Tank Intelligence - Rosemount TankRadar

Rosemount, TankRadar, Enraf, Sakura, Varec, L&J, GPE, Whessoe, Auxitrol, GSI, Tiway, and Tokyo Keiso are registered trademarks of their respective
owners. Foundation is a trademark of the Fieldbus Foundation. The Emerson logo is a trademark and servicemark of Emerson Electric Co.
The contents of this publication are presented for information purposes only, and while efforts have been made to ensure their accuracy, they are not
to be construed as warranties or guarantees, expressed or implied, regarding the products or services described herein or their use or applicability. All
sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications
of our products at any time without notice. Rosemount Tank Radar AB accepts no responsibility for any errors that may appear in this publication.
Emerson Process Management
Rosemount Tank Gauging
Box 13045
SE-402 51 Göteborg
SWEDEN
Phone: +46 31 337 00 00
Fax: +46 31 25 30 22
E-mail: sales.rtg@emerson.com
www.rosemount-tg.com
NORTH AMERICA: Rosemount Tank Gauging North America Inc. Houston, Texas.
Tel: 1-800-722-2865. E-mail: sales.srt.hou@emerson.com MIDDLE EAST:
Rosemount Tank Gauging Middle East SPC, Bahrain. Tel: +973 17 22 66 10.
E-mail: khawaja@rosemounttg.com.bh INDIA: Rosemount Tank Gauging India
Pvt. Ltd., Pune. Tel: +91 20 6602 3747. E-mail: pune@saabtankradar.co.in LATIN
AMERICA & CARRIBEAN: Rosemount Tank Gauging. Tel: +58 212 242 0237.
E-mail: miguel.fattal@emerson.com OTHER COUNTRIES: Find your local representative
at www.rosemount-tg.com
© Rosemount Tank Radar AB. Ref.No. 201019En, Edition 2, Rev A. February 2008

Tank Intelligence is our business
Introduction to the Rosemount Tank Gauging system

What do you call a smart solution for monitoring
storage tank content and transfers
We call it Tank Intelligence
Whether you’re an oil company executive, a refinery operator
or the proud owner of an independent storage tank farm,
the exact quantity of bulk liquids in your storage tanks is of
great importance to your daily work.
Inventory value, loss control, storage capacity utilization,
leak detection and overfill protection are just some
of the important issues that you deal with – and they
all depend on the quality and performance of your tank
gauging system.
Naturally, constant access to reliable and precise tank
content information in real time helps you make better
and more informed decisions. At the end of the day, this
means better productivity, increased safety and higher
profitability.
In short, Tank Intelligence is the sum of all the functions,
benefits, and added value delivered by a Rosemount Tank
Gauging system. All with the same purpose – to improve
your company’s bottom line. The benefits are:
Automatic transfer verification
Product transfers have considerable economic implications.
Precise, automatic tank gauging can be used to directly measure
custody transfer or for checking hand dips or meters.
This means faster and more accurate billing.
Improved inventory management
Inventory data is used for accounting/tax purposes and
as an input for loss control calculations. The trend is towards
more accurate inventory checks in order to better utilize
corporate assets and due to more stringent requirements
from fiscal authorities. Replacing inaccurate tank gauges
with high-accuracy Rosemount TankRadar ® gauges in your
plant can decrease inventory uncertainty corresponding
to net volumes worth hundreds of thousands of dollars
every year.
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Minimized hydrocarbon losses
Loss control management focuses on minimizing hydrocarbon
losses to ensure that you reduce environmental impact, while
maximizing the amount of refined product obtained from
the crude oil that you purchase. Precise tank gauging makes
it easier to identify your loss sources and quantify them. This
way, you can re-evaluate your priorities and thereby quickly
boost savings and profitability.
Reduced OPEX and improved plant efficiency
Maximum safety and environmental protection
To protect your staff, the public and the environment from
damage caused by overfilled or leaking storage tanks, you
need an automatic tank gauging system with reliable alarm
functions. Rosemount TankRadar Rex and Pro gauges are
among the safest overfill alarm sensors in the business.
