Reference Manual 00809-0700-4530, Rev AA September 2013 Rosemount Process Radar in Power Applications Best Practices User Guide
Reference Manual 00809-0700-4530, Rev AA September 2013 Rosemount Process Radar in Power Applications Best Practices User Guide The products described in this document are NOT rated for use in nuclear-qualified applications. Using non-nuclear qualified products in applications that require nuclear-qualified hardware or products may cause failure of the device. For information on Rosemount nuclear-qualified products, contact your local Emerson Process Management Sales Representative.
Reference Manual September 2013 iv 00809-0700-4530, Rev AA
Reference Manual Table of Contents 00809-0700-4530, Rev AA September 2013 Contents 1Section 1: Power applications 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Boiler systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.3 Turbines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reference Manual Table of Contents 00809-0700-4530, Rev AA September 2013 3.3.2 Changing the Upper Null Zone (UNZ) . . . . . . . . . . . . . . . . . . . . . . . . . . 38 3.3.3 Measure and learn function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3.3.4 Vapor compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3.3.5 Remote housing (GWR transmitters) . . . . . . . . . . . . . . . . . . . . . . . . . . 43 3.3.
Reference Manual Table of Contents 00809-0700-4530, Rev AA September 2013 5.5.6 Reconciling radar with other level measurements . . . . . . . . . . . . . . . 79 AAppendix A: Checklists Table of Contents A.1 Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 A.2 Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 A.2.1 Commissioning procedure . . . . .
Table of Contents September 2013 iv Reference Manual 00809-0700-4530, Rev AA Table of Contents
Reference Manual Section 1: Power Applications 00809-0700-4530, Rev AA September 2013 Section 1 Power applications Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boiler systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1: Power Applications 1.2 Reference Manual 00809-0700-4530, Rev AA September 2013 Boiler systems For boiler systems, radar transmitters are commonly used for the following applications: 1.
Reference Manual Section 1: Power Applications 00809-0700-4530, Rev AA 1.6 September 2013 Fuel supply For fuel supply, radar transmitters are commonly used for the following applications: 1.7 Fuel oil storage Natural gas separators Coal crusher hopper Coal mill supply silo (bunker) Coal stack pile and other fuel sources (bark, garbage) Fuel combustion / clean-up For fuel combustion / clean-up, radar transmitters are commonly used for the following applications: 1.
Section 1: Power Applications 1.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Section 2 Installation considerations Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chamber installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2: Installation Considerations 2.2 Reference Manual 00809-0700-4530, Rev AA September 2013 Introduction In addition to selecting the appropriate radar level transmitter, mechanical installation is one of the most critical steps of the commissioning procedure. When done correctly, the subsequent transmitter configuration will be considerably simplified.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Apart from the additional cost of installation, there are some sizing and selection criteria for the radar gauges that must be considered. This document outlines those considerations. GWR is the preferred technology for shorter installations where rigid probes may be used. This makes it a suitable replacement for caged displacers, which are often less than 10 ft. (3 m).
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Any density-based level measurement device will need compensation to discern the actual level from the density-associated errors. Algorithms have been developed to make this compensation as seamless as possible in the control systems, but require input of operating pressure as well as level. Compensation can be slow which results in erroneous reading.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Heavy vibrations Heavy vibrations from pumps can cause a noisy signal from mechanical-based techniques. Advantages of GWR over other techniques Since GWR measurement devices are completely independent of density, these associated errors are not present, thus eliminating the need for this compensation.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 DVC requires a special probe with a built-in reflector for measurement of the dielectric of the steam. DVC works by using a target at a fixed distance. With this target, the vapor dielectric is measured continuously. The transmitter knows where the reflector pulse should have been if there were no vapor present.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Rosemount design advantages Rosemount 5300 GWR extreme temperature and pressure probes are designed to prevent leakage and perform reliably when exposed to extreme process conditions for extended periods of time. Materials are selected to avoid stress fractures commonly induced by changes in temperature and pressure conditions.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 DVC installation best practices The GWR should be mounted in a bypass chamber with flanges appropriately sized for the pressure and temperature of the application. A 3 or 4 inch (75 or 100 mm) diameter chamber is recommended as best practice, but the GWR can also be mounted in a 2 inch (50 mm) chamber.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 For high pressure steam applications above 400 psi (28 bar), it is also important to limit the overall distance from the flange to where the level is controlled (indicated by A in Figure 2-6), since the high pressure affects the dielectric properties of the vapor causing an error in distance measured, see Table 2-1 on page 8(1).
