best practices: installing new radar tank gauging

Rosemount Tank Radar AB Confidential

Best Practices: Installing New Radar Tank Gauging for level and overfilling on all type of tanks with all type of products

Hans Manner

Nicolas Odru

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 2 Rosemount Tank Radar AB Confidential 2

Best Practices Installing New Radar Tank Gauging

Industry Trends

Engineering standards and guidelines

What equipment do I need?

How do I get it installed on my tank?

How do I get the readings in the control room?

Safety & Overfill Prevention


Complience to Standards

API standards

– 3.1B Automatic Tank Gauging

– 7 Temperature Measurements

– 3.3 LPG measurements

– 3.6 Hybrid Measurements

– 2350 Overfill Protection


Accuracy Performance

Pattern approvals for Custody Transfer Accuracy

OIML R85:2008

International Organization of Legal Metrology

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 5 Rosemount Tank Radar AB Confidential

Industry Trends

Radar

Continuous

Redundancy

Safety

IEC 61508

API 2350

Wireless

Openness

Internet

Mechanical

Point Switch

Closed systems


Tank Equipment


Tank Equipment

7


Tank Equipment – Fixed Roof Tank

8


Tank Equipment – Floating Roof Tank

9


Tank Equipment


Tank Equipment

11


Where to install the equipment on the tank?

Look for

– Man ways

– Other nozzles

– Gauge hatches

– Still Pipes


Where to install the Tank Equipment?

Manway 20” Nozzle 8”

Nozzles 2”, 4”, 8” Gauge hatch



Radar

Temp Sensor

On a 24” Man Way


Use existing still pipes


Use the existing Still Pipe


Don’t worry about dirty and slotted pipes



Still Pipes fitted in existing access hatch



Still Pipe fitted in existing access hatch


Where to install the Tank Gauge

What does API Ch 3.1B say?

– Roof mounting

• Close to the tank wall to avoid roof flexing influence

– Still pipe

• Slotted

• Fixed at the bottom end


Where to install the Temperature Sensor?

Same location as the Radar

Separate nozzle

Still pipe arrangements

Floating Roof penetration options

The Temp Sensor can be combined with a Water bottom sensor

Transmitter

Temp sensor


Temperature Measurement

What does Standards say?

– Use RTD type of sensor (Pt100)

– Use at least 6 sensors on tanks > 50 ft




Fixed Roof tank




Floating Roof Tank



Floating Roof Tank

Roof

penetration

thru a rubber

gasket

Support and

cabling at the

platform level


Where to install the Pressure Sensor (Density) ?

Lower end of the tank

Existing nozzles


Where to install the Local Readout?

At the gauge hatch

At grade level

By the road side

Or at all of the above


Local Readout

At Grade Level


Local Readout

Back lit


Where to install the Local Readout?

By the road side

Drive-thru readings

Day and night


How to connect a new system to the Control Room

Use existing cabling

Emulation

Minimized conduit free new cabling

Wireless


32

Emulation: Remove Old, Install New Plug n´ Play

Disconnect the old cabling Remove the old Gauge

Mount the radar antenna Mount the new Gauge

and connect the wiring

Done!



OLD NEW



Minimized new cabling

Intrinsically Safe

Conduit Free



Minimized new cabling

LAX Airport

One pair

cable

Intrinsically

Safe



Wireless



Wireless

Well proven

On 2500+ tanks

Robust

Safe

IEC 62591 standard


Overfill Protection with Rosemount 2160 Wireless Vibrating Forks LeveL Switch

No wires No moving parts

No re-calibration Long power module life

Self Checking

condition monitoring

Virtually unaffected by

process conditions

9 years at 1 minute update rate

Min update rate of 1s for control

Steam,

vapors, dust

Density

changes

Temperature

changes


Instrument Advanced Diagnostics- Health/Self Check Diagnostics The 2160 continuously performs instrument health diagnostics to self-

check the condition of the fork and sensor

Control room can be alerted to emerging issues allowing preventative maintenance to be scheduled- avoid process down-time

2160 Frequency Monitoring : interface detection between oil/water, wet sand/liquid...

Fault conditions detected Standard Enhanced

Process memory failure

External damage to fork

Internal wire disconnect or break

Internal damage to sensor

Excessive corrosion to fork


Overfill Protection with Rosemount 3308 Wireless Guided Wave Radar

No wires No moving parts

No re-calibration Long power module life

Single probe handles

coating better

Virtually unaffected by

process conditions

9 years at 1 minute update rate

Steam,

vapors, dust

Density

changes

Temperature

changes


Proactive Maintenance with Advanced Diagnostics Signal Quality Metrics alerts potential measurement

problems, e.g. caused by probe coating

Field

Time

Sig

nal Q

ualit

y

Control room

Level PV

Signal quality

Low

High


Rosemount Level Wireless 2160 Fork Switch & 3308 Guided Wave Radar

Inaccessible or uneconomic alarms:

