CONCLUSIONES

En función a los resultados obtenidos en la investigación, es decir, el Desarrollo de un

Sistema de supervisión y Control para el Nivel de los Tanques de las Estaciones de Servicio

se concluyó que los procesos de automatización, permiten al proceso tener una eficiencia y

eficacia en el mismo, puesto que se traduce en su mejora y ahorro, aumentando la

comercialización en el mercado nacional.

En relación con las fases desarrolladas, reflejadas en los objetivos específicos, se llegó a

la las siguientes determinaciones:

Se realizó el estudio del actual proceso de medición de nivel y temperatura con la

finalidad de definir el problema existente en el mismo, así como de conocer las fortalezas y

definiciones de este. Por ello se consiguió alcanzar el primer objetivo específico de la

investigación, es decir, el estudio de la situación actual en el proceso de medición, el cual

representa un paso fundamental para el desarrollo de la investigación.

Por otra parte se lleva a cabo el estudio del funcionamiento del microcontrolador

PIC16C71 y de sus dispositivos periféricos con el propósito de relacionarse con los equipos

que allí interactúan y conocer mejor cada uno de sus aspectos, características y

especificaciones, de manera de poder trabajar mejor al comenzar el desarrollo de la

investigación.

Así mismo, se elaboraron una serie de planos eléctricos, diagramas de bloques y

descripción del sistema como tal, donde se plasma el prototipo en donde se indica la

interconexión de cada uno de los elementos, y así como sus respectivas señales de entrada y

salida.

Una vez culminada la elaboración del diseño del prototipo, procedió a realizar pruebas

con los distintos dispositivos que allí interactúan, como lo es la verificación de las señales

de entrada y salida, la alimentación de voltaje adecuada, así como la programación del

microcontrolador.

Con la configuración de cada uno de los elementos electrónicos permitió alcanzar todos

los objetivos específicos de la investigación.

Al cumplir con todos los objetivos queda culminada esta investigación, por lo que ahora

se puede contar con un sistema de supervisión y control electrónico, que servirá de modelo

para todas las Estaciones de Servicio que requieran de los modelos especificados en los

anexos, para así mejorar el proceso de medición de las variables antes mencionadas y de

esta manera haber encontrado los equipos idóneos para la disponibilidad de los procesos en

las mismas.

RECOMENDACIONES

Dado el análisis de la evaluación en caliente del sistema en su forma automática y los

resultados obtenidos se determinó en pro del mejoramiento continuo de las operaciones se

deben realizar una serie de recomendaciones descritas como son:

1. Se debe utilizar una arquitectura abierta al momento de comprar los equipos del

sistema de supervisión y control y de cualquier instalación ya que esto garantiza un mejor

aprovechamiento del hardware y software del mismo, evitándose actuaciones futuras y

teniendo la disponibilidad de conexiones entre varias marcas, lo cual genera ahorro de

dinero y tiempo.

2. Se recomienda tomar en cuenta los requerimientos funcionales y operacionales,

para adaptación del sistema.

3. Se recomienda tomar en cuenta este prototipo a la hora de construir una estación de

servicio para la implantación de los equipos involucrados.

4. Para ganar espacio en los pozos donde se encuentran los tanques de

almacenamiento se deben tomar en cuenta (tomar las provisiones necesarias), comprando

equipos de dimensiones más reducidas y de arquitectura abierta con el avance de la

tecnología.

5. Para lograr optimizar el proceso de medición de nivel , temperatura y el gas para

futuros estudios en los tanques y lograr disminuir los costos, es necesario que las estaciones

de servicio tomen en cuenta las siguientes recomendaciones:

- Instalar el sistema de supervisión y control de manera que queden especificados cuatro

tanques para un solo PIC ya que tiene solo cuatro canales de entrada analógica para las

variables.

- Instalar un dispositivo de medición de gas, con la finalidad de llevar un control de esta

variable que se libera a la atmósfera, todo esto para evitar incendios contraproducentes.

Los sensores a utilizar, deben ser confiables y de alta calidad, pues los mismos son los

encargados de tomar la información y llevarla a el dispositivo, de ocurrir una falla en los

sensores, el sistema no responderá de manera deseada.

Debe colocarse en las estaciones de servicio una alarma sonora para el nivel bajo y alto

la cual alertará a distancia la presencia de una falla en el sistema y para diversos niveles.

REFERENCIAS BIBLIOGRÁFICAS LIBROS:

- ANGULO, José M. Robótica Práctica, Segunda Edición, Caracas-Vzla, 1983.

- ANGULO, Ignacio. Diseño Práctico de Microcontroladores PIC. Aplicaciones/

Ignacio Angulo Martínez, José María Angulo Usategui. 2da Edición. España:

McGraw-Hill, 1997.

- BABARESCO DE PRIETO, Aura M. Proceso Metológico En la Investigación,

segunda Edición, Caracas-Vzla, 1994.

- CREUS, Antonio. Instrumentación Industrial, 5ta Edición, Alfaomega Grupo Editor,

S.A, 1995.

- DORF, Richard C. Sistemas Modernos de Control , Addison-Wesley, México 1986.

- DORF, Richard C. Sistemas de Control Moderno, Séptima Edición, 1995

- G. H. Hostetter. Sistemas de Control. McGraw Hill, 199.........

- KENDALL & KENDALL, Sistemas de Control. 1991

- KUO, Benjamín C. Sistemas de Control Automático, Séptima Edición, 1995.

- OGATA, Katsuhiko. Ingeniería de Control Moderna. Editado por Pretice- Hall

Hispanoamericana, S.A.

- MALONEY, T. Electrónica Industrial. Primera Edición. Editorial Prentice Hall.

- Microchip Tecnology Inc, Embedded Control Handbook. Microchip, 1994.

