Transcript
The contents of this publication are presented for information purposes only, and while efforts have been made to ensure their accuracy, they are not to be construed as warranties or guarantees, expressed or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our products at any time without notice. Rosemount Tank Radar AB accepts no responsibility for any errors that may appear in this publication.
Emerson Process Management Rosemount Tank Gauging Box 13045 SE-402 51 Göteborg SWEDEN Phone: +46 31 337 00 00 Fax: +46 31 25 30 22 E-mail:
[email protected] www.rosemount-tg.com
NORTH AMERICA: Rosemount Tank Gauging North America Inc. Houston, Texas. Tel: 1-800-722-2865. E-mail:
[email protected] MIDDLE EAST: Rosemount Tank Gauging Middle East SPC, Bahrain. Tel: +973 17 22 66 10. E-mail:
[email protected] INDIA: Rosemount Tank Gauging India Pvt. Ltd., Pune. Tel: +91 20 6602 3747. E-mail:
[email protected] LATIN AMERICA & CARRIBEAN: Rosemount Tank Gauging. Tel: +58 212 242 0237. E-mail:
[email protected] OTHER COUNTRIES: Find your local representative at www.rosemount-tg.com
© Rosemount Tank Radar AB. Ref.No. 201019En, Edition 2, Rev A. February 2008
Rosemount, TankRadar, Enraf, Sakura, Varec, L&J, GPE, Whessoe, Auxitrol, GSI, Tiway, and Tokyo Keiso are registered trademarks of their respective owners. Foundation is a trademark of the Fieldbus Foundation. The Emerson logo is a trademark and servicemark of Emerson Electric Co.
Tank Intelligence™ is our business Introduction to the Rosemount Tank Gauging system
What do you call a smart solution for monitoring storage tank content and transfers?
We call it Tank Intelligence™
Whether you’re an oil company executive, a refinery operator or the proud owner of an independent storage tank farm, the exact quantity of bulk liquids in your storage tanks is of great importance to your daily work. Inventory value, loss control, storage capacity utilization, leak detection and overfill protection are just some of the important issues that you deal with – and they all depend on the quality and performance of your tank gauging system. Naturally, constant access to reliable and precise tank content information in real time helps you make better and more informed decisions. At the end of the day, this means better productivity, increased safety and higher profitability. In short, Tank Intelligence is the sum of all the functions, benefits, and added value delivered by a Rosemount Tank Gauging system. All with the same purpose – to improve your company’s bottom line. The benefits are:
2
Automatic transfer verification Product transfers have considerable economic implications. Precise, automatic tank gauging can be used to directly measure custody transfer or for checking hand dips or meters. This means faster and more accurate billing. Improved inventory management Inventory data is used for accounting/tax purposes and as an input for loss control calculations. The trend is towards more accurate inventory checks in order to better utilize corporate assets and due to more stringent requirements from fiscal authorities. Replacing inaccurate tank gauges with high-accuracy Rosemount TankRadar® gauges in your plant can decrease inventory uncertainty corresponding to net volumes worth hundreds of thousands of dollars every year.
Minimized hydrocarbon losses Loss control management focuses on minimizing hydrocarbon losses to ensure that you reduce environmental impact, while maximizing the amount of refined product obtained from the crude oil that you purchase. Precise tank gauging makes it easier to identify your loss sources and quantify them. This way, you can re-evaluate your priorities and thereby quickly boost savings and profitability. Reduced OPEX and improved plant efficiency
Maximum safety and environmental protection To protect your staff, the public and the environment from damage caused by overfilled or leaking storage tanks, you need an automatic tank gauging system with reliable alarm functions. Rosemount TankRadar Rex and Pro gauges are among the safest overfill alarm sensors in the business. Both are TÜV-tested and approved for overfill protection according to the German WHG regulations. Moreover, TankRadar Rex is suitable for SIL 2 applications in accordance with IEC 61508/61511.
