Best Practic instal new radar TGsystem LNG and overfilling_2.pdf

7/18/2019 Best Practic instal new radar TGsystem LNG and overfilling_2.pdf

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Rosemount Tank Radar AB Confidential

Best Pract ices:

Ins tal l ing New RadarTank Gaug ingfor level and overfilling on all typeof tanks with all type of products

Hans Manner

Nicolas Odru


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[File Name or Event]Emerson Confidential27-Jun-01, Slide 2 Rosemount Tank Radar AB Confidential 2

Best Pract ices Ins tal l ing New Radar Tank Gaug ing

Industry Trends Engineering standards and guidelines

What equipment do I need?

How do I get it installed on my tank? How do I get the readings in the control

room?

Safety & Overfill Prevention


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Compl ience to Standards

API standards 3.1B Automatic Tank Gauging 7 Temperature Measurements

3.3 LPG measurements

3.6 Hybrid Measurements 2350 Overfill Protection


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Accu racy Performance

Pattern approvals for Custody Transfer Accuracy OIML R85:2008

International Organization of Legal Metrology


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[File Name or Event]Emerson Confidential27-Jun-01, Slide 5 Rosemount Tank Radar AB Confidential

Indus try Trends

Radar

Continuous

Redundancy

Safety

IEC 61508

API 2350

Wireless

Openness

Internet

Mechanical

Point Switch

Closed systems


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Tank Equipment


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Tank Equ ipment

7


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Tank Equ ipment Fixed Roo f Tank

8


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Tank Equ ipment Float ing Roo f Tank

9


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Tank Equ ipment


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Tank Equ ipment

11


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Where to ins tal l the equ ipment on the tank?

Look for Man ways Other nozzles

Gauge hatches

Still Pipes


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Where to ins tal l the Tank Equipm ent?

Manway 20Nozzle 8

Nozzles 2, 4, 8Gauge hatch


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Use exist ing s t i l l pipes


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Use the exist ing Sti l l Pipe


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Dont worry about dirty and slotted pipes


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Still Pipesfitted inexistingaccesshatch


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Still Pipefitted inexistingaccesshatch


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Where to in stal l the Tank Gauge

What does API Ch 3.1B say?

Roof mounting

Close to the tank wall to avoid roof flexing influence

Still pipe

Slotted

Fixed at the bottom end


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Where to instal l the Temperature Sensor?

Same location as theRadar

Separate nozzle

Still pipe arrangements

Floating Roofpenetration options

The Temp Sensor canbe combined with aWater bottom sensor

Transmitter

Temp sensor


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Same locationas the Radar

Fixed Roof tank


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Same locationas the Radar

Floating RoofTank


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Floating RoofTank

Roofpenetration

thru a rubbergasket

Support andcabling at theplatform level


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Where to in stal l the Pressu re Senso r (Dens ity) ?

Lower end of the tank

Existing nozzles


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Where to instal l the Local Readout?

At the gauge hatch

At grade level

By the road side

Or at all of the above


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Local Readou t

At Grade Level


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Where to instal l the Local Readout?

By the road side

Drive-thru readings

Day and night


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How to connect a new system to the Contro l Room

Use existing cabling

Emulation

Minimized conduit free new cabling

Wireless


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32

Emulat ion : Remove Old, Instal l NewPlug n Play

Disconnect the old cabling Remove the old Gauge

Mount the radar antenna Mount the new Gaugeand connect the wiring

Done!


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OLD NEW


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Minimized new cabling

Intrinsically Safe

Conduit Free


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Minimized new cabling

LAX Airport

One paircable

IntrinsicallySafe


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Wireless


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Wireless


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Wireless


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Wireless

Well proven

On 2500+ tanks

Robust

Safe

IEC 62591 standard

O fi l l P t t i i th R t 2160


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Overfi l l Protect ion w ith Rosemount 2160Wireless Vibrat ing Forks LeveL Switch

