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Reference Manual 00809-0700-4530, Rev AA September 2013 R osemount Proc ess Radar in P o wer Applications Best Prac tices User Guide.
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iii Reference Manu al 00809-0700-4530, Rev AA September 2013 R osemount Proce ss Radar in Po w er Applications Best Prac tice s User Guide The products described in this document are NO T rated f or use in nuc lear-qualified applications.
iv Reference Manu al 00809-0700-4530, Rev AA September 2013.
i Reference Manu al 00809-0700-4530, Rev AA Table of Contents September 2013 Ta b l e o f C o n t e n t s 1 Section 1: Power ap plications 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii Reference Manu al 00809-0700-4530, Rev AA Table of Contents September 2013 T able of Cont ents 3.3.2 Changing the Upper Null Zone (UNZ) . . . . . . . . . . . . . . . . . . . . . . . . . . 38 3.3.3 Measure and learn function . . . . . . . . . . . . .
iii Reference Manu al 00809-0700-4530, Rev AA Table of Contents September 2013 Ta b l e o f C o n t e n t s 5.5.6 R econciling r adar with ot her level mea surements . . . . . . . . . . . . . . . 79 A Appendix A: Checklists A.1 Safety messages . . . .
iv Reference Manu al 00809-0700-4530, Rev AA Table of Contents September 2013 T able of Cont ents.
1 Reference Manu al 00809-0700-4530, Rev AA Section 1: Power Applications September 2013 Pow er applica tions Sec t ion 1 Po we r applications Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Reference Manu al 00809-0700-4530, Rev AA Section 1: Power Applications September 2013 Powe r applications 1.2 Boiler systems For boile r systems, rad ar transmitters are co mmonly used f or the fol.
3 Reference Manu al 00809-0700-4530, Rev AA Section 1: Power Applications September 2013 Pow er applica tions 1.6 F uel supply For fue l supply , radar transmitt ers are comm only us ed for the foll o.
4 Reference Manu al 00809-0700-4530, Rev AA Section 1: Power Applications September 2013 Powe r applications 1.10 Miscellaneous For misce llaneous, radar transmitters are commonly used for the followi.
5 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations Sec t ion 2 Installa tion conside rations Safety m essages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations 2.2 Introduc tion In addition to select ing the appropriate radar le vel transmitter , mechanical inst allation is one of the most critical ste ps of the commis sioning pr ocedure.
7 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations Apar t from the addition al cost of inst allati on, th ere are some sizing and se lec tion criteri a for the radar g auges that m ust be c onsidered.
8 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations Any de nsit y-based leve l measure ment devic e will need compensa tion to disce rn the ac tual lev el from the density-associa ted errors.
9 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations Heavy vibrations Heavy vibratio ns from pumps can cause a noisy signal from mechanical-based tec hn iques.
10 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations DV C requires a sp ecial probe wi th a built-in re flector for me asure ment o f the dielectric of th e steam. DV C works by using a target a t a fixed distance .
11 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations Ro semount design advantages Ro semoun t 5300 GWR extreme te mperat ure .
12 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations D VC installation be st prac tices The GWR should be mounted in a bypa ss chambe r with flanges appropria tely siz ed for the pressure and te mperature of the applica tion.
13 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations For high pressure ste am applications above 400 psi (28 bar), it is also.
14 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations How to c hoose reflector length The long reflector , 20 in. (500 mm), has the best acc urac y and is recommen ded for all chambe rs where the dimensions o f the chamber allo w for it.
15 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations to ce nte r the probe. Ch ambers large r than 6 in. (150 mm) can be u sed, but provide no advantages f or the radar me asureme nt (1) .
16 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations Probe length is between 3 f t (1 m) and 10 f t (3 m) (1) : Use either a rigid single or a flexible single probe with weight and a cen tering disk.
17 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations T able 2-4. T ransition zones for the Rosemo unt 3300 S eries inst alled in met allic pi pes T able 2-5. T ransition zones in chambers for the Rosemount 5300 Series installed in metallic pipes Figure 2-8.
18 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations An example usin g the guid elines for fabricatio n of cages (see T able 2-5 on page 17 for transition z ones). Assuming leve l measure ment of oil (worst-ca se): A > 6.
19 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations 2.3.3 Ch amber moun ting Chambers should be mounted onto the tank to correspond with the desired me asureme nt and area of c ontrol.
