was switched on. The values can thenbe individually edited. It may take up to 10 seconds before the effect of a changed value is seen because the web
page refresh rate is limited in Override mode.

flare.IQ Operation and Maintenance Manual

25

Chapter 3. Software

Be sure to turn Override off to resume normal operation when testing is completed.

Figure 26: Control Page with Override Enabled.

3.3.9

Flare Meter Validation

The flare.IQ Gen 2 system is designed to operate at any GF868/XGF868i installation that employs a Modbus RTU or
Modbus TCP connection between the Panametrics flare flow meter and the DCS. The DCS acts as the Modbus masterreading diagnostic data from the GF868/XGF868i and writing them to flare.IQ Gen 2. The Gen 2 system is designed tooperate on an independent Modbus TCP network without interrupting an existing installation of flare.IQ Gen 1 used forflare control. The basic logic of the digital meter verification feature is described in Section 3.2.2.
When enabled by a valid license, digital verification will be performed automatically on the 1st of every calendar
month at 01:15 AM UTC. Figure 27 shows the validation page of the Web Console that enables an on-demand digital
verification on a specific flare flow meter. Your Panametrics Field Service Engineer will ensure that the firmware anddigital communication hardware of the flare flow meter (GF/XGF) is at the correct version and the units of measure(English/Metric) are set consistently between flare.IQ Gen2 and the flare flow meter. They will configure the digital
verification feature at commissioning by uploading a site-specific meter configuration file via the Service page.

26

flare.IQ Operation and Maintenance ManualChapter 3. Software

Figure 27: Validation page showing system is ready for on-demand digital verification.
As shown in Figure 10 on page 13, running digital verification requires a minimum amount of meter diagnostic datacollected over an 8-hour time window. This ensures verification occurs only when stability criteria for all flow meter
diagnostics are adequately satisfied. The "VALIDATE NOW" button on the validation page in Figure 27 will be enabled
only when this condition is met. The maximum data interval for sending all GF/XGF Modbus data from the DCS toflare.IQ Gen2 is 3 minutes. Occasional communication dropouts that lead to data intervals greater than 3 minutes
are acceptable. In case of loss of power to flare.IQ Gen 2, all validation data accumulated in the FIFO buffer is lost.
Hence, an on-demand verification request will need to wait for 8 hours after power has been restored for the buffer tobe refilled.
Figure 28 shows the results of a passing digital verification for a 2-channel flow meter. The date and time the lastvalidation was completed (regardless of the result) are shown in the top right corner. The results of sound speed
validation vis-à-vis an online gas analyzer are shown on top while the results of the diagnostics validation based onmeter configuration-specific pass/fail criteria are listed in the bottom table.
These results can be downloaded in the tabular format displayed as a CSV (comma-separated value) file. This file isautomatically named by the system using the date and time of the report and saved in a pre-selected directory on
the DPU eMMC storage. Clicking the "DOWNLOAD DATA" button enables saving all the raw data used for generating
this report as a CSV file, again at a preset location on the DPU eMMC storage for archival, or for downloading andsending to Panametrics service.

Figure 28: Validation page showing typical result for passing digital verification
flare.IQ Operation and Maintenance Manual27

Chapter 3. Software

There are two other possible outcomes of the digital verification process as described in Section 3.2.2 See “Flare
Meter Digital Validation (DV)” on page 12. The former result is to be expected when either the Sound speed or the
Diagnostics validation fail their installation-specific pass/fail criteria. The latter outcome is a result of analyzing all
the data in the 8-hour block without being able to identify an adequately long block of "stable" data. In this case, theverification procedure can be repeated after waiting for a minimum of 30 minutes. In either case, you are advised tosave both the report and raw data as separate CSV files and send them to Panametrics field service for further
analysis.
Figure 29 shows the results of an unsuccessful meter validation where analysis of the 8-hour data block is unable toidentify a sufficiently long period of stable data that can be used for verification. Again, these results can be
downloaded as a CSV file for the report and/or for the raw data. Hence, after initial commissioning, the Validation
page will display the results of the last digital verification “Flare Meter Digital Validation (DV)” on page 12 (preset oron-demand) along with a drop-down list of all available reports listed in reverse chronological order. The "VALIDATENOW" button is available immediately after the analysis is complete and results report and data file have been
generated.

Figure 29: Validation page showing results of an unsuccessful digital verification due to process instability.

3.3.10 Emissions (CE/PEMS) - Normal and Override modes

This Emissions tab of the Web Console is enabled only when the PEMS feature is licensed. As shown in Figure 30, it
provides a real-time readout of all CE/PEMS relevant data being sent to the flare.IQ including specific flareconfiguration information, and the outputs the flare.IQ has calculated. Displayed data is organized in 'panes' as
follows:•

The Heading Bar displays the configured flare name or tag, the Modbus connection status, and the user currently
logged in with a running time display indicating time stamps for the data values shown below.

•

There are two selector slide bars on the top right - one to choose the flare assist type (Steam/ Air/ None) and theother to turn the Override mode On/Off.

•The Emissions pane on the left shows key PEMS outputs including:॰ Combustion Efficiency which measures the percentage of hydrocarbons in the flare gas that are completely
combusted and converted into CO2 and H2O.
॰ Destruction/Removal Efficiency which represents the fraction of hydrocarbons being removed or destroyedeven if they are not completely combusted.
॰ Volatile Organic Compound (VOC) emissions from the flare.
॰ Carbon Monoxide (CO) emissions from the flare.
॰ Carbon Dioxide (CO2) emissions from the flare.
॰ Total CO2-Equivalent flare emissions based on Global Warming Potentials of all emissions components.

28

flare.IQ Operation and Maintenance ManualChapter 3. Software

Figure 30: Emissions page without Modbus connection•

The Flare Inputs pane in the top center displays the critical flare measurements such as flare flow, assist flow,
flare temp, pressure, etc. collected by the DCS and sent to the flare.IQ as Modbus inputs. This pane should be
used to verify that the data obtained from the flare flowmeter, temperature, and pressure sensors are being
reliably transferred from the DCS to the flare.IQ.

•

The Flare Configuration pane in the bottom center displays two key flare gas parameters - the ratio of carbon tohydrogen atoms and the fraction of Double bond.

•

The flare.IQ Readouts pane in the top right displays the Net Heating Value and Molecular Weight of the vent gas
as calculated by flare.IQ.

•

The Customer Analyzer Data pane in the bottom right displays the concentration of non-hydrocarbon
components in the flare gas as determined online/offline by a Gas Chromatograph (GC) or Mass Spectrometer(MS). If available, the NHV and Molecular weight of the vent gas as determined by a BTU analyzer such as a
Calorimeter is also displayed.

