Reference Manual
00809-0500-5100, Rev AC
May 2020
Rosemount™ TankMaster
Floating Roof Monitoring
™
Reference Manual
00809-0500-5100, Rev AC
Contents
1Section 1: Introduction
2Section 2: Overview
Contents
May 2020
1.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Manual overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1 Drain sump monitoring and hydrocarbon detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.1 Shell mounted installation at top of tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.2 Installation on tank roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3Section 3: Installation
3.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Installation considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.1 Installation on tank shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.2 Installation on tank roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.3 Tilt gauge position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.4 Drain sump monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3.5 Hydrocarbon detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4Section 4: Configuration
4.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.1 Inventory calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3 Floating roof monitoring setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.1 TankMaster WinSetup workspace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.2 To enable floating roof monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3.3 Shell mounted with level reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.3.4 Shell mounted without level reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Contents
4.3.5 Roof mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3.6 Drain gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3.7 Hydrocarbon gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3.8 Alarm setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Contents
May 2020
Reference Manual
00809-0500-5100, Rev AC
5Section 5: Operation
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2 Tank view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3 Alarm limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3.1 Floating roof alarm limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.4 Alarm disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5 Roof monitoring group view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.5.1 To create a group view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.6 Roof monitoring historical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.6.1 Sample setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.6.2 View setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.7 Roof status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.8 Alarm priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6Section 6: Service and Troubleshooting
6.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
AAppendix A: Commissioning Checklist
ii
Contents
Reference Manual
NOTICE
00809-0500-5100, Rev AC
Title Page
May 2020
Rosemount™ TankMaster
™
Floating Roof Monitoring
Read this manual before working with the product. For personal and system safety, and for optimum
product performance, make sure you thoroughly understand the contents before installing, using, or
maintaining this product.
For equipment service or support needs, contact your local Emerson Automation Solutions
/Rosemount Tank Gauging representative.
Spare Parts
Any substitution of non-recognized spare parts may jeopardize safety. Repair, e.g. substitution of
components etc, may also jeopardize safety and is under no circumstances allowed.
Rosemount Tank Radar AB will not take any responsibility for faults, accidents, etc caused by
non-recognized spare parts or any repair which is not made by Rosemount Tank Radar AB.
The products described in this document are NOT designed for nuclear-qualified applications.
Using non-nuclear qualified products in applications that require nuclear-qualified hardware or
products may cause inaccurate readings.
For information on Rosemount nuclear-qualified products, contact your local Rosemount Sales
Representative.
Title Page
iii
Title Page
May 2020
Reference Manual
00809-0500-5100, Rev AC
iv
Title Page
Reference Manual
00809-0500-5100, Rev AC
Section 1 Introduction
Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1
Manual overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2
1.1 Safety messages
Procedures and instructions in this manual may require special precautions to ensure the safety of the
personnel performing the operations. Information that raises potential safety issues is indicated by a
warning symbol ( ). Refer to the safety messages listed at the beginning of each section before
performing an operation preceded by this symbol.
Failure to follow these installation guidelines could result in death or serious injury.
Make sure only qualified personnel perform the installation.
Use the equipment only as specified in this manual. Failure to do so may impair the protection
provided by the equipment.
Explosions could result in death or serious injury.
Verify that the operating environment of the transmitter is consistent with the appropriate
hazardous locations certifications.
Before connecting a hand held communicator in an explosive atmosphere, make sure the
instruments in the loop are installed in accordance with intrinsically safe or non-incendive field
wiring practices.
Do not remove the gauge cover in explosive atmospheres when the circuit is alive.
Electrical shock could cause death or serious injury.
Use extreme caution when making contact with the leads and terminals.
Introduction
May 2020
Introduction
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of
end user’s equipment. This could be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your
system. Restrict physical access by unauthorized personnel to protect end user’s assets. This is true
for all systems used within the facility.
1
Introduction
May 2020
1.2 Manual overview
This manual provides installation, configuration, and maintenance information for a Rosemount™
TankMaster
Gauging system with a Rosemount 2410 Tank Hub connected to supported level and temperature
measuring devices.
