Best Practic Instal New Radar TGsystem LNG and Overfilling - 2

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
Rosemount Tank Radar AB Confidential

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
[File Name or Event]

Emerson Confidential
Rosemount Tank Radar AB Confidential 2
27-Jun-01, Slide 2
Complience to Standards
 API standards
– 3.1B Automatic Tank Gauging
– 7 Temperature Measurements
– 3.3 LPG measurements
– 3.6 Hybrid Measurements
– 2350 Overfill Protection

27-Jun-01, Slide 3
Accuracy Performance
 Pattern approvals for Custody Transfer Accuracy
 OIML R85:2008
International Organization of Legal Metrology

27-Jun-01, Slide 4
Industry Trends
Radar
Continuous
Redundancy
Safety Mechanical
IEC 61508
Point Switch
API 2350
Closed systems
Wireless
Openness
Internet
27-Jun-01, Slide 5
Tank Equipment

27-Jun-01, Slide 6
Tank Equipment

27-Jun-01, Slide 7
Tank Equipment – Fixed Roof Tank

27-Jun-01, Slide 8
Tank Equipment – Floating Roof Tank

27-Jun-01, Slide 9
Tank Equipment

27-Jun-01, Slide 10
Tank Equipment

27-Jun-01, Slide 11
Where to install the equipment on the tank?
 Look for
– Man ways
– Other nozzles
– Gauge hatches
– Still Pipes

27-Jun-01, Slide 12
Where to install the Tank Equipment?
Gauge hatch Nozzles 2”, 4”, 8”
Nozzle 8” Manway 20”

27-Jun-01, Slide 13
 Radar
 Temp Sensor
 On a 24” Man Way

27-Jun-01, Slide 14
Use existing still pipes

27-Jun-01, Slide 15
Use the existing Still Pipe

27-Jun-01, Slide 16
Don’t worry about dirty and slotted pipes

27-Jun-01, Slide 17
 Still Pipes
fitted in
existing
access
hatch

27-Jun-01, Slide 18
 Still Pipe
fitted in
existing
access
hatch

27-Jun-01, Slide 19
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

27-Jun-01, Slide 20
Where to install the Temperature Sensor?
 Same location as the

Transmitter
Radar
 Separate nozzle
 Still pipe arrangements
 Floating Roof
penetration options Temp sensor
 The Temp Sensor can

be combined with a
Water bottom sensor

27-Jun-01, Slide 21
Temperature Measurement
 What does Standards say?
– Use RTD type of sensor (Pt100)

– Use at least 6 sensors on tanks > 50 ft

27-Jun-01, Slide 22
 Same location
as the Radar
 Fixed Roof tank

27-Jun-01, Slide 23
 Same location
as the Radar
 Floating Roof
Tank

27-Jun-01, Slide 24
 Floating Roof
Tank
Roof
penetration
thru a rubber
gasket
Support and
cabling at the
platform level

27-Jun-01, Slide 25
Where to install the Pressure Sensor (Density) ?
 Lower end of the tank

 Existing nozzles

27-Jun-01, Slide 26
Where to install the Local Readout?
 At the gauge hatch

 At grade level
 By the road side
 Or at all of the above

27-Jun-01, Slide 27
Local Readout
 At Grade Level

27-Jun-01, Slide 28
Local Readout
 Back lit

27-Jun-01, Slide 29
Where to install the Local Readout?
 By the road side

 Drive-thru readings
 Day and night

27-Jun-01, Slide 30
How to connect a new system to the Control Room
 Use existing cabling

 Emulation
 Minimized conduit free new cabling
 Wireless

27-Jun-01, Slide 31
Emulation: Remove Old, Install New
Plug n´ Play
Disconnect the old cabling Remove the old Gauge
Done!
[File Name or Event] Mount the radar antenna Mount the new Gauge 32
27-Jun-01, Slide 32
and connect the wiring
OLD NEW

27-Jun-01, Slide 33
 Minimized new cabling
 Intrinsically Safe
 Conduit Free

27-Jun-01, Slide 34
 Minimized new cabling
One pair
cable
Intrinsically
Safe
LAX Airport
27-Jun-01, Slide 35
 Wireless

27-Jun-01, Slide 36
 Wireless

27-Jun-01, Slide 37
 Wireless

27-Jun-01, Slide 38
 Wireless
 Well proven
 On 2500+ tanks
 Robust
 Safe
 IEC 62591 standard

27-Jun-01, Slide 39
Overfill Protection with Rosemount 2160
Wireless Vibrating Forks LeveL Switch
No moving parts No wires
No re-calibration Long power module life
9 years at 1 minute
update rate
Min update rate of
1s for control
Virtually unaffected by Self Checking

process conditions condition monitoring
Steam, Density Temperature

vapors,
Emerson dust changes
Confidential changes
27-Jun-01, Slide 40
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
Emerson Confidential  
27-Jun-01, Slide 41
Overfill Protection with Rosemount
3308 Wireless Guided Wave Radar
No moving parts No wires
No re-calibration Long power module life
9 years at 1 minute
update rate
Virtually unaffected by Single probe handles

process conditions coating better
Steam, Density Temperature

vapors,
Emerson dust changes
Confidential changes
27-Jun-01, Slide 42
Proactive Maintenance with
Advanced Diagnostics
 Signal Quality Metrics alerts potential measurement
problems, e.g. caused by probe coating
Field Control room
High
Signal Quality
Low
Time
Level PV
Signal quality
27-Jun-01, Slide 43
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

