Saab TankMaster HTG - Spartan Controls/media/resources/rosemount tank... · 4 Technical Description 705010E, Ed.1 Saab TankMaster HTG December 2004 5 Technical Description 705010E,

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Saab TankMaster HTGHigh Precision Tank Gauging System

Technical Description705010E, Ed.1December 2004

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Technical Description705010E, Ed.1December 2004 Saab TankMaster HTG

ContentsAvailable technical documentation for Saab TankMaster HTG: ___________________________ 2Abbreviations used in this document: ___________________________________________________ 3

Saab TankMaster Hydrostatic Tank Gauging__________________________________4Applications_____________________________________________________________________________ 4Installation and commissioning of the TankMaster HTG System __________________________ 5

HTG measurements and calculations _________________________________________6

Director Series 4 ___________________________________________________________________7Base board ______________________________________________________________________________ 7Processor board ________________________________________________________________________ 7HBI boards______________________________________________________________________________ 7Cable connections to DS4_______________________________________________________________ 7Pressure and temperature transmitters__________________________________________________ 7

TankMaster HMI software ________________________________________________________8Interactive configuration and installation with set-up wizard _________________________ 8Inventory and custody transfer functions ____________________________________________ 8Networking and interfacing _________________________________________________________ 9Reports and data sampling __________________________________________________________ 9Alarms _____________________________________________________________________________ 9Others_____________________________________________________________________________10

PC Requirement _______________________________________________________________________10

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Technical Description705010E, Ed.1

December 2004Saab TankMaster HTG

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Copyright © December 2004 by Saab Marine Electronics AB.First edition. December 2004 Ref. no. 705010E.

Technical data is subject to change without prior notice. Saab Marine Electronics AB accepts no responsibility for any errors that may appear in this description.

Allen-Bradley, Bailey, DEC, Enraf, Fisher, Foxboro, GPE, Honeywell, IBM, L&J, Profibus, Rosemount, Saab, Saab TankRadar, Siemens, Tiway, Varec, Vega, Whessoe and Yokogawa are registered trademarks and trademarks of these organizations and companies.

Available technical documentation for Saab TankMaster HTG:• Saab TankMaster Hydrostatic Tank Gauging

Reference Manual• TankMaster HTG Installation and Troubleshooting

Guidelines (To be published)• TankMaster WinSetup User’s Guide• TankMaster WinOpi User’s Guide

The Saab TankMaster Hydrostatic Tank Gauging Reference Manual is used for installing a DS4 and configuring TankMaster for a HTG system.

TankMaster HTG Installation and Troubleshooting Guidelines is used for installing and troubleshooting the HTG equipment in the field.

The TankMaster WinSetup User’s Guide describes how to start-up the system using the WinSetup software on a personal computer. TankMaster is the Human Machine Interface (HMI) software for TankRadar Rex. It includes the WinSetup and WinOpi software modules.

The TankMaster WinOpi User’s Guide describes the inventory and display functions included in the optional TankMaster WinOpi software.

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Abbreviations used in this document:

API American Petroleum Institute

DCS DigitalControl System

DS4 Director Series 4

GOV Gross Observed Volume

GSV Gross Standard Volume

HART Highway Addressable Remote Transducer

HMI Human Machine Interface

HTG Hydrostatic Tank Gauging

ISO International Standard Organization

LAN Local Area Network

NSV Net Standard Volume

OIML International Organization of Legal Metrology

PC Personal Computer

SCADA Supervisory Control and Data Acquisition System

TCP/IP Transmission Control Protocol / Internet Protocol

TCT Tank Capacity Table

TM TankMaster

TOV Total Observed Volume

VCF Volume Correction Factor

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The TankMaster HTG system is an intelligent direct mass measuring system. It takes advantage of the high precision pressure transmitters installed at different levels in the tank. HTG uses product hydrostatic pressure measurements to derive both the specific gravity and liquid level.

ApplicationsBulk liquid storage and process tanks where accurate mass measurement is required.TankMaster HTG can be used for most products.

