Rosemount Process Level Rosemount Process Level solutions solutions

by Ganesh Raman

Process Radar Marketing

Rosemount Asia Pacific

Emerson Process Emerson Process Management & SAAB Management & SAAB Emerson Process Emerson Process Management & SAAB Management & SAAB

Saab is the level segment in the

Rosemount Measurement Organization

Saab & Saab & Rosemount Rosemount Teaming UP in 2001!Teaming UP in 2001!

JAS 39 GripenJAS 39 GripenJAS 39 GripenJAS 39 GripenSAAB’s Core BusinessSAAB’s Core BusinessSAAB’s Core BusinessSAAB’s Core Business

History of SAAB

First tanker delivery

World leaderin level gauging for tankers

First on shoredelivery

World leaderin the oil industry

1997Two new systems: LPG/LNG gauge for tankers & TankRadar Pro for the process industry

No. of. competitors with radar:

0 0 1 12 16

1999TankRadar REX for inventory tank gauging & LoopRadar, loop-powered

>20

1976 1980 1984 1996

Rosemount’s Process Radar products

3300 Series Guided Wave Radar for Level & Interface applications

5600 Series Non- contact Radar for Process Industry

5400 Series 2 wire

Non-contact Radar

Rosemount non Rosemount non contact radarscontact radars

5400 Series 5600 Series

6 GHz Radar10 GHz Radar24 GHz Radar

Beam width is inversely proportional to frequency Beam width is inversely proportional to frequency and antenna diameter.and antenna diameter.

Beam Angle = k ( c/f D)f = frequencyc = speed of lightD = Antenna diameter

FREQ.(GHz.) ANT. DIA.(inches) BEAM WIDTH (ft)*5 4 20

10 4 10.124 4 4.25 19.2 4.2

10 9.6 4.224 4 4.2

* Approx.. calc. of beam width at bottom of 20ft. tank.

24GHZ

10GHZ

6 GHz

24 GHz

10 GHz

6 GHz

Same size antenna produces different signal strengths

Different Antennas are required to produce same signal strength

Signal Strength is affected by beam width Signal Strength is affected by beam width and antenna diameterand antenna diameterSignal Strength is affected by beam width Signal Strength is affected by beam width and antenna diameterand antenna diameter

Frequency - condensationFrequency - condensationFrequency - condensationFrequency - condensation Relationship between condensation and frequency

– General, the thicker condensation layer the higher microwave attenuation

– High frequency is attenuated more than low frequency given the same condensation layer width

Condensation layer

26GHz

6GHz

1/frequency ~ Beam Angle

Frequency ~ Dust, Vapour and contamination sensitivity

--------------• Frequency increase - the

sensitivity for dust, Vapour and contamination increases.

• Frequency decrease - the beam angle becomes larger.

The Optimal FrequencyThe Optimal FrequencyThe Optimal FrequencyThe Optimal Frequency

Reduce operating costs Robust Design

Improve process uptimeMeasurement Reliability

Reduce startup costs Fast Startup

Better Bottom Line

Innovative measurement technologies for a Innovative measurement technologies for a better bottom linebetter bottom line

Pulse radar measurement principlePulse radar measurement principlePulse radar measurement principlePulse radar measurement principle Non-Contact, Pulsed, Continous Radar

– Short Radar pulses (~ns) emitted from Antenna

– Part of puls energy reflected on the product surface

– Antenna receives reflected pulse

– Transmitter electronics and software processes received signal and generates a level value

~ 1 ns

~ 0.5 μs

Distance ~Time between Transmitted and Received Pulse Speed of Light

2

Rosemount 5400 Series Rosemount 5400 Series - Housing features- Housing featuresRosemount 5400 Series Rosemount 5400 Series - Housing features- Housing features

Dual CompartmentDie-cast Aluminum

Housing

Air filled waveguide– no coaxial connections

Housing easy removablewithout opening tank

Integrated CoolingFins for increasedelectronics life time

Rotate Housing inany direction

Rosemount 5402, 26 GHzRosemount 5401, 6 GHz

Rosemount 5400 Series – Rosemount 5400 Series – SAFETYSAFETY with with Dual Seal DesignDual Seal DesignRosemount 5400 Series – Rosemount 5400 Series – SAFETYSAFETY with with Dual Seal DesignDual Seal Design

Primary seal is built to withstand specified pressure and temperature with a safety factor of 4 x’s pressure limit.

