SAMPLE: HEALTH CHECK REPORT Insert Site Name

Transcription

1 Cnnected Industrial SAMPLE: HEALTH CHECK REPORT Insert Site Name Date: Cmpany: Cuntry: Site Representative(s): Mr. Secndary Manager Maintenance & Mr. Maintenance Technician Hneywell-Enraf Engineer: Mr. Eric van der Made

2 Histry & Installed Base CUSTOMER terminal in Ulsan cnsists f 70 tanks, frm which 31 (tank pits 6,7,8,9) are equipped with 971 Smartradar levelgauges and Vit temperature selectrs&prbes. All 31 tanks are cnnected t a CIU Prime interface. The prime is cnnected t a Hst system. See tables belw: N.f Tank Tank numbers tanks Type f instrument Height SW/FS Tank Prduct Tracing/Insulatin

3 Nte: PFA = Palm fatty acid ( R-C-O2-H) Type f Instrument Sftware versin Tank pits 971 series 7 : UIAJ971AZBF0830W 971 NVR1.5-- XPUK1.7-- APUD1.2 HPUC1.7 (TP 6,7,8) 971 series 10: UIAJ971AZBS0630W 971 NVR1.5-- XPUK1.7-- APUD1.2 HPUC1.7 (TP 9) Findings The investigatin cnsisted f: Visual inspectin & site survey at the tank pits 6,7,8,9 3.5 Data-cllectin all 971 Smartradars. 3.6 Fine tuning 971 parameters. 3.1 Visual inspectin TP6 Tank pit 6 cnsists 8 tanks with 971 Smartradars. The 971 s are installed halfway the rf at 2,5 m frm the tankshell. Distance t the Vit prbe is 1,5 meter.

4 3.2 Visual inspectin TP7 Tank pit 7 cnsists f 10 fixed rf tanks with 971 free-space Smartradars installed abut halfway the tank rf. Half f the tanks are insulated and equipped with heat-tracing. The phenl tanks 706 and 710 have ht water tracing and the palm fatty acid tanks 708 and 709 have steam tracing. 3.3 Visual inspectin TP8 Tank pit 8 cnsists f 5 tanks. Tank 805 is insulated and used fr palm fatty acid. The distance 971 Vit is nly 0.8 meter. It is pssible that the temperature prbe is affecting the level radar signal at lw levels. Average distance t the tank shell is 1.9m.

5 3.4 Visual inspectin TP9 Tank pit 9 cnsists f 8 fixed rf tanks with 971 Smartradars, Vit temperature selectrs and P3. T has a 6 stilling well, hanging in the 8 nzzle. See pictures belw (2 flanges + plate). Overall standard f installatin is high. All gauges have been installed crrectly and grunded t the tank. 3.5 Data cllectin Hst prt 2 f the CIU Prime is nrmally used as service prt fr maintenance purpses and field data cllectin. At CUSTOMER, the CIU Prime is cnnected t via Hst prt 2 t a DCS system, s we had t discnnect each field line in rder t cmmunicate with the field gauges. A prtable SmartLink was used in cmbinatin with Engauge 2.4 t cllect all field data. CIU Prime FP1 : CIU Prime FP2 : CIU Prime FP3 : CIU Prime FP4 : Tanks X Tanks X Tanks X Tanks X All data (Cmmissining-, Diagnstics data, diagrams (Reflectin, MinMax)) have been cllected and stred in the Engauge database. A cpy f the database has been handed ver t CUSTOMER and ShinKi.

6 After data cllectin, the radar gauges have been fine-tuned in the limited time available during this visit. See table belw fr items and errr cdes. Tank Prduct TA PR SF FI 5O 5C EE.0.1 WC.0.1 AC T-601 AA : : T-602 Mibk : : T-603 empty : : T-604 Alimet : : T-605 empty : : T-606 PFA : : T-607 H2O : : T-608 H2O : : T-701 Safl : : T-702 Hexene : : T-703 EA : : T-704 Ethanl : : T-705 UCO : : T-706 Phenl : : T-707 A-E-OH : : T-708 PFA : : T-709 PFA : : T-710 Phenl : : T-801 C : : T-802 Prpanl : : T-803 Ethanl : : T-804 Acetne : : T-805 PFA : : T-901 Kersene : : T-902 Kersene : : T-903 Kersene : : T-904 Ethanl : : T-905 Kersene : : T-906 Kersene : : T-907 Ethanl : : T-908 Ethanl : : Explanatin errr cde EE and warning cde WC: EE 7000 = Lw prduct reflectin (all belw threshld) EE 7009 = N peak accepted WC 7007 = Bttm clipping raw samples A-channel WC 21005= Maximum safe fill exceeded 3.6 Fine-tuning 971 Smartradars Based n the data cllected, the fllwing has been fund and mdified: [ZA], [ZP], [ZB] threshld have been mdified and set as lw as pssible in rder t prevent lw prduct reflectin errrs. The bttm zne [BZ] has been set t 1 meter. All Obstructin znes have been remved and a new Obstructin zne frm bttm psitin t -20 meter have been prgrammed fr each radar. Tank 805 still has an bstructin zne at 7.2 m ullage, because there is a bstructin (thermwell supprt) within the radar beam and causing false reflectins. Averaging cnstant [AC] have been set t 94 fr all radars MinMax diagrams have been cleared. Data failure delay [FI] has been set t 99 fr all radars. Sme f them were riginally set t 00.

