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Emerson Rosemount 5900 Safety Manual

Radar level gauge and tank hub
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Safety Manual
00809-0400-5100, Rev AB
November 2019
™
Rosemount
5900 Radar Level Gauge and
2410 Tank Hub
Safety Manual for Use in Safety Instrumented Systems
SIL 2 Model Code Option S

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Summary of Contents for Emerson Rosemount 5900

  • Page 1 Safety Manual 00809-0400-5100, Rev AB November 2019 ™ Rosemount 5900 Radar Level Gauge and 2410 Tank Hub Safety Manual for Use in Safety Instrumented Systems SIL 2 Model Code Option S...
  • Page 2 Safety Manual 00809-0400-5100, Rev AB November 2019...

  • Page 3: Table Of Contents

    Safety Manual Contents 00809-0400-5100, Rev AB November 2019 Contents 1Section 1: Safety Instrumented System 1.1 Safety messages ............1 1.2 Introduction .
  • Page 4 Safety Manual Contents 00809-0400-5100, Rev AB November 2019 A.1.2 Failure values ........... 31 A.2 Product life .
  • Page 5 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 Process Management/Rosemount Tank Gauging representative. Spare Parts Any substitution of non-recognized spare parts may jeopardize safety.
  • Page 6 Safety Manual Title Page 00809-0400-5100, Rev AB November 2019 Title Page...

  • Page 7: Safety Messages

    Safety Manual Safety Instrumented System 00809-0400-5100, Rev AB November 2019 Section 1 Safety Instrumented System Safety messages ............page 1 Introduction .

  • Page 8: Introduction

    Rosemount 5900 The Rosemount 5900 is a radar level gauge developed for a wide range of applications at bulk liquid storage facilities. Different antennas can be used in order to meet the requirements of different applications. The 2-in-1 version of the Rosemount 5900 has two independent and galvanically isolated radar modules in the same transmitter enclosure using a single antenna.

  • Page 9: Safety Instrumented System (Sis) Certification

    Gauging System Data Sheet, Document No. 00813-0100-5100. If there are any echoes measured by the Rosemount 5900 which cannot be traced back to the product surface, note if there are any objects such as beams, heating coils etc. in the tank, that correspond to the found echoes.

  • Page 10: Safety-Certified Identification

    Safety Instrumented System 00809-0400-5100, Rev AB November 2019 Safety-certified identification All Rosemount 5900 Radar Level Gauges and Rosemount 2410 Tank Hubs must be identified as safety-certified before installing into SIS systems. Table 1-1 lists the versions of the Rosemount 5900/2410 Series devices that have been considered for the functional safety assessment, to which this manual applies.

  • Page 11: Functional Specification Of The Safety Function

    Rosemount 5900 Radar Level Gauge, one antenna, and one Rosemount 2410 Tank Hub. SIL 2 2-in-1 (1oo1D) Single channel architecture (1oo1D) complying with SIL 2. This version includes  one “2-in-1” Rosemount 5900 Radar Level Gauge, one antenna, and one Rosemount 2410 Tank Hub. Safety Instrumented System...
  • Page 12 Safety Manual Safety Instrumented System 00809-0400-5100, Rev AB November 2019 Safety Instrumented System...

  • Page 13: Safety Messages

    Safety Manual Installation and Configuration 00809-0400-5100, Rev AB November 2019 Section 2 Installation and Configuration Safety messages ............page 7 Installation in SIS applications .

  • Page 14: Installation In Sis Applications

    Gauging Safety System. Note The Rosemount 5900 Radar Level Gauge and Rosemount 2410 Tank Hub are not safety-rated during maintenance work, configuration changes, or other activity that affects the Safety Function. Alternative means should be used to ensure process safety during such activities.

  • Page 15: Configuration In Sis Applications

    Safety Manual Installation and Configuration 00809-0400-5100, Rev AB November 2019 Configuration in SIS applications 2.3.1 Analog output configuration Alarm and saturation levels DCS or safety logic solver should be configured to handle both High alarm and Low alarm. It is also required that the transmitter is configured for High or Low alarm. Figure 2-1 identifies the alarm levels available and their operation values.
  • Page 16 Safety Manual Installation and Configuration 00809-0400-5100, Rev AB November 2019 Analog output configuration in TankMaster To configure the Rosemount 2410 Tank Hub analog output: In the WinSetup workspace click the right mouse button on the tank hub icon and choose the Properties option. Select the Configuration tab.