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 How to choose reflector length The long reflector, 20 in. (500 mm), has the best accuracy and is recommended for all chambers where the dimensions of the chamber allow for it. If the distance from the flange to the upper inlet is less than 28 in. (710 mm), the short reflector should be chosen.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 to center the probe. Chambers larger than 6 in. (150 mm) can be used, but provide no advantages for the radar measurement(1). When specifying a chamber, it is also important to consider the physical weight of the instrument and chamber, the properties of the liquid, and the chance of plugging due to the build-up of deposits.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Probe length is between 3 ft (1 m) and 10 ft (3 m)(1): Use either a rigid single or a flexible single probe with weight and a centering disk. The rigid single is easier to clean and has smaller transition zones, while the flexible single requires less head-space during installation and is less likely to be damaged.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Table 2-4. Transition zones for the Rosemount 3300 Series installed in metallic pipes Upper Transition Zone Probe Size Single Rigid Single Flexible Coaxial Lower Transition Zone High Dielectric Low Dielectric High Dielectric Low Dielectric 4 in. (10 cm) 5.9 in. (15 cm) 4 in. (10 cm) 4 in. (10 cm) 8 in. (20 cm) 4 in. (10 cm) 2 in. (5 cm) 7.5 in. (19 cm) 1.2 in. (3 cm) 4 in. (10 cm) 10.2 in. (26 cm) 2 in.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 An example using the guidelines for fabrication of cages (see Table 2-5 on page 17 for transition zones). Assuming level measurement of oil (worst-case): A > 6.3 in. (16 cm) and C > 9.8 in. (25 cm) for a rigid single probe with a metallic centering disk, and A > 7.1 in. (18 cm) and C > 9.4 in. (24 cm) for a single flexible probe with a standard weight. There is a 2 in.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA 2.3.3 September 2013 Chamber mounting Chambers should be mounted onto the tank to correspond with the desired measurement and area of control. This is often a small portion of the overall height. For further information on chamber mounting in the control area, see “DVC installation best practices” on page 12. 2.3.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Product Data Sheet for more information. The ambient temperature is affected by the process temperature. Figure 2-11 shows the ambient temperature vs. process temperature. Figure 2-11. Ambient temperature vs. process temperature Ambient temperature °F (°C) Process temperature °F (°C) -40 (-40) -320 (-196) -17 (-27) -40 (-40) NOTE: The final maximum ambient temperature rating depends on the type of approval.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Figure 2-12. Rosemount 5300 Series with remote housing When the remote housing is used together with the Rosemount 5300 Series, there may be a limit on measuring range and a decrease in accuracy. This is because the remote housing introduces a double bounce in the tank signal at 1.5 times the remote housing cable length. Because the double bounce occurs at approximately 1.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 2.3.7 Insulation The chamber should always be insulated in hot applications to prevent personal injuries and reduce the amount of energy needed for heating.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 For the Rosemount GWR transmitters: Do not mount close to inlet pipes and ensure that the probe does not come in contact with the nozzle (X) If there is a chance that the probe may come in contact with the tank wall, nozzle, or other tank obstructions, the coaxial probe is the only recommended choice. However, it should only be used with clean liquids.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 The Rosemount 5400 Series non-contacting radar transmitters should be installed in locations with a clear and unobstructed view of the level surface (A) for optimum performance: Filling inlets creating turbulence (B), and stationary metallic objects with horizontal surfaces (C) should be kept at a distance, outside the signal beam.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA 2.4.2 September 2013 Nozzle considerations Depending on the selection of transmitter model and probe/antenna, special considerations may have to be taken because of the nozzle. Rosemount GWR transmitters The coaxial probe signal is unaffected by the nozzle. The single probe has some nozzle restrictions, e.g. avoid using nozzles with reducers, and nozzles that are too tall or too narrow. Figure 2-16.