Endess + Hauser

8/12/2019 Endess + Hauser

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Toni Ksbeck

Slide 1 / 31

October 2010

Trends in Tank Farm Management

Tank Storage Istanbul


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Toni Ksbeck

Slide 2 / 31

October 2010

Tanks, terminal & technology Best practices

and Optimization

Measurement with two technologies and SIL approved overfill

protection technologies

Redundant measurement and communication

Combination with accurate level measurement

License free tank farm visualization

Use of web servers independent of operating system

Remote configuration

DTM / FDT based configuration of instrumentation in tank

farms

Wireless solutions in tank farms

Remote monitoring via HART and MODBUS


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Toni Ksbeck

Slide 3 / 31

October 2010

Overspill protection and

Redundant measurements


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Toni Ksbeck

Slide 4 / 31

October 2010

Latest Buncefield HSE report

Overfill Prevention System for the tank is the primary task to

prevent any major tank incident!

Overfill Prevention Systems has been therefore set by at latest HSE reportto be at minimum Safety Integrity Level One(SIL 1)based on IEC 61511.

The Overfill Prevention System shall include the following consideration:

design, installation, operation, maintenance and testing of

equipments

redundancy for level measurement, which are:

independentand separatedfor safety and inventory measurement

diverse measurement principlefor safety and inventory measurement

fail-safe loop design and proof test intervals

Source Buncefield reports and HSE report


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Toni Ksbeck

Slide 5 / 31

October 2010

So how can we do this?

WHG

RMA422

Tankvision Scanner

Level, Temperature,

Volume, Pressure,

Alarms,

Ethernet TCP

Level, Temperature,

Pressure

Modbus V1

others

Level,

4-20mA

Limit B

DO

Level

4-20mA

Limit A DO

Level Limit

DO

PLC

Other values required

For Operator

Ethernet OPC

2/4 HART bus(i.s.)

Limit Hi

Display

Fill Limit

Display

Operator Limit

A

Operator Limit

n

Tank Inventory Measurement


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Toni Ksbeck

Slide 6 / 31

October 2010

Signal

transmission

Signal

transmissionField device

WHG

Signal

transmission

RMA422

RMA422

FTL325PSIL 2

SIL 2/3

Tankvision Scanner

IEC 61511 SIS loop

Limit HiDisplay

Signal

interface

Fill Limit

Display

Limit HiHiDisplay

Level, Temperature,

Volume, Pressure,

Alarms,

Ethernet TCP

Operator Limit

A

Logic Solver

Inventory System

Logic Solver

OPC

Level limit

PFM

DO

Namur

Level

4-20mA

Level Limit

DO

SIL 2 SIL 2

Level Limit

DO

Level, Temperature,

Pressure

Modbus

V1

others

Level,

4-20mA

Limit B

DO

Level

4-20mA

Limit A

DO

Level Limit

DO

PLC

Operator Limit

n

Inventory System

Other values required

For Operator

Ethernet OPC

SIS Logic

Limit HiHi

DO

Ethernet OPC

Final Element

Inventory Visualization

OverfillPrevention

TankInvento

ryMeasurement

HMI


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Toni Ksbeck

Slide 7 / 31

October 2010

Redundancy in the field: Dual output from gauges

Options in installations:

Two level gauges installed as primary and secondary gauge

(preferably with different technologies and a difference alarm

in the tank gauging system)

Redundant field cabling (two cables from level devices,

preferably connected on different cabling ways into

independent, not synchronized systems


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Toni Ksbeck

Slide 8 / 31

October 2010

Redundancy in the field: Dual output from gauges


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Toni Ksbeck

Slide 9 / 31

October 2010

Guided radar as over spill protection

Guided radar as SIL 2 overspill protection on Fixed roof tanks and custody transfer

Approved radar or servo on LPG bullets


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Toni Ksbeck

Slide 10 / 31

October 2010

Liquid Bulk Storage

Independent High Level Alarms Best technology available

Tuning forkis always the first solution

Internal Floating Roofs

and External Decks do

require stilling wells

or side mounted

nozzles to be installed.


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Toni Ksbeck

Slide 11 / 31

October 2010

Floating Roof Tanks

Independent High Level Alarms / Radar Proof Testing external

External Swivel

plate for functional

proof testing


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Toni Ksbeck

Slide 12 / 31

October 2010

Secure Switch Settings using Contact Plate


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Toni Ksbeck

Slide 13 / 31

October 2010

Example Overfill protectionTank levels (based on API2350)