  • Page 17: Relay Configuration

    Normally Open/Normally Closed Normally Open (NO) is the default setting for the Rosemount 5900 and Rosemount 2410 in Safety Instrumented Systems (SIS). Verify the relay configuration by, for example, using the proof test function Relays K1/K2 Verification Test. See “Maintenance”...

  • Page 18: Write Protection

    Write protection A Rosemount Tank Gauging safety-certified system should always be write protected in order to avoid unintentional configuration changes. The Rosemount 5900 Radar Level Gauge as well as the Rosemount 2410 Tank Hub should be write protected. It is recommended to use one of the following write protection options: Hardware switch ...

  • Page 19: Safety Messages

    Safety Manual Operation and Maintenance 00809-0400-5100, Rev AB November 2019 Section 3 Operation and Maintenance Safety messages ............page 13 Proof test .

  • Page 20: Proof Test

     A partial test may include one or more of these elements. The Rosemount TankMaster software supports proof testing of the Rosemount 5900 Level Gauge and the Rosemount 2410 Tank Hub. The Rosemount Tank Gauging Safety System should be checked at regular intervals in order to detect Dangerous Undetected (DU) failures.

  • Page 21: Proof Test Methods

    Safety Manual Operation and Maintenance 00809-0400-5100, Rev AB November 2019 Proof test methods The effectiveness of a proof test in finding undetected failures is the proof test coverage. Table 3-1 lists the coverage factor for various proof test methods including combinations of partial proof tests.
  • Page 22 Safety Manual Operation and Maintenance 00809-0400-5100, Rev AB November 2019 Figure 3-1. Flowchart with Combination of Partial Proof Tests High Level Alarm One-Point Level High Level Alarm Verification Test Simulated Reference Reflector Reference Reflector Analog Output Relays K1/K2 Operation and Maintenance...

  • Page 23: Comprehensive Proof Test

    Safety Manual Operation and Maintenance 00809-0400-5100, Rev AB November 2019 Comprehensive proof test A comprehensive proof test of the Rosemount 5900 and Rosemount 2410 includes all the functional elements: Output circuitry (relay, analog output)  Measurement electronics (digital signal processing) ...

  • Page 24: Partial Proof Test

    Safety Manual Operation and Maintenance 00809-0400-5100, Rev AB November 2019 Partial proof test In Rosemount TankMaster partial proof tests are implemented as follows: High level alarm test with reference reflector  High level alarm test with simulated reference reflector  One-point level verification ...

  • Page 25: High Level Alarm Test With Reference Reflector

    The High Alarm Test must be combined with suitable output verification test such as Analog Output or Relays K1/K2. To run a proof test for a Rosemount 5900 with Reference Reflector do the following: Ensure that the TankMaster WinSetup program is up and running.
  • Page 26 Safety Manual Operation and Maintenance 00809-0400-5100, Rev AB November 2019 This window lets you start a proof test. The following measurement data is presented: Parameter Description Level Distance from the Zero Reference Point to the product surface or the Reference Reflector, respectively Ullage Distance from the Tank Reference Point to the product surface Distance...
  • Page 27 Safety Manual Operation and Maintenance 00809-0400-5100, Rev AB November 2019 Note the Warning that appears when starting the Proof Test: Note Ensure that the necessary actions are taken in order to maintain safety during the test. Click the Accept button to run the test. Now the gauge will measure the actual distance to the reference reflector.
  • Page 28 PDF format will be created automatically. It may be printed and saved in the desired network location. The report will be available from the Proof Test History window as well. See the Rosemount 5900 Proof Test Manual Supplement for more information. Operation and Maintenance...