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Rosemount 5400 Series non-contacting radar transmitter Rosemount 5402 with cone antenna The antenna can be used in nozzles equal to or larger than 2.2 in (55 mm). It can be recessed in smooth nozzles up to 6 ft (2 m). However, if the inside of the nozzle contains disturbing objects, use the extended cone, see Figure 2-17. Make sure the antenna is never the same height as the nozzle.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Figure 2-19. Rosemount 5401 with cone antenna (L) 0.4 in. (10 mm) or more If the signal is dampened by heavy condensation at the antenna, it often helps to insulate the nozzle. This is to minimize the temperature disparity between the internal and the ambient temperature. 2.4.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 2.5 Solids measurement Solids generally provide a difficult measuring environment with low dielectric products in tall tanks, where pull forces may act on the probe, and dust, steam, or risk of coating are often present. In addition, the surface is not flat and the angle of repose tends to change. As a result, the signal levels are often very low, and installation is of utmost importance. 2.5.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Probe installation should occur when the silo is empty, and the probe should be regularly inspected for damage. Avoid 10-in. (250 mm) / DN250 or larger diameter nozzles, especially in applications with low dielectric constant. For environments where electrostatic discharges are likely to occur, e.g.
Section 2: Installation Considerations Reference Manual 00809-0700-4530, Rev AA September 2013 When probes are anchored, the forces are two to ten times greater than with free-hanging probes. To prevent an extremely high tensile load when fixing the probe, and to reduce the risk of probe breakage, the probe must be slack. Select a probe longer than the required measuring range so that there is a sag in the middle of the probe that is greater than or equal to 11/2 in.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA 2.5.2 September 2013 Rosemount 5600 Series The Rosemount 5600 Series can be used in tanks up to 165 ft (50 m). As solids generally provide a difficult measuring environment and the signal levels are often very low, installation is of utmost importance. Antenna selection and its location in the tank are the keys to success. Step 1: antenna selection Figure 2-24.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Step 2: tank connection Figure 2-28. Rosemount 5600 Series with cone/parabolic antenna Rosemount 5600 Series with cone antenna Rosemount 5600 Series with parabolic antenna 6.3 in. (160 mm) or less 14.6 in. (370 mm) or less Ø 7.6 in. (Ø 194 mm) min. Ø 19.7 in. (Ø 500 mm) min. HINT: If the signal is dampened by heavy condensation at the antenna, it often helps to insulate the nozzle.
Reference Manual Section 2: Installation Considerations 00809-0700-4530, Rev AA September 2013 Step 4: inclination of antenna If the surface echo is weak, the parabolic antenna can be inclined 0.5° to 2° towards the surface slope in order to increase the reflected signal. NOTE: Too great of an angle can create problems in detecting surface echo at the bottom region. The angle of the slope differs during filling and emptying.
Section 2: Installation Considerations Reference Manual 00809-0700-4530, Rev AA September 2013 Step 5: software settings Note that solids applications in general are difficult, therefore Emerson Process Management has developed a special solids mode in the radar database. This means that the radar database configuration is optimized for solids measurements when the “solids” check-box is selected in the Rosemount Radar Master (RRM) setup window.
Reference Manual Section 3: Commissioning 00809-0700-4530, Rev AA Section 3 September 2013 Commissioning Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Functions of procedures to include during commissioning process . . . . . . . . . . . . 36 3.
Reference Manual Section 3: Commissioning 00809-0700-4530, Rev AA September 2013 3.2 Introduction The transmitter installation should be carried out as described in the Quick Installation Guide that is enclosed with every transmitter. Even though the transmitter may be installed on the bench, it must be configured to the actual process conditions. For the Rosemount GWR transmitters, it is important not to bend the probe during any part of the installation.
Reference Manual Section 3: Commissioning 00809-0700-4530, Rev AA September 2013 Table 3-3.
Reference Manual Section 3: Commissioning 00809-0700-4530, Rev AA September 2013 Figure 3-1. Echo curve before and after TNZ TNZ NOTE: The effect of TNZ is only visible when an echo is present in the near zone. 3.3.2 Changing the Upper Null Zone (UNZ) Measurements are not performed within the Upper Null Zone (UNZ). By setting the UNZ parameter to zero, measurements can be performed in the region close to the flange (near zone). Figure 3-2.