Similar to the Control page, when logged in as an Administrator or Operator, an Override switch is also available to a
PEMS feature user on the Emissions page as shown in Figure 31 In this case, the override mode is meant to be used atroubleshooting and diagnostic tool for CE/PEMS calculations.
IMPORTANT: When placed in Override, all PEMS calculations are based on values entered by the
Operator, NOT by the data from the DCS. Any DCS flare control must be placed in MANUAL
mode before selecting Override. Automatic or 'cascade' control by the DCS MUST be
disabled!
As described in Section 3.3.8, when the Emissions Override mode is switched on, the flare.IQ ignores Modbus datafrom the DCS for all input parameters shown on the Emissions page. These data values can then be enteredmanually by the Operator, overriding any data from the DCS. The flare.IQ will calculate CE/PEMS results based onthese manual entries, which allows the user to observe the effect of changing these parameters without having tootherwise disturb DCS operations or configuration. The changes in calculated values will continue to be read by the
DCS. It is imperative that the DCS be placed in Manual mode before attempting to override any parameter. Otherwise
the DCS would act on the changes in flare control setpoint values, which are no longer valid. When Override isswitched off, the flare.IQ will accept new data from the DCS as soon as it is provided via Modbus. When the calculated
results have stabilized at the new values, the DCS may be returned to the automatic/ cascade control. The
parameters that can be manually entered in the Emissions Override mode (by entering numerical value andpressing ENTER) are:flare.IQ Operation and Maintenance Manual29Chapter 3. Software• Flare sound (box has to be clicked to initiate a new calculation)• Flare flow
• Flare temperature• Flare pressure• Steam/Air assist flow
• Downstream N2 purge• Wind speed• C:H ratio in vent gas• Double bond fraction• Vent gas NHV• Non-HC gas concentrations
These parameters will hold the last value written by the DCS before Override mode was switched on. The values canthen be individually edited. It may take up to 10 seconds before the effect of a changed value is seen because theweb page refresh rate is limited in the Override mode. One significant difference between the Override mode on the
Emissions page (Figure 31) and that on the Control page (Figure 26) is any new calculation is triggered by providing a“new” value of the Sound speed. Hence, even if the value of Sound speed is not changed, none of the outputs will berecalculated until the Sound speed box is clicked.
IMPORTANT: Be sure to turn Override off to resume normal operation when testing is completed.

Figure 31: Emissions page with override enabled

3.3.11

Modbus status

As described in Section 3.3.2 above the end user can set up the IP configuration of both the Configure/Monitor port
(LAN A) and the DCS/Modbus master connection (LAN B) for all DPU's on the flare.IQ. Section 3.4.1 below described
how the DCS/Modbus master can be configured per the Modbus address list for each of the three main flare.IQ
applications. Once this Modbus set up and programming are complete, the Operator can test a live Modbus
connection to the DCS using the Modbus tab of the web console, which is available to all users.

30

flare.IQ Operation and Maintenance ManualChapter 3. Software

Figure 32 shows the Modbus map for flare control while Figure 33 displays the Modbus map for Digital Validation.
There is a slider bar in the top right that lets the Operator switch between the two pages.

Figure 32: Modbus page showing Digital Validation
As shown in the figures above, these parameters for each of the two features are grouped into Holding (analog
input), Input (analog output) and Boolean status and coil registers (where relevant). The intent of displaying live
Modbus data is to enable the Operator to check the DCS/Modbus master configuration for each of these two
features separately. If any of the displayed values are incorrect, out of range or static, the DCS configuration for those
Modbus addresses should be checked.

Figure 33: Modbus page showing flare control

flare.IQ Operation and Maintenance Manual31

Chapter 3. Software

3.4

Modbus3.4.1

Modbus Configuration

The default Modbus TCP configuration is as follows:
Modbus Device Address = 1
TCP Port = 502
Byte Order = Most Significant Byte First.
Word Order = Most Significant Word First.
This configuration can be changed as required on the Network page of the Web Console.

3.4.2

Modbus Address List

flare.IQ Gen 2 uses 32-bit IEEE-754 Floating point representation for all analog inputs (Modbus holding registers) andoutputs (Modbus Input registers). Hence, no scaling is required to maintain numerical accuracy. Please refer to the
Modbus Messaging on TCP/IP Implementation Guide V1.0b from Modbus.org and to your DCS/PLC instruction manualfor how to use this address information properly in Modbus messaging. Note this address list does not follow thelegacy convention of using 00001-10000 for read/write discrete outputs or coils and 30001-40000 for16-bit analog
input registers.
Holding registers should be written using the Modbus Preset Multiple Registers command (function code 16). All
32-bit values must be sent as an even number of registers (minimum 2) with an even starting address. flare.IQ
register addressing is zero-based. The first Modbus register is address 0000. Some DCS configurations use
ones-based addressing, where the first Modbus register is address 0001. In this case, address values may have to becorrected by adding/subtracting 1.
Many of the Modbus values are also displayed on the web console. For these critical parameters, the web console
can be used to verify that Modbus data from the DCS is being sent to the correct register in the correct format.
Extreme numeric values, 'INF', or 'NaN' displayed on the web console are an indication of incorrectly formatted
Modbus data.
A signal is considered bad quality when its link to Modbus is broken, the signal value is unchanging, or the signal isout of range. In these cases, the signal value is held at the last known good value. Additionally, the flare.IQ willvalidate that inputs are reasonable; for example, if the total concentration of all specified composition gases
exceeds 100%, the signal values of all gases will be set to bad quality until the composition is corrected.
Table 3: Modbus Address List - Holding Registers for Flare Control (analog inputs)
Register
Number ofRegister Tag Name
Description
Address
Registers

32

AR

1010

2

Argon Concentration

CO2

1012

2

Carbon Dioxide Concentration

CO

1014

2

Carbon Monoxide Concentration

H2

1016

2

Hydrogen Concentration

N2

1018

2

Nitrogen Concentration

O2

1020

2

Oxygen Concentration

H2O

1022

2

Water Vapor Concentration

MW_INPUT

1030

2

Molecular Weight from GC/MSNHVVG_INPUT

1032

2

Net Heating Value of Vent (flare) Gas

QFUEL_TC

1040

2

Fuel Gas Flow Rate

QFLARE_TC

1050

2

Flare Flow Rate

TFLARE_TC

1052

2

Flare Temperature

PFLARE_TC

1054

2

Flare Pressure

flare.IQ Operation and Maintenance ManualChapter 3. Software

Table 3: Modbus Address List - Holding Registers for Flare Control (analog inputs) (cont.)
Register
Number ofRegister Tag Name
Description
Address
Registers
CFLARE_TC

1056

2

Flare Sound Speed

QSTEAM_TC

1060

2

Steam Flow Rate

TSTEAM_TC

1062

2

Steam Temperature (future use)

PSTEAM_TC

1064

2

Steam Pressure (future use)

CUST_STEAM_OFFSE
T

1066

2

Custom Steam Offset ValueQAIR_TC

1070

2

Air Flow Rate

TAIR_TC

1072

2

Assist Air Temperature

PAIR_TC

1074

2

Assist Air Pressure

QN2_TC

1076

2

Volumetric flow of Nitrogen

MW_LOW_CF

1080

2

Low Molecular Weight Correction Factor

MW_NORM_CF

1082

2

Normal Molecular Weight Correction Factor

MW_HIGH_CF

1084

2

High Molecular Weight Correction Factor

GC_UPDATE_RATE

1090

2

Expected time between GC/MS updates

MW_LOW

1100

2

Low Molecular Weight to apply Correction Factor

MW_NORM

1102

2

Normal Molecular Weight to apply Correction Factor

MW_HIGH

1104

2

High Molecular Weight to apply Correction Factor

QFUEL_MIN

1130

2

Minimum Fuel Flow Parameter

QFUEL_MAX

1132

2

Maximum Fuel Flow Parameter

FLARE_DIAM

1140

2

Flare Tip Diameter

FLARE_METER_DIAM

1142

2

Flare Meter Diameter

QSTEAM_MIN

1150

2

Minimum Steam Flow Parameter

QSTEAM_MAX

1152

2

Maximum Steam Flow Parameter

QAIR_LOW

1160

2

Low Air Flow

QAIR_MID

1162

2

Mid Air Flow

QAIR_HIGH

1164

2

High Air Flow

QAIR_MIN

1170

2

Minimum Air Flow Parameter

QAIR_MAX

1172

2

Maximum Air Flow Parameter

Table 4: Modbus Address List - Holding registers for Digital Validation (analog inputs)
Register Number ofRegister Tag Name
Description
Address
Registers
CO2

