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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
Tec
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Dif
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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
nal
str
eng
thS
ign
al s
tren
gth
Sig
nal
str
eng
thS
ign
al s
tren
gth
DistanceDistanceDistanceDistance
With Dual PortWith Dual PortWith Dual PortWith Dual Port Without Dual PortWithout Dual PortWithout Dual PortWithout Dual Port
Cu
sto
mer
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
Tec
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Dif
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ust
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enef
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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
Tec
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Dif
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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
Tec
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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
Tec
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Dif
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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