Reference Manual Section 3: Commissioning 00809-0700-4530, Rev AA September 2013 Rosemount 3300 Series Radar Configuration Tool > Setup > Tank Config tab (click Receive Page) > Upper Null Zone (enter desired value in field and click Send Page) 3.3.3 Measure and learn function The Rosemount 5300 and 5400 Series have a firmware functionality to automatically adjust threshold settings to make the measurement more robust.
Section 3: Commissioning Reference Manual 00809-0700-4530, Rev AA September 2013 of a Rosemount 5300 Series level transmitter can be configured for static compensation of vapor by manually entering the dielectric constant of vapor, to compensate for the error induced by the saturated steam.
Reference Manual Section 3: Commissioning 00809-0700-4530, Rev AA September 2013 dynamically used to compensate for changes in vapor dielectric constant and eliminates the need to do any compensation in the control system. To check if the DVC function is supported: RRM > Device > Properties (If Vapor Compensation is mentioned in the Device Software Configuration 2 list, the device supports vapor compensation). Figure 3-4.
Section 3: Commissioning Reference Manual 00809-0700-4530, Rev AA September 2013 Installation setup It is important that the vapor compensation function is calibrated after installation and after the basic configuration is complete. The basic configuration includes setup of the unit in a chamber installation and the use of a remote housing connection. Before calibration, do the following: The surface level must be at least 19.7 in. (0.5 m) below the end of the reflector (36 in. (0.9 m) or 39.7 in. (1.
Reference Manual Section 3: Commissioning 00809-0700-4530, Rev AA 3.3.5 September 2013 Remote housing (GWR transmitters) If a remote housing is added to a unit after the DVC calculation is done, the unit needs to be recalibrated. When using remote housing, the remote connection length should be configured. If the remote housing is ordered with a transmitter, it is configured in the factory. For more details, refer to the Rosemount 5300 Series Reference Manual "Appendix D Remote Mounting" (Document No.
Reference Manual Section 3: Commissioning 00809-0700-4530, Rev AA September 2013 Option 1 - Matching the output of +/- deviation from the nominal reference point Choose level as primary variable to show on the local display. For example, if a GWR is replacing a 14 in. (356 mm) displacer, the span would be -7 in. (-178 mm) to +7 in. (+178 mm). Table 3-5. Option 1 example: Gauge height distance to nominal reference point 57 in. (1448 mm) Probe length probe length 87 in.
Reference Manual Section 3: Commissioning 00809-0700-4530, Rev AA September 2013 Option 2 - Setting LRV to 0 in. (0 mm) at the lower tap The tank height should be set to the distance to the zero level point. In this example, it is the lower side-pipe, located 19 in. (483 mm) below the reference point. Output range values will equal the pipe connection heights relative to the zero level point. LRV should be set at 0 in. (0 mm), the URV should be set at 14 in.
Reference Manual Section 3: Commissioning 00809-0700-4530, Rev AA September 2013 Option 3 - Matching displacer output The tank height (reference gauge height) and the probe length should be set to the same value. The LRV is the distance from the bottom of the probe to the lower tap. The URV is the LRV plus the distance to the upper tap. In this example, tank height (reference gauge height) equals the probe length of 23 in. (584 mm), the LRV is 4 in. (102 mm), and the URV is 18 in. (457 mm). Table 3-7.
Reference Manual 00809-0700-4530, Rev AA 3.3.7 Section 3: Commissioning September 2013 Signal Quality Metrics (Rosemount 5300 and 5400 Series) Signal Quality Metrics (SQM) indicates the surface signal integrity compared to the noise. It can be used to schedule maintenance to clean the probe or detect and monitor turbulence, boiling, and foam. The Rosemount 5300 Series with Diagnostics Suite option and the Rosemount 5400 Series have the SQM function.
Reference Manual Section 3: Commissioning 00809-0700-4530, Rev AA September 2013 3.3.9 Probe End Projection (Rosemount 5300 Series solids measurement) Probe End Projection (PEP) handles long measuring ranges on media with low dielectrics, such as solids. If the signal is not reflected at the surface, the Rosemount 5300 Series uses the probe end as a reference to calculate the actual level.