1012

2

Carbon Dioxide Concentration

CO

1014

2

Carbon Monoxide Concentration

H2

1016

2

Hydrogen Concentration

N2

1018

2

Nitrogen Concentration

O2

1020

2

Oxygen Concentration

flare.IQ Operation and Maintenance Manual

33

Chapter 3. Software

Table 4: Modbus Address List - Holding registers for Digital Validation (analog inputs) (cont.)
Register Number ofRegister Tag Name
Description
Address
Registers

34

H2O

1022

2

Water Vapor Concentration

TFLARE_TC

1052

2

Flare Temperature

PFLARE_TC

1054

2

Flare Pressure

CFLARE_TC

1056

2

Flare Sound Speed

CH_CONFIG

2000

2

Chanel Configuration of the Flare meter

UNITS_OF_MEASURE

2002

2

Units of Measure Configuration of the Flare meter

CH4

2020

2

Methane Concentration, percent

C2H4

2022

2

Ethylene Concentration, percent

C2H6

2024

2

Ethane Concentration, percent

C3H6

2026

2

Propylene Concentration, percent

C3H8

2028

2

Propane Concentration, percent

C4H10

2030

2

Butane Concentration, percent

C4H10_ISO2032

2

Iso Butane Concentration, percent

C4Hx

2034

2

C4's (Olefins) Concentration, percent

C5Hx

2036

2

C5's Concentration, percent

C6Hx

2038

2

C6's Concentration, percent

H2S

2040

2

Hydrogen Sulfide Concentration, percent

VELOCITY_CH1

2100

2

Ch 1 velocity from Flare meter

ERRORCODE_CH1

2102

2

Ch 1 Error code from Flare meter

SOUNDSPEED_CH1

2104

2

Ch 1 Sound speed from Flare meter

SIG_STRENGTH_CH1_UP

2106

2

Ch 1 Upstream Signal Strength from Flare meter

SIG_STRENGTH_CH1_DN

2108

2

Ch 1 Downstream Signal Strength from Flare meter

SIG_QUALITY_CH1_UP

2110

2

Ch 1 Upstream Signal Quality from Flare meter

SIG_QUALITY_CH1_DN

2112

2

Ch 1 Downstream Signal Quality from Flare meter

AMPLITUDE_CH1_UP

2114

2

Ch 1 Upstream Amplitude from Flare meter

AMPLITUDE_CH1_DN

2116

2

Ch 1 Downstream Amplitude from Flare meter

PEAKNUM_CH1_UP

2118

2

Ch 1 Upstream Peak Number from Flare meter

PEAKNUM_CH1_DN

2120

2

Ch 1 Downstream Peak Number from Flare meter

TTIME_CH1_SKAN_UP

2122

2

Ch 1 Upstream Transit time, Skan from Flare meter

TTIME_CH1_SKAN_DN

2124

2

Ch 1 Downstream Transit Time, Skan from Flare meter

TTIME_CH1_MEAS_UP

2126

2

Ch 1 Upstream Transit time, Measure from Flare meter

TTIME_CH1_MEAS_DN

2128

2

Ch 1 Downstream Transit Time, Measure from Flare meter

DELTA_T_CH1_SKAN

2130

2

Ch 1 Upstream Delta T, Skan from Flare meter

DELTA_T_CH1_MEAS

2132

2

Ch 1 Upstream Delta T, Measure from Flare meter

PATH_LENGTH_CH1

2134

2

Ch 1 Path Length from Flare meter

AXIAL_LENGTH_CH1

2136

2

Ch 1 Axial Length from Flare meter

VELOCITY_CH2

2200

2

Ch 2 velocity from Flare meter

ERRORCODE_CH2

2202

2

Ch 2 Error code from Flare meter

flare.IQ Operation and Maintenance ManualChapter 3. Software

Table 4: Modbus Address List - Holding registers for Digital Validation (analog inputs) (cont.)
Register Number ofRegister Tag Name
Description
Address
Registers
SOUNDSPEED_CH2

2204

2

Ch 2 Sound speed from Flare meter

SIG_STRENGTH_CH2_UP

2206

2

Ch 2 Upstream Signal Strength from Flare meter

SIG_STRENGTH_CH2_DN

2208

2

Ch 2 Downstream Signal Strength from Flare meter

SIG_QUALITY_CH2_UP

2210

2

Ch 2 Upstream Signal Quality from Flare meter

SIG_QUALITY_CH2_DN

2212

2

Ch 2 Downstream Signal Quality from Flare meter

AMPLITUDE_CH2_UP

2214

2

Ch 2 Upstream Amplitude from Flare meter

AMPLITUDE_CH2_DN

2216

2

Ch 2 Downstream Amplitude from Flare meter

PEAKNUM_CH2_UP

2218

2

Ch 2 Upstream Peak Number from Flare meter

PEAKNUM_CH2_DN

2220

2

Ch 2 Downstream Peak Number from Flare meter

TTIME_CH2_SKAN_UP

2222

2

Ch 2 Upstream Transit time, Skan from Flare meter

TTIME_CH2_SKAN_DN

2224

2

Ch 2 Downstream Transit Time, Skan from Flare meter

TTIME_CH2_MEAS_UP

2226

2

Ch 2 Upstream Transit time, Measure from Flare meter

TTIME_CH2_MEAS_DN

2228

2

Ch 2 Downstream Transit Time, Measure from Flare meter

DELTA_T_CH2_SKAN

2230

2

Ch 2 Upstream Delta T, Skan from Flare meter

DELTA_T_CH2_MEAS

2232

2

Ch 2 Upstream Delta T, Measure from Flare meter

PATH_LENGTH_CH2

2234

2

Ch 2 Path Length from Flare meter

AXIAL_LENGTH_CH2

2236

2

Ch 2 Axial Length from Flare meter

Table 5: Mobdus Address List - Holding Registers for CE/PEMS (analog inputs)
Register
Number ofRegister Tag Name
Description
Address
Registers

EM_QN2_DN

2300

2N2 Flow downstream of Flare flow meter

EM_DOUBLE_BOND_GAS

2310

2

Double Bond gas concentration

EM_CARBON_HYDROGEN_RATIO

2312

2

Ratio of Carbon atoms to Hydrogen atoms

EM_WIND_SPEED

2320

2

Cross wind speed

Table 6: Modbus Address List - Input Registers for Flare Control (analog outputs )Register
Number ofRegister Tag Name
Description
Address
Registers
QFUEL_DEMAND

400

2

Fuel Gas Demand

QSTEAM_DEMAND

402

2

Steam Demand

NHVCZ_ACTUAL

404

2

Net Heating Value in the Combustion Zone derived
from Speed of Sound at Fuel and Steam set-points
calculated by flare.IQ

