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API 2350 4th edition- how to apply on your site?

Overfill protection for storage tanks in petroleum facilities
Aboveground storage tanks

Only a safe plant is

economical

Slide 1

10/01/2013

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API2350 - how to apply on your site?

Overfilling occurs every 3300 filling operations

According to Marsh Ltd. (2011) in the USA overfilling of atmospheric
storage tanks occurs once in every 3300 filling operations.

Slide 2

10/01/2013

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API2350 - how to apply on your site?

API 2350 3rd edition (2005) independence required !!!

overfill protection for storage tanks in petroleum facilities
C.1.2 []overflow protection systems shall be independent
of any tank gauging device or system. []
A.5.3 [] independent level switches must be installed for
single and two-stage level detector systems. [...]
[ ] Tanks equipped with a high-level detection device that
is independent of any tank gauging equipment. []

Slide 3

10/01/2013

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API2350 - how to apply on your site?

API 2350 4th edition (2012) Categories

ATG

Control center

Category 1
Display

ATG
Category 2

Alarm

ATG
Category 3

Slide 4

10/01/2013

Receipt

LAHH

Receipt
Alarm

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API2350 - how to apply on your site?

API 2350 4th edition (2012) Categories

ATG

Control center

Category 1
Display

Fully attended
ATG
Receipt
(min.
Category
2 1h at the start + min. 1h after the
Alarm
end + periodically visual check on site)
Be aware: no manual hand dipping during
ATG LAHH
Receipt
product receipt and until at least 30
min
Category 3
Alarm
after a product receipt!
Slide 5

10/01/2013

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API2350 - how to apply on your site?

API 2350 4th edition (2012) Categories

ATG

Control center

Semi-attended
(min. 30 min at the start +Display
min. 30 min after the end)

Category 1

ATG
Category 2

Alarm

ATG
Category 3

Slide 6

Receipt

LAHH

Receipt
Alarm

10/01/2013

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API2350 - how to apply on your site?

API 2350 4th edition (2012) Categories

Control center
ATG
Category 1
Display
Unattended (ATG and independent
level alarm high-high
sensor)

ATG
Category 2

Alarm

ATG
Category 3

Slide 7

10/01/2013

Receipt

LAHH

Receipt
Alarm

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API2350 - how to apply on your site?

Typically Category 1 tank only 1 transfer at one time

Category 1
Typically 1
transfer at one
time

Slide 8

10/01/2013

Category 2

Category 3

Multiple tanks
can be filled
simultaneously

Multiple tanks
can be filled
simultaneously

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API2350 - how to apply on your site?

API 2350 4th edition (2012) Categories

ATG

Control center

Category 1
Display

ATG
Category 2

Alarm

ATG
Category 3

Slide 9

10/01/2013

Receipt

LAHH

Receipt
Alarm

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API2350 - how to apply on your site?

Definition of AOPS and MOPS

AOPS: An overfill prevention system not requiring the intervention of
operating personnel to function
MOPS: Manual overfill prevention system that depends on the
interaction of operating personnel to terminate the receipt. A person
physically turning a valve or pushing a button that remotely closes a
valve or turns off a pump are both manual operations. In MOPS, the
alerts and alarms provide the operating personnel with information
only.

AOPS can be added to all three categories

Slide 10

10/01/2013

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API2350 - how to apply on your site?

If necessary, add AOPS on all categories

Control center

ATG
Category 1
Display

AOPS
Logic Solver

ATG

Receipt
Alarm

Category 2

AOPS
Logic Solver

ATG
Category 3

LAHH
AOPS

Receipt
Alarm
Logic Solver

Slide 11

10/01/2013

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API2350 - how to apply on your site?

Overfill prevention is best achieved by use of AOPS

Section 4.1.1. of API2350
Prevention of tank overfills is best achieved by:

Slide 12

A) Awareness of available tank capacity and inventory;

B) Careful monitoring and control of product movement;
C) Use of reliable instrumentation, sensors and systems; and
D) use of automatic overfill prevention systems (AOPS) where deemed
appropriate by a risk assessment and risk-based analysis.

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API2350 - how to apply on your site?

API 2350 (2012) independence of AOPS from the ATG

AOPS: to use automated overfill prevention system (instrument,
sensor, logic solvers and final element) you should follow Annex A
(existing site).
Annex A is clearly requesting independence from the ATG.
Annex A states, that sensors with self testing diagnostic features
are preferred.

Slide 13

10/01/2013

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API2350 - how to apply on your site?

