Technical Description
705010E, Ed.1
December 2004
Saab TankMaster HTG
High Precision Tank Gauging System
www.saabrosemount.com
Technical Description
705010E, Ed.1
December 2004
Saab TankMaster HTG
Contents
Available technical documentation for Saab TankMaster HTG: ___________________________ 2
Abbreviations used in this document: ___________________________________________________ 3
Saab TankMaster Hydrostatic Tank Gauging __________________________________ 4
Applications _____________________________________________________________________________ 4
Installation and commissioning of the TankMaster HTG System __________________________ 5
HTG measurements and calculations
_________________________________________ 6
Director Series 4 ___________________________________________________________________ 7
Base board ______________________________________________________________________________ 7
Processor board ________________________________________________________________________ 7
HBI boards ______________________________________________________________________________ 7
Cable connections to DS4_______________________________________________________________ 7
Pressure and temperature transmitters __________________________________________________ 7
TankMaster HMI software ________________________________________________________ 8
Interactive configuration and installation with set-up wizard _________________________ 8
Inventory and custody transfer functions ____________________________________________ 8
Networking and interfacing _________________________________________________________ 9
Reports and data sampling __________________________________________________________ 9
Alarms _____________________________________________________________________________ 9
Others _____________________________________________________________________________ 10
PC Requirement _______________________________________________________________________ 10
1
Technical Description
Saab TankMaster HTG
Copyright © December 2004 by Saab Marine Electronics AB.
First edition. December 2004 Ref. no. 705010E.
Technical data is subject to change without prior notice.
Saab Marine Electronics AB accepts no responsibility for
any errors that may appear in this description.
Allen-Bradley, Bailey, DEC, Enraf, Fisher, Foxboro, GPE,
Honeywell, IBM, L&J, Profibus, Rosemount, Saab,
Saab TankRadar, Siemens, Tiway, Varec, Vega, Whessoe
and Yokogawa are registered trademarks and trademarks
of these organizations and companies.
Available technical documentation for
Saab TankMaster HTG:
• Saab TankMaster Hydrostatic Tank Gauging
Reference Manual
• TankMaster HTG Installation and Troubleshooting
Guidelines (To be published)
• TankMaster WinSetup User’s Guide
• TankMaster WinOpi User’s Guide
The Saab TankMaster Hydrostatic Tank Gauging
Reference Manual is used for installing a DS4 and
configuring TankMaster for a HTG system.
TankMaster HTG Installation and Troubleshooting
Guidelines is used for installing and troubleshooting
the HTG equipment in the field.
The TankMaster WinSetup User’s Guide describes
how to start-up the system using the WinSetup
software on a personal computer. TankMaster is
the Human Machine Interface (HMI) software for
TankRadar Rex. It includes the WinSetup and
WinOpi software modules.
The TankMaster WinOpi User’s Guide describes
the inventory and display functions included in the
optional TankMaster WinOpi software.
2
705010E, Ed.1
December 2004
Technical Description
705010E, Ed.1
December 2004
Saab TankMaster HTG
Abbreviations used in this document:
API
American Petroleum Institute
DCS
DigitalControl System
DS4
Director Series 4
GOV
Gross Observed Volume
GSV
Gross Standard Volume
HART
Highway Addressable Remote Transducer
HMI
Human Machine Interface
HTG
Hydrostatic Tank Gauging
ISO
International Standard Organization
LAN
Local Area Network
NSV
Net Standard Volume
OIML
International Organization of Legal Metrology
PC
Personal Computer
SCADA
Supervisory Control and Data Acquisition System
TCP/IP
Transmission Control Protocol / Internet Protocol
TCT
Tank Capacity Table
TM
TankMaster
TOV
Total Observed Volume
VCF
Volume Correction Factor
3
Technical Description
705010E, Ed.1
December 2004
Saab TankMaster HTG
Saab TankMaster Hydrostatic Tank Gauging
The TankMaster HTG system is an intelligent direct
mass measuring system. It takes advantage of
the high precision pressure transmitters installed
at different levels in the tank. HTG uses product
hydrostatic pressure measurements to derive both
the specific gravity and liquid level.
Applications
Bulk liquid storage and process tanks where
accurate mass measurement is required.
TankMaster HTG can be used for most products.
Examples:
• Hydrogen peroxide
• Molasses
• Butadiene
• Paint resin
• Formaldehyde
• Lube oil
• Water
• Milk
• Beer
• Cider
• Solvents
• Ammonia
• Petroleum products
4
Features
•
No moving parts.