VTIP_ACTUAL

406

2

Flare Tip Velocity Calculated

VTIP_MAX

408

2

Flare Tip Velocity Maximum

MW_CALC410

2

Molecular Weight Calculated

flare.IQ Operation and Maintenance Manual

35

Chapter 3. Software

Table 6: Modbus Address List - Input Registers for Flare Control (analog outputs (cont.))
Register
Number ofRegister Tag Name
Description
Address
Registers
NHVCZ_MEASURED

412

2

Net Heating Value in the Combustion Zone derived
from GC/Calorimeter at Fuel and Steam set-points
calculated by flare.IQ

NHVCZ_CURRENT

414

2

Net Heating Value in the Combustion Zone derived
from Speed of Sound at current Fuel and Steamflow

NHVCZ_MEASURED_TC

416

2

Net Heating Value in the Combustion Zone derived
from GC/Calorimeter at Current Fuel and Steamflow

NHVCZ_UNCORRECTED_TC

418

2

NHVcz uncorrected for H2 derived from
GC/Calorimeter at current Fuel and Steam flow

NHVCZ_UNCORRECTED_ACTUAL

420

2

NHVcz uncorrected for H2 derived from Speed ofSound at Fuel and Steam set-points calculated byflare.IQ

NHVCZDIL_ACTUAL

422

2

NHV Dilution Parameter derived from Speed ofSound (Air Assist only) at Fuel and Air set-points
calculated by flare.IQ

NHVCZDIL_MEASURED

424

2

NHV Dilution Parameter derived from
GC/Calorimeter (Air Assist only) at Fuel and Air
set-points calculated by flare.IQ

NHVCZDIL_MEASURED_TC

426

2

NHV Dilution derived from GC/Calorimeter at
Current Conditions (Air Assist only) at current Fueland Air flow

CF_ASSIST

428

2

Air/Steam Correction Factor as a function of Mol
Weight

QAIR_DEMAND

430

2

Air Demand

Table 7: Modbus Address List - Input registers for Digital Validation (analog outputs)
Register Tag Name

Register
Address

Number ofRegisters
2

Timestamp of most recently attempted Meter Validation

MV_LAST_PASS

448

2

Timestamp of most recently passed Meter Validation

MV_LAST_RESULT450

2Previous Meter Validation result: - Pass (0), Fail (-1),
Unavailable (-2), Unstable (-3)

MV_LAST_ATTEMPT

36

446

Description

flare.IQ Operation and Maintenance ManualChapter 3. Software

Table 8: Modbus Address List - Input registers for CE/PEMS (analog outputs)
Register Tag Name

Register

Number of

Address

Registers

Description

EM_CO

432

2

Carbon Monoxide emissions

EM_CO2434

2

Carbon Dioxide emissions

436

2

CO2-equivalent emissions based on Global Warming
Potentials

EM_VOC

438

2

Volatile Organic Compound emissions

EM_DRE

440

2

Destruction & Removal Efficiency

442

2

Calculated Combustion Efficiency (corrected for wind,velocity, and smoke)444

2

Emissions Net Heating Value of vent gas

EM_CO2_EQUIVALENT

EM_CE_CORRECTED
EM_NHVVG

Register Tag Name

Table 9: Modbus Address List - Boolean status registers (read only)
Register
Number of
Description
Address

Registers

HEARTBEAT

0

1

Heartbeat (from flare.IQ)

COMM_FAIL

1

1

Modbus Comm Failed (Timeout)

RESERVED_02

2

1

Reserved, returns 0

FUEL_DEMAND_BQ

3

1

Fuel Demand Exceeds Capacity

STEAM_DEMAND_BQ

4

1

Steam Demand Exceeds Capacity

AIR_DEMAND_BQ

51

Air Demand Exceeds Capacity

AR_BQ

6

1

Argon Content Value Bad

CO2_BQ

7

1

Carbon Dioxide Content Value Bad

CO_BQ

8

1

Carbon Monoxide Content Value Bad

H2_BQ

9

1

Hydrogen Content Value Bad

N2_BQ

10

1

Nitrogen Content Value Bad

O2_BQ

11

1

Oxygen Content Value Bad

H2O_BQ

12

1

Water Content Value Bad

MW_INPUT_BQ

131

Mol Weight from GC/MS Value Bad

NHVVG_INPUT_BQ

141

NHV (Vent Gas) from GC/MS Value Bad

RESERVED_15

15

1

Reserved, returns 0

RESERVED_16

16

1

Reserved, returns 0

QFUEL_BQ

17

1

Fuel Gas Flow Measurement Bad

RESERVED_18

18

1

Reserved, returns 0

QFLARE_BQ

19

1

Flare Flow Measurement Bad

TFLARE_BQ

20

1Flare Temperature Measurement Bad

PFLARE_BQ

21

1

Flare Pressure Measurement Bad

CFLARE_BQ

22

1

Flare Sound Speed Measurement Bad

RESERVED_23

23

1

Reserved, returns 0

flare.IQ Operation and Maintenance Manual37

Chapter 3. Software

Table 9: Modbus Address List - Boolean status registers (read only) (cont.)
Register Tag Name
Register
Number of
Description
Address

Registers

QSTEAM_BQ

24

1

Steam Flow Measurement Bad

TSTEAM_BQ

25

1

Steam Temperature Measurement Bad

RESERVED_26

26

1

Reserved, returns 0

QAIR_BQ

27

1

Air Flow Measurement Bad

TAIR_BQ

28

1

Air Temperature Measurement Bad

PAIR_BQ

29

1

Air Pressure Measurement Bad

RESERVED_30

30

1

Reserved, returns 0

CALC_SS_BQ

311

Calculated Sound Speed Invalid

EM_QN2_DN_BQ

32

1

N2 Flow downstream Measurement Bad

EM_WIND_SPEED

33

1

Double Bond Gas Concentration Bad

EM_DOUBLE_BOND_GAS_BQ

34

1

Ratio of Carbon to Hydrogen atoms Bad

EM_CARBON_HYDROGEN_RATIO_BQ 35

1

Cross Wind Speed Measurement Bad

RESERVED_36

36

1

Reserved, returns 0

RESERVED_37

37

1

Reserved, returns 0

RESERVED_38

38

1

Reserved, returns 0

RESERVED_39

39

1

Reserved, returns 0

METERVAL_DATA_AVAILABLE

40

1

Validation has enough data to run*Modbus Command 16 (Preset Multiple Registers) may be used if Command 06 (Preset Single Register) is notavailable.

Register Tag Name

Table 10: Modbus Address List - Boolean coil registers (read/write)
Register
Number of Description
Address

Registers

AIR_ASSIST

1

1

TRUE = Continous Variation; FALSE = Discrete/3-speed

ASSIST_TYPE

2

1

TRUE = Air Assist; FALSE = Steam Assist

CALORIMETER

3

1

TRUE = Flare Energy Content from Calorimeter

EM_N2_PURGE

4

1

TRUE = PEMS N2 Purge (Up/Down) Enabled

FUEL_BYPASS

5

1

TRUE = Fuel line bypasses BOTH flare flow meter and
GC/Calorimeter; FALSE = Fuel line goes through flare flow
meter AND GC/Calorimeter

H2_BTU_CORR_ENABLE

6

1

TRUE = Customer GC/MS does NOT apply 1212 Rule

MB_OVERRIDE

7

1

TRUE = Modbus Override in effect

N2_CONST_VOL_ENABLE

8

1

TRUE = N2 Supplied at constant volume

SI_UNITS

9

1

TRUE = Data in SI Units; FALSE = Data in English Units

3.4.3

flare.IQ units

As shown in Figure 16 on page 18, the end user can configure the flare.IQ Gen 2 software to work with either SI (Metric)
or English (Imperial) units using the Services page. The specific units that will be displayed on Flare, Fuel and Control
pages of the Web Console for either choice are shown in Table 11.