– Fast installation of additional instruments

Gain access to advanced diagnostics:

– Self Check Diagnostics

– Signal Quality Metrics

Integrate more information into any control room host without new I/O:

– Eliminate costly cable runs

– System integration

http://www2.emersonprocess.com/en-US/plantweb/wireless/products/Pages/SmartWirelessGateway.aspx

http://www2.emersonprocess.com/en-US/brands/rosemount/Temperature/High-Density-Measurement/848T-Wireless/Pages/index.aspx

http://www2.emersonprocess.com/en-US/brands/rosemount/Temperature/Single-Point-Measurement/648-Wireless/Pages/index.aspx


Readout


Extended Readout

Intranet

Internet

Portable devices


Get Tank info distributed

Open protocols

OPC

Modbus

WebServer


Overfill Safety – Tank Gauging plays an important part

Passive protection layer

Emergency response layer

Process control layer Process

Shutdown

Active protection layer

Process

Value Process control layer

Safety layer Emergency

Shut Down

Time In Use

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 50

Why overfill prevention is important for Industry ? EU Safety and Environmental directives

are more and more restrictive :

– Member States are obliged to transpose it into a national law within the set deadline

– Directive 96/61/EC on integrated pollution prevention and control

– Directive 96/82/EC on the control of major accident hazards involving dangerous substance

Tank overfill is an important concern :

– Industry have to improve the Safety of their sites to reduce pollution risks

Industrial requests for overfill

prevention device applications

have risen in recent years


Buncefield oil storage, UK Dec. 2005

Overfill of fuel storage tank

Bad configuration and faulty independent high level switch on floating roof

20 large storage fuel tanks took fire

Over 40 people injured

UK Health and safety Executive investigation resulted in 25 recommendations on fuel storage sites

//upload.wikimedia.org/wikipedia/commons/6/67/Hemel_Hempstead_fuel_explosion_map.jpg


Tank Overfill Prevention : Key Points

Detection should be independant of the primary level measurement device and separate failure alarm is preferable

Proof testing is required : manual test or internal diagnostics can be used

Redundancy with different technologies is a common strategy for critical level detection


Tank Overfill Prevention : Customer challenge

Customers need to increase the Safety of their existing installation :

– More information needed for continual supervision in the control room (less operators round)

– Additional independent high level alarm on your primary level measurement

– Remote tank locations / No local power supply


Single Point for Overfill Protection

Advantages :

Independent safety system

Not affected by process changes

Different types of on/off alarm output available

Functionality is less dependant on configuration, mechanical installation and start up

To be considered :

≈ One device for each level alarm

≈ Power supply needed for electronics

≈ No separate fault signal output

Vibrating Forks is one of the most common technology used in process industry


Rosemount Vibrating Forks Portfolio

OEM Core Premier

Advanced Health Diagnostic

PlantWeb alerts

Direct load,

PNP,

DPDT Relay, 8/16

IS NAMUR

Direct Load,

PNP/PLC

Direct load,

PNP, 12V

Relay, 8/16

IS NAMUR

Wireless HART

-70 +260°C

SIL 2 High & Low Level

-70 +260°C

Diagnostic

Diagnostic

-40 +180°C

-40 +150°C

-40 +150°C


Basic or Advanced : What is the difference ?

Forks

Frequency Circuit

Output Circuit

Forks

Frequency Circuit

Output Circuit

Self Check Diagnostics


The frequency band below show the six sensors states of the 2130 switching bands divided into three groups :

Valid sensor frequency : Wet or Dry

Fault Sensor frequency :

Too Wet : broken wire to the cassette, over-temperature, build-up

Too Dry : sensor body lost mass due to damage to sensor, corrosion

Zero Frequency

2130/2160 Sensor States

*DFF : Dry Forks Frequency Sensor switching limits are percentage of the calibrated frequency

Wet Dry Too Dry

Frequency Switching Bands

Too Wet

0HZ DFF – 28% DFF + 4.5%

DFF* 1400 Hz


Direct Load

PNP

Relay

Namur

8-16mA*

Fault Relay*

2130 – Self Check available on all Cassettes :