Reference Manual 00809-0700-4530, Rev AA 3.3.10 Section 3: Commissioning September 2013 Store backup and verification files As the last step of the commissioning procedure, it is recommended that both the transmitter settings and the echo curve be stored. For example, these can be used for subsequent transmitter verification or troubleshooting. Note that the echo curve should also be stored once more at operating conditions.
Reference Manual Section 3: Commissioning 00809-0700-4530, Rev AA September 2013 Figure 3-11. The difference between the amplitude of surface peaks in the case of simulated and actual liquid levels Water Amplitude How it would look with actual product (oil) in tank Distance Example A Rosemount 5300 Series transmitter mounted in a chamber can be verified by connecting flexible transparent tubing to the bottom drain, ensuring that there are no crimps or folds in the bend to impede the flow.
Reference Manual Section 4: Measurement validation 00809-0700-4530, Rev AA September 2013 Section 4 Measurement validation Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measurement validation at operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4: Measurement validation Reference Manual 00809-0700-4530, Rev AA September 2013 Any substitution of non-authorized parts or repair, other than exchanging the complete transmitter head or probe assembly, may jeopardize safety and is prohibited. Unauthorized changes to the product are strictly prohibited as they may unintentionally and unpredictably alter performance and jeopardize safety.
Reference Manual Section 4: Measurement validation 00809-0700-4530, Rev AA September 2013 Figure 4-1. The verification of measurement data using a sight-glass Step 2: analog output signal validation Note that this section refers to 4-20 mA/HART units only. Ensure that the loop has been set to manual mode in the Distributed Control System (DCS) for the applicable transmitter. Use the transmitter's built-in simulation mode to verify the analog output settings.
Section 4: Measurement validation Reference Manual 00809-0700-4530, Rev AA September 2013 Figure 4-3. Loop test for Analog Out 1 Step 3: echo-curve verification at operating conditions At normal operating conditions, download and review the echo-curve according to the following steps: 1. Check reference pulse amplitude and position Compare the result against the previous plots, taken during commissioning, and previous verification rounds.
Reference Manual Section 4: Measurement validation 00809-0700-4530, Rev AA September 2013 Figure 4-4. GWR transmitter peak amplitudes and threshold settings Surface peak Surface threshold Amplitude UNZ Reference peak Distance Figure 4-5.
Section 4: Measurement validation Reference Manual 00809-0700-4530, Rev AA September 2013 Figure 4-6. Diagnostics Step 5: monitor level while emptying During Step 1, the current level (and/or interface) reading was verified. This step will verify that the transmitter correctly tracks the surface during the emptying of the tank. Begin by activating log functionality for the transmitter level output. Either the DCS-trend or a standalone tool can be used: RRM > Tools > Log Figure 4-7.
Reference Manual Section 4: Measurement validation 00809-0700-4530, Rev AA September 2013 Figure 4-8. Emptying a tank or chamber 2: Open vent 1: Close valves 3: Open drain Finally, review the level trend for accuracy. Step 6: echo-curve verification with empty tank When the tank or chamber is empty, download and review the echo-curve according to the following steps: 1. 2. Compare echo-curve with previous plots Compare the echo-curve with previous plots, taken during commissioning.
Section 4: Measurement validation 4.4 Reference Manual 00809-0700-4530, Rev AA September 2013 Operation and maintenance - proof testing for SIS The Rosemount 5300 Series Prior-Use option must be tested at regular intervals to confirm that the overfill and empty tank protection function result in the desired system response. The required proof test intervals are dependent on the configuration of the transmitter and the process environment.
Reference Manual Section 4: Measurement validation 00809-0700-4530, Rev AA 5. September 2013 Perform a two-point calibration check of the transmitter by applying the level to two points on the probe within the measuring range(1). Verify that the current output corresponds to the level input values using a known reference measurement. This step verifies that the analog output is correct in the operating range and that the primary variable is properly configured. 6. Enable write protection. 7.