Examples:• Hydrogen peroxide• Molasses• Butadiene• Paint resin• Formaldehyde• Lube oil• Water• Milk• Beer• Cider• Solvents• Ammonia• Petroleum products

Saab TankMaster Hydrostatic Tank Gauging

Features

• No moving parts.• The product mass is constant even if

the level changes due to changes in temperature

• Modern, state-of-the-art, OPC compatible operator software

• Inventory calculations according to API and ISO standards

• Mass custody transfer approved by NMI• Networking possibilities• Fewer devices compared to the old HTG

systems• Worldwide service and support

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Summary of functions & system overview

The TankMaster HTG system measures and calculates tank data for:• Inventory calculations• Mass Custody transfer• Product movement

The HTG system is primarily calculating the mass of the product. These parameters are shown in the Tank Inventory windows:• Level• Flow rate• Gross observed volume• Net observed volume• Gross standard volume• Net standard volume• Weight• Mass• Density

The pressure and temperature values from the tanks are communicated to the PC via the DS4 (a multiplexer which also converts HART to Modbus). One DS4 can collect data from 60 HART transmitters, so by using just one or many DS4s the HTG system can easily be adapted to small sites with just a few tanks as well as large sites with several hundred tanks.

The HTG system is configured and operated using the OPC compatible TankMaster software package. It is a user-friendly HMI software that calculates the mass, volume, density and level of the product, and that gives the operator a good overview and quick access to any measured or calculated values. The software also provides a wide range of inventory and custody transfer functions such as net standard volumes according to API standards, reporting, alarms, graphics, trends etc.

A whole range of plant host computer systems, DCS or SCADA systems can be connected to the

TankMaster HTG system for display of measured and calculated values. Protocols for communication with major suppliers of plant host computers have been developed and certified.

TankMaster HTG system overview.

TankMaster PC for data communication, calculations, displaying and reporting

Modem

LAN

Two alternative interfaces, RS-232 or RS-485 with modem

Director Series(DS4) Modbus communication

HART communication

Host

RS-485 RS-232

Installation and commissioning of the TankMaster HTG SystemThe pressure and temperature transmitters should be configured and installed according to the installation instructions and installation drawings from Rosemount. Installation guidelines for the HTG equipment in the field can be found in the TankMaster HTG Installation and Troubleshooting Guidelines. Commissioning is normally done by a trained engineer from our local representative, or in some cases by the customer. The TankMaster WinSetup PC software is used to configure the system. A HART communicator is used to configure the pressure and temperature transmitters. The DS4 is pre-configured in the factory.

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HTG measurements and calculations HTG uses product hydrostatic pressure measurements to derive both specific gravity and liquid level. A typical HTG system uses three pressure transmitters: one near the bottom of the tank, another above the first, and a third at the top. All measured data are transmitted on the field bus and are further processed in the control room by the TankMaster PC software.

Comparison of the pressure readouts from the two submerged transmitters P1 and P2 are used to calculate the specific gravity of the liquid, thus generating mass and density. The pressure transmitter P2 is optional, and if P2 is not used, the density can be entered manually into TankMaster. The liquid level can be determined by comparing readouts from P3 (which measures the vapor pressure in the tank) and P1.

The accuracy of the mass, level and density calculations largely depends on the accuracy of the pressure transmitters. The DS4 can interface to any pressure transmitter with a standard output of 4-20 mA HART. The 4-20 mA signal is converted to Modbus in the DS4. The standard pressure transmitter supplied with the TankMaster HTG system for in-liquid mounting is Rosemount 3051S Ultra A1014.

The system calculates the following data:• Mass• Observed density• Weight • Level (corrected for thermal tank wall expansion)• Flow rate• Gross observed volume• Net observed volume• Gross standard volume• Net standard volume

All data is calculated according to updated API and ISO standards. The temperature calculations include API algorithms to handle elements close to the bottom.

Both metric and USA/UK units are supported. TankMaster performs net volume calculations with very high accuracy using up to 2000 strapping points. TankMaster is using quadratic interpolation for spheres and horizontal cylinders, which increases volume accuracy and reduces number of strapping points. The TankMaster HTG system is NMi certified for mass custody transfer. A hardware key is required for HTG calculations to be available.

Vapor pressure

Liquid pressure

Temperature

Liquid pressure

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Director Series 4The Director Series 4 (DS4) is a gateway for enabling operational data to be acquired, transformed and utilized through full TCP/IP communication. The DS4 polls the HART transmitters for Primary Values (PV) and Secondary Values (SV) and sends information to the TankMaster network.

Base boardThe base board is connecting everything together inside the DS4. The base board also includes the power supply.

Processor boardThe processor board is the heart of the DS4.

HBI boardsThe HBI boards provides 2 HART channels each.

Cable connections to DS4The electrical interface uses RS-232 or RS-485 standard interface. The interface is hardware controlled by jumper settings. A modem is needed for converting the RS-485 to RS-232 when communicating with a PC.

