Flow measurement and flow control computers

In this article, Daniel Goodwin, Managing Director, EX~i Flow Measurement, discusses the ongoing evolution of flow measurement technology, highlighting the SFC3000 flow computer as a versatile and advanced solution for the hydrocarbon, water, CO2, and hydrogen industries.

As one of the leading flow computer manufacturers, Ex~i Flow Measurement specialises in researching, developing, and manufacturing measurement systems for the gas and liquid measurement industry, with a commitment to continuous product development and enhancement.

Introducing the SFC3000

The SFC3000 is far more than just a dedicated flow computer. It can operate on a number of levels from a supervisory machine to a stand-alone flow computer or as a complex system component. With its touch screen, VGA display, and extensive processing capabilities, combined with simple to use controls and unique operating software it can function as a complete station supervisor integrated into a flow computer housing. Designed primarily to meet the needs of the worldwide liquid hydro-carbon and gas measurement markets, the SFC3000 is intended to positively contribute to both management and conservation of the world’s dwindling energy resources by providing both versatile and accurate measurement and incorporating state of the art designs and components. But can also be used in other measurement scenarios, e.g., water, Hydrogen, and emissions.

Applications

Since its introduction in 2009 Ex~i Flow Measurement has produced over 8,500 flow computers for applications including oil rigs and gas platforms, at international transfer points, gas fired power stations, and for truck/ship loading/unloading. Others can be found in the distribution network on both sides of the supply chain for producer/transporter and user. Flow computers can also be used by government entities to calculate emissions for tax purposes.

Development

The SFC3000 was released in 2009 with Nmi approvals for gas and liquid MID and continues to be under further development of additional features and updates.

Timeline:

• Development of Standard Gas machine completed in 2008
• CE approvals obtained January 2009 – KEMA report
• Nmi / MID Module B type approval complete January 2009 – Nmi T 10159
• Ex~i approved to use Nmi Logo, in certain material
• LVD test report and passport by DEKRA May 2011
• Over 4,000 machines manufactured and installed by end 2017
• Operational in projects in Middle East, UK, Europe
• MID sealed and approved units operational in France, Netherlands
• Nmi Orifice Calculation Verification January 2010 complete
• Development of Liquid and Liquid Prover machine complete
• OIML 117 and MID Liquid approval complete December 2010 – Nmi TC 7856
• Nmi extension to MID gas approval complete December 2010              
• Including US meter operation and operation at –25°C to +55°C - Nmi T10159-2
• Nmi extension for Twin Turbine Meter complete in January 2014 – Nmi TC8090
• New features added 2015
• Remote display, spread sheets, ISO 20765 Part 2 2015

Key features:

• Stand-alone flow computing function
• Extremely accurate
• Flow computing combined with supervisory function
• Optional 2GB SD memory card for alarm, audit, and data logging
• Interfaces to most types of metering equipment and all popular GC’s
• Freely configurable display offering system diagrams, trending and graphical displays, language options
• Easy Installation and interfacing
• Industry standard half width 3U High19” construction
• Panel or chassis mount
• Approval operating temperature ranges:

• –10°C to 55°C (15°F to 130°F) PRT inputs
• –25°C to 55°C (–15°F to 130°F) Hart and 4-20mA

What’s in the box:

• The SFC3000 flow computer features technology including:
• Multiple 32bit microprocessors
• Full VGA 5.7” colour display screen
• Touch screen incorporating full QWERTY keyboard
• 360° rotary control for menu navigation
• Expandable SD card memory
• Multiple high speed Ethernet connections – web enabled, Modbus over TCP I/P
• Front panel high speed USB connection – local configuration and downloading
• Simple to use Windows based software
• Surface mount technology on multiple layer circuit boards

Capability

The versatile Stream I/O Board versions fit all measurement application types and support the use of standard meters such as Ultrasonic, Turbine, Orifice, and Coriolis. The Stream I/O Card provides the complete capability for a single stream fiscal flow measurement with redundant inputs and a two-stream capability for non-fiscal applications.

Up to five I/O cards can be fitted in the SFC3000 chassis providing a five-stream fiscal capability.

In addition to a high speed 32bit central microprocessor performing all the display and calculation tasks, the SFC3000 has individual high speed 32bit processors on each plug-in card to perform the measurement, communication, and input/output functions.

The SFC3000 maintains the highest accuracy and uses double precision (64 Bit) floating point numbers throughout for all calculations. It also boasts an impressive true half second cycle time.

Local configuration and data downloading is achieved using the supplied Windows software through the dedicated front panel high speed USB communication port.

Remote communication is via the communication card or Dual Ethernet card, with RS232/485 serial capability and Ethernet 10/100 connectivity. Multiple communication cards can be installed.

The Stream Switch I/O Board supplements the number of available Digital Inputs and Outputs for Prover applications where a large number of Valves may be required.

Functionality

The SFC3000 makes measurements conforming to AGA, ISO, API standards of, dry and wet natural gas, hydrocarbon liquids, other gases (e.g., Nitrogen) and other Liquids (e.g., water).

Measuring meter types:

• Pulse generating flow meters
• Most common Ultrasonic flow meters
• DP transmitters with Orifice or Venturi measurements

Individual stream I/O boards can measure one to five fiscal streams

Future development

In common with any well-established product there is always the issue of component obsolescence. In the aftermath of the covid period many electronic component manufacturers took the opportunity to rationalise their product ranges. This has prompted Ex~i to redesign some of the internal circuitry of the flow computer to enable continued supply of a product that is widely used and respected. A further benefit of this design work will be a product range expansion through increased modularity.

The SFC3000 flow computer has been selected as a finalist in the 2024 Instrumentation Excellence Awards. The Awards celebrate the very best measurement, sensing and control sectors and the winners will be announced on 24th October 2024, at The Grand Connaught Rooms, London.