Replacing Displacers with Guided Wave Radars

Replacing Displacers with Guided Wave Radars: Agenda Introduction of Rosemount level Advantages of GWR over Displacers Transmitter and probe selection and 3300/5300 probe styles, size, and options Best practices for measurements in chambers Successful Application Examples in Refining, upstream O&G and Power

Rosemount Radar Types Variety of Rosemount Radars: 2-wire Guided Wave Radar (3300) General applications – Level & Interface 2-wire Guided Wave Radar (5300) High sensitivity for very low dielectric fluids and other difficult applications – Level & Interface 2-wire Pulse Non-Contacting (5400) Applications in buffer tanks, chemicals, sump pits, etc which require non-contact measurement – Level only 4-wire FMCW Non-Contacting (5600) Difficult applications such as sulfur, solids, and very tall tanks – Level only

Rosemount 3300 and 5300 Used to Replace Mechanical Gauges Many of our 3300 and 5300 Guided Wave Radars are installed to replace mechanical gauges such as displacers Use the existing wiring and chambers No DCS reconfiguration

Displacement of Mechanical Gauges Has Many Advantages No influence by density changes High accuracy and repeatability No moving parts, no frequent cleaning, no freezing Unaffected by mechanical vibration and turbulence Virtually maintenance free (Savings have been reported in the range of €1000 to € 8000 per unit annual maintenance and repair savings) GWR works under very low ambient temperatures (-50ºC for model 3300!) GWR probes can be easily cut-to-fit on site  less spare parts Reduce Cost Increase Safety Increase efficiency 5

Mechanical Type Level Measurement GWR Measurement Stability: Less Influence by Density Changes and Turbulence High measurement stability result in: Better control Higher efficiency Higher safety Surge Drum Level FIG-3 2 4 6 8 10 12 14 1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65 69 73 77 81 85 89 93 97 101 105 109 113 117 121 125 Minutes Inches Before GWR After GWR Mechanical Type Level Measurement Guided Wave Radar Increase Safety Increase efficiency

Measurement with a Displacer Gauge: Practical Measurement Issues Displacer gauge has moving parts causing: Problems with freezing weather Frequent maintenance needed Coating on displace body and inside chamber causes undetected dangerous failures: Hysteresis Loss of sensitivity Reduced measurement quality Measurement freeze Displacer body can unlock caused by product flashing

Guided Wave Radar Solution: Removes Measurement Issues GWR has no moving parts: No Performance issues No Hysteresis Operates at -40ºC (3300 at -50ºC) Virtually maintenance free 3300 and 5300 single probe solution: Single probe can handle significant coating More space: Less issues with viscous fluids 3300 and 5300 require no recalibration Decrease operational cost Increase safety

Rosemount 3300 and 5300 GWR: Advantages 3300 and 5300 software diagnostic tools enables on-line preventative maintenance On-line check-up of probe status Only open chamber when necessary No unnecessary dismounting, pressure and leak testing 5300 supported by Enhanced EDDL Decrease operational cost Increase safety

Rosemount 5300 GWR: Advanced Diagnostics 5300 opens path to on-line advanced diagnostics On-line continuous diagnosis of probe status indicates partially coated probes 12 months of operation, medium build-up SQ=3,3 SNM=6,0 18 months of operation, heavy build-up SQ=0,9 SNM=5,0 Probe needs cleaning! 6 months of operation, little build-up SQ=8,1 SNM=9,1 SQ=9,2 SNM=9,6 Margin between surface peak & threshold Margin between noise and threshold Increase Safety Decrease operational costs

Rosemount High P/T Process Seal: Full Proof Process Seal Integrity Brazed hermetic seal Spring loaded locking system compensates for thermal expansion secure continuous force on the gaskets Double sealing with graphite gaskets Flexible frame to protect ceramics during shipment and installation Increase Safety

Properties for saturated water vapor 5300 Dynamic Vapor Compensation (DVC): Improves Accuracy in Steam Applications Properties for saturated water vapor Density-based level can cause up to 30% SG error in saturated steam applications GWR is independent of density however steam at high pressure can have influence on level accuracy (vapor DC) DVC automatically compensates for varying steam DC using a reference reflector in probe Increase Safety and Efficiency

5300 for SIS Safety Loops Increase Safety Evaluated by Exida per hardware assessment IEC 61508 SFF = 90.7 %  Prior-use SIL2 suitable 5 year Proof test interval for SIL 2 loops Increase Safety