38

flare.IQ Operation and Maintenance ManualChapter 3. Software

Table 11: English and Metric (SI) units used in flare.IQ Gen2
Parameter
SI
EnglishFlare Page
Flare Diameterinin

Flare Low Cut-off

m/s

ft/s

Steam Rate Limit

MTPH/min

PPH/minSteam Min

MTPH

PPH

Steam Max

MTPH

PPH

Air Minm3/secCFM

Air Max

m3/sec

CFM

Volumetric Flow of N2

Nm3/h

SCFH

Flowmeter Flare DiameterinIn

Fuel Net Heating Value

MJ/m3

BTU/SCF

Update Rate

Seconds

Seconds

Fuel Page

Fuel Min

3/h

Nm

SCFH

Fuel Max

Nm3/h

SCFH

Net Heating Value (actual)

MJ/m3

BTU/SCF

Fuel Demand

Nm3/h

SCFH

Steam Demand

MTPH

PPH

Air Demand

3/s

m

CFM

Flare Flow

Nm3/h

SCFH

Flare Sound

m/s

ft/s

Flare Temperature°C°F

Flare Pressure

bara

PSIa

Net Heating Value (vent gas)

MJ/m3

BTU/SCF

Molecular Weight (calc)

g/mol

g/mol

Monitor Page

3

NHVcz Measured

MJ/m

BTU/SCFTip velocity

m/s

ft/s

Assist Air

m3/sec

CFM

Assist Air Pressure

pag

iwg

Assist Air Temperature

°C

°F
3/h

Fuel

Nm

SCFH

Net Heating Value (current)

MJ/m3

BTU/SCF

Molecular Weight

g/mol

g/mol

flare.IQ Operation and Maintenance Manual39

Chapter 3. Software[no content intended for this page]40

flare.IQ Operation and Maintenance ManualChapter 4. Installation & Maintenance

Chapter 4. Installation & Maintenance
4.1

Power Distribution

Installation and startup must only be carried out by qualified personnel. The relevant country-specific electricalsafety codes and regulations (e.g., VDE, DIN) must be observed. Before startup it is important to ensure that:• The mains have been connected correctly and adequate protection is provided against electric shock.
• The device can be switched off outside the power supply according to EN 60950 regulations (e.g., by the line
protection on the primary side).
• All supply lines have sufficient fuse protection and are the correct size.
• All output cables are the correct size for the maximum device output current or have separate fuse protection.
• Adequate convection is available.
After installation the terminal area must be covered to provide sufficient protection against unauthorized access tolive parts. This is ensured by installing the system in the control cabinet or distributor box. For reliable andsafe-to-touch connections strip 7 mm (0.28 in.) from the connector ends. The following cable cross sections can beused (Copper wiring recommended):
Table 12: Wiring specification for MINI 24 VDC power supply
Solid [mm2]Stranded [mm2]
AWG
Torque [Nm]Torque [lb in]

1 – Input

0.2 - 2.5

0.2 - 2.5

25 - 14

0.5 - 0.6

4.4 - 5.3

2 – Output

0.2 - 2.5

0.2 - 2.5

25 - 14

0.5 - 0.6

4.4 - 5.3

3 – Signal

0.2 - 2.5

0.2 - 2.5

25 - 14

0.5 - 0.6

4.4 - 5.3

Figure 34: Phoenix Contact MINI-PS-100-240AC/24DC/C2LPS I/O connections

4.1.1

Input (1, Figure 34)

The 100 - 240 V AC connection is made using the L and N screw connections. The power supply in the top module canbe connected to single-phase AC networks or to two external conductors for 3-phase networks (TN, TT or IT network
according to VDE 0100 T300/IEC364-3) with nominal voltages of 100 - 240 V AC. The device must be installedaccording to the specifications of EN 60950. It must be possible to switch off the device using a suitabledisconnecting device outside the power supply. Note that an all-pole disconnecting device must be provided for
2-phase operation using two external conductors for a three-phase network. For this, line protection on the primaryside, for example, is suitable. Further device protection is not required, as an internal fuse is present.

flare.IQ Operation and Maintenance Manual41

Chapter 4. Installation & Maintenance

4.1.2

Output (2, Figure 34)

4.1.3

Wiring Diagram

The power supply unit meets the requirements of NEC Class 2. The 24 V DC connection is made using the "+" and "-"screw connections on the screw connection 2. The output voltage set upon delivery is 24 VDC and can be adjusted
from 22.5 to 26 V DC on the potentiometer 4. The device is electronically short-circuit-proof and idling-proof. In theevent of an error, the output voltage is limited to a maximum of 35 V DC. It should be ensured that all output cables
are the correct size for the maximum output current or have separate fuse protection. The cable cross sections in thesecondary circuit should be large enough to keep the voltage drops on the cables as low as possible.
The control requires a single or redundant power source(s) and safety ground connection. While the Ethernet
switches have built-in terminals to accept two redundant diode-OR'd inputs of 18-36 V DC, the DPU's are powered
though a separate Diode redundancy module. The power and Ethernet wiring scheme for individual DPU's is modular
in that slots 4 - 6 in the bottom module for redundant DPU's can be left empty (for Digital Validation and PEMS
applications) without making any changes to the top module. See detailed wiring diagram in Figure 35 below for
more details.

42

flare.IQ Operation and Maintenance ManualChapter 4. Installation & Maintenance

Figure 35: System Wiring Diagram

flare.IQ Operation and Maintenance Manual

43

Chapter 4. Installation & Maintenance

4.2

Communication Network Diagram

4.2.1

Functional Description

The flare.IQ Gen 2 has two independent unmanaged 8-port network switches installed on the top module – onelabeled Flare Control/DCS (Modbus TCP) and the other labeled Configure/Monitor. As shown in Figure 36 below, each
DPU installed in the bottom module has two independent ethernet ports – one dedicated to a Web console for
configuration and monitoring via the fiqWeb application described in Section 3.3(LAN A), and the other dedicated toModbus TCP for exclusive use by the plant DCS (LAN B). This scheme of DPU LAN A for plant/DCS inputs and DPU LAN B
for system configuration/monitoring also applies to DV and PEMS applications. Any available Ethernet port on the top
switch may be used for the Modbus TCP connection from the DCS, while any available port bottom switch may be
used for an IP connection to the fiqWeb Web Console.

Figure 36: System I/O network connections

44

flare.IQ Operation and Maintenance ManualChapter 4. Installation & Maintenance

4.3

19" Rack Mounting

4.3.1

Functional Description

The flare.IQ Gen 2 system is designed to be mounted in a standard 19" rack mount cabinet. Please note mounting
hardware is not included in the shipping box. The top power distribution and network module has 4 mounting points,
and the bottom DPU module has 4 mounting points. Recommended mounting hardware is #10-32 X 0.75" longmachine screws in conjunction with #10-32 snap-in cage nuts.