• The product mass is constant even if
the level changes due to changes in
temperature
• Modern, state-of-the-art, OPC compatible
operator software
• Inventory calculations according to API and
ISO standards
• Mass custody transfer approved by NMI
• Networking possibilities
• Fewer devices compared to the old HTG
systems
• Worldwide service and support
Technical Description
705010E, Ed.1
December 2004
Summary of functions & system overview
The TankMaster HTG system measures and
calculates tank data for:
• Inventory calculations
• Mass Custody transfer
• Product movement
The HTG system is primarily calculating the mass
of the product. These parameters are shown in the
Tank Inventory windows:
• Level
• Flow rate
• Gross observed volume
• Net observed volume
• Gross standard volume
• Net standard volume
• Weight
• Mass
• Density
The pressure and temperature values from the
tanks are communicated to the PC via the DS4
(a multiplexer which also converts HART to
Modbus). One DS4 can collect data from 60 HART
transmitters, so by using just one or many DS4s
the HTG system can easily be adapted to small
sites with just a few tanks as well as large sites with
several hundred tanks.
The HTG system is configured and operated using
the OPC compatible TankMaster software package.
It is a user-friendly HMI software that calculates the
mass, volume, density and level of the product, and
that gives the operator a good overview and quick
access to any measured or calculated values. The
software also provides a wide range of inventory
and custody transfer functions such as net standard
volumes according to API standards, reporting,
alarms, graphics, trends etc.
A whole range of plant host computer systems,
DCS or SCADA systems can be connected to the
Saab TankMaster HTG
TankMaster HTG system for display of measured
and calculated values. Protocols for communication
with major suppliers of plant host computers have
been developed and certified.
TankMaster HTG system overview.
TankMaster PC for
data communication,
calculations, displaying
and reporting
RS-485
Modem
Director Series
(DS4)
LAN
Host
RS-232
Two alternative
interfaces, RS-232 or
RS-485 with modem
Modbus communication
HART communication
Installation and commissioning of the
TankMaster HTG System
The pressure and temperature transmitters should
be configured and installed according to the
installation instructions and installation drawings
from Rosemount. Installation guidelines for the
HTG equipment in the field can be found in the
TankMaster HTG Installation and Troubleshooting
Guidelines. Commissioning is normally done by a
trained engineer from our local representative, or
in some cases by the customer. The TankMaster
WinSetup PC software is used to configure the
system. A HART communicator is used to configure
the pressure and temperature transmitters. The DS4
is pre-configured in the factory.
5
Technical Description
705010E, Ed.1
December 2004
Saab TankMaster HTG
HTG measurements and calculations
HTG uses product hydrostatic pressure
measurements to derive both specific gravity
and liquid level. A typical HTG system uses three
pressure transmitters: one near the bottom of the
tank, another above the first, and a third at the top.
All measured data are transmitted on the field bus
and are further processed in the control room by the
TankMaster PC software.
Vapor pressure
Liquid pressure
Temperature
Liquid pressure
Comparison of the pressure readouts from the
two submerged transmitters P1 and P2 are used
to calculate the specific gravity of the liquid,
thus generating mass and density. The pressure
transmitter P2 is optional, and if P2 is not used, the
density can be entered manually into TankMaster.
The liquid level can be determined by comparing
readouts from P3 (which measures the vapor
pressure in the tank) and P1.
The accuracy of the mass, level and density
calculations largely depends on the accuracy of
the pressure transmitters. The DS4 can interface
to any pressure transmitter with a standard output
of 4-20 mA HART. The 4-20 mA signal is converted
to Modbus in the DS4. The standard pressure
transmitter supplied with the TankMaster HTG
system for in-liquid mounting is Rosemount 3051S
Ultra A1014.
6
The system calculates the following data:
• Mass
• Observed density
• Weight
• Level (corrected for thermal tank wall expansion)
• Flow rate
• Gross observed volume
• Net observed volume
• Gross standard volume
• Net standard volume
All data is calculated according to updated API and
ISO standards. The temperature calculations include
API algorithms to handle elements close to the
bottom.
Both metric and USA/UK units are supported.
TankMaster performs net volume calculations with
very high accuracy using up to 2000 strapping
points. TankMaster is using quadratic interpolation
for spheres and horizontal cylinders, which
increases volume accuracy and reduces number of
strapping points. The TankMaster HTG system is
NMi certified for mass custody transfer. A hardware
key is required for HTG calculations to be available.
Technical Description
705010E, Ed.1
December 2004
Saab TankMaster HTG
Director Series 4
The Director Series 4 (DS4) is a gateway
for enabling operational data to be acquired,
transformed and utilized through full TCP/IP
communication. The DS4 polls the HART
transmitters for Primary Values (PV) and Secondary
Values (SV) and sends information to the
TankMaster network.
Processor board
The processor board is the heart of the DS4.
HBI boards
The HBI boards provides 2 HART channels each.
Cable connections to DS4
The electrical interface uses RS-232 or RS-485
standard interface. The interface is hardware
controlled by jumper settings. A modem is needed
for converting the RS-485 to RS-232 when
communicating with a PC.
Pressure and temperature transmitters
Rosemount pressure and temperature transmitters
support the DS4 with measurement data. Different
types and numbers of transmitters are used
depending on tank configuration. For example, a
tank with vapor pressure requires three transmitters
for online measurement. Two transmitters measuring
the liquid pressure and one at the top measuring the
vapor pressure.
