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Rosemount Process Level solutions

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.

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Rosemount Process Level solutions

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  1. Rosemount Process Level solutions by Ganesh Raman Process Radar Marketing Rosemount Asia Pacific

  2. Emerson Process Management & SAAB Saab & Rosemount Teaming UP in 2001! Saab is the level segment in the Rosemount Measurement Organization

  3. SAAB’s Core Business JAS 39 Gripen

  4. History of SAAB 1984 1976 1980 1996 1999 TankRadar REX for inventory tank gauging & LoopRadar, loop-powered 1997 Two new systems: LPG/LNG gauge for tankers & TankRadar Pro for the process industry World leader in the oil industry World leader in level gauging for tankers First on shore delivery First tanker delivery No. of. competitors with radar: >20 16 12 1 0 0

  5. 5600 Series Non- contact Radar for Process Industry 3300 Series Guided Wave Radar for Level & Interface applications Rosemount’s Process Radar products 5400 Series 2 wire Non-contact Radar

  6. Rosemount non contact radars 5400 Series 5600 Series

  7. 6 GHz Radar 10 GHz Radar 24 GHz Radar Beam width is inversely proportional to frequency and antenna diameter. Beam Angle = k ( c/f D) f = frequency c = speed of light D = Antenna diameter * Approx.. calc. of beam width at bottom of 20ft. tank.

  8. 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

  9. 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

  10. 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.

  11. Improve process uptime Measurement Reliability Reduce startup costs Fast Startup Reduce operating costs Robust Design Better Bottom Line

  12. Innovative measurement technologies for a better bottom line

  13. ~ 1 ns ~ 0.5 μs Speed of Light Time between Transmitted and Received Pulse Distance ~ 2 Pulse 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

  14. Rosemount 5400 Series - Housing features Rosemount 5401, 6 GHz Rosemount 5402, 26 GHz Dual Compartment Die-cast Aluminum Housing Rotate Housing inany direction Integrated CoolingFins for increasedelectronics life time Housing easy removablewithout opening tank Air filled waveguide– no coaxial connections

  15. Secondary Seal Primary Seal 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

  16. Cones 3” 4” 6” 8” Antenna Program Rosemount 5401 Rosemount 5402 Cones 2” 4” 3” Cone extensions Teflon Rod Cone extensions Process Seal 100 mm 2”, 3”, 4” 250 mm

  17. Ideally, the antenna end should be inside tank, slightly beyond nozzle • It should not be even with tank roof • Potential concerns if antenna is shorter than nozzle 10 mm 5401 5402 • Use antenna extension with caution • Performance is reduced ifplugging or deposits occur • Heavy vibrations !

  18. TM Measurement Reliability Echosensitivity Echologics Echodynamics EchoSensitivity The skill to detect weak radar echoes in a changing process environment EchoLogics The intelligence to tell true echo from false EchoDynamics The ability to handle weak and strong radar echoes simultaneously with equal reliability

  19. Standard 2-wire radar level transmitters: • one common port for transmitting & receiving signals Tx Rx • 5400 uses dual ports for transmitting and receiving Traditional design: Rosemount 5400: Tx Rx Transmitting / Receiving Port #2 Microwave Module Microwave Module Transmitting / Receiving Port #1 EchoSensitivity5400’s Dual Port Technology 5400 Technology Differentiator 100 50 50 25 25 100 50

  20. With Dual Port Without Dual Port Signal strength others 5400 Distance EchoSensitivity5400’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 less downtime, higher safety, better quality Customer Benefit

  21. TM EchoSensitivity –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 Rosemount 5402 enlarged seal Ø 34 mm Standard 2-wire transmitter seal Ø 6 mm

  22. EchoSensitivity5400’s Condensation Resistant Antenna Customer Benefit 5400 Technology Differentiator • Greater measurement reliability margins result in less downtime, higher safety, better quality

  23. Raw Signal Gain Curve Amplified Signal = * * = EchoDynamicsDistance Attenuation and Gain Curve Surface highMUCH energyback to antenna • Greater measurement reliability results inless downtime, higher safety and better quality 5400 Technology Differentiator Surface lowlittle energyback to antenna

  24. EchoLogicsMeasure & Learn™ Transmitter Software False Echo Registration unique ! Up to 5 echoes tracked simultaneously 5400 Technology Differentiator Automatic threshold settings Distance, ft Measure & Learn™ available via 275/375, AMS and RadarMaster

  25. Tank being emptied Gauge Output 100 % Could lock onto false echo ! Time 0 % EchoLogicsStandard xmtrs w/o False Echo Registration Echo Strength Echo Strength 5400 Technology Differentiator Gauge has no false echo registration !

  26. Tank being emptied Gauge Output Time EchoLogics5400 uses False Echo Registration Echo Strength Echo Strength 5400 Technology Differentiator 5400 has registered the false echo 100 % Will keep tracking surface ! 0 %

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

  28. Installation and Configuration • Mechanical • Transmitter head, Tank Seal and Antenna is delivered in one package. • Electrical • 2-wire! SAFE &Easy!

  29. Plant Integration 275 / 375 3420

  30. Application Example: Concentrated Black Liquor Storage: 5401, 6” • Temp: About 110 C • Dielectric of black liquor: high • Vapors; some foam • Previous technology: • Vega low frequency 6” /DN 150 flange Fill line 11 m

  31. Application Example: Spent Caustic: 5402, 3” Tall nozzle 3” diameter Teflon window

  32. Application Example: Foam: 5401 Example of an application where the 5401 worked beautifully!

  33. 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)

  34. 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

  35. Industry 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 ofresin Tank Height: 3.5 m Pressure: Ambient Temp: 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.

  36. Industrial applications Customer comment: • ”The 5400 handles the application very well”. Process: Storage tank Product: Resin, viscous and sticky Tank Height: 7 m (5 m wide) Pressure: Ambient Temp: 20-50 C DC: Water based 4 mA: 0 m 20 mA: 6.7 m 6”, DN 150 • 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

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