Installation shall be in an enclosed rack that requires tool access.
It is recommended that all mounting hardware be either steel with zinc plating or stainless steel. Note that required
mounting hardware may vary with 19" rack design. Figure 37 below shows the recommended mounting method.

Figure 37: Recommended rack mounting method
The flare.IQ Gen 2 modules will be labelled with location and safety labels to indicate the order in which they arerecommended to be installed in the rack. For example, a system with 3 flares will have 2 modules, 1 top power
distribution and networking module (with two independent network switches) and 1 bottom DPU module with 6 DPU's.
The top module must be installed right above the bottom module with networking cables routed through and theycannot be installed on separate racks.
The bottom module has an open design with the ability to swap out and add DPUs as required by field service
engineers. The two Advantech UNO DPU modules for Flare 1 will be labeled #1 and #2, the DPU modules for Flare 2 will
be labeled #3 and #4, and so on. The section labels will correspond with the DPU IP addresses for flare numbers asshown below in Table 2 on page 17. The section labels are located on the back of the modules, in the upper rightcorners. Figure 38 below shows recommended module placement for an example system with 3 flares.

flare.IQ Operation and Maintenance Manual45

Chapter 4. Installation & Maintenance

Figure 38: Recommended module and DPU placement (primary #1 and redundant #2 for each flare)

4.4

Replacing a DPU

4.4.1

Installation

The Advantech DPU mounts directly to the panel sheet metal.
To remove the controller
1.
2.
3.

Unplug the 24V dc power cable from DPU.
Remove the Ethernet cables from the controller.
Loosen the upper and lower setscrews mounted on the controller. Slightly lift the module and take out the controller.

To install the controller
1.
2.
3.
4.
5.

Mount an upper screw on the panel. Hang the controller on the screw and align it with the panel's lower screw
hole.
Mount a lower screw and tighten both screws to secure the controller.
Connect the corresponding communication interface cables.
Plug the system network cables into the Ethernet ports (LAN A & LAN B) of the controller.
Plug the dual-24V dc power cable into the power input socket on the top of the controller.

Electronic controls contain static-sensitive parts. Observe the following precautions to prevent
damage to these parts. Discharge body static before handling the control equipment.
Do not touch the components or connectors on electronic equipment with your hands.

46

flare.IQ Operation and Maintenance ManualChapter 4. Installation & Maintenance

4.5

Environment

4.5.1

Mounting Location

Consider these requirements when selecting the mounting location:• Adequate ventilation for cooling.
• Space for servicing and repair.
• Protection from direct exposure to water or to a condensation-prone environment; a cabinet with at least an
IP52 rating.
• Protection from high-voltage or high-current devices, or devices which produce electromagnetic interference.
• Avoidance of vibration.
• Selection of a location that will provide an operating temperature range of 0°C to 40°C (32°F to 104°F) with lessthan 95% humidity (non-condensing).

4.6

Spare Parts List

The following is the recommended spare parts list for flare.IQ Gen 2 hardware.
Part Number

Part Name

Table 13: Spare parts list
Part Description

flare.IQ_KT_DPU

flare.IQ Gen2 DPU &accessories Kit

Advantech UNO 2271G DPU with mounting hardware and cables

144M2082

Power Supply

Phoenix Contact 24VDC Power Supply

144M2722

Ethernet Switch

8 Port Ethernet Switch

144M5276

Power harness

Wiring harness (Top Module to Red Module)

144M5852,
144M5850

Ethernet cable

Ethernet Cables CAT5E Shielded (Blue, Yellow)

4.7

Reliability

The failure rates of the 4 major hardware components (Advantech UNO 2271G DPU, GEAE ESWx Network switch,
Phoenix Contact MINI-PS-100 power supply, Puls MLY10.241 Dual redundancy module) are specified at an ambient
temperature of 30°C or 40°C. Based on these specifications, the calculated Mean Time Between Failures (MTBF) for
the flare.IQ Gen 2 system at 30°C ambient is 386,650 hours or 44.14 years.

4.8

Technical Regulations & Standards

The flare.IQ Gen 2 complies with IEC 61010-1:2010, AMD1:2016 and additional national differences. It also bears the CE
mark in compliance with the 2014/30/EU EMC and the 2014/35/EU LVD directives.

4.9

Cyber Security

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

4.9.1

Precautions

4.9.2

Exposed Ports and Services

As such, the flare.IQ Gen 2 DPU ports LAN A / LAN B and the Ethernet switches they are connected to should neverconnect to a switch or computer that is connected to the internet or business IT infrastructure. The flare.IQ Gen 2's
Ethernet switch should only be connected to the DCS's Modbus communications module as a direct connection if
possible. The default password should also be changed to a password of 8 or more characters.
The flare.IQ Gen 2 DPU uses or exposes the following ports and services to provide network communications:flare.IQ Operation and Maintenance Manual47

Chapter 4. Installation & MaintenancePort

Table 14: Network port assignments on DPU
Service/Description

80

Web Console (TCP), http443

Web Console (TCP), https / TLS

502*

Modbus/TCP

The port used by Modbus/TCP can be reassigned using the Web Console to another value if required by the local
network infrastructure
The two Ethernet ports provided on each DPU are isolated from each other at both the hardware and software level.
This is to isolate the DCS subnet carrying the Modbus/TCP traffic from any possible interference from a web console
user connected to the alternate Ethernet port. Two independent TCP/IP network stacks run as separate processes on
the DPU. There is no means or provision to 'bridge' the connections together. Network traffic on LAN A is not visible on
LAN B, or the reverse. Care should be taken to only connect LAN A to the Configure/Monitor network switch, and LAN B
only to the DCS/Control network switch. The two network switches should never be connected to each other.
Both LAN A and LAN B support Internet Control Message Protocol (ICMP), or 'ping' echo request and reply messages.
As described in Section 3.3.2, DHCP is not supported. Static IP addresses must be reserved and assigned for each DPU
connection.
The Web Console provides user accounts and pre-defined roles to limit access to authorized personnel. As shipped,
only a single Web Console 'admin' account is provided. The default password for the admin account is 'admin'.
It is essential that the admin password be changed immediately by the customer and recorded in asecure location.
BH cannot retrieve a lost or forgotten admin password. Passwords are never stored or transferred in plaintext, only asa 'salted' hash, which is considered a 'one-way' function that is unfeasible to reverse.
Note that accounts created via the Web Console only provide access to the Web Console. These accounts have noaccess permissions on the host operating system.
The flare.IQ Gen 2 only requires that passwords be a minimum of eight characters in length. The product does notenforce specific combinations of numbers, symbols, or upper/lower case characters. It is expected that the customer
is aware of the risks inherent in the use of weak passwords and will apply their own requirements at the time ofaccount creation.
From time to time, BH may make available software updates to add features or correct defects. These updates will
typically be provided by Panametrics Service, and available for download over the internet from a designatedlocation. Depending on the agreed terms and conditions, please note these software updates to correct for defects
are provided free of charge. Any newly added product software features have to be purchased.
BH digitally signs the software update packages it provides, and the flare.IQ Gen 2 verifies the digital signature before
performing an update. Update packages not signed by BH are automatically refused by the flare.IQ. This is toprevent installation of malicious software that could damage the flare.IQ Gen 2, affect its accuracy, or compromise
the network security of its customers.