API 2350 4th edition (2012): Annex A, which is normative

Annex A provides good practices for implementation of an automated
overfill prevention system (AOPS) for existing tank systems.
Annex A.3 Independence
The term independent means that the AOPS shall be separate from
any device or method used to measure, calculate or monitor tank
receipts.
The independent AOPS shall be designed and installed such that no
fault in the ATG gauging and monitoring system is capable of causing a
fault in the AOPS.
Annex A.4.2 Sensors
Sensors with self testing diagnostic features are preferred for all AOPS
tank level detection applications
Slide 14

10/01/2013

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API2350 - how to apply on your site?

Competition: 2 in 1 feature?
Competitor claims to have two redundant electronic boards in one
radar/device, but they are still using the same/one antenna.
This is not allowed by API2350 for an AOPS
What happens, if moisture/water is in the electronic compartment
or having water built-up in the antenna?
What happens, if the radar beam is not reflected (e.g. liquid is
boiling, obstacles in the radar beam)?
What happens, if cables breaks?

Slide 15

10/01/2013

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API2350 - how to apply on your site?

2 in 1 feature? Homogenous vs. diverse redundancy

Would you allow your
child to do bungee
jumping with redundant
ropes?

Slide 16

10/01/2013

I prefer diverse redundancy

(rope and net)
not API2350 request

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API2350 - how to apply on your site?

High-High tank response time

The high-high tank response time is the period of time required to
terminate the receipt of flow to a tank in response to reaching the
high-high tank level in order not to reach the critical high level.
Minimum High-High Tank (HH) Level Response Time
(if not calculated)
Category

Time in Minutes

45

30

15

Slide 17

10/01/2013

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API2350 - how to apply on your site?

Different maximum working levels due to different

minimum level response time (if not calculated)
Category 2

Category 1
CH

Category 3
CH

HH
MW

Best tank capacity utilization

with AOPS

Slide 18

10/01/2013

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CH

API2350 - how to apply on your site?

Best capacity utilization with AOPS system.

Category 1
CH
AOPS=HH

Category 2

Category 3
CH

MW

Slide 19

10/01/2013

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CH

API2350 - how to apply on your site?

API2350 relation to IEC 61511

AOPS for new sites: follow ANSI/ISA 84.00.01-2004 (IEC 61511
modified)
1. Generic standard
Valid for all relevant sectors

2. Application standard
Implementation for Process industries
Safety
Regulations

IEC 61508

Supplier and
manufacturers

IEC 61511
ISA 84

System
integrator/
Operator/User

Common Target - Plant Safety!

Slide 20

10/01/2013

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Simply reliable: Process safety from Endress+ Hauser

Prevention

Mitigation

Layers of protection
Plant emergency response

Emergency response
layer

Embankment

Passive protection layer

Relief valve, rupture disk, F+G

system

Active protection layer

Safety instrumented system

Emergency
Shutdown

Isolated protection layer

Alarm & operator intervention

Wild
process

Process control layer

Basic process control system or

DCS

Normal
process

Process control layer

Plant and process design

Slide 21

10/01/2013

Ngo

Trip level alarm

Inherent safe plant

design

API2350 - how to apply on your site?

Overfill prevention process (OPP) in API2350 4th Edition

Overfill prevention process (OPP) consists of

Slide 22

A) management system
B) risk assessment system
C) defining operational parameters
D) requirements for procedures
E) equipment systems

10/01/2013

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API2350 - how to apply on your site?

Simulated Proof testing according API 2350

Proof testing of point-level sensor systems shall be conducted semiannually unless otherwise supported by technical justification (e.g.
PFDavg)
Proof testing of AOPS components shall be conducted annually unless
otherwise supported by technical justification (e.g. PFDavg)
The testing should simulate an actual high liquid level situation as
realistically and as closely as possible; however, the test need not
require filling the tank above its maximum working level.

Slide 23

10/01/2013

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API2350 - how to apply on your site?

Swivel plates for functional proof testing

Swivel plate integrated in the

Endress+Hauser device for
functional proof testing

External Swivel
plate for functional
proof testing

Slide 24

10/01/2013

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Free space radar SIL2 with reflector plate

FMR51 (SIL2) DN100

Floating Roof

oil
Slide 25

10/01/2013

Alain ENGELS

FMR51

Total Olefins Antwerpen

2 different reflector types for different tanks heights

700 mm version

20 m

13 m

1000 mm version

Slide 26

10/01/2013

Alain ENGELS

Simply reliable: Process safety from Endress+ Hauser

Proof testing without dismounting the device

Not necessary to interrupt or manipulate the production process for
partial proof test.
Recommended
proof test
interval

Slide 27

10/01/2013

12 years

Ngo

3 years

2 years

API2350 - how to apply on your site?