MANUALES:

- Edres + Hauser (1994). Multicap TDC 12 TE, DC 11/15/21/26 TEN, DC 11/16/21/26

TES, Level. Probes, Operating Instructions.

- SUÁREZ, Arturo M, y Correa. Controladores Lógicos Programables. Controladores

Lógicos Programables. Centro de Formación y Adiestramiento Petrolero (CEPET),

1988.

- DRAVO, Dino. Operadores de Producción. (1999)

REVISTAS:

- CEKIT. Electrónica y Computadores. 1999

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Hauser+Endress

FCX-A-E

FXW

TRANSMISOR INTELIGENTE HIDROSTATICO DE NIVEL

COMUNICADOR PORTATIL HART

Instrumento que permite medir nivel en tanques tanto venteados como

presurizados (presión positiva o vacio) y genera una señal de salida bifilar de 4 - 20 mA, posee ademas protocolo HART. Amplia variedad de materiales mojados. Rangos disponibles desde 0 a 100 mm hasta 0 a 50.000 mm de columna de

agua.

Con este equipo se accede en forma remota a los parámetros de configuración

y calibración de los transmisores inteligentes FCX-A/C. Admite una

impresora térmica integral para registrar las características de cada instrumento.

TP-750-Nx

TP-740-Sx

TRANSMISOR HIDROSTATICO DE NIVEL

TRANSMISOR HIDROSTATICO SANITARIO DE NIVEL

Apto para la medición en tanques venteados a la atmósfera. Conexión con brida ANSI de 2", 3" o 4". Primario en

inoxidable AISI-316. Rangos de medición entre 0 a 500 mm y 0 a 25000 mm de

columna de agua. Señal de salida bifilar de 4 - 20 mA. Opcionalmente posee

indicador local digital.

Mide nivel en tanques venteados. Disponible con conexión tipo Union Doble

Sanitaria Danesa de 38 mm o Clamp según normas americanas de 1 1/2".

Primario construido en inoxidable AISI-316. Rangos de medición entre 0 a 500 y

0 a 25000 mm de columna de agua. Salida analógica bifilar de 4 - 20 mA.

TP-740-TSN

LTS-1610

TRANSMISOR HIDROSTATICO SUMERGIBLE DE NIVEL

TRANSMISOR CONTINUO MAGNETICO DE NIVEL

Especialmente apto para la medición de nivel de cisternas, pozos de agua, etc. De muy fácil instalación, el cuerpo hermético

se deja colgar del cable especial de conexión. Diámetro del cuerpo 25 mm. Rangos de medición de 0 a 2000 mm hasta 0 a 15000 mm de columna de

agua. Salida análogica bifilar de 4 - 20 mA.

Destinable a la medición de nivel o interfase entre líquidos. No es afectado por la densidad del líquido medido. Apto para servicio en tanques presurizados. Rangos entre 0 a 1000 mm y 0 a 5000

mm. Señal de salida bifilar de 4 a 20 mA. Opcionalmente se provee con doble nivel

de alarma y/o control.

SLT

LIT

TRANSMISOR - CONTROLADOR ULTRA_SONICO DE NIVEL

TRANSMISOR ULTRA_SONICO DE NIVEL

Permite la medición de nivel de liquidos, inclusive los muy corrosivos. Rango de

medición programable hasta 8 Mts. Posee display configurable con indicación de nivel y volumen. Tiene tres contactos

SPDT con función de alarna o control de bombas. Salida analógica de 4 - 20 mA.

Equipo económico; totalmente equivalente al SLT, pero solo posee un

contacto SPDT para ser empleado como alarma de alto o bajo nivel.

TFT

TRANSMISOR ULTRA_SONICO DE NIVEL PARA PLAYAS DE

TANQUES

Es un instrumento de costo accesible especialmente diseñado para que varias

unidades sean puestas en red con un master que puede ser un PLC o una computadora tipo PC. El medio de

comunicación es RS-485 y hasta 32 unidades pueden ser conectadas. Esta disponible un práctico software para administración de playas de tanques.

LS-1600

LS-1620

INTERRUPTOR TERMICO DE NIVEL O INTERFASE

DETECTOR DE HIDROCARBUROS

SOBRENADANTES EN AGUA

Genera una señal de alarma o control al cuando el líquido cubre o descubre el

extremo sensor. Puede ser calibrado para detectar interfase entre dos líquidos no

miscibles (Ej.: agua-hidrocarburo). Primario fabricado en AISI -316 con conexión roscada o bridada. Salida

mediante contacto SPDT libre de tensión.

Este equipo esta especialmente destinado a la detección de líquidos no conductores

(petroleo, combustibles, aceites, etc) sobrenadantes en agua, con el objetivo

de prevenir situaciones de contaminación ambiental o detectar mal funcionamiento

de equipos de proceso. Posee hasta cuatro niveles de detección con contactos

SPDT independientes.

Temperature Gauging Systems

S t o r a g e T a n k M e a s u r e m e n t

“The Tank Gauging People”

The answer to complete liquid temperatureinformation

Enraf temperature measuring systems make use ofproven technology and offer the highly efficienttemperature parameter for total inventory control.Our Multiple Thermo Sensor Thermometer (MTT)provides:

• Accurate product temperature• Accurate vapor temperature• Temperature profiles

In combination with SmartRadar and Servo levelgauges, and as part of Hydrostatic gauging systems,we provide you with accurate on-line informationincluding:

• Liquid levels• Water/product interface level• Volume• Mass• Alarms

All measured and calculated data and parameters areavailable to higher level systems (DCS, SCADA, MIS,etc.) by means of an extended number of communication protocols.

Accurate temperature gauging pays back veryquickly!

Enraf introduced a line of very rigid and accuratetemperature gauging devices.