48

flare.IQ Operation and Maintenance ManualAppendix A. Modbus map for legacy flare.IQ Gen 1 installations

Appendix A. Modbus map for legacy flare.IQ Gen 1 installations
flare.IQ Gen 2 is designed to be backward compatible with Gen 1 installations for flare control applications (digitalmeter verification feature is not available in Gen 1). For those customers that wish to continue to use their existing
DCS configuration for flare control, the Gen 2 system supports the Modbus Map of unsigned integers shown in Table 11(analog inputs) and Table 12 (analog outputs). Since all analog values sent and received must be integers, thesevalues have to be scaled appropriately as described in section A.1 to maintain the desired range and accuracy. The"Scaling" column in the table below shows the scaling factor to multiple or divide a value by before sending or after
receiving (/ = divide, * = multiply) on DCS master.
Table 15: Modbus address list for flare.IQ Gen 1 legacy customers (analog inputs) for flare control with scaling
factors
Register Tag
Register Number of Units
Description
Scaling
Name

Address

Registers

factorAR

101

Fraction

Argon Concentration (0.0 to 1.0)

*10

CO2

11

1

Fraction

Carbon Dioxide Concentration (0.0 to 1.0)

*10

CO

12

1

Fraction

Carbon Monoxide Concentration (0.0 to 1.0)

*10

H2

13

1

Fraction

Hydrogen Concentration (0.0 to 1.0)

*10

N2

14

1

Fraction

Nitrogen Concentration (0.0 to 1.0)

*10

O2

15

1

Fraction

Oxygen Concentration (0.0 to 1.0)

*10

H2O

16

1

Fraction

Water Vapor Concentration (0.0 to 1.0)*10

MW_INPUT

20

1

g/mol

Molecular Weight from GC/MS*100

NHVVG_INPUT

21

1

BTU/SCFNet Heating Value of Vent (flare) Gas*10

QFUEL_TC

30

1

SCFH

Fuel Gas Flow Rate

/10

QFLARE_TC

40

1

SCFH

Flare Flow Rat/100

TFLARE_TC

41

1

Deg F

Flare Temperature*10

PFLARE_TC

42

1

PSIa

Flare Pressure*100

CFLARE_TC

43

1

ft/s

Flare Sound Speed*10

QSTEAM_TC

50

1

PPH

Steam Flow Rate

/10

TSTEAM_TC

51

1

Deg F

Steam Temperature*10

PSTEAM_TC

52

1

PSIg

Steam Pressure*100

QAIR_TC

60

1

CFM

Air Flow Rate

/10

TAIR_TC

61

1

Deg F

Assist Air Temperature*10

PAIR_TC

62

1

iwg

Assist Air Pressure*100

QN2_TC

70

1

SCFH

Volumetric flow of Nitrogen*10

MW_LOW_CF

81

1

Low Molecular Weight Correction Factor*100

MW_NORM_CF

82

1

Normal Molecular Weight Correction Factor*100

MW_HIGH_CF

83

1

High Molecular Weight Correction Factor*100

GC_UPDATE_RATE

90

1

Expected time between GC/MS updates*1

MW_LOW110

1

Low Molecular Weight to apply Correction*100

seconds

Factor
MW_NORM

111

1

Normal Molecular Weight to apply*100

Correction Factor

flare.IQ Operation and Maintenance Manual49Appendix A. Modbus map for legacy flare.IQ Gen 1 installations

Table 15: Modbus address list for flare.IQ Gen 1 legacy customers (analog inputs) for flare control with scaling
factors (cont.)
Register Tag
Register Number of Units
Description
Scaling
Name

Address

Registers

112

1

MW_HIGHfactorHigh Molecular Weight to apply Correction*100

FactorQFUEL_MIN

130

1

SCFH

Minimum Fuel Flow Parameter*1

QFUEL_MAX

131

1

SCFH

Maximum Fuel Flow Parameter/10

FLARE_DIAM

140

1

in

Flare Tip Diameter*100

FLARE_METER_DIA

141

1

in

Flare Meter Diameter*100

QSTEAM_MIN

150

1

PPH

Minimum Steam Flow Parameter*1

QSTEAM_MAX

151

1

PPH

Maximum Steam Flow Parameter/10

QAIR_LOW

160

1

CFM

Low Air Flow

/10

QAIR_MID

161

1

CFM

Mid Air Flow

/10

QAIR_HIGH

162

1

CFM

High Air Flow

/10

QAIR_MIN

170

1

CFM

Minimum Air Flow Parameter*1

QAIR_MAX

171

1

CFM

Maximum Air Flow Parameter

/100

M

Table 16: Modbus address list for flare.IQ Gen 1 legacy customers (analog outputs) for flare control with scaling
factors
Register Tag Name
Register
Number of Units
Description
Scaling
Address

Registers

FactorQFUEL_DEMAND

0

1

SCFH

Fuel Gas Demand*10

QSTEAM_DEMAND

1

1

PPH

Steam Demand*10

NHVCZ_ACTUAL

2

1

BTU/SCFNet Heating Value in the1

Combustion Zone Calculated
VTIP_ACTUAL

3

1

ft/s

Flare Tip Velocity Calculated/100

VTIP_MAX

4

1

ft/s

Flare Tip Velocity Maximum/100

MW_CALC

5

1

g/mol

Molecular Weight Calculated/100

NHVCZ_MEASURED

6

1

BTU/SCFNet Heating Value in the*1

Combustion Zone derived from
GC/Calorimeter
NHVCZ_CURRENT

7

1

BTU/SCFNet Heating Value in the*1

Combustion Zone derived fromMol Weight
NHVCZ_MEASURED_TC

8

1

BTU/SCFNet Heating Value in the*1

Combustion Zone at Current
Fuel and SteamNHVCZ_UNCORRECTED_TC

9

1

BTU/SCFNHVcz uncorrected for H2 at*1

Current Fuel and Steam50

flare.IQ Operation and Maintenance ManualAppendix A. Modbus map for legacy flare.IQ Gen 1 installations

Table 16: Modbus address list for flare.IQ Gen 1 legacy customers (analog outputs) for flare control with scaling
factors (cont.)
Register Tag Name
Register
Number of Units
Description
Scaling
NHVCZ_UNCORRECTED_ACTUA

Address

Registers

10

1

FactorBTU/SCFL
NHVCZDIL_ACTUAL

NHVcz uncorrected for H2 at*1

Demand Fuel and Steam
11

1

BTU/SCFNHV Dilution Parameter/10

Calculated (Air Assist only)
NHVCZDIL_MEASURED

12

1

BTU/SCFNHV Dilution Parameter from

/10

GC/Calorimeter (Air Assist
only)
NHVCZDIL_MEASURED_TC

13

1

BTU/SCFNHV Dilution from

/10

GC/Calorimeter at Current
Conditions (Air Assist only)
CF_ASSIST

14

1

Air/Steam Correction Factor as*1

a function of Mol Weight
QAIR_DEMAND

flare.IQ Operation and Maintenance Manual

15

1

CFM

Air Demand

*10

51

Appendix A. Modbus map for legacy flare.IQ Gen 1 installations

A.1

Scaling Modbus Data (for legacy Gen 1 systems only)