  • Page 29: High Level Alarm Test With Simulated Reflector

     Output verification test such as Analog Output or Relays K1/K2.  To run a proof test for a Rosemount 5900 with simulated reference reflector do the following: Ensure that the TankMaster WinSetup program is up and running. In the WinSetup workspace, click the right mouse button on the Rosemount 5900...
  • Page 30 Safety Manual Operation and Maintenance 00809-0400-5100, Rev AB November 2019 Click the Start Guided Proof Test button to open the High Level Alarm Test with Simulated Reference Reflector window: This window lets you start a proof test. The following measurement data is presented: Parameter Description...
  • Page 31 Safety Manual Operation and Maintenance 00809-0400-5100, Rev AB November 2019 Click the Start Proof Test button to perform a test for the specified proof test time. Note the Warning that appears when starting the Proof Test: Note Ensure that the necessary actions are taken in order to maintain safety during the test. Click the Accept button to run the test.
  • Page 32 PDF format will be created automatically. It may be printed and saved in the desired network location. The report will be available from the Proof Test History window as well. See the Rosemount 5900 Proof Test Manual Supplement for more information. Operation and Maintenance...

  • Page 33: One-Point Level

    Safety Manual Operation and Maintenance 00809-0400-5100, Rev AB November 2019 3.5.3 One-point level The One-point level test should be combined with one of the following output verification tests: Analog Output  Relays K1/K2  To run a One-Point Level Verification test do the following: Ensure that the TankMaster WinSetup program is up and running and open the Proof Test window.

  • Page 34: Relay Output Verification

    Safety Manual Operation and Maintenance 00809-0400-5100, Rev AB November 2019 3.5.4 Relay output verification This proof test verifies the relay output, i.e. whether the relay is able to open and close. The relay output may be verified by using a multimeter or the SIF logic solver (Safety PLC) to ensure that relay output from the Rosemount 2410 corresponds to indicated relay state in TankMaster.

  • Page 35: Maintenance

    The devices in the Rosemount Tank Gauging Safety System may only be repaired or modified by authorized personnel trained by Emerson Automation Solutions / Rosemount Tank Gauging. For firmware upgrade use the procedure in the Rosemount 5900S Radar Level Gauge Reference Manual.
  • Page 36 Safety Manual Operation and Maintenance 00809-0400-5100, Rev AB November 2019 Operation and Maintenance...

  • Page 37: Aappendix A: Specifications And Reference Data

    Safety Manual Specifications and Reference Data 00809-0400-5100, Rev AB November 2019 Appendix A Specifications and Reference Data SIS reference ................page 31 Product life .
  • Page 38 Specifications and Reference Data Safety Manual November 2019 00809-0400-5100, Rev AB Specifications and Reference Data...
  • Page 39 Terms and Definitions Safety Manual 00809-0400-5100, Rev AB November 2019 Appendix B Terms and Definitions Table B-1. Terms Used in Safety Instrumented Systems Term Description BPCS Basic Process Control System Demand rate How often it will be required from a safety integrity system (or the safety function) to react on inputs from process to bring it into a safe state, i.e.
  • Page 40 Terms and Definitions Safety Manual November 2019 00809-0400-5100, Rev AB Terms and Definitions...
  • Page 41 Dry-run Configuration Safety Manual November 2019 00809-0400-5100, Rev AB Appendix C Dry-run Configuration This section describes the recommended procedure to configure the Safety System for Dry-run applications. Prior to setting up the Safety System for Dry-run it Amplitude has to be installed and configured as a standard A.
  • Page 42 Distance 8. Click the Apply button in order to download the A. Amplitude threshold ATP to the Rosemount 5900 level gauge. B. High Alarm Limit C. Product surface D. Minimum operation distance E. Hold Off Distance F.
  • Page 43 Safety Manual Index 00809-0400-5100, Rev AB November 2019 Index ......Proof Test Time .
  • Page 44 Safety Manual Index 00809-0400-5100, Rev AB November 2019 Index...
  • Page 46 Standard Terms and Conditions of Sale can be found at: Emerson.com/en-us/pages/Terms-of-Use.aspx +973 1722 6610 The Emerson logo is a trademark and service mark of Emerson Electric Co. +973 1722 7771 Rosemount and Rosemount logotype are trademarks of Rosemount Inc. All other marks are the property of their respective owners.

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Rosemount 2410

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