No wiresNo moving parts

No re-calibration Long power module life

Self Checkingcondition monitoring

Virtually unaffected byprocess conditions

9 years at 1 minuteupdate rate

Min update rate of1s for control

Steam,vapors, dust

Densitychanges

Temperaturechanges

I t t Ad d Di t i


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Inst rument Advanced Diagnos t ics-Health /Self Check Diagnos t ics The 2160 continuously performs instrument health diagnostics to self-

check the condition of the fork and sensor Control room can be alerted to emerging issues allowing preventative

maintenance to be scheduled- avoid process down-time

2160 Frequency Monitoring : interface detection between oil/water,wet sand/liquid...

Fault conditions detected Standard Enhanced

Process memory failure

External damage to fork

Internal wire disconnect or break

Internal damage to sensor

Excessive corrosion to fork

O fil l P t t i i th R t


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Overf il l Protect ion w i th Rosemount3308 Wireless Guided Wave Radar

No wiresNo moving parts

No re-calibration Long power module life

Single probe handlescoating better

Virtually unaffected byprocess conditions

9 years at 1 minuteupdate rate

Steam,vapors, dust

Densitychanges

Temperaturechanges

P ti M i t i th


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Proact ive Maintenance w ithAdvanced Diagnos t ics Signal Quality Metrics alerts potential measurement

problems, e.g. caused by probe coatingField

Time

SignalQuality

Control room

Level PV

Signal quality

Low

High


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Rosemount Level Wireless2160 Fork Switc h & 3308 Guided Wave Radar

Inaccessible or uneconomic alarms: Fast installation of additional instruments

Gain access to advanced diagnostics: Self Check Diagnostics

Signal Quality Metrics

Integrate more information into any controlroom host without new I/O:

Eliminate costly cable runs System integration
http://www2.emersonprocess.com/en-US/brands/rosemount/Temperature/Single-Point-Measurement/648-Wireless/Pages/index.aspxhttp://www2.emersonprocess.com/en-US/plantweb/wireless/products/Pages/SmartWirelessGateway.aspxhttp://www2.emersonprocess.com/en-US/brands/rosemount/Temperature/Single-Point-Measurement/648-Wireless/Pages/index.aspxhttp://www2.emersonprocess.com/en-US/brands/rosemount/Temperature/High-Density-Measurement/848T-Wireless/Pages/index.aspxhttp://www2.emersonprocess.com/en-US/plantweb/wireless/products/Pages/SmartWirelessGateway.aspx


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Readout


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Readout


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Extended Readout

Intranet

Internet

Portabledevices


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Get Tank info d istr ibu ted

Open protocols

OPC

Modbus

WebServer

Overfi l l Safety


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Overfi l l Safety Tank Gaug ing plays an important par t

Passive protection layer

Emergency response layer

Process control layerProcessShutdown

Active protection layer

ProcessValue

Process control layer

Safety layerEmergencyShut Down

Time In Use

Why overf i l l prevent ion


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[File Name or Event]Emerson Confidential27-Jun-01, Slide 50

Why overf i l l prevent ionis impo rtant for Industry ? EUSafety and Environmental directives

are more and more restrictive : Member States are obliged to transpose it

into a national law within the set deadline

Directive 96/61/EC on integrated pollutionprevention and control

Directive 96/82/EC on the control of majoraccident hazards involving dangeroussubstance

Tank overfill is an important concern :

Industry have to improve the Safetyof theirsites to reduce pollution risks

Industrial requests for overfillprevention device applications

have risen in recent years

Buncef ield o i l s torage UK


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Buncef ield o i l storage, UKDec . 2005

Overfill of fuel storage tank Bad configuration and faulty

independent high level switchon floating roof

20 large storage fuel tankstook fire

Over 40 people injured

UK Health and safetyExecutive investigation

resulted in 25recommendations on fuelstorage sites

Tank Overf i l l Prevent ion :
http://localhost/var/www/apps/conversion/tmp/scratch_3//upload.wikimedia.org/wikipedia/commons/6/67/Hemel_Hempstead_fuel_explosion_map.jpg


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Tank Overf i l l Prevent ion :Key Points

Detection should beindependantof the primarylevel measurement device andseparate failure alarm ispreferable

Proof testing is required :manual test or internaldiagnostics can be used

Redundancy with differenttechnologies is a commonstrategy for critical leveldetection