The highly reliable Rosemount TankRadar gauges are virtually maintenance free, since they don’t have any moving parts. The switch to a Rosemount Tank Gauging system will quickly pay for itself through reduced maintenance and operation costs. Furthermore it will offer new possibilities to increase revenue through improved plant efficiency.
3
Your entire bulk liquid storage, just a click away. Major oil companies around the world use Rosemount Tank Gauging systems from Emerson to improve the efficiency, safety, and profitability of refineries, tank farms and terminals. The main benefits include proven reliability, multi-certified accuracy and minimum maintenance. Also, the Rosemount Tank Gauging system is in full compliance with all existing oil industry standards. The system includes both the custody transferclass TankRadar ® Rex gauges and the multipurpose TankRadar ® Pro gauges. Depending on your setup, you may benefit most from a single stand-alone radar gauge with a local read-out or from a complete system solution that is able to handle hundreds of tanks and distribute data globally via the Internet.
Level and Volume A single Rosemount TankRadar gauge mounted on top of an oil tank will deliver measured liquid level values as well as calculated content values such as Total Observed Volume (TOV). In stand-alone applications, the read-out typically comprises a Remote Display Unit on the tank top or on the ground. Temperature, Water Interface, and Pressure Add a Multispot Thermometer with an integrated Water Level Sensor (WLS), and the system will not only deliver measured liquid level and volume, but also calculated average temperature and water interface level. With such temperature data available, level values are corrected for any thermal expansion of the tank walls. A Multispot Thermometer (MST) with six PT100 temperature elements can be connected directly to the TankRadar Rex transmitter head together with two Digital Pressure
4
Transmitters. Should you require more than six temperature elements per tank, a Data Acquisition Unit (DAU) will be added. Using the TankMaster software, you get Gross Observed Volume (GOV), Gross Standard Volume (GSV), and Net Standard Volume (NSV). Hybrid Tank Gauging (HTG) Add two Digital Pressure Transmitters; one at the bottom of the tank to measure the liquid pressure, and an optional one for vapor space pressure measurement. Together with the TankMaster software, this provides a complete hybrid tank gauging system, delivering measured values such as observed density, hydrostatic and vapor pressure, as well as calculated hybrid values such as density and mass – all online! Flexible field communication The system can communicate in several ways: via standard
buses, such as Foundation™ fieldbus and Profibus, via our proprietary TRL/2 bus, or by emulation of other vendors’ fieldbuses. Via the fieldbus, the gauge is connected to a Field Communication Unit (FCU), which continuously polls and stores tank content data from groups of radar tank gauges, and DAUs. The FCU delivers tank content data to the Rosemount TankMaster inventory management software. This ensures that the system is continuously updated with fast and reliable tank data. If you prefer, data can also be delivered directly to your DCS/SCADA system or plant host computer via various protocols. Wireless installation The Rosemount Tank Gauging system offers different options for wireless communication: between each tank and the control room, or between the FCU and TankMaster.
TankRadar Rex and Pro gauges support Emerson’s Smart Wireless concept. It utilizes self-organizing (mesh) networks to ensure that your measurement information will always be available. Self-organizing networks automatically optimize connectivity to achieve the highest data reliability. Unlike other approaches to in-plant wireless, which require direct line-of-sight between the instrument and the communication gateway, Emerson’s Smart Wireless concept ensures maximum network integrity by allowing devices to communicate with each other. Every device serves as a network connector, which means there is no single point of failure. Should a temporary obstruction block a direct connection, the network automatically reroutes the signal to an adjacent device, ensuring network reliability and data integrity.
5
The custody transfer-class tank inventory gauge.