Section 4: Measurement validation September 2013 60 Reference Manual 00809-0700-4530, Rev AA Measurement validation
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA September 2013 Section 5 Troubleshooting procedures Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5: Troubleshooting Procedures Reference Manual 00809-0700-4530, Rev AA September 2013 Any substitution of non-authorized parts or repair, other than exchanging the complete transmitter head or probe assembly, may jeopardize safety and is prohibited. Unauthorized changes to the product are strictly prohibited as they may unintentionally and unpredictably alter performance and jeopardize safety.
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA 5.3 September 2013 Diagnostics Basic rules and philosophy about the diagnostic messages is that the transmitter will generate an alarm current if the diagnostic message indicated is a "device error" or a "lost measurement" alarm.
Section 5: Troubleshooting Procedures 5.4 Reference Manual 00809-0700-4530, Rev AA September 2013 Echo curve analysis The echo curve represents the tank, as seen by the radar transmitter. Each peak corresponds to a reflection of the radar signal - the surface of the level, an obstacle, or something else. By viewing single instances or movies of the echo curve, how and why the transmitter behaves as it does can be understood, and it can be configured accordingly to achieve a reliable level measurement.
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA 5.4.1 September 2013 Echo curve constituents Figure 5-2.
Section 5: Troubleshooting Procedures September 2013 Reference Manual 00809-0700-4530, Rev AA Figure 5-3. Rosemount 5300 Series with DVC - Echo curve presentation in RRM In a typical measurement situation, the following peaks appear in the echo curve: Reference peak. This reference pulse is caused by the transition between the transmitter head and the probe/antenna.
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA September 2013 Table 5-1. Typical peak amplitudes for the Rosemount 5300 Series with a single lead probe in 4 in. (100 mm) chambers Peak Approximate signal strength, ideal conditions for single lead probe in 4 in.
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA September 2013 Rosemount 5400 and 5600 Series Various amplitude thresholds are used to filter out unwanted signals and pick up the different peaks. The transmitter uses certain criteria to select which peaks correspond to the actual level surface. For GWR transmitters counting from the top of the tank, the first echo above the surface threshold is considered the product surface.
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA 5.4.2 September 2013 Rosemount GWR transmitter threshold settings Recommendations for the Rosemount 3300 and 5300 Series: 1. Use the automatic threshold settings and ensure that the dielectric constants of the vapor and products have been entered correctly 2. If needed, apply the Measure & Learn function 3.
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA September 2013 Figure 5-7. Surface peak is below the surface threshold The surface peak is undetected because it is below the surface threshold Rosemount 5301 Amplitude Surface threshold (ATC) Distance Figure 5-8.
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA September 2013 Disturbance misinterpreted as level In this example, the transmitter incorrectly identifies the reflection from an inlet-pipe as the product surface, because it is the first peak above the surface threshold, see Figure 5-9. Tall, narrow, and/or rough nozzles can also create disturbance echo in the form of double bounces. The double bounce will always appear at twice the disturbance distance.
Section 5: Troubleshooting Procedures Reference Manual 00809-0700-4530, Rev AA September 2013 Incorrect reading due to bent probe or probe contacting the nozzle wall A bent, twisted probe (in the case of flexible probes) in contact with metal creates a strong echo that the measurement will lock onto, see Figure 5-11. If this is the case, the mechanical installation will need to be redone ensuring that the recommendations in Section 2: Installation considerations are followed.
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA September 2013 Strong antenna echo and weak surface echo Water condensation in a cone antenna or build-up on a process seal window will create a strong echo from the antenna and a weak surface echo. Examine installation and adjust Hold-Off and surface threshold if the surface echo is still strong enough. Insulating the nozzle generally reduces the condensation or build-up.
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA September 2013 Figure 5-14. Installation error - level/interface range is not covered adequately Error Error The connections between the vessel and the chamber must allow for flow of the product. Clogging should be avoided. Figure 5-15. Inlet-pipe clogged Error Inlet-pipe clogged The radar transmitter is not temperature-dependent.
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA September 2013 Rosemount 5600 Series solids measurement In a nozzle installation, review the installation considerations. For solids measurement with weak surface echo, mechanical installation is especially important, since nozzle disturbances will disrupt the surface measurement. For best practice, ensure that the antenna reaches into the tank (at least 2 in. (50 mm)).