Typically, a Rosemount Tank Gauging Floating Roof Monitoring system is based on using Rosemount
3308 or Rosemount 5408 level transmitters for roof tilt monitoring. Rosemount 5900C radar gauges is
also an option. In addition to that, level gauges and temperature transmitters are used for standard level
measurements and inventory calculations.
Section 2: Overview provides a brief description of the Rosemount Tank Gauging floating roof
monitoring system and recommended installation procedure.
Section 3: Installation covers installation considerations and mechanical installation.
Section 4: Configuration describes how to configure a Rosemount Tank Gauging floating roof monitoring
system by using the Rosemount TankMaster software package.
Section 5: Operation describes how to operate the floating roof system by using various tank view
functions in the Rosemount TankMaster WinOpi program.
™
Floating Roof Monitoring system. The manual is based on a typical Rosemount Tank
Reference Manual
00809-0500-5100, Rev AC
Section 6: Service and Troubleshooting covers troubleshooting a Rosemount Tank Gauging floating roof
system.
Appendix A: Commissioning Checklist provides a list of installation and configuration actions to check
prior to putting the system in operation.
2
Introduction
Reference Manual
00809-0500-5100, Rev AC
Section 2 Overview
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
2.1 Introduction
The floating roof monitoring function in Rosemount™ TankMaster detects whether a roof in a storage
tank is stuck, sinking, floating higher or lower than normal, covered by water or product, or is tilted.
TankMaster uses three to six tilt gauges to track inclination of a floating tank roof. Roof floating high/low
status may be monitored as well. The monitoring function is based on using Rosemount 3308 wireless
level transmitters mounted on the tank roof, or shell mounted free propagation radar level gauges
measuring distance to the tank roof.
Overview
May 2020
If roof inclination exceeds a maximum alarm limit, TankMaster triggers an alarm. Also, if the tank roof
floats higher or lower than normal, it may indicate that the roof is stuck or is about to sink. An alarm is
triggered in TankMaster if the floating roof passes high or low alarm limits.
One or two extra transmitters can be used to detect if the roof drain gets plugged or if there is any
hydrocarbons (product) present on the tank roof. The drain gauge can be either a Rosemount 3308
wireless transmitter providing an online level value of tank roof drain sump, or a wireless vibrating fork
which will act as a high level alarm switch.
Hydrocarbons may be detected by any hydrocarbon detection system which can provide a digital output
signal to be connected with a Rosemount 702 Wireless Discrete Transmitter.
The roof monitoring function is enabled by an option in the Rosemount TankMaster hardware key. Also,
in TankMaster WinSetup a tank must be configured as a Floating Roof Tank in order to be able to use the
floating roof monitoring function.
Level radars are installed at multiple points, spaced evenly around the perimeter of the roof. The
following installation options are available:
Shell mounted with/without level reference
Roof mounted
2.1.1 Drain sump monitoring and hydrocarbon detection
A drain gauge and/or a hydrocarbon gauge can be added to the floating roof monitoring system. The
drain gauge is installed in the drain sump and detects if the drain clogs and water does not run off.
Rosemount 3308 Wireless Guided Wave Radar or Rosemount 2160 Wireless Vibrating Fork can be used
for drain sump monitoring.
Overview
Installed at the floating roof, the hydrocarbon gauge detects potential hydrocarbons on the roof.
Typically, a Rosemount 702 Wireless Discrete Transmitter with Liquid Hydrocarbon Detection is used.
3
Overview
A
B
C
D
A
A
May 2020
2.2 System overview
The floating roof monitoring function is based on using one of two tilt gauge installation options:
shell mounted at the top of the tank
on the tank roof
The shell mounted version is also suitable for fixed roof tanks with inner floating roof.
2.2.1 Shell mounted installation at top of tank
Three to six non-contacting level gauges are installed at the top of the tank. The gauges are mounted on
brackets and measure distance to reflector plate on top of the tank roof.
Roof tilt is monitored by comparing distance to the tank roof measured by the different tilt level gauges.
Tank roof floating high/low calculations can be done by comparing distance to floating roof with
distance to the product surface measured by a reference level gauge in a still-pipe.