Wireless communication is not allowed

Annex A.3
Correct operation of the AOPS shall not require communications to or
from any location remote from the facility where the AOPS has been
installed. AOPS shall not rely on wireless communication to initiate
diversion or termination of receipt.

Slide 32

10/01/2013

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API2350 - how to apply on your site?

Key points of API 2350 4th Edition 2012:

Above ground storage tanks

Introduction of Tank Category 1, 2, 3
Differences between AOPS and MOPS
Independence of AOPS
AOPS for new sites
follow ANSI/ISA 84.00.01-2004 (IEC 61511 modified)

Overfill Prevention Process

Proof testing
A HHLA sensor on a floating roof tank have to detect the oil, even if it
is above floating roof.
No wireless communication for AOPS

Slide 33

10/01/2013

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API2350 - how to apply on your site?

Where can you get the complete standard API2350?

The standard itself is available for about 120 USD from the website of
API (www.api.org)

Slide 34

10/01/2013

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API2350 - how to apply on your site?

Fixed roof solutions

Functional Safety

Tuning
Fork

Radar

Slide 35

IEC 61508 design

Proven in use
Suitable for SIL 2 / 3
Discrete output (relays)
or 4..20 mA output

Proof testing
Push button
activated test
generator
High proof test
coverage

Proven in use

Suitable for SIL 2/3

Internal redundancy (EOP)
Analogue output (4-20 mA)
Switching in safety
system or RMA422

10/01/2013

By proof test
simulation
Proof test
coverage
depends on
inspection depth

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Mounting
Top
adjustable
Side

Top

Top

API2350 - how to apply on your site?

(External) floating roof failure scenarios

Snow cover

Free
space
Radar

Damaged deck

May lead to lost echo

Fails Safe

May lead to lost and

deflected echo
depending on deck
position
Fails Safe

May lead to some

switch point
deviation (up to
100 mm)
No failure

No Failure

No Failure

No failure

Tuning
Fork

Slide 36

Lost deck

10/01/2013

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Simply reliable: Process safety from Endress+ Hauser

Buncefield report

Buncefield Report:
http://www.buncefieldinvestigation.gov.uk
Slide 37

10/01/2013

Ngo

Simply reliable: Process safety from Endress+ Hauser

Improve safety with state of art technology - Liquiphant

Explosion and fire at Buncefield Oil
Storage Depot - Five companies to
face prosecution
http://www.buncefieldinvestigation.
gov.uk/press/b08002.htm

Failed !!!

Slide 38

10/01/2013

Ngo

Simply reliable: Process safety from Endress+ Hauser

Separation of process monitoring and safety function

Buncefield report, Volume 2, Annex 4, Recommendation 3, page 11

Slide 39

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Level measurement in Oil & Gas

Tuning Fork with diagnostics

Slide 40

10/01/2013

Ngo

Level measurement in Oil & Gas

Furthermore, Safety Integrity Level

Slide 41

10/01/2013

Ngo

Level measurement in Oil & Gas

Vibronic level switches: 300.000 pieces/year

Measuring Principle

Liquiphant in practice

Liquiphipant in safety
Click the blue box
Oil detection in pipes/sump pits

Slide 42

10/01/2013

Ngo

Leakage detection presentation

Level measurement in Oil & Gas

Operation Independent of Medium Properties

changing
media

built-up

suspension

air bubbles

viscosity change
pressure and
temperature change

electrical properties

foam

plant
vibration
Slide 43

10/01/2013

turbulences
Ngo

Safety in the process industry

New: Liquiphant Fail Safe FTL 8x

SIL3 MIN/MAX

4..20mA +
LIVE-Signal
Liquiphant FailSafe FTL80/81/85
Nivotester
FTL825

PLC

Liquiphant FailSafe
FTL80/81/85

Slide 44

Safety function
420 mA output with life signalRisk
(every 3
reduction:
seconds self checking procedure)
~48.000
SIL 3 capable in single device
min/max safety function
proof test simulation with push-button
proof test interval can be extended up to
12 years !

4..20mA +
LIVE-Signal
Optional

10/01/2013

Jana Kurzawa / Hai-Thuy Ngo

API2350 - how to apply on your site?

Thats it relax now it was not that difficult :-D

Slide 45

10/01/2013

Ngo Consult AG Sales Support