27-Jun-01, Slide 44
Readout

27-Jun-01, Slide 45
Readout

27-Jun-01, Slide 46
Extended Readout
 Intranet
 Internet
 Portable
devices

27-Jun-01, Slide 47
Get Tank info distributed
 Open protocols
 OPC
 Modbus
 WebServer

27-Jun-01, Slide 48
Overfill Safety –
Tank Gauging plays an important part
Time In Use
Emergency response layer
Passive protection layer
Active protection layer
Emergency
Safety layer
Shut Down
Process
Process control layer
Shutdown
Process Process control layer

Value

27-Jun-01, Slide 49
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
[File Name or Event] have risen in recent years
27-Jun-01, Slide 50
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

27-Jun-01, Slide 51
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

27-Jun-01, Slide 52
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

27-Jun-01, Slide 53
Single Point for Overfill Protection
Vibrating Forks is one of the most common
technology used in process industry
 Advantages :  To be considered :
 Independent safety system ≈ One device for each level
 Not affected by process alarm
changes ≈ Power supply needed for
 Different types of on/off alarm electronics
output available ≈ No separate fault signal
 Functionality is less dependant output
on configuration, mechanical
installation and start up

27-Jun-01, Slide 54
Rosemount Vibrating Forks Portfolio
OEM Core Premier
-70 +260°C
-40 +180°C -70 +260°C

PlantWeb alerts
-40 +150°C SIL 2 High & Low Level
-40 +150°C Diagnostic Advanced Health Diagnostic
Diagnostic Direct load, Direct load,

PNP, 12V PNP,
Wireless HART
Direct Load, Relay, 8/16 DPDT Relay, 8/16
PNP/PLC
[File Name or Event] IS NAMUR IS NAMUR
27-Jun-01, Slide 55
Basic or Advanced :
What is the difference ?
Output Circuit
Output Circuit
Self Check Diagnostics
Frequency Circuit
Frequency Circuit
Forks
Forks

27-Jun-01, Slide 56
2130/2160 Sensor States
 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
Frequency Switching Bands
Too Wet Wet Dry Too Dry
0HZ DFF – 28% DFF + 4.5%
DFF* 1400 Hz
[File Name or Event] *DFF : Dry Forks Frequency
Emerson Confidential Sensor switching limits are percentage of the calibrated frequency
27-Jun-01, Slide 57
2130 – Self Check available on all
Cassettes :
 Direct Load
 PNP
 Relay
 Fault Relay*
 Namur
 8-16mA*
[File Name or*Provide

Event]
Separate fault signal output
27-Jun-01, Slide 58
Electrical Installation of the 2130
8-16mA – High Level Alarm
U = 24 Vdc Nominal
PE
(Ground)
+ -
ION = 15...17 mA
PSU- +
Heartbeat LED On
Drives 4-20 mA Analog Intput

Compatible with NAMUR NE43
Dry = On
Safe Area Hazardous Area

27-Jun-01, Slide 59
8-16mA – High Level Alarm
U = 24 Vdc Nominal
PE
(Ground)
+ -
IOFF = 7.5...8.5 mA
PSU- +
Heartbeat LED Flashing

1Hz
Dry = On

27-Jun-01, Slide 60
8-16mA – Fault Conditions
U = 24 Vdc Nominal
PE
(Ground)
+ -
IFAULT < 3.7 mA
PSU- +
Heartbeat LED Pulsed

Dry = On

27-Jun-01, Slide 61
Overfill Safety – Tank Gauge Redundancy

27-Jun-01, Slide 62

27-Jun-01, Slide 63
Level & Roof Gauging

27-Jun-01, Slide 64
Overfill Safety
Level & Roof Gauging

27-Jun-01, Slide 65
Common Situation:
Only One Tank Opening
 Need for two
Radars but only one
opening available I want two Radars
on one nozzle!
 What to do?