In addition to primary seal there is a secondary seal

– Secondary seal is designed to withstand temperature and pressure conditions to which it could be subjected

Primary Seal

Secondary Seal

Antenna ProgramAntenna Program

Rosemount 5401 Rosemount 5402

3”3”3”3” 4”4”4”4” 6”6”6”6” 8”8”8”8”

ConesConesConesCones

2”2”2”2” 3”3”3”3” 4”4”4”4”

ConesConesConesCones

Teflon RodTeflon RodTeflon RodTeflon RodCone extensionsCone extensionsCone extensionsCone extensions Process SealProcess SealProcess SealProcess SealCone extensionsCone extensionsCone extensionsCone extensions

2”, 3”, 4”2”, 3”, 4”100 mm100 mm100 mm100 mm

250 mm250 mm250 mm250 mm

Ideally, the antenna end should be inside Ideally, the antenna end should be inside tank, slightly beyond nozzletank, slightly beyond nozzleIdeally, the antenna end should be inside Ideally, the antenna end should be inside tank, slightly beyond nozzletank, slightly beyond nozzle

It should not be even with tank roof

Potential concerns if antenna is shorter than nozzle

5401 5402

10 mm

!

• Use antenna extension with caution– Performance is reduced ifplugging or deposits occur– Heavy vibrations

EchoSensitivity

The skill to detect weak radar echoes in a changing process environment

EchoSensitivity

The skill to detect weak radar echoes in a changing process environment

EchoDynamics

The ability to handle weak and strong radar echoes simultaneously with equal reliability

EchoDynamics

The ability to handle weak and strong radar echoes simultaneously with equal reliability

EchoLogics

The intelligence to tell true echo from false

EchoLogics

The intelligence to tell true echo from false

TMTMTMTMMeasurement Reliability

EchosensitivityEchologics

Echodynamics

Tx RxMicrowave Module

Rosemount 5400:

Transmitting / Receiving

Port #1

Transmitting / Receiving

Port #1

Transmitting / Receiving Port #2

Transmitting / Receiving Port #2

5400 uses dual ports for transmitting and receiving

Standard 2-wire radar level transmitters:

– one common port for transmitting & receiving signals

Tx RxMicrowave Module

Traditional design:

EchoEchoSensitivitySensitivity5400’s Dual Port Technology5400’s Dual Port TechnologyEchoEchoSensitivitySensitivity5400’s Dual Port Technology5400’s Dual Port Technology

100 5050

50

2525 100

5400

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Others lose 75% in the Radar, plus need to cope with tank conditions

5400 loses no energy in the Radar

– Greater measurement reliability margins result in less downtime, higher safety, better quality

EchoEchoSensitivitySensitivity5400’s Dual Port Technology5400’s Dual Port Technology

Sig

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Sig

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DistanceDistanceDistanceDistance

With Dual PortWith Dual PortWith Dual PortWith Dual Port Without Dual PortWithout Dual PortWithout Dual PortWithout Dual Port

Cu

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Ben

efit

Larger active area (PTFE) towards the tank environment compared with standard transmitters

Less sensitive to dirt and liquid-film buildup on antenna

EchoEchoSensitivity –Sensitivity –Condensation Resistant AntennaCondensation Resistant AntennaEchoEchoSensitivity –Sensitivity –Condensation Resistant AntennaCondensation Resistant Antenna

Rosemount 5402 enlarged seal

Ø 34 mm

Standard 2-wire transmitter seal

Ø 6 mm

TM

EchoEchoSensitivitySensitivity5400’s Condensation Resistant Antenna5400’s Condensation Resistant AntennaEchoEchoSensitivitySensitivity5400’s Condensation Resistant Antenna5400’s Condensation Resistant Antenna

5400

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Greater measurement reliability margins result in less downtime, higher safety, better quality

Raw Signal

EchoEchoDynamicsDynamics Distance Attenuation and Gain CurveDistance Attenuation and Gain CurveEchoEchoDynamicsDynamics Distance Attenuation and Gain CurveDistance Attenuation and Gain Curve

Surface highMUCH energy

back to antenna

Surface lowlittle energy

back to antenna

Gain Curve

*

*

=

=

Amplified Signal

Greater measurement reliability results inless downtime, higher safety and better quality

5400

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EchoEchoLogicsLogicsMeasure & LearnMeasure & Learn™™ Transmitter Software Transmitter SoftwareEchoEchoLogicsLogicsMeasure & LearnMeasure & Learn™™ Transmitter Software Transmitter Software

False Echo Registration

Up to 5 echoes tracked simultaneously

Automatic threshold settings

Measure & Learn™ available via 275/375, AMS and RadarMaster

Distance, ft

5400

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EchoEchoLogicsLogicsStandard xmtrs w/o False Echo RegistrationStandard xmtrs w/o False Echo RegistrationEchoEchoLogicsLogicsStandard xmtrs w/o False Echo RegistrationStandard xmtrs w/o False Echo Registration

Tank being emptied

Gauge has no false echo registration !