*Provide

Separate fault signal output


Electrical Installation of the 2130

8-16mA – High Level Alarm

PSU

Hazardous Area Safe Area

Dry = On

Heartbeat LED On

+

- ION = 15...17 mA

PE

(Ground)

U = 24 Vdc Nominal

Drives 4-20 mA Analog Intput

+

-

Compatible with NAMUR NE43



8-16mA – High Level Alarm

PSU


Dry = On

+

-

PE

(Ground)

U = 24 Vdc Nominal


+

-

Heartbeat LED Flashing

1Hz

IOFF = 7.5...8.5 mA




8-16mA – Fault Conditions

PSU


Dry = On

+

-

PE

(Ground)

U = 24 Vdc Nominal


+

-

Heartbeat LED Pulsed

IFAULT < 3.7 mA



Overfill Safety – Tank Gauge Redundancy



Level & Roof Gauging


Overfill Safety

Level & Roof Gauging


Common Situation: Only One Tank Opening

Need for two Radars but only one opening available

What to do?

66

I want two Radars

on one nozzle!


2 Radar in 1

Only one tank opening

Easy installation

Total electric separation

Operates in parallel

Put 2 Radar in 1 On-Tank Redundancy Made Easy


2-in-1 Radar On-Tank Redundancy Made Easy

Redundancy

Dual operation

Gauging

Overfill Alarm

Separated

”Built in Spare”


Safety Standard Compliant


Safety Standard Compliant

API 2350 compliant

IEC 61508 certified

Certified SIL2

Certified SIL3

TÜV, (WHG) certified


Summary

Its easy to install new Tank Gauging

Minimum Wiring

Wireless

Use existing tank opening

Use exisiting Still Pipes

Easy to connect to other systems

Get Overfil Protection at the same time


Rosemount Raptor System

5900S Radar

Level Gauge

2410 Tank Hub

2240S Multi-input

Temperature

Transmitter

2120/2160

Liquid Level switch

2230 Graphical

Field Display

5300/5400

Radar Level

Transmitter

375 /475 Field

Communicator

Smart Wireless

THUM Adapter

644 Temperature

Transmitter with Single

Point Temperature Sensor

3051S Pressure

Transmitter

2160/65/75 Field

Communication Unit

2180 Field Bus

Modem

TankMater PC

Workstation in

Network

Smart Wireless

Gateway

2410 2410 2410

2410

2230

5900S

THUM 5900S 2240S

5900S 2240S 5400

5300

644

3051S

TankMaster.net

644

5400


Typical instruments on LNG storage tanks


Raptor 5900S radar for LNG Radar replacing servo in almost all

applications

Primary, secondary and HLA measurement using only radar

Highest accuracy over full range

Advanced signal processing

– FMCW @ 10 GHz

– High sensitivity for long range

Digital accuracy reference

– No aging or temperature effects

Verification during operation

SIL 2 and SIL 3 certified

Unique 2-in-1 redundancy


Antenna – 5900S LPG/LNG

Designed for

– Liquefied gas in LPG/LNG tanks

– 4 in still-pipes sch 10 or 40

– 100 mm still-pipes

Quartz/Ceramic window as pressure sealing

Verification pin function

Optional

– Ball valve, fire-proof

– Rosemount 2051 Pressure sensor

Flange available in six versions

– 4 in. class 150, class 300



New Adapter Seal & ball

valve


-0.001

0

0.001

0 5 10 15 20 25 30

Downwards manual log

Upwards manual log

Downwards autolog

Upwards autolog

76

Level Accuracy: 5900S exceeds OIML R85:2008

4

-4

2

-2

0

Old (R85:1998)

New (R85:2008)

(mm

)

3

1

-1

-3

Old (R85:1998)

New (R85:2008)


Verification of Level measurement

On-line verification during normal operation

Verification is made inside the tank

Tank remains closed and no valves need to be maneuvered

A reference pin is mounted inside the still-pipe for level verification

A bottom reflection ring mounted at the end of the pipe is used for zero verification

Photos

Photos


Raptor – SIL 2 and 3 Certified


Built In Proof Testing

The two Radars will constantly ”safety-check” each other

Long time between manual Proof Testing

”No man on the tank”

Saves $$$

Avoid Manual Proof Testing


Online proof-testing

-check

Blue and Red lines separated for visibility.