Notification

Alarm

Trip

Source Buncefield reports


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Toni Ksbeck

Slide 14 / 31

October 2010

So how can we do this? Overfill Prevention

RMA422

FTL325PSIL 2

SIL 2/3

Logic Solver

Level limit

PFM

DO

Namur

Level

4-20mA

Level Limit

DO

SIL 2 SIL 2

Level Limit

DO

SIS Logic

Limit HiHi DO

Ethernet OPC

Limit HiHi

Display

IEC 61511 SIS loop


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Toni Ksbeck

Slide 16 / 31

October 2010

Simple instrument safety rules still apply

A goodOverfill Prevention System:

is based on a different physical phenomenon (avoid systematicfailures)

is Fail to Safe classified for SIL services acc. IEC61508/61511

is proven technology

has all appropriate certificates

is provided with internal diagnostics/ health check

is provided with a separate failure alarm

can be checked easily Proof testing! has a long, predictable lifetime

can be repaired fast without process interference and fits forused tank shape


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Toni Ksbeck

Slide 17 / 31

October 2010

Browser based visulization


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Toni Ksbeck

Slide 18 / 31

October 2010

Technology behind

A web server is software that serves web pages (files) in response to

requests from web browsers. A web server is sometimes called an

HTTP server.

The standardized Interface guaranteed the world wide success, like

MS Windows did in the past


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Toni Ksbeck

Slide 19 / 31

October 2010

Architecture of browser based applications

Availability of not PC based web servers: A dedicated industrial

control unit and not a PC hosts an application, which visualizes

its own data

All configuration and all visualization is provided via HTML

pages generated on the unit

No software needs to be installed on the PC. The correctversions of software is always on the unit, including

documentation.

This reduces the need to keep documentation and diagnostictools on service computers. When you need it, its with the

unit. When the unit gets updated, the software gets updated


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Toni Ksbeck

Slide 20 / 31

October 2010

System architecture for web server

(Field Protocol)

V1, Modbus,

WM550,

Tank Scanner

OPC

SCADA

LAN TCP/IP

Modbus

Data Concentrator

Host Link

Tank Scanner


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Toni Ksbeck

Slide 21 / 31

October 2010

Advantages of web server based technologies

Usage of standard technologies instead of proprietary tools for

Real-time data via Java applets

HTML programming for reports, visualization on PDAs

Web browsers in full screen mode, automatic retrieval of web

pages for archiving


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Toni Ksbeck

Slide 22 / 31

October 2010

FDT / DTM based remote

configuration


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Toni Ksbeck

Slide 23 / 31

October 2010

Open Independent Standard for Integration

of Field Equipment into Control Systems

Ethernet

Profibus DP

Profibus PA

Master Cl 1, (Cl 2) Master Cl 2

FDT frame

(stand alone)

FDT frame

(integrated in DCS)


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Toni Ksbeck

Slide 24 / 31

October 2010

FDT Communication

Each component wraps the communication frame from the

component below, WITHOUT knowing the contents

Routing through system topology

DTM below does not have any knowledge about the network

topology

DTM must only support its own communication protocol

Communication / routing through ANY network topology, no

limitations

Communication / routing is possible even if the underlying

protocol is unknown by the engineering or standalone tool

This is standard on many process plants, but not in tank farms

yet!


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Toni Ksbeck

Slide 25 / 31

October 2010

Example Tank Gauging Architecture

(Field Protocol)

V1, Modbus,

WM550,

Tank Scanner

OPC

SCADA

LAN TCP/IP

Modbus

Data Concentrator

Host Link

Device

configuration

via FDT

Tank Scanner


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Toni Ksbeck

Slide 26 / 31

October 2010

FieldCare configuration of tank gauging instruments

Hardware Between PC & HART Device is Invisible to Service Tool

FG4TG

Tank Scanner

LAN

NetworkNRF590

TSM, ID 1

FMR

Radar

Field

Protocol

Real

COM Port

Virtual

COM Port

HART Bus

Adapter

Service

Tool

Serial / USB HART Bus

Tool sees to

difference

betweenGreenor

Redpaths.

Except Timing

FMR

NRF

Web ConfigurationNRF590 is both

part of the Tunnel

and a HART Device

Windows

Configuration


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Toni Ksbeck

Slide 27 / 31

October 2010

Wireless solutions

for tank farms


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Toni Ksbeck

Slide 28 / 31

October 2010

WirelessHART solutions for inventory monitoring

and maintenance


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Toni Ksbeck

Slide 29 / 31

October 2010

Wireless solutions for tank gauging protocols

System configuration

Tanks with Tank Side

Monitors and guided

radar, spot

temperature and

pressure transmitter

Wireless from tank

field to control room

(tank gauging system)


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Toni Ksbeck

Slide 30 / 31

October 2010

Advantages and Benefits

Measurement with two technologies and SIL approved overfill

protection technologies

Increase of plant safety

License free tank farm visualization

Cost reduction. More flexibility

Remote configuration via FDT/DTM

Uniform concept in refinery: Reduced training

Wireless solutions in tank farms

Cost reduction


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