20 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations Product Data Sheet f or more inf ormation. The ambient t empera ture is affected by the pr ocess temperatu re. Figure 2-11 shows the ambient te mperature vs.
21 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations Figure 2-12. Ro semount 5300 Series with remote housing When the re mote housing is u sed togethe r with the Ro semount 5300 Se ries, there m ay be a limit on meas uring range and a decrea se in ac curacy .
22 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations 2.3.7 Insula tion The chamber should always be insulated in hot applications to prevent pe r sonal injuries and reduce the amount of ener gy needed for hea ting.
23 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations For the R ose mount GWR tr ansmitte rs: Do not mount clo se to inlet.
24 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations The Rose mount 5400 Series non-contac ting radar transmitters should be .
25 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations 2.4.2 Nozzle c onside rations Depending on the selectio n of transmitter model and probe/ante nna, special considera tions may h ave t o be taken becau se of the nozzle .
26 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations Ro semount 5400 Series non-co nt ac ting radar transmitter Ro semount 5402 with c one ante nna The antenn a can be used in nozzles equal to or l arger than 2.
27 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations Figure 2-19. R osemount 5401 with cone ante nna If the signal is dampened by hea v y condensation at the ante nna, it of ten helps to insulat e the nozzle .
28 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations 2.5 Solids measurement Solids generally provide a difficult measuring en.
29 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations Probe installation should occur when the silo is empt y , and the probe should be regularly insp ec ted f or damage . Av oid 10-in.
30 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations When probes are anchore d, the forces are t wo to ten times gre ater than with free-hanging probes.
31 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations 2.5.2 R ose mount 5600 Se ries The Ro semoun t 5600 Series can be us ed in tanks up to 165 f t (50 m).
32 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations Step 2: ta nk co nn ec ti on Figure 2-28. Ro semount 5600 Series with cone/parabolic ant enna HINT: If the signal is dampened by hea v y condensation at the ante nna, it of ten helps to insulat e th e nozzle .
33 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerations September 2013 Installation conside rations Ste p 4: inclination of antenna NOTE: T oo grea t of an angle can creat e problems in de tecting sur face echo at the bottom region.
34 Reference Manu al 00809-0700-4530, Rev AA Section 2: Installation Considerat ions September 2013 Installation considerations Step 5: soft ware settings Note that solids applications in general are diff icult, therefore Emerson Pro cess Manage ment ha s developed a spec ial solids mode in the radar database .
35 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissioning September 2013 Commis sioning Sec t ion 3 Commis sioning Safety m essages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissionin g September 2013 Commis sioning 3.2 Introduc tion The transmitter installa tion should be carr ied out as described in the Qu ick Installation Guide that is enc losed with ever y transmi tter .
37 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissioning September 2013 Commis sioning T able 3-3. Solids measurement 3.3.1 T rim Ne ar Zone (GWR transmitte rs) The Ro semoun t 3300 and 5300 Series are equipped with a fi rmware functionalit y that minimiz es the Uppe r T ransition Z one based on actual moun ting condit ions.
38 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissionin g September 2013 Commis sioning Figure 3-1. Echo curve before and after TNZ NOTE : The eff ec t of TNZ is only visible whe n an e cho is present in the near zone .
39 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissioning September 2013 Commis sioning Ro semoun t 3300 Series Radar C onfiguration T ool > Se tup > T ank Con fig tab (click Rec ei ve P ag e ) > Upper Null Zon e (ent er desired value in fie ld and click Send Page ) 3.
40 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissionin g September 2013 Commis sioning of a R osemoun t 5300 Series le vel transmitte r can be configured f or static compe nsation of vapor by manu all y en tering the dielectric cons tant of va por , to comp ensate fo r th e er ror induced b y the saturated st eam.
41 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissioning September 2013 Commis sioning dynamica lly used to c ompensa te for c hanges in vapor die lec tric constant and elimina tes the ne e d to d o any co m p ens a ti o n i n t h e co nt r ol s y s t em.
42 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissionin g September 2013 Commis sioning Installation setup It is important tha t the vapor compe nsation function is calibr ated afte r installation an d af te r the basic con figuration is complete .
43 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissioning September 2013 Commis sioning 3.3.5 R emo te hou sing (GWR transmitters) If a remo te housing is added to a unit af ter th e D VC calcul ation is done, the unit needs to be recalibrated.