Rosemount 9901 Chambers: Complete Point Solution Manufacturing according to: ASME B31.3 – Chemical Plant and Petroleum refinery Piping Code Pressure Equipment Directive 97/23/EC (PED) Welding in accordance to: EN ISO 15614-1:2004 ASME Boiler and Pressure Vessel Code Section IX Welders qualified to: EN 287-1:2004 Rosemount offers a complete spectrum of high quality chambers Easy to select with comprehensive Product Data Sheet Wide material and process connection selection The chamber is designed to the ASME B31.3 standard, and is Pressure Equipment Directive (PED) compliant Only certified and traceable materials are used Welders and welding procedures qualified to both ASME and European standards Decrease Capex

Why is the Rosemount 5300 GWR the Best Choice for Replacing Displacers? The 5300 can use a single probe in virtually all applications  no more coax related issues like clogging and bridging Port #2 Port #1 The highly sensitive 5300 transmitter can measure liquids with a DC of 1.2 and higher There is no equal to the 5300 The 5300 opens the path to future developments of advanced diagnostics tools 18 months in operation It offers advanced software capabilities to solve extreme difficult applications SQ=0,9 SNM=5,0 Probe needs cleaning!

Extra Slides for Internal Guidelines

Displacer Terminology

Chamber Mounting Flanges Vary With Manufacturer Some manufacturers like Masoneilan use proprietary flanges as instrument connection For higher pressure (600# or higher) they use standard ANSI or EN flanges Most other manufacturers use standard ANSI or EN flanges Tank connection flange are usually standard ANSI or EN flanges and can be different from instrument connections Tank connections are usually standard flanges Instrument connection flanges vary with manufacturer

Flange Determination Required information: Displacer gauge manufacturer + type number Flange outside diameter or circumference and thickness Number of bolts Flange face type and rating RF Large face Tongue/groove Ring type joint EN V13/R13 Gost Other Material Provide to Emerson for determination if required Refer to tech note 00840-2200-4811 displacer replacer

Connection Location Refers to Displacer Chamber Style For most installations: simply remove electronics and displacer float assembly. Replace with GWR flange and probe assembly. For Top to Side and Top to Bottom: A tailor made solution needs to be used 80% 6% 10 % 4% Side to Side Side to Bottom Top to Side Top to Bottom 1 to 1 replacement with standard GWR probe assembly Needs tailor made GWR probe assembly

Transmitter Type & Probe Style Selection Selection is simple and uniform Use 3300or 5300 with single probe Exceptions: All heavy oil applications above 40 bar and or 150ºC: require 5300 transmitter with single probe All liquefied gas applications above 40 bar: require 5300 transmitter with coax probe Saturated steam/water at pressures >40 bar require 5300 with single steam probe (DVC)

Probe Length Selection Probe length is longer than the displacer length. 9 to 10 inches (225 to 250mm) is common, but can be more Probe should extend full length of chamber Consider type of flushing connection Consider a centering disk for longer single rigid probes Allow for dead zones (varies w/probe style, dielectric) URV LRV Upper dead zone Displacer length Probe length Lower dead zone Lower Dead Zone Probe Style High Dielectric Low Dielectric Single Rigid 5 cm (2-in.) 10 cm (4-in.) Bulk Sulfuric Acid Tank 7 cm (2.8-in.) High and Low Alarms 3 cm (1.2-in.)

Calculate GWR Probe Length Calculate probe length from displacer length Displacer length = measurement span = distance between process connections Usual displacer lengths : 14” (356 mm) 24” (609 mm) 32” (812 mm) 48” (1219 mm) 60” (1524 mm) GWR Probe length = displacer length + 250 mm Consider type of flushing connection Consider a centering disk for longer single rigid probes Probe Length ~150 mm GWR Probe Length Displacer Length ~100 mm GWR Probes are easily cut-to-fit in the field

GWR Solutions, Options, and Accessories Flushing connection for Calibration verification Purging gas pocket Cleaning Available with flushing ring and proprietary flange with flushing connection GWR probe can handle significant coating Gas pocket does not have to be vented for GWR – 3302/5302 can detect and compensate automatically For ANSI flanges Available with 1½” NPT threaded connection

Probe Style Options Rigid probes are recommended instead of flexible for chamber installations Easier to keep centered in chamber Centering devices are available for end of single lead probe Coaxial probes can be used for level measurements of clean fluids and low dielectrics (e.g. liquefied hydrocarbon gasses) Consider flexible single probe with chamber installation weight for taller chambers and when head space is limited

Solutions for Top – Bottom and Top – Side Chambers Flange size/type B Dimensions A,B and flange size/type required information. Proprietary flanges available Centering disk