• The Multiple Thermo sensor Thermometer• The Spot temperature thermometers *)

Temperature changes in liquid alter level, volumeand density. These potential changes make temperature gauging very important. For exampleeach 1 °C (1.8 °F) uncertainty causes a deviation ofmore than 0.1 %. For a storage tank holding 50,000 m3 (300,000 bbl) this results in an uncertaintyof 50 m3 (300 bbl).

Enraf temperature measurement is the result ofalmost 40 years of innovation.

Continuous development means:

• Innovative temperature measurement technology• Maintenance-free temperature gauges• Solutions for any application

Characteristics MTT

Measuring range :up to 33,000 mm (108 ft) **)

Instrument accuracy :Temperature < 0.1 °C (0.18 °F) ***)

Housing material :Polyamide (Nylon)Stainless Steel AISI 316 L, corrugated tube

Operating temperature :Low temperature:

range -55 °C to +135 °C (-65 °F to +275 °F)High temperature:

range -55 °C to +200 °C (-65 °F to +390 °F)Very low temperature:

range -200 °C to +70 °C (-330 °F to +160 °F)

Mounting :In 2", 150 lb or otherFrom tank roof or side mounted

*) through Enraf from third party**) other ranges on request***) under reference conditions

1234

1 compound2 copper (Cu)3 solder connection4 constantane (CuNi)5 shrink sleave

Reliable sealed temperature detectors

5

Outstanding accuracy

The inventive use of thermosensors, in combinationwith a high class reference resistance, providesoutstanding accurate measurements. Temperaturemeasurements ensure that temperature differencescan be detected to within 0.1 °C (0.18 °F).

Weights & Measures

Enraf developed its temperature gauging systems infull compliance with international standards. MTT has received full certification from Custody &Excise and official Weights & Measures authorities. It meets all international requirements for custodytransfer.

Unique safety features

Enraf MTTs are approved and meet all internationalsafety standards for use in hazardous areas. Among its many safety features is a unique lightningprotection system to avoid damage duringthunderstorms.

Two wire interface to level gauge

Features Your Benefits !

Sturdy construction

Electronic element selectorand digital conversion

No moving parts

Versatile mounting configuration

Nylon or Stainless steel

Sixteen measuring poins

Platinum RTD

Efficient, and reliable

No maintenance costs

Very vast and reliable information

A solution for every mounting situation

Preserves life of instrument

Minimal cabling and wiring

Average temperature, profilingand vapor temperature

Accuratye differential measurement

Galvanic lightning protection Safe and reliable in all weather conditions

Compact and lightweight Easy to install

Temperature at any level

“The Tank Gauging People”

TC15TC14TC13TC12

TC0

TC1

TC2

TC3

TC4

CuNi

Pt100

INDUSTRIAL TEMPERATURE MEASUREMENT?

Temperature measurement is particularly importantfor facilities that store liquids and want stockquantification either by volume or by mass.Automatic temperature gauging is safe and laborcost saving.

How to measure temperature?

There are several systems for temperaturemeasurement available.

• Spot temperature measurement

Spot or single point, temperature measurement iscommonly done with an RTD probe of a definedinsertion length mounted from the tank wall. A spot element is, in many cases, able to do the job.The position for a single point temperature probe isvery important for registering the true averageproduct temperature in a tank.

• Average temperature measurement *)

For the volume calculation, it is necessary to knowthe average temperature of the product’s totalvolume.

Because most stored liquids do not havehomogenous temperatures, a more sophisticatedmeasuring system is required.

For example, products loaded into the tank indifferent batches can have a difference intemperature.

With the new Multiple Thermosensor Thermometers(MTT), Enraf supplies a robust and reliableinstrument. It makes use of the most robustthermocouples available.

A unique differential measuring technique

The accuracy of the MTT is assured by a uniquedifferential measuring technique.Instead of measuring the absolute temperature,Enraf’s MTT measures the difference compared witha precision reference platinum RTD located near thebottom of the assembly. As a result we achieve ameasuring accuracy better than ± 0.1 °C (0.18 °F).

Each MTT incorporates 16 equally spacedtemperature detectors which, combined with themultiple temperature interface and selector, providea true average temperature. As a unique feature, determination of temperatureprofiles is possible! The MTT also provides thetemperature of the vapor area which can be usefulin case of gas storage.

Sturdy Polyamide (Nylon) or corrugated stainlesssteel protection tubes with special top and bottomfittings seal the temperature detectors completelyfrom the atmosphere.

Advanced techniques continuously monitor and/orcorrect for the influence of terminal and resistancechanges, thermal voltages and temperature drift.

A unique measuring principle

*) We will be glad to advise for a change to MTT, for installation already equipped with Multiple Resistance Thermometers (MRT).

Internal tank data Externaldata

Density

Dens. Ref.(from lab or gauge)

Processpara-

meters

Measure-ment

Tables

DerivedData

Tank Level Temp.

LevelGauge Temp. M

T.C.T. A.S.T.M.54

G.O.V. V.C.F.

G.S.V.

Mass

Level based Stock Inventory

It is important to understand how the GrossObserved Volume of the product is determined in alevel based tank gauging system, althoughtemperature information is also an importantparameter in Enraf’s hydrostatic tank gaugingsystems.

Starting with level, the Gross Observed Volume ofthe product is determined by utilizing TankCalibration Tables which relate liquid level to liquidvolume.

Combining the Gross Observed Volumetric quantitywith the liquid temperature measurement, a GrossStandard Volume can be calculated. The GrossStandard Volume is the volume at a referencetemperature.

From the Gross Standard Volume the Mass can becalculated by introducing the Reference Density. In general, Volume multiplied by density equals itsmass.

Installation

MechanicalA two inch entry in the tank is sufficient for theinstallation. The MTT can be installed eithersuspended in the tank secured by means of an anchorweight or in a two inch thermowell.For pressurised applications, a non-slottedthermowell is recommended. For caverns, we supplyspecial MTTs adapted to your application.