44 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissionin g September 2013 Commis sioning Option 1 - Matching the output of +/- devia tio n from the nominal refere nce point Choos e leve l as primary variable t o show on the local displ ay .
45 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissioning September 2013 Commis sioning Opt ion 2 - Setting LR V to 0 in. (0 mm) at the lowe r tap The tank height should be set to the distance to the zero leve l point. In this example, it is the lower side-pipe , located 19 in.
46 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissionin g September 2013 Commis sioning Option 3 - Ma tching displace r output The t an k h eigh t ( referen ce gau ge heig ht ) a nd th e probe length should be set to the same value. The LRV is th e distance from the bott om of the probe to the lower tap .
47 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissioning September 2013 Commis sioning 3.3.7 Signal Qu alit y Metrics (R os e mount 5300 and 5400 Se ries) Signal Quality Metrics (SQM) indicat es the sur face signal in tegrit y compared to the noise.
48 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissionin g September 2013 Commis sioning 3.3.9 Probe End Projection (Ro s emo u nt 53 0 0 S er i es so l i ds meas u rem ent ) Probe End Projec tion (PEP) handles long measurin g ranges on media with lo w dielectrics, such as soli ds.
49 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissioning September 2013 Commis sioning 3.3.10 St ore backup and v eri fication file s As the last st ep of the c ommissioning pro cedure, it is recomme nded that bo th the transmitte r settings and the echo cur ve be stored.
50 Reference Manu al 00809-0700-4530, Rev AA Section 3: Commissionin g September 2013 Commis sioning Figure 3-11. The d ifference bet ween the a mplitude of sur face peaks in the case of simulated an .
51 Reference Manu al 00809-0700-4530, Rev AA Section 4: Measurement validation September 2013 Meas ur ement v al idat io n Sec tion 4 Me asure men t valid ation Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52 Reference Ma nual 00809-0700-4530, Rev AA Section 4: Measurement va lidation September 2013 Measurement valid atio n 4.2 Introduc tion In this sec tio n, the steps of me asurement validation at operating c ondit ions are descr ibed.
53 Reference Manu al 00809-0700-4530, Rev AA Section 4: Measurement validation September 2013 Meas ur ement v al idat io n Figure 4-1. The verification of m easurement data using a sight-glass St ep 2: analog output signal validation Note th at this section re fers to 4-20 mA/HAR T units only .
54 Reference Ma nual 00809-0700-4530, Rev AA Section 4: Measurement va lidation September 2013 Measurement valid atio n Figure 4-3. Loop test f or Analog Out 1 Step 3: e ch o- cu r ve ve ri f ic a tion at operating conditions At normal opera tin g conditions, download and review the echo-cur ve acc ording to the foll owing ste ps: 1.
55 Reference Manu al 00809-0700-4530, Rev AA Section 4: Measurement validation September 2013 Meas ur ement v al idat io n Figure 4-4. GWR transmitter peak amplit udes and threshold settings Figure 4-5.
56 Reference Ma nual 00809-0700-4530, Rev AA Section 4: Measurement va lidation September 2013 Measurement valid atio n Figure 4-6. Diagnostics St ep 5: mo nitor leve l while em pt ying During St ep 1, the curren t level (and/or interface) re ading was ve rified.
57 Reference Manu al 00809-0700-4530, Rev AA Section 4: Measurement validation September 2013 Meas ur ement v al idat io n Figure 4-8. Emptying a tank o r chamber Finally , review the level trend f or accurac y.
58 Reference Ma nual 00809-0700-4530, Rev AA Section 4: Measurement va lidation September 2013 Measurement valid atio n 4.4 Operation and maintenanc e - proof testing f or SIS The Ro semount 5300 Seri.
59 Reference Manu al 00809-0700-4530, Rev AA Section 4: Measurement validation September 2013 Meas ur ement v al idat io n 5. Pe r form a two-point calibra tion check o f the transmitte r by applying the le vel t o t wo points on the probe within the measuring range (1) .
60 Reference Ma nual 00809-0700-4530, Rev AA Section 4: Measurement va lidation September 2013 Measurement valid atio n.
61 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s Sec tion 5 T roubleshoo ting procedure s Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s 5.2 Introduc tion This sec tion provides information on identifyin g the most common problems found with radar level transmitters.
63 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s 5.3 Diagnostics Basic rules and philosophy about the diagnostic messages .