Both are TÜV-tested and approved for overfill protection
according to the German WHG regulations. Moreover,
TankRadar Rex is suitable for SIL 2 applications in accordance
with IEC 61508/61511.
The highly reliable Rosemount TankRadar gauges are virtually
maintenance free, since they don’t have any moving
parts. The switch to a Rosemount Tank Gauging system
will quickly pay for itself through reduced maintenance and
operation costs. Furthermore it will offer new possibilities to
increase revenue through improved plant efficiency.
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Your entire bulk liquid
storage, just a click away.
Major oil companies around the world use
Rose mount Tank Gauging systems from Emerson to
improve the efficiency, safety, and profitability of
refineries, tank farms and terminals. The main
benefits include proven reliability, multi-certified
accuracy and minimum maintenance. Also, the
Rosemount Tank Gauging system is in full compliance
with all existing oil industry standards.
The system includes both the custody transferclass
TankRadar ® Rex gauges and the multipurpose
TankRadar ® Pro gauges. Depending on
your setup, you may benefit most from a single
stand-alone radar gauge with a local read-out or
from a complete system solution that is able to
handle hundreds of tanks and distribute data
globally via the Internet.
Level and Volume
A single Rosemount TankRadar gauge mounted on top
of an oil tank will deliver measured liquid level values as
well as calculated content values such as Total Observed
Volume (TOV). In stand-alone applications, the read-out typically
comprises a Remote Display Unit on the tank top or on
the ground.
Temperature, Water Interface, and Pressure
Add a Multispot Thermometer with an integrated Water
Level Sensor (WLS), and the system will not only deliver
measured liquid level and volume, but also calculated average
temperature and water interface level.
With such temperature data available, level values are
corrected for any thermal expansion of the tank walls.
A Multispot Thermometer (MST) with six PT100 temperature
elements can be connected directly to the TankRadar
Rex transmitter head together with two Digital Pressure
Transmitters. Should you require more than six temperature
elements per tank, a Data Acquisition Unit (DAU) will
be added.
Using the TankMaster software, you get Gross Observed
Volume (GOV), Gross Standard Volume (GSV), and Net Standard
Volume (NSV).
Hybrid Tank Gauging (HTG)
Add two Digital Pressure Transmitters; one at the bottom of
the tank to measure the liquid pressure, and an optional one
for vapor space pressure measurement. Together with the
TankMaster software, this provides a complete hybrid tank
gauging system, delivering measured values such as observed
density, hydrostatic and vapor pressure, as well as calculated
hybrid values such as density and mass – all online!
Flexible field communication
The system can communicate in several ways: via standard
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uses, such as Foundation fieldbus and Profibus, via our
proprietary TRL/2 bus, or by emulation of other vendors’
fieldbuses.
Via the fieldbus, the gauge is connected to a Field Communication
Unit (FCU), which continuously polls and stores
tank content data from groups of radar tank gauges, and
DAUs. The FCU delivers tank content data to the Rosemount
TankMaster inventory management software. This ensures
that the system is continuously updated with fast and reliable
tank data.
If you prefer, data can also be delivered directly to your
DCS/SCADA system or plant host computer via various
protocols.
Wireless installation
The Rosemount Tank Gauging system offers different
options for wireless communication: between each tank and
the control room, or between the FCU and TankMaster.
TankRadar Rex and Pro gauges support Emerson’s Smart
Wireless concept. It utilizes self-organizing (mesh) networks
to ensure that your measurement information will always be
available. Self-organizing networks automatically optimize
connectivity to achieve the highest data reliability.
Unlike other approaches to in-plant wireless, which
require direct line-of-sight between the instrument and the
communication gateway, Emerson’s Smart Wireless concept
ensures maximum network integrity by allowing devices
to communicate with each other. Every device serves as
a network connector, which means there is no single point
of failure.
Should a temporary obstruction block a direct connection,
the network automatically reroutes the signal to an adjacent
device, ensuring network reliability and data integrity.
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The custody transfer-class tank inventory gauge.