ElectricalAn average temperature gauging loop consists of anMTT connected to a Multi-element InterfaceThermosensor converter (MIT) in most cases mountedon top of the MTT. The MIT is in turn connected viaone twisted pair with a temperature processingboard in a Enraf Servo tank gauge, a SmartRadarlevel gauge or a Field Display & Interface (FDI).

Temperature an important parameter

“The Tank Gauging People”

Your guarantee of accuracy and safety at yourplant

Enraf’s temperature measuring systems are approvedand fully certified by numerousorganizations throughout the world, includingWeight & Measures, Custody & Excise andMeteorological institutes.Enraf instruments also comply with regulations setby the worlds leading storage industryorganizations.

Accreditation include:

CENELEC EuropeUL/FM USACSA CanadaBASEEFA United KingdomPTB GermanySIM FranceNMI the NetherlandsSEV SwitzerlandBEV/TÜV AustriaKDB/Prochem PolandSAA AustraliaSAA CanadaSIRIM MalaysiaGOS Standard RussiaNEPSI ChinaCCE IndiaMIGAS Indonesia

OIML Organization International de MétrologieLégaleAPI American Petroleum InstituteCEN Comité Européen de NormalisationISO International Standardization Organization

............. and many others

Enraf is an ISO 9001 certified company.

In use by companies all over the world

Enraf temperature gauging systems can be found onall types of bulk storage tanks, storing a huge varietyof liquids. They are the first choice of many of theworld’s top companies, including:

Petrochemical industriesRefineriesIndependent terminalsMarketing terminalsPipeline terminalsGas terminalsChemical industriesFood and beverage industriesAviation fuel supply companiesUtilitiesStrategic oil & gas storage organizations

For more detailed Information

If you would like more information on the Enraftemperature gauging systems or any product fromthe Enraf range (a selection is shown opposite)please contact your nearest Enraf office. Full contactdetails are given on the overleaf.

The following Enraf Product Sheets are available ontemperature gauging:

- Multiple Thermo sensor Thermometers (MTT)- Spot temperature sensors

For a wide range of tanks an liquids

The complete system

LAN/WAN Ethernet / Tokenring

InventoryManagementSystem

CIU Plus

CIU Prime

Field bus

SmartRadar

Servo

HIMS HTG

Entis ProEnrafs new age Windows-NT basedinventory systems provides superb datafor effective tank farm management.With there latest technology they havegained official recognition from officialmeasurement authorities.

Communication Interface UnitsEnraf Communication Interface Unit CIU Plus and CIU Prime are the mostpowerful tank gauging data collecting,processing and communication units.

SmartRadarA unique tank gauge with the newestradar technology is the most advanceddevelopment in non-intrusive levelmeasurement. SmartRadar gives optimalmeasuring performance in anyapplication.

Servo GaugesAn intelligent tank gauge for liquidstorage tanks. The first automatic servogauge to receive certification fromleading weights & measures authorities.It is very compact and needs only a smallmounting flange.

Hydrostatic Tank GaugingThe Enraf HTG system is an example oftrend-setting technology at its best,using high accuracy digital pressuretransmitters. The best solution for directmass measurement.

Hybrid Inventory Management SystemsThe Hybrid Inventory ManagementSystem (HIMS) brings together the bestof servo tank gauging or SmartRadarwith digital pressure transmitter toprovide maximum accuracy in level, mass,density and volume.

Other instruments in the Enraf range• WaterScout for product/water

interface measurement• Portable Enraf Terminal (PET) for easy

commissioning and field configuration• Indicators – for data display in the

field or any location• Securiterre – for any grounding

application as road trucks, trains, etc.• AlarmScout – to prevent overfill and

spills. It detects liquids, slurries, foam aswell as interfaces (e.g. oil/water).

The Tank Gauging People

Enraf B.V.Röntgenweg 1, 2624 BD DelftP.O. Box 812, 2600 AV DelftThe NetherlandsTel.: +31 (0)15 269 86 00, Fax: +31 (0)15 261 95 74Email: info@enraf.nlhttp://www.enraf.com

China: Enraf B.V. (Shanghai Rep. Office)# 18-01, Suncome Liauw's Plaza, 738 Shangchen Road, Pudong, Shanghai 200120Tel.: +86 21 58311611, Fax: +86 21 58313011

France: ENRAF S.a.r.l.ZAC Les Beaudottes, 15 rue Paul Langevin,93270 SEVRANTel.: +33 (0)1 49 36 20 80, Fax: +33 (0)1 43 85 26 48

Germany: Enraf GmbHObere Dammstrasse 10, 42653 SolingenPostfach 101023, 42648 SolingenTel.: +49 (0)212 58 750, Fax: +49 (0)212 58 7549

Singapore: Enraf B.V. (Singapore Rep. Office)Lam Soon Industrial Building63 Hillview Avenue, # 05 - 03, Singapore 669569Tel.: +65 76 94 857, Fax: +65 76 94 348

United Kingdom: Enraf Ltd.Unit 11, Sandridge Park, Porters WoodSt. Albans, Herts AL3 6PHTel.: +44 (0)1 727 843 376, Fax: +44 (0)1 727 842 185

USA: ENRAF Inc.500 Century Plaza Drive, Suite 120Houston, Texas 77073Tel.: +1 281 443 4291, Fax: +1 281 443 6776

Russia: Enraf B.V. (Moscow Rep. Office)c/o Nucletron - Oldelft2nd Donskoy Proezd, Building 6/4117071 MoscowTel.: +7 095 935 7877. Fax: +7 095 935 7877

vW-IN-4416.026-V2.0

vW-U

S-44

16.0

71-V

2.0

About us

The Swiss Endress+Hauser Group,manufacturers of measurement andautomation technology is one of thelargest producers of process controlinstrumentation in the world.More than 5000 employees worldwideensure that the pace of internationalismwill continue to gain momentum asE+H´s most important customers areincreasingly investing outside of Europe.Design and production is undertaken in12 Product Centres throughout theworld, with a clear centre around theBasle region. Twenty-six individual salescompanies, apart from many marketingpartners, serve the customersthroughout the world at a local level andguarantee reliable service. The holdingcompany of the very decentralized andevenly organized Group has itsheadquarters in Reinach, Switzerland.