Still-pipe array antenna gauge RTG 3950
Parabolic antenna gauge RTG 3930
Horn antenna gauge RTG 3920
LPG/LNG gauge RTG 3960
TankRadar Rex ®
6
TankRadar Rex is designed to deliver reliable tank inventory data with custody transfer accuracy, for all tank farm and refinery applications. Instrument level accuracy is ±0.5 mm (0.020 in.) under an ambient operating temperature of -40 to +70 °C (-40 to +158 °F). It features built-in multiple temperature inputs, analog inputs/outputs, HART inputs for pressure transmitters and relay outputs for complete inventory, hybrid and custody transfer functions. Furthermore, TankRadar Rex is thirdparty assessed and considered to be SIL 2 suitable. It is also TÜV-tested for overfill protection.
densed. This makes the gauge an excellent choice for all products, from the very clean to asphalt and blown bitumen.
Horn antenna gauge RTG 3920 RTG 3920 is specifically designed for mounting in existing small tank nozzles (min. 8 inches) near the tank wall on fixed roof tanks. False radar echoes from the tank wall will not affect the measurement quality, thanks to our intelligent signal polarization. This gauge measures all types of liquids, but is less suitable for asphalt and similar products.
LPG/LNG gauge RTG 3960 RTG 3960 is designed for measuring in pressurized LPG spheres or bullets. It is also ideal for cryogenic applications such as LNG. A still-pipe makes the signal sufficiently stronger even from a boiling surface. A patented reference pin is used to verify measurements when the tank is pressurized. Options include vapor pressure sensor and ball valve items.
Parabolic antenna gauge RTG 3930 RTG 3930 has a large heavy-duty stainless steel and PTFE antenna. Thanks to its drip-off design, the antenna is extremely tolerant to products that become sticky or con-
Complete technical information is available in the “TankRadar Rex Technical Description” which can be downloaded from www.rosemount-tg.com
Still-pipe array antenna gauge RTG 3950 RTG 3950 is suitable for tanks with a still-pipe, such as crude oil tanks and gasoline tanks. It has a drip-off design array antenna and features Low Loss Mode technology that enables highly-accurate measurements even in rusty and deposit-coated still-pipes. A removable waveguide facilitates hand-dips and sampling.
The powerful, versatile level gauge.
TankRadar Pro ®
the drip-off design, the parabolic antenna is insensitive to contamination and can therefore be used in harsh environments, for example with asphalt. Still-pipe array antenna gauge The small-sized antenna has a drip-off design and fits perfectly in existing still-pipes. It measures accurately, even if the still-pipe is rusty or deposit-coated. The gauge is available with flange, or hatch mounting for easier hand-dipping and product sampling. It is suitable for tanks with floating roofs and inner floating roofs. Still-pipe array antenna gauge
Parabolic antenna gauge
Cone antenna gauge
TankRadar Pro is a powerful, multi-purpose radar level gauge for all types of bulk storage applications. It has an instrument level accuracy of up to ± 3 mm (0.12 in.) and built-in temperature inputs, making it ideal for inventory control. In addition, it is TÜV-tested for overfill protection. Parabolic antenna gauge The parabolic antenna has very high antenna gain, which makes it suitable for measuring distances up to 100 m (330 ft), and tank openings from 450 mm (18 in.). Due to
Cone antenna gauge The cone antenna is suitable for most liquid applications and it fits 3, 4, 6-or 8-inch tank openings. The existing flange can be used as a tank connection due to the antenna’s unique plate design. A 2-inch version is available for installation in bullet shaped tanks. The antenna is available in stainless steel as well as a variety of other materials. There is also a selection of different tank seal and O-ring options for a wide range of stored products. Complete technical information is available in the “TankRadar Pro Technical Description,” which can be downloaded from www.rosemount-tg.com
7
Supplementary tank sensors
Rosemount 2120 Vibrating Fork Liquid Level Switch
Rosemount 3051S Series Digital Pressure Transmitter
Rosemount 5400 Series Two-wire Radar Level Transmitter
Multispot Thermometer with integrated Water Level Sensor
As a supplement to the high-precision TankRadar Rex and TankRadar Pro, we supply reliable, cost efficient medium accuracy radar gauges for smaller tanks. This enables system integration of slop oil tanks and additive tanks in your tank gauging system. The complete Rosemount Tank Gauging product portfo-
Rosemount 5300 Series High Performance Guided Wave Radar Transmitter
lio also comprises a range of pressure transmitters, temperature sensors, water level sensors and communication units to customize your tank gauging system. For detailed technical information, please visit www.rosemount-tg.com or contact your local Rosemount Tank Gauging sales representative.