Tank Overf i ll Prevent ion :


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Tank Overf i ll Prevent ion :Customer chal lenge

Customers need to increase theSafetyof their existinginstallation :

More information needed forcontinual supervision in the

control room (less operatorsround)

Additionalindependent highlevel alarm on your primarylevel measurement

Remote tank locations / Nolocal power supply


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Sing le Point fo r Overf i ll Protect ion

Advantages :

Independent safety system

Not affected by processchanges

Different types of on/off alarmoutput available

Functionality is less dependanton configuration, mechanicalinstallation and start up

To be considered :

One device for each levelalarm

Power supply needed forelectronics

No separate fault signaloutput

Vibrat ing Forks is one of the most common

techno logy used in process industry


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Rosemount Vibrating Forks Port fo l io

OEM Core Premier

Advanced Health Diagnostic

PlantWeb alerts

Direct load,PNP,DPDT Relay, 8/16

IS NAMUR

Direct Load,

PNP/PLC

Direct load,PNP, 12VRelay, 8/16

IS NAMUR

Wireless HART

-70 +260C

SIL 2 High & Low Level

-70 +260C

Diagnostic

Diagnostic

-40 +180C

-40 +150C

-40 +150C

Basic or Advanced :


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Basic or Advanced :What is the d if ference ?

Forks

Frequency Circuit

Output Circuit

Forks

Frequency Circuit

Output Circuit

Self Check Diagnostics


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The frequency band below show the six sensors states of the 2130

switching bands divided into three groups :Valid sensor frequency : Wet or DryFault Sensor frequency :

Too Wet : broken wire to the cassette, over-temperature, build-upToo Dry : sensor body lost mass due to damage to sensor, corrosion

Zero Frequency

2130/2160 Sensor States

*DFF : Dry Forks FrequencySensor switching limits are percentage of the calibrated frequency

Wet Dry Too Dry

Frequency Switching Bands

Too Wet

0HZ DFF28% DFF + 4.5%

DFF* 1400 Hz

2130 Self Check available on all


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Direct Load

PNP

Relay

Namur

8-16mA*

Fault Relay*

2130Self Check available on allCassettes :

*ProvideSeparate fault signal output

Electr ical Ins tal lat ion o f the 2130


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8-16mAHigh Level A larm

PSU

Hazardous AreaSafe Area

Dry = On

Heartbeat LED On

+

-ION= 15...17 mA

PE

(Ground)

U = 24 Vdc Nominal

Drives 4-20 mA Analog Intput

+

-

Compatible with NAMUR NE43



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8-16mAHigh Level A larm

PSU


Dry = On

+

-

PE

(Ground)

U = 24 Vdc Nominal


+

-

Heartbeat LED Flashing1Hz

IOFF= 7.5...8.5 mA




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8-16mAFaul t Condi t ions

PSU


Dry = On

+

-

PE

(Ground)

U = 24 Vdc Nominal


+

-

Heartbeat LED Pulsed

IFAULT< 3.7 mA



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Overfi l l Safety Tank Gauge Redundancy


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Level & Roof Gauging


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Overf i l l Safety

Level & Roof Gauging

Common Si tuat ion :


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Common Si tuat ion :Only One Tank Opening

Need for two

Radars but only oneopening available

What to do?

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I want two Radarson one nozzle!

Put 2 Radar in 1


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2 Radar in 1 Only one tank

opening

Easy installation

Total electricseparation

Operates in parallel

On-Tank Redundancy Made Easy

2-in -1 Radar


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On-Tank Redundancy Made Easy