All transmitter configuration is done using 275/375
handheld communicator or AMS suite software.
Base board
The base board is connecting everything together
inside the DS4. The base board also includes the
power supply.
Technical Data for DS4
Temperature
-40 to +70° C (-40 to +160 °F)
Humidity
Input
0 to 95% relative, non-condensating
Update rate to TankMaster PC
53 tanks per second.
HART channels
Converts information from up to four HART channels (up to 60 HART addresses) to Modbus
Non-Ex housing
Should be mounted in IP 54 rated enclosure if exposed to the elements
Power Supply
24 VDC, 0.5 A nominal (18-36 V range)
7
Technical Description
705010E, Ed.1
December 2004
Saab TankMaster HTG
TankMaster HMI software
• WinSetup is the software package used for
configuration. The program supports installation
of the DS4 device and mapping of the connected
pressure transmitters to tanks.
• WinOpi is a complete inventory software
package. In order to display special HTG
windows and HTG values, a special hardware
key with HTG option is needed.
TankMaster is a powerful Windows-based Human
Machine Interface (HMI) for complete tank inventory
management. It provides configuration, service and
set up, inventory and custody transfer functions for
TankMaster HTG systems. All calculations are based
on current API and ISO standards. TankMaster
follows the OPC standard and can communicate
with Microsoft® programs and OPC compatible
systems like Intellution’s iFIX® and Wonderware’s
InTouch®. TankMaster is developed and supported
by Saab Rosemount Tank Radar. TankMaster has
two main software modules:
Available main functions in TankMaster include the
following:
Interactive configuration and installation with setup wizard
Inventory and custody transfer functions
• Real time tank gauging data such as pressure
and temperature.
• Real time, gross and net volume inventory
calculations based on API and ISO.
• Metrologically sealed data.
• API calculator.
TankMaster distributes essential
inventory tank gauging data.
SCADA
OPC client level
Ethernet
Engineering
Management
Modbus
Modbus
TankMaster
OPC Server
TankMaster
OPC Server
DCS
Modbus
DS4
HART
8
TRL2 Field Bus
FCU
PLC
Tank data, Level, Temperature, Pressure, Volume, etc.
Technical Description
705010E, Ed.1
December 2004
Saab TankMaster HTG
Reports and data sampling
• Batch report for internal and external transfers.
• Customized Reports to Microsoft Office
programs.
• Automatic reports.
• Reports via e-mail.
• Audit log for events.
• Historical data sampling.
TankMaster gives the most important inventory data for a specific tank in
one easy-to-read window.
Networking and interfacing
• OPC server with browser for easy interface with
other plant computer systems.
• Full network capabilities.
• SCADA / DCS communication via MODBUS.
• SCADA / DCS communication via OPC.
• Integration with other tank gauging systems by
taking in and displaying data from other vendors’
gauges.
Alarms
• Reliable alarm handling of measured values with
high, high-high, low and low-low level alarms.
• Alarms to mobile phones.
• Alarms via e-mail.
• Leakage alarms based on net volume.
You can easily organize the tanks in e.g. geographical or product groups,
with associated sub-groups. For example you can choose to see the
actual tank gauging and inventory data in a bargraph group, giving a quick
overview of tank farm activity.
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Technical Description
705010E, Ed.1
December 2004
Saab TankMaster HTG
Others
• User manager with different access levels for
personnel.
• Customized views with graphic plant layouts.
• Easy translation to other languages than English.
• Advanced group configuration in geographical or
product groups etc.
• Compatibility with Saab’s earlier platform OPI
which can easily be replaced by TankMaster.
PC Requirement
Required operating system:
Windows XP SP1, 2000 SP3, NT 4.0 SP5 or later.
Distributed COM (DCOM), which is used for network
computing.
Required hardware (PC):
Windows XP/2000/NT approved PC. 800 MHz
Intel or compatible. 256 MB RAM. 4 GB disk drive
(TankMaster requires approx. 200 MB).
Graphics card 1024*768 pixels, 65536 colors.
Required hardware (network server PC):
1-2 Network clients – same/better performance on
the server than on the client PC.
3 or more Network clients – 1.6 GHz Intel or
compatible, 512 MB RAM on the server PC.
For further information a separate TankMaster
brochure is avaialble.
The “tank farm explorer” makes it easy to navigate in TankMaster. Just
like in “Windows explorer” it is possible to expand and minimize fields
and get direct group and tank access by double-clicking the specific
group or tank icon.
10
Technical Description
Saab TankMaster HTG
Emerson Process Management
Saab Rosemount Tank Gauging
Box 130 45
SE-402 51 Göteborg
SWEDEN
Tel (Intenational): +46 31 337 00 00
Fax (Intenational): +46 31 25 30 22
E-mail: [email protected]
www.saabrosemount.com
705010E, Ed.1
December 2004