Endress+Hauser production sites inMaulburg, Germany (level andpressure), Reinach, Switzerland (flow:mass, emf, vortex shedding), Cernay,France (flow, circuit boards),Greenwood, USA (level and flow),Tokyo, Japan (tank inventorymanagement), Manchester, UK (thermalgas measurement), Schopfheim,Germany (circuit boards), Gerlingen,Germany (analysis equipment),Cernusco, Italy, (temperature) andBeijing, China (level and flow) makeavailable a wide range ofinstrumentation for every application inall industries.

This Technical Information CD cataloguefrom E+H features an overview ofTechnical Information sheets (TI) ofmeasurement and automation devicesavailable from the E+H Group. Pleasenote that many more measuring devicesnot found in this CD are available to youon request from your local E+H dealer.The list of E+H companies andrepresentativers near you is located onthe address page.

Endress + HauserNothing beats know-how

SystemInformationSI 005F/00/en

Hauser+EndressNothing beats know-how

prosonic / nivosonic

Non-contact, ultrasonic levelmeasurement in liquids and solids

Internet: http://www.endress.com

PLC

PLC

Simple and Compact – Prosonic T

Prosonic T measuresthe level of liquids andgranular solids in tanks,e.g. buffer tanks, onconveyor belts or at belttransfer points

Prosonic TThe Prosonic T family is a newgeneration of ultrasonic transmittersfeaturing a highly compact constructionand available as a 2-wire or 4-wireversion.

Its application range covers• non-contact limit detection of liquids

and solids through to• continuous level measurement.

Several communication options areavailable allowing simple on-siteoperation through to operation anddisplay from a process control system.

An empty and fullcalibration can becarried out directly onthe transmitter with the4 pushbuttons.

Two externally visibleLEDs show the status ofthe instrument evenwhen the cover isclosed.

Continuousmeasurement in astorage tank

In addition: Liquiphant(for limit detection) asoverspill protection.

Continuous levelmeasurement in filterbasins (measurement ofwater levels).

2

At Home in the Field – Prosonic

For mounting in thefield: ProsonicA positioning unitenables the sensor tobe accurately focusedon the solids cone.

Level measurement forpump control.

Level measurement inchemical wastes.

Rackbus RS-485 giveslow-cost installation formany ultrasonicmeasuring points.

Up to 50 measuringpoints can be operatedon a max. 1200 m bus.

ProsonicProsonic is a measurement systemconsisting of a field transmitter andsensors for various measuring ranges.The transmitter is available with one ortwo channels, for level or flowmeasurement, with current output, avolume counter, and up to five relayoutputs.

It offers a complete and customisedcommunications package with optionsfor either local operation using the HARTprotocol right through to centralisedmonitoring and operation with standardbus systems.

Fields of application:• Level and volumetric measurement in

tanks containing liquids or solids• Water levels, levels differential water,

e.g. screen control• Flowrate measurement in channels

and weirs

3

Level measurement inan incineration plant.

Ultrasonic sensors in alimestone quarry.

Centralised evaluationwith Commutectransmitters in thecontrol room.

NivosonicNivosonic is a measuring system whichuses 19" Racksyst transmitters toevaluate oncoming sensor signals.Rugged ultrasonic sensors are availablefor a wide variety of measuring ranges.

Ideal applications for non-contactultrasonic measurement:• Level measurement in liquids• Level measurement in solids• Perfect for applications with high

mechanical loads, e.g. during filling.

The sensor can be accurately directedto any point within the silo, e.g. at theoutlet, by using a positioning unit.

Saving Space in the Control Room – Nivosonic

Evaluation, operationand display at a centralpoint.

4

A Rounded Communications Concept

Commuwin IIOperating and Display Program forall Ultrasonic TransmittersCommuwin II is the open operatingprogram for process automationsystems using intelligent instrumentsboth in the field and the control room.The graphic user interface enablesinstruments to be calibrated andmonitored using a wide variety ofstandard communication protocols.

Commuwin II operates on any personalcomputer using MS-Windows 3.1 or3.11, Windows 95 and Windows NT 4.The advantage: all common Windowsstandards such as printer drivers andwindows editing are also available withCommuwin II.

Connecting Smart UltrasonicTransmittersField transmitters such as Prosonic T,operating with standardised HARTprotocol or Endress+Hauser's ownINTENSOR protocol, can be simplyconnected to a personal computerusing the Commubox. This also appliesto instruments from other manufacturers.

Connecting to FieldbusAll intelligent instruments in the field andin the control room produced byEndress+Hauser and othermanufacturers can be calibrated withCommuwin II via PROFIBUS-PA.

Connecting to Process ControlSystemsAll transmitters from Endress+Hausercan be connected to higher processcontrol systems via 19" Commutectransmitters and the gateways ZA 672(MODBUS), ZA 673 (PROFIBUS), orZA 674 (FIP).

This enables all ultrasonic transmittersto be simply integrated into standardnetworks with maximum flexibility.