Open communication standards The Rosemount Tank Gauging system is compatible with all existing fieldbus standards. It can be connected to all major suppliers of DCS, SCADA systems, plant host computers or terminal automation systems. All data is transmitted on the fast and reliable two-wire TRL/2 field bus, using the Modbus protocol. As an option, TankRadar Rex can communicate via other buses, such as Foundation™ fieldbus, Profibus, or proprietary fieldbuses from other tank gauging vendors.
8
Communication Supported Profibus® DP
• Standard TRL/2 field bus (Modbus RTU) • Emulation of other vendor's fieldbuses
Rosemount TankMaster Tank Intelligence software TankMaster is a powerful Windows based Human Machine Interface (HMI) for complete tank inventory management, designed to deliver all the benefits of Tank Intelligence. Your operators get a quick overview, as well as detailed views, of all tank gauging data – in real-time as well as historically, for the entire tank farm, tank-by-tank and product-by-product. Calculations of inventory and custody transfer quantities are performed in real time, following API, ISO and other industry standards. TankMaster is fully OPC-compatible and communicates with SCADA/DCS systems, plant host computers, and Microsoft Office programs via OPC or the Modbus protocol. The benefits include: • Quick interactive setup and configuration of gauges and tank parameters • User-friendly tank content and activities display • Alarm and event status continuously checked and reported • Full inventory data display in DCS/plant host system • All tank data stored in a dedicated database • Runs on a standard PC with Windows operating system • Customized views
Tank Intelligence on the Web The Web version, TankMaster.net, makes storage tank data accessible via the Internet or corporate intranet. You can obtain an updated view of your inventory at any time, whatever your location. Authorized parties can monitor contents and transfers in real-time. Terminals can promote available tank capacity online, increasing plant efficiency and customer service.
Field Communication Unit 2160/2165/2175
Alternative Connections to DCS
Radio Modem
Field Bus Modem OPC/Network
Data Acquisition Unit
Remote Display Unit
Water Level Sensor
Temperature Sensor
Pressure Transmitter
TankRadar Gauge
TankMaster PC workstation in network
www Customer PC
TankMaster.net PC
9
Gauges emulated by TankRadar Rex • Auxitrol® • Enraf ® • GPE ® • GSI® • L&J® • Tiway® • Sakura® • Tokyo Keiso® • Varec® • Whessoe®
Smart and easy retrofit with tank gauge emulation.
This list will be continuously updated as other emulated gauges are added.
The Rosemount Tank Gauging system is compatible with all other major tank gauge vendors. Step-by-step modernization of your current tank gauging system is possible thanks to flexible field and control room solutions. Just plug-and-gauge The TankRadar® Rex gauge is designed with an open interface, covering everything from electrical interface and communication protocol to utilization of many different power sources. This feature enables you to replace old mechanical or servo gauges with modern Rex gauges, without having to replace the control system or field cabling. Simply connect the Rex to your existing system and you’re operational.
TankRadar Rex gauge
10
With TankRadar Rex, you no longer need to remain “stuck” with your old system. By replacing old servo gauges, you can avoid re-calibration and the expenses associated with spare parts and maintenance.
CIU858
Seamless control room connectivity The FCU 2165/2175 allows you to emulate different host systems and other control room devices. You can replace your old tank monitoring software with the latest version of Rosemount TankMaster. This solution provides seamless connectivity meaning problem-free communication with your existing field devices and a lean, clean installation.