Pressure and temperature transmittersRosemount pressure and temperature transmitters support the DS4 with measurement data. Different types and numbers of transmitters are used depending on tank configuration. For example, a tank with vapor pressure requires three transmitters for online measurement. Two transmitters measuring the liquid pressure and one at the top measuring the vapor pressure.All transmitter configuration is done using 275/375 handheld communicator or AMS suite software.

Technical Data for DS4

Temperature -40 to +70° C (-40 to +160 °F)

HumidityInput

0 to 95% relative, non-condensating

Update rate to TankMaster PC 53 tanks per second.

HART channels Converts information from up to four HART channels (up to 60 HART addresses) to Modbus

Non-Ex housing Should be mounted in IP 54 rated enclosure if exposed to the elements

Power Supply 24 VDC, 0.5 A nominal (18-36 V range)

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TankMaster distributes essential inventory tank gauging data.

TankMaster HMI software

TankMaster is a powerful Windows-based Human Machine Interface (HMI) for complete tank inventory management. It provides configuration, service and set up, inventory and custody transfer functions for TankMaster HTG systems. All calculations are based on current API and ISO standards. TankMaster follows the OPC standard and can communicate with Microsoft® programs and OPC compatible systems like Intellution’s iFIX® and Wonderware’s InTouch®. TankMaster is developed and supported by Saab Rosemount Tank Radar. TankMaster has two main software modules:

• WinSetup is the software package used for configuration. The program supports installation of the DS4 device and mapping of the connected pressure transmitters to tanks.

• WinOpi is a complete inventory software package. In order to display special HTG windows and HTG values, a special hardware key with HTG option is needed.

Available main functions in TankMaster include the following:Interactive configuration and installation with set-up wizard

Inventory and custody transfer functions• Real time tank gauging data such as pressure

and temperature.• Real time, gross and net volume inventory

calculations based on API and ISO.• Metrologically sealed data.• API calculator.

SCADA EngineeringOPC client level

Ethernet

Management

TankMasterOPC Server

TankMasterOPC Server

Modbus

Modbus

Modbus

DCS

PLCFCU

TRL2 Field Bus Tank data, Level, Temperature, Pressure, Volume, etc.HART

DS4

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You can easily organize the tanks in e.g. geographical or product groups, with associated sub-groups. For example you can choose to see the actual tank gauging and inventory data in a bargraph group, giving a quick overview of tank farm activity.

TankMaster gives the most important inventory data for a specific tank in one easy-to-read window.

Networking and interfacing• OPC server with browser for easy interface with

other plant computer systems.• Full network capabilities.• SCADA / DCS communication via MODBUS.• SCADA / DCS communication via OPC.• Integration with other tank gauging systems by

taking in and displaying data from other vendors’ gauges.

Reports and data sampling• Batch report for internal and external transfers.• Customized Reports to Microsoft Office

programs.• Automatic reports.• Reports via e-mail.• Audit log for events.• Historical data sampling.

Alarms • Reliable alarm handling of measured values with

high, high-high, low and low-low level alarms.• Alarms to mobile phones.• Alarms via e-mail.• Leakage alarms based on net volume.

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Others• User manager with different access levels for

personnel.• Customized views with graphic plant layouts.• Easy translation to other languages than English.• Advanced group configuration in geographical or

product groups etc.• Compatibility with Saab’s earlier platform OPI

which can easily be replaced by TankMaster.

PC Requirement

Required operating system: Windows XP SP1, 2000 SP3, NT 4.0 SP5 or later. Distributed COM (DCOM), which is used for network computing.

Required hardware (PC): Windows XP/2000/NT approved PC. 800 MHz Intel or compatible. 256 MB RAM. 4 GB disk drive (TankMaster requires approx. 200 MB).Graphics card 1024*768 pixels, 65536 colors.

Required hardware (network server PC): 1-2 Network clients – same/better performance on the server than on the client PC.3 or more Network clients – 1.6 GHz Intel or compatible, 512 MB RAM on the server PC.

For further information a separate TankMaster brochure is avaialble.

The “tank farm explorer” makes it easy to navigate in TankMaster. Just like in “Windows explorer” it is possible to expand and minimize fields and get direct group and tank access by double-clicking the specific group or tank icon.



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Emerson Process ManagementSaab Rosemount Tank GaugingBox 130 45SE-402 51 GöteborgSWEDENTel (Intenational): +46 31 337 00 00Fax (Intenational): +46 31 25 30 22E-mail: [email protected]

Documents

Saab TankMaster HTG - Spartan Controls/media/resources/rosemount tank... · 4 Technical Description 705010E, Ed.1 Saab TankMaster HTG December 2004 5 Technical Description 705010E,