Rosemount Process Level solutions

by Ganesh Raman Process Radar Marketing Rosemount Asia Pacific

Emerson Process Management & SAAB

Saab & Rosemount Teaming UP in 2001!

Saab is the level segment in the Rosemount Measurement Organization

SAAB’s Core Business

JAS 39 Gripen

History of SAAB

1976 First tanker delivery

No. of. competitors

with radar: 0 1980 1984 World leader in level gauging for tankers First on shore delivery 1996 World leader in the oil industry 1997 Two new systems: LPG/LNG gauge for tankers & TankRadar Pro for the process industry 1999 TankRadar REX for inventory tank gauging & LoopRadar, loop-powered 0 1 12 16 >20

Rosemount’s Process Radar products

5600 Series Non- contact Radar for Process Industry 3300 Series Guided Wave Radar for Level & Interface applications 5400 Series 2 wire Non-contact Radar

Rosemount non contact radars

5400 Series 5600 Series

Beam width is inversely proportional to frequency and antenna diameter.

6 GHz Radar 10 GHz Radar 24 GHz Radar

Beam Angle = k ( c/f D) f = frequency c = speed of light D = Antenna diameter FREQ.(GHz.) 5 10 24 5 10 24 ANT. DIA.(inches) 4 4 4 19.2

9.6

4 BEAM WIDTH (ft)* 20 10.1

4.2

4.2

4.2

4.2

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

Signal Strength is affected by beam width and antenna diameter

24 GHZ 10 GHZ 6 GHz 24 GHz 10 GHz 6 GHz Same size antenna produces different signal strengths Different Antennas are required to produce same signal strength

Frequency - 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 26GHz 6GHz Condensation layer

The Optimal Frequency

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.

Improve process uptime Measurement Reliability Reduce operating costs Robust Design Reduce startup costs Fast Startup

Better Bottom Line

Innovative measurement technologies for a better bottom line

Pulse radar measurement principle



Non-Contact, Pulsed, Continous Radar

– Short Radar pulses (~ns) emitted from Antenna ~ 1 ns – – – ~ 0.5 μs 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 Distance ~ Time between Transmitted and Received Pulse 2 Speed of Light

Rosemount 5400 Series - Housing features

Rosemount 5401 , 6 GHz

Dual Compartment Die-cast Aluminum Housing

Rosemount 5402 , 26 GHz

Rotate Housing in any direction Integrated Cooling Fins for increased electronics life time Housing easy removable without opening tank Air filled waveguide – no coaxial connections

Rosemount 5400 Series – SAFETY with Dual 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 Secondary Seal Primary Seal

Antenna Program

Rosemount 5401

Cones

Rosemount 5402

Cones 3” 4” 6” Cone extensions 8” Teflon Rod 2” 3” 4” Cone extensions Process Seal 100 mm 250 mm 2”, 3”, 4”

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

10 mm 

It should not be even with tank roof

5401 5402 

Potential concerns if antenna is shorter than nozzle

• Use antenna extension with caution – Performance is reduced if plugging or deposits occur – Heavy vibrations !

Echo Sensitivity

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

TM

Measurement Reliability Echo sensitivity Echo logics Echo dynamics

Echo Logics

The intelligence to tell true echo from false

Echo Dynamics

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

Echo

Sensitivity

5400’s Dual Port Technology



Standard 2-wire radar level transmitters:

– one common port for transmitting & receiving signals 

5400 uses dual ports for transmitting and receiving

Traditional design: Microwave Module Rx Rosemount 5400 : Rx Microwave Module Transmitting / Receiving Port #2 50 Transmitting / Receiving Port #1

Echo

Sensitivity

5400’s Dual Port Technology



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 higher safety, better quality less downtime,

With Dual Port Without Dual Port Distance

Echo Sensitivity – Condensation Resistant Antenna



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



Less sensitive to dirt and liquid-film buildup on antenna

TM

Rosemount 5402 enlarged seal

Ø 34 mm

Standard 2-wire transmitter seal

Ø 6 mm

Echo

Sensitivity

5400’s Condensation Resistant Antenna



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

Echo

Dynamics

Distance Attenuation and Gain Curve

Raw Signal Gain Curve Amplified Signal Surface high MUCH energy back to antenna * = Greater measurement reliability results in less downtime, higher safety and better quality * = Surface low little energy back to antenna

Echo

Logics

Measure & Learn ™ Transmitter Software

False Echo Registration Up to 5 echoes tracked simultaneously

Distance, ft

Measure & Learn

™

available via 275/375, AMS and RadarMaster Automatic threshold settings

Echo

Logics

Standard xmtrs w/o False Echo Registration

Echo Strength Echo Strength Tank being emptied 100 % Gauge Output Could lock onto false echo !

0 % Gauge has no false echo registration !

Time

Echo

Logics

5400 uses False Echo Registration

Echo Strength Echo Strength Tank being emptied 100 % Gauge Output Will keep tracking surface !

0 % 5400 has registered the false echo Time

Target 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

Pipe/Bridle installations

- Isolates device from most application conditions -Low Dielectric constant liquids -To mechanically avoid turbulence



Installation and Configuration

Mechanical

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



Electrical

– 2-wire!

SAFE &Easy!

Plant Integration

275 / 375 3420

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

  Temp: About 110 C  Dielectric of black liquor: high  Vapors; some foam Previous technology: Fill line –

Vega low frequency

6” /DN 150 flange 11 m

Application Example: Spent Caustic: 5402, 3”

Tall nozzle 3” diameter Teflon window

Application Example: Foam: 5401

Example of an application where the 5401 worked beautifully!

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 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 applications

Customer: Casco Adhesives, Kristinehamn Sweden Customer comments:

– Customer anticipated a 4-wire transmitter for this application – Reduced operation and maintenance costs     

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.

Process: Tank Height: Pressure: Temp:

Mixing and cooling of resin 3.5 m Ambient 20-50 C   

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 applications

Customer comment:

– ”The 5400 handles the application very well”.

6 ”, DN 150

Process: Product:

Storage tank Resin, viscous and sticky

Tank Height:

7 m (5 m wide)

Pressure: Temp: DC: 4 mA: 20 mA:

Ambient 20-50 C Water based 0 m 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