TankMaster
FCU 2165/2175
Rosemount TankMaster can replace an existing inventory management system, still being able to communicate with the field devices in use.
The Tank Intelligence staff will back you up All Rosemount TankRadar® gauges are designed to be maintenance free, self-calibrating and highly reliable. Moreover, installation, setup, configuration, and commissioning are simple operations that can be done by almost anyone. However, your tank gauging system deals with enormous quantities of petroleum products, representing huge financial values and considerable safety risks. Therefore, your Tank Intelligence solution also includes access to local technical support from Emerson’s Tank Gauging specialists, just in case you should need it. We are never far away Emerson’s Rosemount Tank Gauging representatives are located worldwide, providing you with service and support from over 200 highly trained service engineers, in more than 80 countries. We also organize product training for our customers. We hope to see you there!
11
Protecting your plant All refineries, tank farms and fuel depots have a huge responsibility in ensuring that overfill incidents do not occur. In this context the most important task for an automatic tank gauging system is to prevent incidents, by providing a reliable High-High level alarm function. You can rest assured that Rosemount TankRadar® gauges provide you with one of the safest possible overfill alarm solutions on the market. Ensuring a reliable overfill alarm Conventional overfill alarm sensors used in storage tanks, such as floats or switches, have one major weakness: the only time you really know that they are functioning is when you run a test. With a Rosemount TankRadar gauge connected to your system, it’s the other way around. The gauge gives the operator continuous information about its status and performance since it is being used in the everyday operations of the tank farm. Failures detected by the diagnostic capabilities of the gauge, will alert the operator to take appropriate action under safe conditions.
Approved for overfill protection Both Rosemount TankRadar Rex and Pro gauges are TÜVtested and approved for overfill protection according to the German WHG (Wasserhaushaltsgesetz) regulations. The approval means that the TankRadar gauge can complement a traditional High-High switch thereby introducing redundancy into the safety system. In this way, the safety level of your plant is improved. SIL 2 safety Rosemount TankRadar Rex has been third-party assessed by Exida and is considered suitable for use in SIL 2 safety functions, in accordance with IEC 61508/61511. The safety function is based on the relay outputs. One relay, or a combination of two, can be used for overfill or dry run protection. Any decision to operate proven-in-use devices always rests with the end user. However, third party assessment by Exida provides a good basis for such decisions, in accordance with section 11.5.3 of IEC 61511.
EX approvals • International: IECEx • Belarus: GOST Standard • Brazil: CEPEL • Canada: C-UL • China: CNACL • EU: ATEX Directive • India: Nagpur • Japan: JIS • Kazakhstan: GOST Standard • South Korea: KOSHA • Russia: GOST Standard • Ukraine: GOST Standard • USA: UL
Safety approvals and acknowledgement • SIL 2 Suitable • Belgium: Vlarem II • Germany: WHG approval for overfill protection, tested by TÜV 12
Metrological certificates
Every drop counts Tank gauging readings for net volumes, which form the basis for inventory calculations and billing, must be exact because any deviation can lead to negative consequences. In recent years, the price of crude oil has quadrupled and it will probably continue upwards during the foreseeable future. The increased value of stored petroleum assets has made most refineries, pipelines and oil storage companies aware that precise and efficient tank gauging is business critical for all companies in the oil supply chain.
USD/bbl 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 99
00
01
02
03
04
05
06
07 Year
Price trend for crude oil. The higher the price of crude oil, the greater the value of the products in your tanks and return on investment for a highly accurate tank gauging system.