7 Stilling well diameters [BD] f the tanks were set t 8, instead f 6. This must have caused level errrs up t mm. There is a 8 nzzle installed at the rf, in which a 6 sch40 pipe is munted. Old [BD]= New [BD]= Old [0A] = F08300 New [0A] = S06300 After mdifying the pipe diameter, the level reading jumped with a significant value: Level befre [BD]= Level after mdificatin f [BD] t mm Difference Cnclusin & Recmmendatins The tank cnstructin and installatin f the 971 Smartradars is crrect. Mst f the radars are installed at xTankheigth and therefre within specs. Althugh remarks can be made by sme the prducts such as acetne and ethanl. These prducts can be measured by radar, but nt within W&M specificatins, mainly due t vapur influence and variable signal prpagatin speed. Mst f the level jump prblems ccur n the Palm Fatty Acid (R-C-O2-H) tanks. These tanks are equipped with heating cils at the bttm and the prduct is quite sticky and humid. Insulatin f the radar nzzle is required and duble reflectins (bttm & heating cils at cm) might ccur in the bttm area. All tanks have been inspected and cnfiguratin data have been retracted frm the radars via the field lines and a Smartlink interface unit in the MCC. Accrdingly all radars have been fine-tuned based n Reflectin & MinMax diagrams. Mdificatins are mainly dne at the threshlds, different znes, fail delay cunters and pipe diameter settings. Large level differences at the 900 tanks can be explained by an incrrect setting f the stilling well diameter. It was set fr S08 instead f S06 antenna. His has been set crrectly nw. All settings (items) are stred in the Engauge database. All tanks have been mnitred tday in a static situatin. In case prblems re-ccur in the future then the fllwing infrmatin is required fr analysing purpses: Tank number Level and temperature values Operatinal status f the tank (filling, emptying, static) Level trend (frm DCS) Errr cdes : EE.0.1, WC.0.1, 4V, 4S, 4P, RB, RD, 5C, 5E.0.3, 5D.0.3 Reflectin diagram & MinMax diagram. The 873 and 971 Gauges was declared bslete. Please cnsider upgrading t 990 Radar The 862 MIT interface was declares bslete. Please cnsider upgrading t Vit technlgy. Recmmendatins fr nn-custdy transfer applicatins (tanks):

8 Fr replacement f a brken level instrument: We recmmend replacement f the current brken level measurement system in tank XXX with a prcess type Guided Wave Radar level instrument SLG700. The prpsed level instrument prvides reliable, cntinuus level measurement with accuracy f ±3 mm (r 0.03% f measured distance whichever is greater) and is perfectly suited fr level cntrl and indicatin in nn-custdy transfer applicatins. Fr replacement f ld, mechanical type level instrument: The level measurement system currently installed n tank XXX is a mechanical / flat type gauge. It requires extensive maintenance. We recmmend replacement f the current system with a prcess type Guided Wave Radar level instrument SLG700. Guided Wave Radar technlgy is a fully electrnic measurement with n mving parts, and virtually n maintenance required. SLG700 prvides reliable, cntinuus level measurement with accuracy f ±3 mm (r 0.03% f measured distance whichever is greater) and is perfectly suited fr level cntrl and indicatin in nncustdy transfer applicatins. Fr adding a new cntinuus level measurement n a tank with n cntinuus level indicatin: We recmmend equipping tank XXX with a prcess type Guided Wave Radar level instrument SLG700, fr cntinuus level indicatin, and verfill prtectin. The prpsed level instrument prvides reliable, cntinuus level measurement with accuracy f ±3 mm (r 0.03% f measured distance whichever is greater) and is perfectly suited fr level cntrl and indicatin in nn-custdy transfer applicatins. Abve mentined data shuld be send t the Hneywell-Enraf Helpdesk in The Netherlands. enraf.helpdesk@hneywell.cm and tel n: The data can be retracted frm the radars by cnnecting the field line t a Smartlink interface and by the use f Engauge cnfiguratin tl. These can be btained via Hneywell Enraf f ShinKy systems August 7, 2016 Fr Hneywell Enraf: Eric van der Made Manager Service Operatins