Still-pipe array antenna
gauge RTG 3950
Parabolic antenna
gauge RTG 3930
Horn antenna gauge
RTG 3920
LPG/LNG gauge
RTG 3960
TankRadar ® Rex
TankRadar Rex is designed to deliver reliable tank inventory
data with custody transfer accuracy, for all tank farm and
refinery applications. Instrument level accuracy is ±0.5 mm
(0.020 in.) under an ambient operating temperature of -40
to +70 °C (-40 to +158 °F).
It features built-in multiple temperature inputs, analog
inputs/outputs, HART inputs for pressure transmitters and
relay outputs for complete inventory, hybrid and custody
transfer functions. Furthermore, TankRadar Rex is thirdparty
assessed and considered to be SIL 2 suitable. It is also
TÜV-tested for overfill protection.
Horn antenna gauge RTG 3920
RTG 3920 is specifically designed for mounting in existing
small tank nozzles (min. 8 inches) near the tank wall on fixed
roof tanks. False radar echoes from the tank wall will not
affect the measurement quality, thanks to our intelligent
signal polarization. This gauge measures all types of liquids,
but is less suitable for asphalt and similar products.
Parabolic antenna gauge RTG 3930
RTG 3930 has a large heavy-duty stainless steel and PTFE
antenna. Thanks to its drip-off design, the antenna is
extremely tolerant to products that become sticky or condensed.
This makes the gauge an excellent
choice for all products, from the very clean
to asphalt and blown bitumen.
Still-pipe array antenna gauge RTG 3950
RTG 3950 is suitable for tanks with a still-pipe, such as
crude oil tanks and gasoline tanks. It has a drip-off design
array antenna and features Low Loss Mode technology that
enables highly-accurate measurements even in rusty and
deposit-coated still-pipes. A removable waveguide facilitates
hand-dips and sampling.
LPG/LNG gauge RTG 3960
RTG 3960 is designed for measuring in pressurized LPG
spheres or bullets. It is also ideal for cryogenic applications
such as LNG. A still-pipe makes the signal sufficiently stronger
even from a boiling surface. A patented reference pin is
used to verify measurements when the tank is pressurized.
Options include vapor pressure sensor and ball valve items.
Complete technical information is available in the “TankRadar
Rex Technical Description” which can be downloaded from
www.rosemount-tg.com
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The powerful, versatile level gauge.
TankRadar ® Pro
the drip-off design, the parabolic antenna is insensitive to
contamination and can therefore be used in harsh environments,
for example with asphalt.
Still-pipe array antenna gauge
The small-sized antenna has a drip-off design and fits perfectly
in existing still-pipes. It measures accurately, even if
the still-pipe is rusty or deposit-coated. The gauge is available
with flange, or hatch mounting for easier hand-dipping
and product sampling. It is suitable for tanks with floating
roofs and inner floating roofs.
Still-pipe array
antenna gauge
Parabolic
antenna gauge
Cone antenna
gauge
TankRadar Pro is a powerful, multi-purpose radar level gauge
for all types of bulk storage applications. It has an instrument
level accuracy of up to ± 3 mm (0.12 in.) and built-in
temperature inputs, making it ideal for inventory control.
In addition, it is TÜV-tested for overfill protection.
Parabolic antenna gauge
The parabolic antenna has very high antenna gain, which
makes it suitable for measuring distances up to 100 m
(330 ft), and tank openings from 450 mm (18 in.). Due to
Cone antenna gauge
The cone antenna is suitable for most liquid applications and
it fits 3, 4, 6-or 8-inch tank openings. The existing flange can
be used as a tank connection due to the antenna’s unique
plate design. A 2-inch version is available for installation in
bullet shaped tanks. The antenna is available in stainless
steel as well as a variety of other materials. There is also a
selection of different tank seal and O-ring options for a wide
range of stored products.
Complete technical information is available in the “TankRadar
Pro Technical Description,” which can be downloaded from
www.rosemount-tg.com
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Supplementary tank sensors
Rosemount 2120
Vibrating Fork Liquid Level Switch
Rosemount 3051S Series
Digital Pressure Transmitter
Rosemount 5400 Series
Two-wire Radar Level Transmitter
Multispot Thermometer with
integrated Water Level Sensor
Rosemount 5300 Series
High Performance Guided
Wave Radar Transmitter
As a supplement to the high-precision TankRadar Rex and
TankRadar Pro, we supply reliable, cost efficient medium
accuracy radar gauges for smaller tanks. This enables system
integration of slop oil tanks and additive tanks in your tank
gauging system.