Figure 2-1. Shell Mounted Tilt Gauges Installed at the Top of the Tank
Reference Manual
00809-0500-5100, Rev AC
A. Tilt gauge mounted on top of tank
B. Reflector
4
C. Reference gauge for product level measurements
D. Floating roof
Overview
Reference Manual
A
B
C
D
A
A
00809-0500-5100, Rev AC
2.2.2 Installation on tank roof
Three to six tilt gauges are installed on the tank roof. Probes penetrate the tank roof measuring distance
from roof to product surface.
By comparing the distance to the product surface measured by each tilt gauge, both roof tilt and
buoyancy can be monitored.
Wireless Rosemount 3308 tilt gauges communicate with the host system via a repeater at the top of the
tank.
Figure 2-2. Roof Mounted Wireless Rosemount 3308 Transmitters
Overview
May 2020
Overview
A. Tilt gauge mounted on tank roof
B. Radar gauge for product level measurements
C. Floating roof
D. Repeater
5
Overview
D
E
F
H
G
A
B
A
I
E
B
C
E
May 2020
Figure 2-3. Floating Roof Monitoring System with Shell Mounted and Roof Mounted Tilt Gauges
00809-0500-5100, Rev AC
Reference Manual
A. Tilt gauge F. Rosemount 2460 System Hub
B. Reference level gauge for product level measurements G. Emerson Wireless 1420 Gateway
C. Reflector H. Rosemount TankMaster host
D. Repeater I. Emerson Wireless 775 THUM Adapter
E. Rosemount 2410 Tank hub
6
Overview
Reference Manual
00809-0500-5100, Rev AC
Overview
May 2020
Table 2-1. Floating Roof Tank Installation Characteristics
Shell mounted with/without level reference Roof mounted
Radar device Rosemount 5408 or 5900C non contacting radars Rosemount 3308 Wireless Guided Wave Radars
Number of radar devices Minimum three, maximum six Minimum three, maximum six
Installed at top of tank shell
Installation
Also suitable for fixed roof tanks with inner floating
roof
Level Measures distance to the floating roof Measures distance to the liquid
(1)
Directly on floating roof
Tilt
Roof floating
Possible alerts/alarms
Data transmission to
control room
1. Local site license may be required for compliance to frequency spectrum approval.
2. Requires level reference (inventory level gauge in still-pipe).
3. Requires drain sump gauge.
4. Requires hydrocarbon detection gauge.
Tracks tilt by comparing measured distance from
radars to the floating roof
Tracks roof floating high/low by referencing liquid
(2)
surface
Roof tilt
Roof floating high/low
Drain sump full with water
Hydrocarbons detected
(2)
(3)
(4)
Wired connection from level gauge to tank hub
Wired or wireless communication from tank hub to
control room
Tracks tilt by comparing measured distance to the
liquid
Tracks roof floating high/low by measuring
distance to the liquid
Roof tilt
Roof floating hight/low
Drain sump full with water
Hydrocarbons detected
(3)
(4)
Wireless communication
Overview
7
Overview
2. Review mounting considerations for the devices
(“Installation considerations” on page 10).
5. Configure the devices.
4. Wire and power up the devices.
3. Install the devices
(“Mechanical installation” on page 11).
1. Make sure that a site plan is available with tank
tags, device tags, and device addresses.
6. Setup the floating roof monitoring function.
(“Configuration” on page 21).
May 2020
2.3 Installation procedure
Follow these steps for proper installation of the Rosemount TankMaster Roof Monitoring system:
Reference Manual
00809-0500-5100, Rev AC
8
Overview
Reference Manual
00809-0500-5100, Rev AC
Section 3 Installation
Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
Installation considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11
3.1 Safety messages
Procedures and instructions in this section may require special precautions to ensure the safety of the
personnel performing the operations. Information that raises potential safety issues is indicated by a
warning symbol ( ). Please refer to the following safety messages before performing an operation
preceded by this symbol.
Installation
May 2020
Failure to follow safe installation and servicing guidelines could result in death or serious injury.
Make sure only qualified personnel perform the installation.
Use the equipment only as specified in this manual. Failure to do so may impair the protection provided
by the equipment.
Do not perform any service other than those contained in this manual unless you are qualified.