5

SupplementaryDocumentation

RackbusDigital communication with fielddevices for operation, visualisationand system integrationSystem Information SI 014F/00/en

PROFIBUS-PAHigh performance "informationhighway" for process controlSystem Information SI 027F/00/en

Commuwin IIOperating program for intelligentinstruments using MS-Windows™System Information SI 018F/00/en

SI 005F/00/en/02.98RÜ/CV5

Ultrasonics at a glance

Prosonic TFTU / FMU

Prosonic FDU 80…85 Nivosonic DU 40…DU 61

Liquids Sensor Solids Liquids Sensor Solids Liquids

Measuringrange

1½" sensor:0.25…5 m

2" sensor:0.4…8 m

Sensor DN 100:0.6…15 m

FDU 80/80FFDU 81/81FFDU 82FDU 83FDU 84FDU 85

0.3… 2 m0.5… 5 m0.8…10 m1.0…15 m0.8…25 m0.8…45 m

0.3… 5 m0.5… 9 m0.8…20 m1.0…25 m

——

DU 40 CDU 41 CDU 42 C/SDU 43 C/SDU 73 C/SDU 46 ZDU 60 ZDU 61 Z

0.6… 5 m0.9…10 m1.0…18 m0.8…25 m0.8…45 m2.5…60 m0.5… 6 m0.8…10 m

0.6…10 m0.9…20 m1.0…28 m

———

0.5…12 m0.8…20 m

Temperature max. 80 °C max. 95 °C max. 80 °C

Pressure max. 3 bar max. 3 bar max. 3 bar

Certificates

EEx ia IIC T6FM/CSA Cl. I,II, III, Div. 1Dust-Ex

EEx m II T6FM/CSA Cl. I, II, III, Div. 1Dust-Ex Zone 10

EEx iaDust-Ex Zone 10

TechnicalInformation

TI 247F/00/enTI 246F/00/en

TI 189F/00/enTI 066F/00/en, TI 078F/00/enTI 129F/00/en, TI 145F/00/enTI 175F/00/en, TI 215F/00/en

10.97/MTM

Endress+HauserGmbH+Co.Instruments InternationalP.O. Box 2222D-79574 Weil am RheinGermany

Tel. (07621) 975-02Tx 773926Fax (07621) 975345http://www.endress.com

Hauser+EndressNothing beats know-how

ApplicationThe DU 51 Z ultrasonic sensor can beused in liquid tanks of all kinds up to15 m (50 ft) high and in coarse orfine-grained bulk solids silos up to 7 m(23 ft) high.The «measuring blind flange» isdesigned especially for use with aggressive and flammable vapours andgases.It is approved for use in explosionhazardous area, Zone 0.Intrinsically safe sensor power issupplied by the Nivosonic FMU 673 Z or FMU 678 Z transmitter.

Features and Benefits• The flange and oscillating diaphragm

are made from a single unit of 1.4571stainless steel. This ensures nosealing problems can occur.

• High chemical resistance toaggressive vapours coming from thematerial.

• The resonant frequency of the sensorautomatically compensates forcondensation or material build-up toensure maximum operating efficiencyat all times.

• The connection between thetransmitter and sensor is intrinsicallysafe, i.e. simple laying of three-core(unscreened) cable.

• The ultrasonic sensor is fed by thetransmitter so that no auxiliary poweris required.

Ultrasonic Level MeasurementSensor DU 51 Z

Continuous, non-contact level measurement forliquids and solids,with approval for explosion hazardous area Zone 0

TechnicalInformationTI 078F/00/en

Hauser+EndressNothing beats know-how

The ultrasonicmeasuring systemfor continuous,non-contact level measurementin tanks and silos

Measuring system andfunctionB = blocking distance

(maximum level)D = distance from

sensor to surface of material

L = level in tankor silo

F = maximum level (100 %, Full)E = zero point of

measurement (0 %, Empty)

Operating Principle

Measuring System

Measurement Conditions The principal requirement for ultrasonicmeasurement is the reflection of anecho from the surface of the material.Gas layering can affect the accuracy ofthe measuring system.

• LiquidsThe sensor must be positioned exactlyperpendicular to the surface of theliquid.The surface must not be fully coveredby a thick layer of foam.

• Bulk SolidsThe sensor receives a sufficiently highproportion of diffuse echoes when thesurface roughness of the mounds isgreater than 4 mm (diffuse reflection). With fine-grained or powdery bulksolids, e.g. quartz sand, cement,powdered plastics, raw meal, etc.,function is dependent on the surfacecontours of the material (mirroredreflection).

Blocking DistanceDue to the decay characteristic of thesensor, there is a zone immediatelybelow it in which returning echoescannot be detected. This is known asthe blocking distance B and determinesthe minimum distance between thesensor diaphragm and the maximumlevel of the material in the tank or silo.This blocking distance is approx. 0.8 m(2.6 ft).

Measuring Range The maximum measuring range islimited by the attenuation of theultrasonic pulse by the air as well as bythe strength of the reflections from theproduct surface.

The complete measuring systemconsists of• the Nivosonic FMU 673 Z or FMU

678 Z transmitter in the control roomand

• the ultrasonic sensor DU 51 Z on thetank or silo

A temperature probe integrated in thesensor is used to compensate for runtime errors caused by temperaturevariations.

FMU 678 ZFMU 673 Z

DU 51 Z

DU 51 Z

explosion hazardous area

intrinsically safe

Ex Zone 0

ExZone 0

DU 51 Z

FMU

LD

BE

F

The ultrasonic emitter in the sensor isexcited electrically and sends anultrasonic pulse in the direction of thesurface of the material. The surfacepartially reflects the pulse. This echo isdetected by the same sensor, nowacting as a directional microphone, andconverted back into an electrical signal.The time between transmission andreception of the pulse – the sonic runtime – is directly proportional to thedistance from the surface of the materialto the sensor. The distance D isdetermined from the velocity of sound cand the run time t using the formula:

D = c ⋅ t2

2

Right:Echo attenuation as afunction of measuringrange with an examplefor calculating themeasuring range.

In mounting pipe, thesensor generates aninterference signalwhich decreases with increasing path

Above:Attenuation in dB with interference factors inthe tank or silo.