Redundancy

Dual operation

Gauging

Overfill Alarm Separated

Built in Spare


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Safety Standard Compliant


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Safety Standard Comp liant

API 2350 compliant

IEC 61508 certified

Certified SIL2

Certified SIL3

TV, (WHG) certified


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Summary

Its easy to install new

Tank Gauging Minimum Wiring

Wireless

Use existing tankopening

Use exisiting Still Pipes

Easy to connect toother systems

Get Overfil Protectionat the same time


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Rosemount Raptor System

5900S RadarLevel Gauge

2410 Tank Hub

2240S Multi-inputTemperatureTransmitter

2120/2160Liquid Level switch

2230 Graphical

Field Display

5300/5400Radar LevelTransmitter

375 /475 FieldCommunicator

Smart WirelessTHUM Adapter

644 TemperatureTransmitter with SinglePoint Temperature Sensor

3051S PressureTransmitter

2160/65/75 FieldCommunication Unit

2180 Field BusModem

TankMater PCWorkstation inNetwork

Smart WirelessGateway

2410 2410 2410

2410

2230

5900S

THUM 5900S2240S5900S2240S

5400

5300

644

3051S

TankMaster.net

644

5400


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Typical ins truments on LNG storage tanks


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Rapto r 5900S radar fo r LNG Radar replacing servo in almost all

applications

Primary, secondary and HLAmeasurement using only radar

Highest accuracy over full range

Advanced signal processing

FMCW @ 10 GHz High sensitivity for long range

Digital accuracy reference

No aging or temperature effects

Verification during operation

SIL 2 and SIL 3 certified Unique 2-in-1 redundancy


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Antenna5900S LPG/LNG Designed for

Liquefied gas in LPG/LNG tanks 4 in still-pipes sch 10 or 40

100 mm still-pipes

Quartz/Ceramic window as pressure sealing

Verification pin function

Optional Ball valve, fire-proof

Rosemount 2051 Pressure sensor

Flange available in six versions 4 in. class 150, class 300

6 in. class 150, class 300

8 in. class 150, class 300

New AdapterSeal & ballvalve

Level Accuracy: 5900S


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-0.001

0

0.001

0 5 10 15 20 25 30

Downwards manual log

Upwards manual log

Downwards autolog

Upwards autolog

76

yexceeds OIML R85:2008

4

-4

2

-2

0

Old (R85:1998)

New (R85:2008)

(mm)

3

1

-1

-3Old (R85:1998)

New (R85:2008)


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Veri f icat ion of Level measu rement

On-line verification duringnormal operation

Verification is made inside thetank

Tank remains closed and novalves need to be

maneuvered A reference pin is mounted

inside the still-pipe for levelverification

A bottom reflection ring

mounted at the end of thepipe is used for zeroverification

Photos

Raptor
http://localhost/var/www/apps/conversion/tmp/scratch_3/Photoshttp://localhost/var/www/apps/conversion/tmp/scratch_3/Photos


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SIL 2 and 3 Cert i f ied


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Bui l t In Proo f Test ing

The two Radars

will constantlysafety-checkeach other

Long time betweenmanual ProofTesting

No man on the

tank Saves $$$

Avoid Manual Proof Testing

Onl ine pro of test ing


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Onl ine pro of-test ing

-check

Blueand Redlines separated for visibility.An alarm is given if the exceeds a defined limit


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2-in -1 Radar

81

Radar #1Radar #2 High Level of Safety

SIL3 Rated

Low Cost Installation

On Tank Redundancy

High Availability

Less Proof Testing

Less Verification

Saves $$$in many ways


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2x Radars on the same tank - wel l pro ven

Some LNG si tes using radar from Emerson:Radar gauges have been used for more than 10 years to measure level at several LNG


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Radar gauges have been used for more than 10 years to measure level at several LNGimport terminals in Japan. So far 15+ tanks.

Trunkline LNG Co.Terminal, Lake Charles, USA

Gaz de FranceTerminal, Fos Cavaou, France Complete Emerson system solution CPC Taiwan - Receiving terminal, Northern Taiwan Qatargas II - Production site, 5 new tanks,

Complete Emerson system solution Radar for all Level measurements (primary, secondary, HLA)

FreeportQuintana Island - Receiving terminal, Texas, USA

Recent projects system solutions, Rex radar gauges combined with Whessoe LTDs

Cheniere - Sabine PassReceiving terminal, Louisiana, US. 5 tanks

Fluxys - Zeebrgge - Existing receiving terminal, Belgium

Exxon - Golden Pass LNGReceiving terminal, Texas US. 5 tanks

Woodside - Pluto LNGNew export terminal. 2 tanks in Ph I.

