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Toni Ksbeck
Slide 1 / 31
October 2010
Trends in Tank Farm Management
Tank Storage Istanbul
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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
Toni Ksbeck
Slide 8 / 31
October 2010
Redundancy in the field: Dual output from gauges
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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
Toni Ksbeck
Slide 12 / 31
October 2010
Secure Switch Settings using Contact Plate
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Trends in Tank Farm Management
Toni Ksbeck
Slide 13 / 31
October 2010
Example Overfill protectionTank levels (based on API2350)
Notification
Alarm
Trip
Source Buncefield reports
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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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Trends in Tank Farm Management
Toni Ksbeck
Slide 28 / 31
October 2010
WirelessHART solutions for inventory monitoring
and maintenance
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Trends in Tank Farm Management
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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Trends in Tank Farm Management
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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