Effects Attenuation (dB)

Temperature layering *

Difference in air up to 20 °Ctemperature between up to 40 °Csensor and product up to 60 °Csurface

05...10

10...20

Filling curtainoutside the detection zonesmall amounts within the detectionzone large amounts within the detection zone

05...10

10...20

Liquid of liquidcalmwavesstrong turbulence (e.g. agitator)

05...10

10...20

FoamPlease contact Endress+Hauser

Surface of bulk solidhard, roughsofte.g. peat, dust-covered clinker

2020...40

Dustnonelowhigh

05

5...10

Maximum Range The maximum measuring rangedepends upon the following factors: • The strength of the signal coming from

the surface of the material (diffuseecho)

• The attenuation of the signal in thespace between the sensor and theproduct

• The level of background interferencecaused by, e.g. noise when filling.

• Interference echoes from fittings in thesilo

The first three factors depend upon therequirements of the application.

Interference echoes can be prevented ifthe recommendations given in thistechnical information brochure areobserved.

Optimum conditions are achieved if: • no internal fittings are located within

the detection zone • the tank or silo is not filled or emptied

during measurement• the surface of the liquid is calm and

without foam • there is no high concentration of

vapour in the tank • the solid is hard and coarse-grained

• there is no dust in the silo • the air temperature is not high.

Calculate the measuring range of theultrasonic sensor for your particularapplication:

• By using the table, check whichfactors affect the measurement.

• Add together the attenuation values(dB).

The diagram shows the ideal echoattenuation curve for the DU 51 Zsensor. • Move the ideal curve downwards by

the amount which corresponds to thesum of the attenuation values.

• Subtract the noise expected from the120 dB noise level. A typical noiselevel of approx. 20 dB is caused bythe silo filling or emptying and byinterference echoes coming from thesilo walls. The interference level isincreased for short measuring pathsdue to stronger interference echoes.

• The maximum range is indicated bythe point where the ideal curve andthe interference level line meet. Please refer to the example.

Planning Recommendations

Range m

Example: measuring range approx. 9 m

ideal curve DU 51 Z

possible background interference

Example: 30 dB

Blocking distance DU 51 Z: 0.8 m

Echo attenuation dB

B

Interference levelwith sensorin mounting pipe

(16 ft) (33 ft) (50 ft)

Example for calculating the range: (liquid tank):

Factor: Attenuation

Temperature difference in the tank max. 60 °C 20 dBFilling curtain outside the detection zone 0 dBAgitated liquid surface 10 dB

Total sum of attenuation values 30 dB

Measuring range under these conditions approx. 9 m

∗ x °C = (x ⋅ 95

+ 32) °F

3

Avoid interferenceechoes from internalfittings and rough silowalls!a) correct installation, no interference echoesb) non-critical installation,weak interference echoes onlyc) incorrect installation, strong interference echoes from internal fittings and from wall irregularities (e.g. welding seams)

Detection zone as afunction of applicationconditions.Continuous lines: goodreflectioncharacteristics, lowattenuation giving lowamplification in theNivosonic FMUtransmitter.

Broken lines: poorreflectioncharacteristics, strongattenuation giving highamplification in theNivosonic FMUtransmitter.

Detection Limits and InterferenceSignalsIf fixtures are present in the tank or silo,then careful positioning of the sensor iscritical in order to keep the interferencelevel as low as possible. The ultrasonicpulse should arrive unobstructed at theproduct surface. The pulse leaves thesensor as a narrow beam which widensas the distance increases. Every objectwithin this beam causes an echo whichis received by the sensor.• Edges, internal fittings, etc. in the first

third of the measuring range are morecritical since the sonic energy is stillhighly concentrated: small objects cancause large echoes.

• In the last third of the measuringrange, the sonic energy is spreadacross a much larger area. Internalfittings and edges are much lesscritical.

• Objects in the middle of the beam(continuous lines in the diagram)produce strong echoes.

• Echoes from the outside zone (brokenlines) are only significant when theworking signal from the surface of thesolid is weak.

Accuracy• The effect of pressure variations is

< 0.1% (in air or nitrogen).• A constant temperature and sonic

velocity along the entire measuringpath ensure a high degree ofaccuracy with error limits ≤1%. Theeffect of steep temperature gradientsalong the measuring path andchanging product components mustbe calculated and the Nivosonicprogrammed accordingly. A layer ofnitrogen above the product alters thesonic velocity by only +1%. Liquidswith high partial pressures must havegas compositions which remainconstant.

• The resolution is 1.7 cm at a sonicvelocity of 340 m/s.

surface of liquid

surface ofbulk

*

*

interferenceechoesshould beespeciallyavoidedin this zone!

*

(23 ft)

(5 ft)

(50 ft)

(5 ft)

B B

a) b) c)

B

4

signal

time

➃

➀

➁

➄

➂

a)b)

B

max.

Installation

Suppression ofinterference echoesfrom fixed installations:① Signal decay of the

sensor② Time dependent

threshold which an echo signal mustexceed to be

processed by the transmitter.

③ Interference echoes④ Interference echo suppression

(adjusted detection threshold)⑤ Working signal from the surface of the bulk solid

Right:Installation point forpowdery bulk solids.c) A trough between slopesreflects a strong echo in the direction of the sensor.d) Slightly rising surfaces with angles up to 5°still reflect enough sonic energy towards the sensore) The centre of the outflow cone reflects a sufficiently strong echo towards the sensor.

a) Do not carry out measurement through the filling curtainb) Distance B (blocking distance) to maximum level must be observed. See diagram on the next page for height of the mounting pipe

Recommendations when Mounting on a Silo• Direct the sensor to the centre of the

outflow funnel so that an echo isreceived even when the silo is empty.

• Avoid measuring through the fillingcurtain.

• The smooth surface of a veryfine-grained bulk solid or oneproducing dust gives no significantlydiffuse reflection. The beam isreflected like light (angle of incidence= angle of reflection). The installationpoint is, therefore, of criticalimportance for correct measurement.