PTT LNGMap Ta PutNew receiving terminal

AGANynashamn LNGNew receiving terminal. 1 tk Ph. 1

Chevron - GorgonNew tanks at export site, 2 LNG + 4 Condensate tanks. Totally 24

radars

Polskie LNGNew receivin terminal 2 tks.


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Rosemount LNG Radar Benefi ts

No moving parts

No re-calibration No maintenance

SIL2 / SIL3 safety functions

Built in High Alarm

On-Line verification during operation inside the tank

Custody Transfer Accuracy

Conformance to API, OIML, ISO and other standards

Proven Technology

Many excellent references on LNG and LPG

Anything for a single gauge to a complete LNG Management System

E d W t il (Wh )


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Emerson and Wrts il (Whessoe)

Combining the skills and experience from two

organizations into an LNG storage management solutionprovider

Rosemount Tank Gauging

Rosemount is the measurement division within Emerson

Focus on high accuracy radar level gauges and supportinginstruments for temperature and pressure

System supplier, incl project management

Wrtsil Calais (Whessoe product name)

Focus on LTD gauges and LNG management software

Total LNG Tank Ins trumentat ion Solut ion


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Loop 1

Loop 2

5900S +2410

Hi-Hi alarm

5900S LNG + 2410Secondary level

1146 LTD

TANKN1

Level alarms to ESD

5900S LNG + 2410

Primary level

2240S and 566multiple spot

temp

2240S and 566multiple spot

temp

Total LNG Tank Ins trumentat ion Solut ion
http://localhost/var/www/apps/conversion/tmp/scratch_3//SERVEURP/PUBLIC/Commerciaux/DOCUMENTATION%20COMMERCIALE/leaflets/last%20version/level/FICHE%201706B.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_3//SERVEURP/PUBLIC/Commerciaux/DOCUMENTATION%20COMMERCIALE/leaflets/last%20version/level/FICHE%201706B.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_3//SERVEURP/Users/pversluijs/Mes%20documents/Documentation/level/FICHE%201146-EN-1.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_3//SERVEURP/PUBLIC/Commerciaux/DOCUMENTATION%20COMMERCIALE/leaflets/last%20version/level/FICHE%201706B.pdf


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TANK N

2

Loop 2

TANK N

1

951020 mA lo op / RS232C

951020 mA lo op / RS232C

Loop 1

Loop 2

Loop 1

LNG Manager

LNG Manager

DCS

LNG Roll-OverPredictor

Serial l ink

Serial l ink

Serial l ink

Serial link

TRL2 bus for Raptor/2410 if not using

WM660

FCU 2160

T k d t i l (R l l O )
http://localhost/var/www/apps/conversion/tmp/scratch_3//SERVEURP/Users/pversluijs/Mes%20documents/LNG%20Expert%20Product%20Demo%20full.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_3//SERVEURP/Users/pversluijs/Mes%20documents/LNG%20Expert%20Product%20Demo%20full.ppt


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Tank detai l (Roll-Over)

S l f j t d


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Sample of pro ject awardsCombined Emerson / Rosemount Tank Radar and Whessoe LTD

- recent projects realized at LNG terminals or production sites : ChenieresSabine Pass Exxons Golden Pass Fluxys (Zeebrugge, Belgium) Pluto LNG Australia

Nynashamn Sweden PTT LNG Map Ta Put Thailand Sonatrach Skikda LNG Algeria Gorgon Australia Polskie LNG Many new projects to be decided shortly

LNG f ( t i d)


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LNG references (con t inued)

Golden Pass LNG - new receiving terminal in

Texas; Five tanks. Installation 2008. CB&I US is the main EPC for the complete project

Whessoe LTD + software (Wrtsil)

Emerson partner to Wrtsil and supplied: 5 x Radar Rex 3960 5 x SDAU

5 x MST Cryo

2 x FCU 2160
http://www.goldenpasslng.com/assets/files/Sabine_locale_map.pdf

Documents

Best Practic instal new radar TGsystem LNG and overfilling_2.pdf