An alarm is given if the exceeds a defined limit


2-in-1 Radar

81

Radar #1 Radar #2 High Level of Safety

SIL3 Rated

Low Cost Installation

On Tank Redundancy

High Availability

Less Proof Testing

Less Verification

Saves $$$ in many ways


2x Radars on the same tank - well proven


Some LNG sites using radar from Emerson:

Radar gauges have been used for more than 10 years to measure level at several LNG import terminals in Japan. So far 15+ tanks.

Trunkline LNG Co. – Terminal, Lake Charles, USA

Gaz de France – Terminal, Fos Cavaou, France

– Complete Emerson system solution

CPC Taiwan - Receiving terminal, Northern Taiwan

Qatargas II - Production site, 5 new tanks,

– Complete Emerson system solution

– Radar for all Level measurements (primary, secondary, HLA)

Freeport – Quintana Island - Receiving terminal, Texas, USA

Recent projects system solutions, Rex radar gauges combined with Whessoe LTDs

Cheniere - Sabine Pass – Receiving terminal, Louisiana, US. 5 tanks

Fluxys - Zeebrügge - Existing receiving terminal, Belgium

Exxon - Golden Pass LNG – Receiving terminal, Texas US. 5 tanks

Woodside - Pluto LNG – New export terminal. 2 tanks in Ph I.

PTT LNG – Map Ta Put – New receiving terminal

AGA – Nynashamn LNG – New receiving terminal. 1 tk Ph. 1

Chevron - Gorgon – New tanks at export site, 2 LNG + 4 Condensate tanks. Totally 24

radars

Polskie LNG – New receiving terminal, 2 tks.


Rosemount LNG Radar Benefits

No moving parts

No re-calibration

No maintenance

SIL2 / SIL3 safety functions

Built in High Alarm

On-Line verification during operation inside the tank

Custody Transfer Accuracy

Conformance to API, OIML, ISO and other standards

Proven Technology

Many excellent references on LNG and LPG

Anything for a single gauge to a complete LNG Management System


Emerson and Wärtsilä (Whessoe)

Combining the skills and experience from two organizations into an LNG storage management solution provider

Rosemount Tank Gauging

– Rosemount is the measurement division within Emerson

– Focus on high accuracy radar level gauges and supporting instruments for temperature and pressure

– System supplier, incl project management

Wärtsilä Calais (Whessoe product name)

– Focus on LTD gauges and LNG management software


Loop 1

Loop 2

5900S +

2410

Hi-Hi alarm

5900S LNG + 2410

Secondary level 1146 LTD

Total LNG Tank Instrumentation Solution

TANK

N°1

Level alarms to ESD

5900S LNG + 2410

Primary level

2240S and 566

multiple spot

temp

2240S and 566

multiple spot

temp

//SERVEURP/PUBLIC/Commerciaux/DOCUMENTATION COMMERCIALE/leaflets/last version/level/FICHE 1706B.pdf

//SERVEURP/Users/pversluijs/Mes documents/Documentation/level/FICHE 1146-EN-1.pdf

//SERVEURP/PUBLIC/Commerciaux/DOCUMENTATION COMMERCIALE/leaflets/last version/level/FICHE 1706B.pdf


TANK N°2

Loop 2

TANK N°1

Total LNG Tank Instrumentation Solution

9510

20 mA loop / RS232C

9510

20 mA loop / RS232C

Loop 1

Loop 2

Loop 1

LNG Manager

LNG Manager

DCS

LNG Roll-Over

Predictor

Serial link

Serial link

Serial link

Serial link

TRL2 bus for Raptor

/2410 if not using

WM660

FCU 2160

//SERVEURP/Users/pversluijs/Mes documents/LNG Expert Product Demo full.ppt


Tank detail (Roll-Over)


Sample of project awards Combined Emerson / Rosemount Tank Radar and Whessoe LTD

- recent projects realized at LNG terminals or production sites :

Cheniere’s Sabine Pass

Exxon’s Golden Pass

Fluxys (Zeebrugge, Belgium)

Pluto LNG Australia

Nynashamn Sweden

PTT LNG Map Ta Put Thailand

Sonatrach Skikda LNG Algeria

Gorgon Australia

Polskie LNG

Many new projects to be decided shortly


LNG references (continued)

Golden Pass LNG - new receiving terminal in Texas; Five tanks. Installation 2008.

– CB&I US is the main EPC for the complete project

– Whessoe LTD + software (Wärtsilä)

– Emerson partner to Wärtsilä and supplied:

• 5 x Radar Rex 3960

• 5 x SDAU

• 5 x MST Cryo

• 2 x FCU 2160

http://www.goldenpasslng.com/../assets/files/Sabine_locale_map.pdf

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