All analog data is transferred to/from the flare.IQ as 16-bit, unsigned integers. Each input parameter and output
value occupy a single 16-bit Modbus register. To maintain the desired dynamic range or turndown, data may bescaled by multiplying or dividing by a multiple of ten.
Example 1:
XH2_INPUT is a value written to the flare.IQ containing the percentage of Hydrogen in the flare gas, expressed in the
Modbus Address List as:
Cmd: Address

Signal Name

Description

X:0013

XH2_INPUT

Hydrogen Content (from GC/MS)

Cfg

Scaling

Units

*10

%

The GC/MS data indicates that the H2 content is 27.5%. Applying the Scaling factor (*10):27.5 * 10 = 275.
275 is the integer value that should be written to Modbus register 0013 with Command 06 (Preset Single Register).
Example 2:
QFUEL_DEMAND is a value read from the flare.IQ containing the amount of supplemental fuel in Standard Cubic Feetper Hour (SCFH) required for compliance. It is expressed in the Modbus Address List as:
Cmd: Address

Signal Name

Description

4:0001QFUEL_DEMAND

Fuel Gas Demand

Cfg

Scaling

Units

*10

SCFH

Reading Modbus register 0001 with Command 04 (Read Input Register) returns the integer value 3125.
Applying the Scaling factor (*10):3125 * 10 = 31,250
31,250 SCFH is the amount of supplemental fuel required for compliance.
Example 3:
EVTIP_ACTUAL is a value read from the flare.IQ containing the velocity of the flare gas through the flare tip in feet per
second (ft/s). It is expressed in the Modbus Address List as:

Cmd: Address

Signal Name

Description

4:0004

VTIP_ACTUAL

Flare Tip Velocity Calculated

Cfg

Scaling

Units

/100

ft/s

Reading Modbus register 0004 with Command 04 (Read Input Register) returns the integer value 4833. Applying the
Scaling factor (/100):4833/100 = 48.33
48.33 ft/s is the calculated flare gas velocity.

52

flare.IQ Operation and Maintenance ManualAppendix B. flare.IQ Secure Operations Guide

Appendix B. flare.IQ Secure Operations Guide
The following guidelines will help the end user operate the flare.IQ software application securely within their DCS
network:•

To configure flare.IQ using the Web Console application, a direct hardwired connection between the PC and theflare.IQ Gen 2 DPU is recommended. Use of any USB to TCP/IP conversion software or devices is strictly prohibited.

•

Regularly check for flare.IQ software upgrades and patches from Baker Hughes.

•

When receiving any flare.IQ software installer or upgrade package, always check the software Checksum/Hashbefore installation or usage.

•

Install and scan any PC's connected to the flare.IQ regularly with well-known and updated Anti-Virus software.

•

For any flare.IQ software related problems, please contact Panametrics Tech Support at
panametricstechsupport@bakerhughes.com•

Be vigilant and report back to Panametrics Tech Support any unusual activity on a PC connected to the flare.IQ
DPU (which may not always be running the Web Console application) such as:••

Unknown installed software applications•

Change of security configurations without knowledge•

Unknown files

Ensure that any files generated using the flare.IQ software application are circulated only amongst trusted
members.

IMPORTANT:

It is the end user's responsibility to abide by the above cyber security recommendations. Baker
Hughes has no control over the flare.IQ usage environment or misuse of this product. The end user
assumes all risk and responsibility for proper use of the product.

flare.IQ Operation and Maintenance Manual53Appendix B. flare.IQ Secure Operations Guide[no content intended for this page]54

flare.IQ Operation and Maintenance ManualAppendix C. Glossary of Terms and Abbreviations

Appendix C. Glossary of Terms and Abbreviations
bara

Bars absolute (pressure relative to vacuum)

BTU/SCF

British Thermal Units Per Standard Cubic Foot

CFM

Cubic Feet Per Minute

DCS

Distributed Control System

DPU

Digital Processing Unitft/sfeet per second

g/mol

grams per mole

ICMP

Internet Control Message Protocol (Internet Engineering Task Force RFC 792)

In

Inchesiwg

Inches of Water Gauge

Nm3/hNormal Cubic Meters Per Hour

MACT

Maximum Achievable Control Technology (EPA Standard)

Mbps

Megabits Per Second

MBps

Megabytes Per Second

MJ/m3

Megajoules Per Cubic Meter

m/s

Meters Per Second

m3/s

Cubic Meters Per Second

MTPH

Metric Tons Per Hour

MTPH/minMetric Tons Per Hour Per Minute (rate of change)

PPH

Pounds Per Hour

PPH/minPounds Per Hour Per Minute (rate of change)

PSIa

Pounds Per Square Inch Absolute (pressure relative to vacuum)

SCFH

Standard Cubic Feet Per Hour

TCP

Transmission Control Protocol

UDP

User Datagram Protocol

flare.IQ Operation and Maintenance Manual55

Appendix C. Glossary of Terms and Abbreviations[no content intended for this page]56

flare.IQ Operation and Maintenance ManualWarranty

Warranty
Each instrument manufactured by Panametrics is warranted to be free from defects in material and workmanship.
Liability under this warranty is limited to restoring the instrument to normal operation or replacing the instrument, atthe sole discretion of Panametrics. Fuses and batteries are specifically excluded from any liability. This warranty iseffective from the date of delivery to the original purchaser. If Panametrics determines that the equipment was
defective, the warranty period is:• One year from delivery for electronic or mechanical failures.
• One year from delivery for sensor shelf life.
If Panametrics determines that the equipment was damaged by misuse, improper installation, the use ofunauthorized replacement parts, or operating conditions outside the guidelines specified by Panametrics, the repairs
are not covered under this warranty.

The warranties set forth herein are exclusive and are in lieu of all other warranties whether
statutory, express or implied (including warranties or merchantability and fitness for aparticular purpose, and warranties arising from course of dealing or usage or trade).

Return Policy
If a Panametrics instrument malfunctions within the warranty period, the following procedure must be completed:1.

Notify Panametrics, giving full details of the problem, and provide the model number and serial number of the
instrument. If the nature of the problem indicates the need for factory service, Panametrics will issue a RETURN
MATERIAL AUTHORIZATION (RMA), and shipping instructions for the return of the instrument to a service center will
be provided.

2.

If Panametrics instructs you to send your instrument to a service center, it must be shipped prepaid to theauthorized repair station indicated in the shipping instructions.

3.

Upon receipt, Panametrics will evaluate the instrument to determine the cause of the malfunction.

Then, one of the following courses of action will then be taken:• If the damage is covered under the terms of the warranty, the instrument will be repaired at no cost to theowner and returned.
• If Panametrics determines that the damage is not covered under the terms of the warranty, or if the warranty
has expired, an estimate for the cost of the repairs at standard rates will be provided. Upon receipt of theowner’s approval to proceed, the instrument will be repaired and returned.

flare.IQ Operation and Maintenance Manual57

Warranty[no content intended for this page]58

flare.IQ Operation and Maintenance Manual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: panametricstechsupport@bakerhughes.com

IrelandSensing House
Shannon Free Zone East
Shannon, County Clare
IrelandTel: +353 (0)61 470291
E-mail: panametricstechsupport@bakerhughes.com

Scan here for Panametrics
support and service information

Copyright 2024 Baker Hughes company.
This material contains one or more registeredtrademarks of Baker Hughes Company and its
subsidiaries in one or more countries. All third-party
product and company names are trademarks of theirrespective holders.
BH013C11 EN B (05/2024)