Echo Strength Echo Strength

Gauge Output

Time

Could lock onto false echo !

0 %

100 %

5400

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Tank being emptied

Gauge Output

Time

5400 has registered the false echo

Will keep tracking surface !

Echo Strength Echo Strength

0 %

100 %

5400

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rEchoEchoLogicsLogics5400 uses False Echo Registration5400 uses False Echo RegistrationEchoEchoLogicsLogics5400 uses False Echo Registration5400 uses False Echo Registration

Pipe/Bridle installations- Isolates device from most application conditions-Low Dielectric constant liquids-To mechanically avoid turbulence

Target ApplicationsTarget ApplicationsTarget ApplicationsTarget Applications

Storage/Buffer tank- Calm or slightly moving surface- Narrow nozzle-E.g. Solvent storage, sumps, chemical storage tanks

Process tanks- Slightly turbulent conditions- Agitators, inlets, etc- Condensation and Vapor- Possibly foam

Installation and ConfigurationInstallation and ConfigurationInstallation and ConfigurationInstallation and Configuration Mechanical

– Transmitter head, Tank Seal and Antenna is delivered in one package.

Electrical

– 2-wire! SAFE &Easy!

Plant IntegrationPlant Integration

Rosemount Radar Master.lnk

275 / 375 3420

Application Example: Concentrated Black Application Example: Concentrated Black Liquor Storage: 5401, 6”Liquor Storage: 5401, 6”Application Example: Concentrated Black Application Example: Concentrated Black Liquor Storage: 5401, 6”Liquor Storage: 5401, 6”

Temp: About 110 C

Dielectric of black liquor: high

Vapors; some foam

Previous technology:

– Vega low frequency

Fill line

6” /DN 150 flange

11 m

Application Example: Spent Caustic: Application Example: Spent Caustic: 5402, 3”5402, 3”Application Example: Spent Caustic: Application Example: Spent Caustic: 5402, 3”5402, 3”

Tall nozzle3” diameter

Teflon window

Application Example: Foam: 5401Application Example: Foam: 5401

Example of an application where the 5401 worked beautifully!

Application- Leachate: 5401, 6”Application- Leachate: 5401, 6”Application- Leachate: 5401, 6”Application- Leachate: 5401, 6” Product: Leachate (acid waste-water

containing mud etc)

Tank Height: 3.8 m

Heavy turbulence due to top-filling and agitation. Layers of mud.

Two identical fiberglass tanks.

– Only one transmitter had to be configured – all the settings were transferred to the second transmitter in less than 2 minutes

Previous technologies:

– GWR ( interfered w/ agitator)

– DP (clogging issues)

Power Power Industry applications Industry applications Power Power Industry applications Industry applications

Customer : REGCO, Thailand Process details

– Fuel Storage Tank– Diesel

Rosemount 5401 with 8” cone antenna

– 2 wire installation

– Maintenance free

– Remote configuration

Industry applicationsIndustry applicationsIndustry applicationsIndustry applications Customer: Casco Adhesives, Kristinehamn

Sweden Customer comments:

– Customer anticipated a 4-wire transmitter for this application

– Reduced operation and maintenance costs

Process: Mixing and cooling of resinTank Height: 3.5 mPressure: AmbientTemp: 20-50 C

Continuous cooling and mixing of different solvents to get resin

Resin is a highly viscous and sticky product

Tank has two agitators to keep fluids mixed, no foam though

Baffles on the sides

Varying DC. End resin product has approximately 6.

The customer is currently using a glass window to keep track of level. Since they are moving towards an automated process in order to cut operation and maintenance costs they need to have a reliable level measurement.

A pressure transmitter has been tested but does not work sufficiently due to density variations.

Heating coils are present in the lower part of the tank.

Industrial applicationsIndustrial applicationsIndustrial applicationsIndustrial applicationsCustomer comment:

– ”The 5400 handles the application very well”.

Process: Storage tankProduct: Resin, viscous and stickyTank Height: 7 m (5 m wide)Pressure: AmbientTemp: 20-50 CDC: Water based 4 mA: 0 m20 mA: 6.7 m

Large angled agitator blades, moderate stirring 0.5 m above bottom

Turbulence/splashing and occasionally foam during filling

Heating coils at approximately 0.5 m above tank bottom

Storage tank for resin that holds the product before it is shipped

Currently a floating device is used that causes continuous maintenance since the wire gets stuck

6”, DN 150