The complete Rosemount Tank Gauging product portfolio
also comprises a range of pressure transmitters, temperature
sensors, water level sensors and communication units to
customize your tank gauging system. For detailed technical
information, please visit www.rosemount-tg.com or contact
your local Rosemount Tank Gauging sales representative.
Open communication standards
The Rosemount Tank Gauging system is compatible with all
existing fieldbus standards. It can be connected to all major
suppliers of DCS, SCADA systems, plant host computers or
terminal automation systems.
All data is transmitted on the fast and reliable two-wire
TRL/2 field bus, using the Modbus protocol. As an option,
TankRadar Rex can communicate via other buses, such as
Foundation fieldbus, Profibus, or proprietary fieldbuses
from other tank gauging vendors.
Communication Supported
• Standard TRL/2 field bus (Modbus RTU)
• Emulation of other vendor's fieldbuses
Profibus ® DP
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Rosemount TankMaster
Tank Intelligence software
TankMaster is a powerful Windows based Human Machine
Interface (HMI) for complete tank inventory management,
designed to deliver all the benefits of Tank Intelligence. Your
operators get a quick overview, as well as detailed views, of
all tank gauging data – in real-time as well as historically, for
the entire tank farm, tank-by-tank and product-by-product.
Calculations of inventory and custody transfer quantities
are performed in real time, following API, ISO and other
industry standards. TankMaster is fully OPC-compatible and
communicates with SCADA/DCS systems, plant host computers,
and Microsoft Office programs via OPC or the Modbus
protocol. The benefits include:
• Quick interactive setup and configuration of gauges and
tank parameters
• User-friendly tank content and activities display
• Alarm and event status continuously checked
and reported
• Full inventory data display in DCS/plant host system
• All tank data stored in a dedicated database
• Runs on a standard PC with Windows operating system
• Customized views
Tank Intelligence on the Web
The Web version, TankMaster.net, makes storage tank
data accessible via the Internet or corporate intranet. You
can obtain an updated view of your inventory at any time,
whatever your location. Authorized parties can monitor
contents and transfers in real-time. Terminals can promote
available tank capacity online, increasing plant efficiency
and customer service.
Field Communication Unit
2160/2165/2175
Alternative
Connections
to DCS
Data
Acquisition
Unit
Remote
Display
Unit
Water Level
Sensor
Temperature
Sensor
Pressure
Transmitter
TankRadar
Gauge
Field
Bus
Modem
Radio
Modem
TankMaster
PC workstation
in network
OPC/Network
TankMaster.net PC
www
Customer PC
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CIU858
Gauges emulated by
TankRadar Rex
• Auxitrol ®
• Enraf ®
• GPE ®
• GSI ®
• L&J ®
• Tiway ®
• Sakura ®
• Tokyo Keiso ®
• Varec ®
• Whessoe ®
Smart and easy retrofit with
tank gauge emulation.
This list will be continuously
updated as other emulated
gauges are added.
The Rosemount Tank Gauging system is compatible with all
other major tank gauge vendors. Step-by-step modernization
of your current tank gauging system is possible thanks
to flexible field and control room solutions.
Just plug-and-gauge
The TankRadar ® Rex gauge is designed with an open interface,
covering everything from electrical interface and communication
protocol to utilization of many different power
sources. This feature enables you to replace old mechanical
or servo gauges with modern Rex gauges, without having to
replace the control system or field cabling. Simply connect
the Rex to your existing system and you’re operational.
TankRadar Rex
gauge
With TankRadar Rex,
you no longer need to
remain “stuck” with
your old system. By
replacing old servo
gauges, you can avoid
re-calibration and the
expenses associated
with spare parts and
maintenance.
Seamless control room connectivity
The FCU 2165/2175 allows you to emulate different host
systems and other control room devices. You can replace
your old tank monitoring software with the latest version
of Rosemount TankMaster. This solution provides seamless
connectivity meaning problem-free communication with
your existing field devices and a lean, clean installation.