International: OIML R85 (E) Algeria: ONML Austria: BEV Belarus: GOST Standard Belgium: BMS China: CMI Croatia: DZM Czech Republic: CMI (Czech) Estonia: TJI France: LNE Germany: PTB Hungary: OMH India: W & M Indonesia: MIGAS Italy: Metric Office Kazakhstan: GOST Standard Malaysia: Sirim Netherlands: NMi Poland: GUM Portugal: IPQ Romania: BRML Russia: GOST Standard Serbia/Montenegro: FBMPM Switzerland: METAS Thailand: Thai Excise and Customs Ukraine: GOST Standard
Precise tank gauging pays Inaccurate tank gauging costs money, since you could lose the value of any In addition to the accuracy approvals lisproduct volumes that canted above, many countries are presently not be verified. Improving in the process of defining custody transfer requirements. the measurement accuracy in your tank gauging system reduces your uncertainty during both transfer control/verification and inven- tory management. At the same time, loss control is improved. Improved accuracy can give substantial savings. In a large storage tank equipped with a mediocre gauging system, the value of the uncertain volume (i.e. the oil volume within the gauge’s error margin) is so large that this alone justifies the investment in a high-class system such as the Rosemount Tank Gauging system. If you wish to calculate the potential savings using your own figures, please visit www.every-drop-counts.com Certified custody transfer-class accuracy Rosemount TankRadar Rex is metrologically approved for custody transfer and legal custody transfer in virtually all countries that use automatic tank gauging for billing purposes.
13
Special TankRadar applications ®
Liquefied Natural Gas (LNG) Radar is the fastest growing technology for level gauging in LNG tanks. No wonder – in a huge cryogenic tank that may not be opened for years, you need a highly reliable and maintenance free level gauging system. Rosemount TankRadar gauges require no physical contact when measuring the liquid level and there are no components inside the tank that will require service. Thus, the system provides continuous, highly reliable and accurate level data, for the entire service life of the LNG tank.
by photo courtesy of Center for Liquefied Natural Gas
Distilleries The distillery business typically sets high demands on tank gauging precision, for blending, billing and taxation purposes. With non-contact level measurement and a reliable, maintenance free design, these features make the Rosemount TankRadar gauges particularly valuable for distillery and other food & beverage applications. Rosemount VatRadar is a special distillery level gauge range, successfully proven at many of the world’s most famous distilleries.
Asphalt Level gauging in asphalt tanks is a very challenging appli cation made easy by specially designed antennas for the Rosemount TankRadar gauges. High accuracy is often re quired in the large bitumen storage tanks (approx. 20 m/ 66 ft. high) that are typically used at refineries and terminals. In such tanks, the most reliable measurements are attained with a parabolic antenna. Rosemount TankRadar has a proven track record of effectively solving tank gauging issues for asphalt and blown bitumen tanks.
14
Liquefied Petroleum Gas (LPG) At refineries and terminals, LPG is normally stored in spherical or bullet-shaped tanks. Due to the high pressure needed to keep the gas liquefied, opening the tank for inspection or maintenance of measurement devices is very complicated and expensive. Rosemount TankRadar gauges measure the liquid level without any components inside the tank that may require service. In addition, all TankRadar Rex LPG gauges are easily calibrated. A patented reference device function enables measurement verification with the tank in operation.
Biofuels Renewable energy sources are rapidly becoming important economic and environmental factors. A Rosemount TankRadar gauge is the perfect choice for measuring biodiesel (including the plant and waste cooking oils from which it is produced), bioethanol and blends of biofuels and petroleum products. Rosemount TankRadar gauges have been used for several years to increase efficiency at palm oil terminals and other plants, because of their outstanding reliability and accuracy.
Underground tanks Storing large quantities of oil, LPG and LNG in underground tanks or caverns has many advantages, such as increased safety, lower operational costs and less impact on the environment. Rosemount TankRadar gauges fit perfectly in underground applications, including those with very long measurement ranges; over 80 m (260 ft) for free propagation installations and 110 m (360 ft) if a still-pipe is used. Both TankRadar Rex and Pro gauges are designed for harsh environments and can be installed inside the cavern, as well as outside.
15