64 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s 5.4 Echo cur ve analysis The echo cur ve represen ts the t ank, as seen by the radar tr ansmitter . Each peak corresponds to a reflection of the radar signal - the sur face of the level, an obstacle, or something else.
65 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s 5.4.1 E cho cur v e constitue nts Figure 5-2.
66 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s Figure 5-3. Rosemount 5300 Series with D V C - Echo curve presentation in RRM In a t ypica l measureme nt situation, the following peaks appear in the echo cur ve : Reference peak.
67 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s T able 5-1. T ypical peak amplitudes for the Ros emount 5300 Series with a single lead probe in 4 in. (100 mm) chamber s T able 5-2.
68 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s R osemount 5400 and 5600 Series V arious amplitude thresholds are u sed to filter out unw anted signals and pi ck up the diffe rent peaks.
69 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s 5.4.2 R ose mount GWR transmitt er threshold se tting s R ecommend ations for the R osemount 3300 and 5300 Se ries: 1.
70 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s Figure 5-7. Sur face peak is below the sur face threshold Figure 5-8.
71 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s Disturbance misinterpret ed as leve l In this example, the transmitter in.
72 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s Incorrect reading due to be nt probe or probe contac ting the nozzle w al.
73 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s Strong ant enna echo and w eak sur face ec ho W ate r conde nsation in a c one anten na or build-up on a proc ess se al window will cre ate a stro ng echo from the an tenna and a we ak sur face echo .
74 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s Figure 5-14. Installation error - le vel/inte r face r ange is not co vered adequately The connections bet ween the ve ssel and the c h amber mu st allow for flow of the product.
75 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s R osemount 5600 Series solids measurement In a nozzle installation, review th e installation considerations.
76 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s 5.5.3 Probe End Pulse offse t (only rele vant f or PEP) An offset of the probe end pulse is n ormal if there is produ ct in the vessel.
77 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s Figure 5-20. Analog output settings - range values and reference points The analog out put depe nds on how the range valu es are set, see Figur e 5-21 for ex am pl es .
78 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s 5.5.5 Incorrect static vapor compe nsation Specific high-te mperature and.
79 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s 5.5.6 R ec onciling radar with o ther lev e l mea sureme nts When c omparing lev el me asurem ents to e ach othe r , they often do no t matc h up as expected.
80 Reference Manu al 00809-0700-4530, Rev AA Section 5: Troubleshooting Procedures September 2013 T roubleshooting procedure s Po tenti al problems inc lude: Fluid density changes: sourc e, grade , produc t and temperature a ffect the density of the fluid, and th ere by the level output.
81 Reference Manu al 00809-0700-4530, Rev AA Appendix A: Checklists September 2013 Checklists Appe ndix A Checklists Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Checklists .
82 Reference Manu al 00809-0700-4530, Rev AA Appendix A: Checkl ists September 2013 Checklists A .2 Checklists A .2.1 Commissioning procedure Step Ta s k Comple ted 1 Syste m readines s is confirmed (R osemoun t 5300 and 5400 Series only) a. HART revision capabili t y is checked b .
83 Reference Manu al 00809-0700-4530, Rev AA Appendix A: Checklists September 2013 Checklists A .2.2 M e asure ment valid ation proc edure Step Ta s k Comple ted 1 The tran smitter is in operation 2 Level re ading correc tness is verified a.
84 Reference Manu al 00809-0700-4530, Rev AA Appendix A: Checkl ists September 2013 Checklists A .2.3 T roubleshooting proc edure Step Ta s k Comple ted 1 V oltage at transmitt er te rminals are check ed 2 DCS trends are check ed 3 T a nk sur vey is done to iden tif y the application 4 Basic e rror s (cables, transmitte r diagnostics etc .
Index-1 Reference Manu al 00809-0700-4530, Rev AA Index September 2013 Index A Amplitude Threshold Curve (AT C) . . . . . . . . . . . . . . . . . . . 39 Analog output settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Antenna selection .
Index-2 Reference Manu al 00809-0700-4530, Rev AA Index September 2013 Index T Tank instal lations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Threshold settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Reference Manual 00809-0700-4530, Rev AA September 2013 St andard T erms and Con ditions of Sale c an be found at www .rosem ount.com/te rms_of_sale . The Emerson logo is a trademark and service mark of Emerson Electric Co. Ro semount and the Rose mount logotype are registered trad emarks of Ro semount In c.
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