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA September 2013 5.5.3 Probe End Pulse offset (only relevant for PEP) An offset of the probe end pulse is normal if there is product in the vessel. However, it can also be caused by mis-configured probe length. Ensure that correct probe length is configured by emptying the tank and reading the probe end pulse or measuring the probe.
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA September 2013 Figure 5-20. Analog output settings - range values and reference points 20 mA Upper Range Value (URV) = 100 % Range 0 - 100 % Tank Height (Reference Gauge Height) Upper Reference Point 4 mA Lower Range Value (LRV) = 0 % Lower Reference Point (Level = 0) The analog output depends on how the range values are set, see Figure 5-21 for examples. Figure 5-21.
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA September 2013 5.5.5 Incorrect static vapor compensation Specific high-temperature and high-pressure applications, like those with saturated steam vapors, require that a compensated value be entered for the vapor dielectric constant. This compensation is fixed and will only adjust the level reading at a specific condition.
Reference Manual Section 5: Troubleshooting Procedures 00809-0700-4530, Rev AA 5.5.6 September 2013 Reconciling radar with other level measurements When comparing level measurements to each other, they often do not match up as expected. There are numerous reasons for this with the most prominent one being related to what is actually being measured. Few instruments measure the level directly as radar does.
Section 5: Troubleshooting Procedures Reference Manual 00809-0700-4530, Rev AA September 2013 Potential problems include: Fluid density changes: source, grade, product and temperature affect the density of the fluid, and thereby the level output. In case of a wet leg, is it completely filled? Or, if a dry leg is used, is it really dry? Loss of fluid and condensed fluid respectively create an offset in the level reading. Consider using either an electronic or a capillary remote seal.
Appendix A: Checklists Reference Manual September 2013 00809-0700-4530, Rev AA Appendix A Checklists Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 A.
Reference Manual Appendix A: Checklists 00809-0700-4530, Rev AA September 2013 A.2 Checklists A.2.1 Commissioning procedure Step 82 Task 1 System readiness is confirmed (Rosemount 5300 and 5400 Series only) a. HART revision capability is checked b. The latest Device Driver is downloaded c.
Appendix A: Checklists Reference Manual September 2013 00809-0700-4530, Rev AA A.2.2 Measurement validation procedure Step Task 1 The transmitter is in operation 2 Level reading correctness is verified a. The transmitter level reading is compared with an independent measurement 3 The analog output signal is validated (for 4-20 mA/HART units only) a. Loop is set to manual mode in the Distributed Control System (DCS) b. Transmitter is in simulation mode (accessed in RRM) c.
Reference Manual Appendix A: Checklists 00809-0700-4530, Rev AA September 2013 A.2.3 Troubleshooting procedure Step 84 Task 1 Voltage at transmitter terminals are checked 2 DCS trends are checked 3 Tank survey is done to identify the application 4 Basic errors (cables, transmitter diagnostics etc.) are checked a. Cables are connected properly b.
Reference Manual Index 00809-0700-4530, Rev AA September 2013 Index A Amplitude Threshold Curve (ATC) . . . . . . . . . . . . . . . . . . . 39 Analog output settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Antenna selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27, 31 C Chamber Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Insulation . . .
Reference Manual Index 00809-0700-4530, Rev AA September 2013 T Tank installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Threshold settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guided Wave Radar (GWR) . . . . . . . . . . . . . . . . . . . . . Non-contacting radar . . . . . . . . . . . . . . . . . . . . . . . . . . Transition zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trim Near Zone (TNZ) . . . . . . . . . . . . . . .
Reference Manual 00809-0700-4530, Rev AA September 2013 Emerson Process Management Rosemount Division 8200 Market Boulevard Chanhassen, MN 55317 USA Tel (US) 1 800 999 9307 Tel (International) 952 906 8888 Fax 952 906 8889 www.rosemount.com Emerson Process Management Blegistrasse 23 P.O. Box 1046 CH 6341 Baar Switzerland Tel +41 (0) 41 768 6111 Fax +41 (0) 41 768 6300 Emerson FZE P.O.
