DigitalFlow GF868-1-2-1-2-0-4-1-4-0-0-0-CC Ultrasonic mass flow meter

Description

1. Product Overview

Full Model: GF868-1-2-1-2-0-4-1-4-0-0-0-CC 

Manufacturer: DigitalFlow

Product Name: Explosion-Proof Ultrasonic Mass Flowmeter for Flare Gas

Product Description: The GF868 is a classic ultrasonic mass flowmeter dedicated to flare gas by DigitalFlow. Adopting proprietary transit-time measurement technology, it is designed for flare exhaust gas metering in petrochemical, chemical, oil & gas terminal and refining facilities. Featuring no flow obstructions and zero mechanical wear, the unit accurately measures gas velocity, volumetric flow, mass flow and average molecular weight of flare gas. It supports leak tracing, quantification of flare emissions and energy-saving control of steam ratio, fully meeting requirements for environmental emission supervision and plant material balance management.

This model is a fully configured customized unit equipped with single-channel measurement, industrial explosion-proof protection, standard signal outputs and local configuration display. It is suitable for harsh flare gas conditions involving high temperature, moisture and minor impurities. Unlike conventional gas flowmeters, it dynamically adapts to fluctuations in gas composition without frequent calibration and delivers high long-term stability. It serves as core metering equipment for environmental monitoring, energy consumption optimization and hidden hazard inspection of industrial flare systems.

2. Model Code Explanation (Configuration for This Unit)

Model: GF868-1-2-1-2-0-4-1-4-0-0-0-CC 

1: Measurement Channel Configuration → Single-channel measurement mode 

2: Power Supply Specification → 220~240 VAC power supply 

1: Housing Structure → Standard explosion-proof aluminum housing, IP65 protection, Ex d IIC T6 explosion-proof rating 

2: Process Medium Condition → Optimized for standard flare gas operating conditions within normal temperature and pressure range 

0: Reserved Function Configuration → No special customized extended functions 

4: Analog Output Configuration → Multiple channels of standard 4-20 mA analog outputs 

1: Communication Configuration → Equipped with standard basic digital communication interface 

4: Display & Configuration → Local high-definition display with keypad operation for on-site parameter modification 

0, 0, 0: Optional Accessories → No high-temperature customization, no special cables, no redundant customization 

CC: Software Version & Regional Format → Standard industrial firmware, supporting Chinese / English, calibrated for domestic operating conditions

3. Core Functions

1. Proprietary transit-time ultrasonic measurement enables non-intrusive detection to accurately collect flare gas velocity, volumetric flow and mass flow data.

   
   

2. Dynamic sound velocity algorithm calculates average molecular weight of gas to precisely identify minor leaks and composition anomalies in flare systems for leak source tracing.

   
   

3. Adapts automatically to gas composition fluctuations, eliminating frequent manual calibration and accommodating complex and variable characteristics of flare gas.

   
   

4. Standard 4-20 mA analog outputs plus digital communication enable seamless connection with DCS and PLC systems for remote data transmission and centralized monitoring.

   
   

5. Local large-screen display and keypad configuration support on-site parameter editing, flow zero reset, range calibration and fault inquiry.

   
   

6. Embedded multi-condition compensation algorithms provide automatic temperature and pressure compensation to eliminate metering errors caused by variations in ambient and medium operating conditions.

   
   

7. Built-in equipment self-diagnosis identifies signal anomalies, transducer faults, out-of-range operating conditions and circuit failures with alarm upload.

   
   

8. Supports flare steam ratio regulation and energy conservation management to reduce ineffective combustion and steam consumption, applicable to factory energy optimization scenarios.

4. Technical Features

1. Wear-free maintenance-free measurement: No impellers or throttling components to avoid mechanical jamming and abrasion. No disassembly required for long-term operation with extremely low maintenance costs.

   
   

2. High-precision adaptive metering: Based on proprietary molecular weight measurement algorithm, it adapts to changes in flare gas composition and solves inaccurate measurement issues of traditional flowmeters under variable gas composition, maintaining stable accuracy.

   
   

3. Suitable for stringent explosion-proof industrial environments: Ex d IIC T6 explosion-proof construction with IP65 high protection rating, perfectly suited for hazardous classified areas in petrochemical plants and outdoor flare installations.

   
   

4. Wide turndown ratio and fast response: Extremely wide measuring range accurately captures tiny leakage flow and large flare vent flow with rapid response and no measurement lag.