To prevent ignition of flammable or combustible atmospheres, disconnect power before servicing.
Substitution of components may impair Intrinsic Safety.
Installation
9
Installation
May 2020
3.2 Installation considerations
Verify that the tank roof is designed to allow tilt gauge installation according to requirements.
Ensure that roof mounted tilt gauges are installed properly to allow reliable measurements when the
roof tilts or sinks.
Ensure that shell mounted tilt gauges are installed at a sufficient distance from the highest roof
position.
See “Mechanical installation” on page 11 for instructions on how to install tilt gauges in a Rosemount
Tank Gauging system.
Note
Local site license may be required for compliance to frequency spectrum approval.
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00809-0500-5100, Rev AC
10
Installation
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A
B
C
A
A
B
D
00809-0500-5100, Rev AC
3.3 Mechanical installation
The Floating Roof Monitoring system is based on using a number of tilt gauges which measure the
distance to the tank roof. There is also an option which is based on installing level gauges on the tank
roof in order to monitor the distance between tank roof and product surface. Throughout this manual
we will refer to these two versions:
Shell mounted
Roof mounted
3.3.1 Installation on tank shell
This option uses three to six tilt gauges mounted on brackets. It is recommended that tilt gauges are
mounted on a bracket arm and not a wide plate.
In case there is a level gauge for product level measurements as well, it can be used as a reference for tank
roof floating high/low calculations.
Figure 3-1. Floating Roof With Tilt Gauges on Top of Tank
Installation
May 2020
Installation
A. Tilt gauge mounted on top of tank
B. Reflector
C. Reference level gauge
D. Temperature transmitter
11
Installation
A
B
D
C
E
E
May 2020
Reference Manual
00809-0500-5100, Rev AC
It is important that each tilt gauge is installed at a position where the roof and reflector can not come
into contact with the antenna.
Ensure that the bracket is long enough to fulfill minimum recommendations for distance from wall to tilt
gauge.
The tilt gauge should be installed at zero degrees vertical inclination as shown in “Inclination” on
page 15.
Figure 3-2. Installation Recommendations
12
A. Tilt gauge
B. Reflector (see “Reflector design” on page 13)
C. Antenna (see “Antenna orientation” on page 14)
D. Minimum distance 800 mm (31.5 in.)
E. Recommended free space 800 mm (31.5 in.). Minimum distance 500 mm (19.7 in.)
Installation
Reference Manual
B
A
C
E
D
F
G
00809-0500-5100, Rev AC
Reflector design
Installation
May 2020
Shell mounted tilt gauges measure the distance to a reflector
(1)
placed on the tank roof. Ensure that the
reflector meets recommended design specifications in order to prevent contamination build-up. The
gap (B) between ridges will ensure that water and snow can drip off the reflector.
Note
It is recommended to regularly make visual inspections to verify that each reflector is placed in the right
position.
Figure 3-3. Reflector for Measuring Distance to Tank Roof
A. 130 mm (5.12 in.) E. 500 mm (19.7 in.)
B. 35 mm (1.4 in.) F. 1200 mm (47.2 in.)
C. 260 mm (10.2 in.) G. 780 mm (30.7 in.)
D. 40 mm (1.6 in.)
1. The reflector is designed for radar gauge using FMCW 10 GHz technology.
Installation
13
Installation
B
A
C
Center of tank
Min 800 mm
(31.5 in.)
May 2020
Reference Manual
00809-0500-5100, Rev AC
Antenna orientation
Figure 3-4. Antenna Orientation with Rosemount 5900C Transmitter Head as Reference
A. Tilt gauge
B. Reflector (see “Reflector design” on page 13)
C. Tank wall
Figure 3-5. Antenna orientation for Rosemount 5408
90°
External ground screw
Tank wall
Tank wall
14
Installation
Reference Manual
90°
B
A
90°
00809-0500-5100, Rev AC
Inclination
Make sure that the tilt gauge is vertically aligned with the reflector. This will ensure that maximum signal
strength is reflected back to the gauge.
Figure 3-6. Antenna Inclination
Installation
May 2020
Installation
A. Tilt gauge
B. Reflector (see “Reflector design” on page 13)
15
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