The step-by-step commissioning procedures for Emerson FLOBOSS S600 Flow Manager
Pre-Commissioning Safety Checks
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Power Verification
- Confirm input voltage matches terminal block rating (24 VDC ±10% or 115/230 VAC).
- Ensure chassis ground resistance <1 Ω using Megger tester.
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Sensor Validation
- PT/CT inputs: Apply 4–20 mA simulation signal; verify raw value readback within ±0.1% FS.
- Piping leakage test: Hold test pressure at 150% operating range for 15 mins (zero drop tolerance).
Hardware Initialization
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1. Mount unit vertically (max. 5° deviation) per Section 3.2 of IM-0063.
2. Connect RTD/TC: Use shielded twisted pairs ≤100m; shield grounded at S600 end only.
3. Impulse lines: Purge with inert gas (N2) before pressure transmitter wiring.
Software Configuration
Using ROCLINK 800 (v4.1+):
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Communication Setup
- Connect via USB/RS-485; set baud rate to 19.2kbps (default).
- Assign unique IP address if Ethernet-enabled (subnet mask: 255.255.255.0).
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Flow Equation Load
textCopy CodeConfiguration > Flow Churches > Select AGA-8 / API MPMS Ch.14.3
Enter gas composition (mole % accuracy: 0.001)
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I/O Mapping
Hardware Point Software Tag Engineering Unit AI1 PT_Wellhead psi DI3 Valve_Fail Boolean
Calibration Sequence
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Zero Calibration
- Isolate pressure sensors; vent to atmosphere → Execute
AutoZeroin Service Tools. - Accept if offset <0.05% URL (Unified Range Limit).
- Isolate pressure sensors; vent to atmosphere → Execute
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Prover Loop Verification
textCopy Codea) Initiate 10 consecutive prove runs via HART command.
b) Calculate meter factor: MF = (Proved Vol / S600 Vol)
c) Pass criteria: |1-MF| ≤ 0.15% with σ ≤ 0.02%.
Operational Testing
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1. Force DI alarms (e.g., close ESDV) → Confirm SOE timestamps ≤100ms latency.
2. Inject 10% step change in flow rate → Check control valve response time <2s.
3. Validate Modbus TCP registers:
- Flow Totalizer (register 40001) vs local total ≤ ±0.01% variance.
‼️ Critical Fault Resolutions
| Alarm | Corrective Action |
|---|---|
| FST_FAIL | Check sensor excitation voltage (min. 10.5 VDC) |
| COMM_FAULT | Verify termination resistors (120 Ω for RS-485) |
| PV_OUT_OF_RANGE | Recalibrate using master gauge (ASME B40.100 Grade 3A) |
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