27-Jun-01, Slide 66
Put 2 Radar in 1
On-Tank Redundancy Made Easy
 2 Radar in 1
 Only one tank
opening
 Easy installation
 Total electric
separation
 Operates in parallel

27-Jun-01, Slide 67
2-in-1 Radar
On-Tank Redundancy Made Easy
 Redundancy
 Dual operation
 Gauging
 Overfill Alarm
 Separated
 ”Built in Spare”

27-Jun-01, Slide 68
Safety Standard Compliant

27-Jun-01, Slide 69
Safety Standard Compliant
 API 2350 compliant
 IEC 61508 certified

 Certified SIL2
 Certified SIL3
 TÜV, (WHG) certified

27-Jun-01, Slide 70
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

27-Jun-01, Slide 71
Rosemount Raptor System
THUM 5900S
2240S 5400
2240S 5400 5900S
5900S
2410 Smart Wireless
644 Gateway
3051S
5300
644
2160/65/75 Field
Communication Unit
2230 2410 2410 2410
2180 Field Bus

Modem
2240S Multi-input
Temperature 375 /475 Field
5900S Radar 5300/5400
Transmitter Communicator
Level Gauge Radar Level
TankMater PC
Transmitter
Workstation in
2410 Tank Hub Network TankMaster.net
2230 Graphical Smart Wireless

Field Display THUM Adapter
644 Temperature
3051S Pressure 2120/2160 Transmitter with Single
Transmitter Liquid Level switch Point Temperature Sensor

27-Jun-01, Slide 72
Typical instruments on LNG storage tanks

27-Jun-01, Slide 73
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

27-Jun-01, Slide 74
Antenna – 5900S LPG/LNG
 Designed for
– Liquefied gas in LPG/LNG tanks
Seal & ball
– 4 in still-pipes sch 10 or 40 New Adapter
valve
– 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

27-Jun-01, Slide 75
Level Accuracy: 5900S
exceeds OIML R85:2008
4
Old (R85:1998)
0.001 New (R85:2008)

1 Downwards manual log
(mm)
Upwards manual log

0
0 0 5 10 15 20 25 30 Downwards autolog
Upwards autolog
-1
-0.001
New (R85:2008)
-2
-3
Old (R85:1998)
-4

27-Jun-01, Slide 76
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

27-Jun-01, Slide 77
Raptor –
SIL 2 and 3 Certified

27-Jun-01, Slide 78
Built In Proof Testing
 The two Radars
will constantly
”safety-check”
each other Avoid Manual Proof Testing
 Long time between
manual Proof
Testing
 ”No man on the
tank”
 Saves $$$

27-Jun-01, Slide 79
Online proof-testing
-check
Blue and Red lines separated for visibility.

An alarm is given if the  exceeds a defined limit

27-Jun-01, Slide 80
2-in-1 Radar
Radar #1
 High Level of Safety Radar #2
 SIL3 Rated
 Low Cost Installation
 On Tank Redundancy
 High Availability
 Less Proof Testing
 Less Verification
 Saves $$$ in many ways

27-Jun-01, Slide 81
2x Radars on the same tank - well proven

27-Jun-01, Slide 82
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
[Fileradars
Name or Event]
Polskie LNG – New receiving terminal, 2 tks.
 27-Jun-01, Slide 83
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

27-Jun-01, Slide 84
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

27-Jun-01, Slide 85
Total LNG Tank Instrumentation Solution
Level alarms to ESD
Loop 1
Loop 2
5900S LNG + 2410

5900S LNG + 2410
Secondary level
Primary level 5900S + 1146 LTD
2410
Hi-Hi alarm
2240S and 566 2240S and 566

multiple spot multiple spot
temp temp
TANK
N°1

27-Jun-01, Slide 86
Total LNG Tank Instrumentation Solution
LNG Manager
TANK N°1
Loop 1 Serial link
Loop 2
9510
20 mA loop / RS232C DCS
Serial link Serial link
TANK N°2
Loop 1
Serial link LNG Roll-Over
Predictor
Loop 2
9510
20 mA loop / RS232C
LNG Manager
TRL2 bus for Raptor FCU 2160

/2410 if not using
WM660

27-Jun-01, Slide 87
Tank detail (Roll-Over)

27-Jun-01, Slide 89
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

27-Jun-01, Slide 90
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

27-Jun-01, Slide 93

Best Practic Instal New Radar TGsystem LNG and Overfilling - 2

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Best Practic Instal New Radar TGsystem LNG and Overfilling - 2

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Best Practices:

Installing New Radar

Rosemount Tank Radar AB Confidential

[File Name or Event]

[File Name or Event]

International Organization of Legal Metrology

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

Gauge hatch Nozzles 2”, 4”, 8”

Nozzle 8” Manway 20”

[File Name or Event]

 On a 24” Man Way

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

 What does API Ch 3.1B say?

[File Name or Event]

 Same location as the

 The Temp Sensor can

[File Name or Event]

 What does Standards say?

– Use RTD type of sensor (Pt100)

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

 Lower end of the tank

[File Name or Event]

 At the gauge hatch

[File Name or Event]

[File Name or Event]

[File Name or Event]

 By the road side

[File Name or Event]

 Use existing cabling

[File Name or Event]

Disconnect the old cabling Remove the old Gauge

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

No re-calibration Long power module life

Virtually unaffected by Self Checking

Steam, Density Temperature

Fault conditions detected Standard Enhanced

No re-calibration Long power module life

Virtually unaffected by Single probe handles

Steam, Density Temperature

 Gain access to advanced diagnostics:

 Integrate more information into any control

[File Name or Event]

[File Name or Event]