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TankMaster
FCU 2165/2175
The Tank Intelligence staff will back you up
All Rosemount TankRadar ® gauges are designed to be maintenance
free, self-calibrating and highly reliable. Moreover,
installation, setup, configuration, and commissioning are
simple operations that can be done by almost anyone.
However, your tank gauging system deals with enormous
quantities of petroleum products, representing huge financial
values and considerable safety risks. Therefore, your
Tank Intelligence solution also includes access to local technical
support from Emerson’s Tank Gauging specialists, just
in case you should need it.
Rosemount TankMaster can replace
an existing inventory management
system, still being able to communicate
with the field devices in use.
We are never far away
Emerson’s Rosemount Tank Gauging representatives are
located worldwide, providing you with service and support
from over 200 highly trained service engineers, in more
than 80 countries. We also organize product training for our
customers. We hope to see you there!
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Protecting your plant
All refineries, tank farms and fuel depots have a huge responsibility
in ensuring that overfill incidents do not occur. In
this context the most important task for an automatic tank
gauging system is to prevent incidents, by providing a reliable
High-High level alarm function. You can rest assured
that Rosemount TankRadar ® gauges provide you with one
of the safest possible overfill alarm solutions on the market.
Ensuring a reliable overfill alarm
Conventional overfill alarm sensors used in storage tanks,
such as floats or switches, have one major weakness: the
only time you really know that they are functioning is when
you run a test.
With a Rosemount TankRadar gauge connected to your
system, it’s the other way around. The gauge gives the
operator continuous information about its status and performance
since it is being used in the everyday operations of the
tank farm. Failures detected by the diagnostic capabilities of
the gauge, will alert the operator to take appropriate action
under safe conditions.
Approved for overfill protection
Both Rosemount TankRadar Rex and Pro gauges are TÜVtested
and approved for overfill protection according to the
German WHG (Wasserhaushaltsgesetz) regulations. The
approval means that the TankRadar gauge can complement
a traditional High-High switch thereby introducing redundancy
into the safety system. In this way, the safety level of
your plant is improved.
SIL 2 safety
Rosemount TankRadar Rex has been third-party assessed by
Exida and is considered suitable for use in SIL 2 safety functions,
in accordance with IEC 61508/61511. The safety function
is based on the relay outputs. One relay, or a combination
of two, can be used for overfill or dry run protection.
Any decision to operate proven-in-use devices always
rests with the end user. However, third party assessment by
Exida provides a good basis for such decisions, in accordance
with section 11.5.3 of IEC 61511.
EX approvals
• International: IECEx
• Belarus: GOST Standard
• Brazil: CEPEL
• Canada: C-UL
• China: CNACL
• EU: ATEX Directive
• India: Nagpur
• Japan: JIS
• Kazakhstan: GOST Standard
• South Korea: KOSHA
• Russia: GOST Standard
• Ukraine: GOST Standard
• USA: UL
Safety approvals
and acknowledgement
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• SIL 2 Suitable
• Belgium: Vlarem II
• Germany: WHG approval for
overfill protection, tested by TÜV

Metrological certificates
Every drop counts
Tank gauging readings for net volumes, which form the
basis for inventory calculations and billing, must be exact
because any deviation can lead to negative consequences.
In recent years, the price of crude oil has quadrupled and
it will probably continue upwards during the foreseeable
future. The increased value of stored petroleum assets has
made most refineries, pipelines and oil storage companies
aware that precise and efficient tank gauging is business
critical for all companies in the oil supply chain.
USD/bbl
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
99 00 01 02 03 04 05 06 07 Year
Price trend for crude oil. The higher the price of crude oil, the greater the
value of the products in your tanks and return on investment for a highly
accurate tank gauging system.