   
   

5. Comprehensive signal and configuration capability: Supports both local configuration display and remote data communication. Traceable and uploadable data satisfies requirements of environmental monitoring, production control and audit tracking.

   
   

6. Strong anti-interference and high stability: Digital signal filtering effectively resists on-site electromagnetic interference, airflow turbulence and ambient temperature & humidity fluctuations for continuous and stable metering data.

5. Specification Parameters

6. Working Principle

The GF868 flowmeter operates on the correlated transit-time ultrasonic principle. Paired transducers are mounted on the pipe wall of the flare line to transmit and receive ultrasonic signals bidirectionally. The time difference between ultrasonic propagation downstream and upstream has a linear correlation with gas velocity. A high-precision digital processor acquires time difference signals and calculates instantaneous gas velocity and volumetric flow rate.

Equipped with proprietary sound velocity calculation algorithms, the unit dynamically computes average molecular weight of flare gas combined with real-time temperature and pressure data to accurately convert medium mass flow. Meanwhile, continuous comparison of gas composition and flow variations enables detection of minor flow fluctuations and composition abnormalities to precisely locate leaks within flare systems.

Condition compensation and signal self-check functions run continuously during operation to automatically correct measurement errors induced by ambient temperature, pressure and airflow turbulence. Transducer status, circuit communication and signal strength are monitored in real time. Alarms and fault codes are triggered immediately upon abnormalities. The system ensures long-term continuous, accurate and stable metering output, providing reliable data support for environmental emission statistics, plant material balance and equipment risk inspection.

7. Common Faults & Solutions

1. No flow display, reading returns to zero, no metering data

   Causes: Loose transducer wiring, damaged signal cables; contaminated or scaled transducers blocking ultrasonic signals; abnormal power supply; incorrect range settings; failed channel configuration.

   Solutions: Check supply voltage and inspect cable continuity and damage; clean oil, dust and scale on transducer surfaces; verify meter range and channel parameters; restart the unit for initialization. Restore factory settings and reconfigure if configuration failure occurs.

   
   

2. Fluctuating and unstable flow readings

   Causes: Severe on-site electromagnetic interference; turbulent pipeline airflow and violent operating condition variations; misaligned or poorly fitted transducers; improper signal filtering parameters; external vibration affecting the unit.

   Solutions: Optimize shielding and grounding of signal cables and route away from high-power electrical equipment; inspect transducer mounting position and fitting, re-tighten and calibrate; adjust internal filtering parameters to improve data smoothing; eliminate vibration interference and retest after stabilizing operating conditions.

   
   

3. Abnormal 4-20 mA output, inaccurate or missing remote transmission data

   Causes: Incorrect wiring and loose terminals of analog output loop; mismatched output range between flowmeter and DCS; aging output circuit; excessive loop load resistance.

   Solutions: Verify analog wiring definition and fasten terminals; align range parameters between flowmeter and control system; measure loop load resistance to comply with standard specifications; repair or replace core module if output circuit malfunctions.

   
   

4. Transducer fault alarm, insufficient signal strength warning

   Causes: Aging transducers with reduced sensitivity; dust or liquid accumulation in pipeline obstructing signals; signal cable attenuation and corroded connectors; excessive deviation of transducer installation spacing.

   Solutions: Clean transducers and pipeline detection area to remove liquid and dust; inspect cable connectors, remove oxidation or replace signal wires; recalibrate transducer mounting spacing; replace genuine matched transducer assembly if transducer performance degrades.

   
   

5. Normal local display but failed remote data upload

   Causes: Incorrect communication parameters, address conflict; faulty communication wiring, abnormal shielding grounding; faulty control system port; defective communication module of the flowmeter.

   Solutions: Verify baud rate, device address and communication protocol and unify system settings; inspect communication cable continuity and grounding; test by switching control system port; repair or replace communication module if faulty.

   
   

6. Large metering deviation, inconsistent data with actual conditionsCauses: Incorrect gas composition parameters; erroneous temperature & pressure compensation settings; lack of regular calibration; insufficient upstream/downstream straight pipe length leading to distorted flow field.Solutions: Check medium composition and temperature/pressure compensation parameters and correct invalid configuration; confirm straight pipe sections comply with installation specifications; perform calibration to eliminate systematic metering deviation.