Interference Signal SuppressionInterference echoes from stationaryinternal fittings can be suppressedusing then fixed target suppression“mode of the Nivosonic FMU673 ... 678 Z. This adjusts the detection limits suchthat interference echoes are no longeridentified and are therefore excludedfrom further signal processing. Note thatadjusting the detection limits to theinterference profile reduces themeasuring range. With weak workingsignals especially, (e.g. cement silos)the interference level should beminimised at the start by correctlyinstalling and positioning the sensor.

Recommendations for Mounting on a Tank• Position the sensor exactly

perpendicular to the surface of theliquid.

• Avoid measuring through the fillingcurtain.

• Mount the sensor high enough so thatno material enters the blockingdistance even with overfilling.

• Use the recommended sizes formounting pipes.

a) b)

Left:a) Correct installation As far from the silo wall and material inflow as possible. The centre of the outflow funnel reflects an echo which is received by the sensor even when the silo is empty.

b) Incorrect installation1. Detection through the filling curtain2. With an empty silo, the echo is reflected to one side so that the sensor cannot receive a working signal.

c)

d)

e)

5

Mounting

Electrical Connection

Connecting the ultrasonic sensor DU 51 Z to theNivosonic FMU ...

Mounting examples forclosed tanks or silos

All dimensions in mm100 mm = 3.94 in1 in = 25.4 mm

• No material build-up and nocondensation should occur in anarrow mounting pipe.

• Select a mounting pipe with thelargest possible diameter.

• The internal wall of the mounting pipeshould be as smooth as possible (noedges or welding seams).

• Insulate the mounting pipe whenmounting in the open to avoidcondensation.

• With cylindrical tanks or silos: Avoidmounting the sensor in the centre ofthe roof. This applies especially tocurved roofs as interference ormultiple echoes will tend to occur.

• When mounting the DU 51 Z, thecounter flange must be as smooth aspossible.Lay the gasket supplied on thecounterflange to ensure sonicdecoupling. When using other types ofgasket: The same thickness of gasketmust have a hardness of 60 ... 70Shore A.

• Install securely using all 8 screwssupplied.

• Tighten the screws crosswise with aneven pressure applied, recommended torque: approx.100 Nm ... 110 Nm, (75 ... 80 ft lbs).maximum torque 120 Nm (90 ft lbs).

Intrinsically safe connection of the DU 51 Z ultrasonic sensor to theNivosonic FMU 673 Z or FMU 678 Zusing normal, unscreened, three-coremultipurpose cable,max. 25 Ω per core.(Observe all explosion protectionregulations when laying cables!)Screened and twisted cabling isrecommended if it is to be laid in strongmagnetic or electrical fields.Connect the screening to the DU 51 Zonly!If a Pt100 sensor is required, then thismust be stated when ordering the DU51 Z sensor. Connect it to Terminals 4and 6 without jumper 5 – 6.

∅ 150

trimmed

TO avoid materialbuild-up by spattering,e.g. milk of lime vessels internal edge 45° x 2 mm

ideal mounting

∅ 150

∅ min. 350

∅ 150

45 o

Use gasket to DIN 2690 for all types of installation(supplied)

max. 400max. 700

max. 200

Ø 150

explosionhazardousarea

non-Exarea

potentialequalisation

externaltemperaturesensor

DU 51 Z

NivosonicFMU 673 ZFMU 678 Z

6

Dimensions of the DU 51 Z ultrasonic sensor in mm

100 mm = 3.94 in1 in = 25.4 mm

Sizes for the standard flange DN 150, PN 16,DIN 2501

Technical Data Measuring RangeUp to 15 m (liquids),under ideal conditions:• ambient temperature 0 . . . 30 °C• atmospheric pressure• ideal mounting, see Page 6• calm liquid surface, no foam or

turbulence• measuring path free of obstacles

Up to 7 m (solids) underideal conditions• ambient temperature 0 . . . 30 °C• atmospheric pressure• ideal mounting, see Page 6• dust-free, hard surface with a grain

size of greater than 10 mm (e.g. ballast)

• measuring path free of obstacles

Operating Data• Bursting pressure: 5 bar (70 psi)• Operating temperature in the tank or

silo: –20 °C . . . +80 °C ( 4 ... 170 °F)• Ambient temperature for

the housing: –20 °C . . . +60 °C(4 ... 140 °F)

• Ultrasonic run time compensation:silicon temperature sensor mountedbehind the diaphragm of the sensor

• Operating pressure pe: max. 3 bar• Ultrasonic frequency: approx. 21 kHz• Pulse frequency: approx. 2 Hz• Blocking distance: approx. 0.8 m• Emission angle at – 3 dB: 3°

Construction and Materials• Flange and oscillator: machined from

a single piece of stainless steel 1.4571• Flange size: DN 150, PN 16• Gasket supplied: NBR• Housing: aluminium (AISi 9)• Protection according to DIN 40050:

IP 65• Degree of protection: EEx de ib IIC T 6• Weight: 16.2 kg

Subject to modification.

∅ 22

∅ 240

∅ 285

222 x water-tightPG 16

295

40

380

140

7

SupplementaryDocumentation

How to Order

TI 078F/00/en/05.93Printed in Germany/Gw/Gw

Ultrasonic sensor DU 51 Z

Order Code DU 51 Z - A11 A1

Certificate of conformityPTB No. Ex-89.C.2069 and Certificate of design01/PTB No. Ex-89.C.2069 Certificate ZE 023/00/e

Level measurement transmitter Nivosonic FMU 673 Z, FMU 678 ZTechnical Information TI 128/00/e

10.97/MTM

Endress+HauserGmbH+Co.Instruments InternationalP.O. Box 2222D-79574 Weil am RheinGermany

Tel. (07621) 975-02Tx 773926Fax (07621) 975345http://www.endress.com

Hauser+EndressNothing beats know-how