International: OIML R85 (E)
Algeria: ONML
Austria: BEV
Belarus: GOST Standard
Belgium: BMS
China: CMI
Croatia: DZM
Czech Republic: CMI (Czech)
Estonia: TJI
France: LNE
Germany: PTB
Hungary: OMH
India: W & M
Indonesia: MIGAS
Italy: Metric Office
Kazakhstan: GOST Standard
Malaysia: Sirim
Netherlands: NMi
Poland: GUM
Portugal: IPQ
Romania: BRML
Russia: GOST Standard
Serbia/Montenegro: FBMPM
Switzerland: METAS
Thailand: Thai Excise and Customs
Ukraine: GOST Standard
In addition to the accuracy approvals listed
above, many countries are presently
in the process of defining custody transfer
requirements.
Precise tank
gauging pays
Inaccurate tank gauging
costs money, since you
could lose the value of any
product volumes that cannot
be verified. Improving
the measurement accuracy
in your tank gauging system
reduces your uncertainty
during both transfer control/verification and inventory
management. At the same time, loss control is improved.
Improved accuracy can give substantial savings. In a
large storage tank equipped with a mediocre gauging system,
the value of the uncertain volume (i.e. the oil volume
within the gauge’s error margin) is so large that this alone
justifies the investment in a high-class system such as the
Rosemount Tank Gauging system.
If you wish to calculate the potential savings using your
own figures, please visit www.every-drop-counts.com
Certified custody transfer-class accuracy
Rosemount TankRadar Rex is metrologically approved for
custody transfer and legal custody transfer in virtually all
countries that use automatic tank gauging for billing purposes.
13

Special TankRadar ®
applications
Liquefied Natural Gas (LNG)
Radar is the fastest growing technology for level gauging in
LNG tanks. No wonder – in a huge cryogenic tank that may
not be opened for years, you need a highly reliable and maintenance
free level gauging system. Rosemount TankRadar
gauges require no physical contact when measuring the
liquid level and there are no components inside the tank that
will require service. Thus, the system provides continuous,
highly reliable and accurate level data, for the entire service
life of the LNG tank.
by photo courtesy of Center for Liquefied Natural Gas
Distilleries
The distillery business typically sets high demands on tank
gauging precision, for blending, billing and taxation purposes.
With non-contact level measurement and a reliable, maintenance
free design, these features make the Rosemount Tank-
Radar gauges particularly valuable for distillery and other
food & beverage applications. Rosemount VatRadar is a
special distillery level gauge range, successfully proven at
many of the world’s most famous distilleries.
Asphalt
Level gauging in asphalt tanks is a very challenging application
made easy by specially designed antennas for the
Rosemount TankRadar gauges. High accuracy is often re -
quired in the large bitumen storage tanks (approx. 20 m/
66 ft. high) that are typically used at refineries and terminals.
In such tanks, the most reliable measurements are
attained with a parabolic antenna. Rosemount TankRadar
has a proven track record of effectively solving tank gauging
issues for asphalt and blown bitumen tanks.
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Liquefied Petroleum Gas (LPG)
At refineries and terminals, LPG is normally stored in spherical
or bullet-shaped tanks. Due to the high pressure needed
to keep the gas liquefied, opening the tank for inspection or
maintenance of measurement devices is very complicated
and expensive. Rosemount TankRadar gauges measure the
liquid level without any components inside the tank that
may require service. In addition, all TankRadar Rex LPG
gauges are easily calibrated. A patented reference device
function enables measurement verification with the tank in
operation.
Biofuels
Renewable energy sources are rapidly becoming important
economic and environmental factors. A Rosemount Tank-
Radar gauge is the perfect choice for measuring biodiesel
(including the plant and waste cooking oils from which it is
produced), bioethanol and blends of biofuels and petroleum
products. Rosemount TankRadar gauges have been
used for several years to increase efficiency at palm oil
terminals and other plants, because of their outstanding
reliability and accuracy.
Underground tanks
Storing large quantities of oil, LPG and LNG in underground
tanks or caverns has many advantages, such as increased
safety, lower operational costs and less impact on the
environment. Rosemount TankRadar gauges fit perfectly in
underground applications, including those with very long
measurement ranges; over 80 m (260 ft) for free propagation
installations and 110 m (360 ft) if a still-pipe is used.
Both TankRadar Rex and Pro gauges are designed for harsh
environments and can be installed inside the cavern, as well
as outside.
15