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Accurate Level Gauging

Tank Inventory Calculations
By: Chan Sitaram
Senior Training Officer

1
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Document control number
 Introduction

Eerste Nederlandse Röntgen Apparaten Fabrieken

First Netherlands x-Ray Apparatus Factories

1925 Today

Honeywell Enraf training Slide 2

 • Port of Rotterdam: ≥3000 tanks,
90% automatic level gauging
≥95 % Honeywell Enraf
≥ 75% Custody Transfer
Honeywell Enraf training Slide 3
 Tank Inventory Systems
Introduction

• Tank Gauging is the generic name for the static quantity

assessment of liquid products in bulk storage tanks

• Tank Gauging is essential to determine the inventory of

liquid bulk storage tanks.

• The following types of operation can be categorised:

• Inventory Control
• Custody Transfer
• Oil Movement & Operations
• Leak Control & Reconciliation

Honeywell Enraf training Slide 4

 Tank Inventory Systems
Custody Transfer

• Measurement of product transfer

Error
between ship and shore and/or shore
and pipeline transmission systems
(batch dependant).

• Use as verification tool for Flow

meters. Static inventory

• Where Custody Transfer or Batch size

assessment of taxes, duties or
royalties are involved, the complete
system must be officially approved and
certified.

Honeywell Enraf training Slide 5

 Tank Inventory Systems
We think Tank
• Types of tanks:
– Fixed Roof Tanks (Cone Roof)
– Floating Roof tanks
– Pressurized tanks
– Cryogenic tanks
– Refrigerated tanks
– Caverns

Understanding the users Tank Gauging

needs, starts with understanding their
way of storage, i.e. their tanks.

Honeywell Enraf training Slide 6

 Accurate Level Gauging
Understanding Tanks
• Gauging Platform Stability 1)
UR? – Requirement of a stilling well constructed UR
in accordance with W&M requirements.

• Upper Reference Stability 1)

– Generally for temperature influence
and for radar gauges only
– Correction possible as gauge feature

• Hydrostatic Deformation 1)
– Correction possible as gauge feature
(only in absent of stilling well).
ULL
• Tank Shell Thermal Expansion 2)
– I required, correction are done using shell
temperatures and construction details.

• Roof Weight 2)
– Correction possible for a constant Equalization holes
roof weight as a Entis ** feature

• Tank Bottom Movements

– No corrections done because of presence of
datum plate.

1) Feature in level gauge Datum plate

2) Feature in Inventory system

Honeywell Enraf training Slide 7

Accurate Level Gauging
Tank References (1)
• Level measurement is distance measurement,
the distance between product surface and a fixed reference.
The fixed reference can be near the bottom (low reference LR) or at UR
the tank top (upper reference UR) or both.

• ULL (Ullage level) is the distance between an

upper reference [UR] and product surface.
ULL = Ullage
• INN (Innage level) is the distance between
product surface and tank zero.
In tank inventory systems usually innage level is used.
Level
• A Tank zero is a calibrated point required for all distance
measurements.
It is also required to determine the positions of LR and UR in the tank, INN = Innage
however it is not a fixed point nor it is visible in a tank.

LR
Tank zero

Honeywell Proprietary
Slide 8
Accurate Level Gauging
Tank References (2)
• Low Reference is a reference plate, datum or dip plate) and is usually
the plate at the lower end of a guide pipe.
UR
• Low reference is usually the lowest point in tank operation:
– product volume below is referred as dead stock
– dead stock is obtained after calibration.

• The position of Low reference is: ULL = Ullage

– Equal to zero level (0 mm, thus no offset)
or
– Calibrated (level ≠ 0 mm, thus with offset).
– The offset is the distance between the low reference [LR] en the Level
real tank zero and is obtained after a bottom calibration.

• Tanks for custody transfer require a calibrated low reference [LR],

thus requiring a bottom calibration. INN = Innage

LR
Tank zero

Honeywell Proprietary
Slide 9
Accurate Level Gauging
Bottom Calibration (1)
• Preparations before bottom calibration:
– fill and empty new tank few times or keep full for a while to settle.
– clean and dry tank after emptying
• Bottom calibration procedure:
– Manually fill tank with water using calibrated flow meter and
– measure level at North, West, Center, East and South (1m from tank shell).
(Tanks for custody transfer may be provided with these 5 nozzles on the roof).
– calculate average level → L0 = (N+W+4C+E+S)/8.
– procedure produces level L0 and volume V0 (first point of the tank capacity table).
– tank operation (level measurement and volume calculation) below L0 is not allowed.
– obtain the position of Low Reference [LR] and Upper Reference [UR]

W C E
LR
Dipstick
L0 V0
Foundation Foundation

Honeywell Proprietary
Slide 10
Accurate Level Gauging
Bottom Calibration (2)
• Example of a wet calibration of the tank bottom:
– Volume North West Center East South Average N
(liters) (mm) (mm) (mm) (mm) (mm) (mm)
10025 55 40 - 19 45
20007 80 66 - 45 72
40010 123 109 10 87 115 59,25
60024 163 150 51 128 156 100,125
W C E
Bottom calibration produces L0 = 110 mm and V0 = 64859 liters.
• Tank is provided with reference nozzles:
– Position North West Center East South
to bottom 14039 14099 15416 14069 14018

W C E
L0 ,V0 LR
Virtual zero

Honeywell Proprietary
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Accurate Level Gauging
Manual Dipping
• Manual Innage dipping [INN]
– Lower diptape* to [LR];
– Read wet section on diptape; UR
– Product level equals to reading plus offset in [LR]
– Make 3 subsequent dippings.
Result should be within 1 mm form each other, otherwise start all over.

– The average from the 3 dippings is the actual [INN]. ULL

• Manual Ullage dipping [ULL]
– Lower diptape* to product surface;
– Take reading against [UR] Level
– Read wet section on diptape;
– [ULL] is the difference between both readings;
– Make 3 subsequent dippings.
Result should be within 1 mm form each other, otherwise start all over.
INN
– The average from the 3 dippings is the actual [ULL]
– Innage level [INN] = [UR] – [ULL]
LR

Honeywell Proprietary
Slide 12
Accurate Level Gauging
Requirements for manual dipping
• Use of a calibrated diptape.
– A calibrated diptape is certified by W&M authority.
– The certificate includes temperature correction
• Only when product is in rest
– Min. 0.5 hours after last product transfer
• Innage or Ullage dip?
– Innage dipping is required by authorities
- but is complicated (wet and thirty diptape)
- sediments on dip plate causes inaccuracy
– Ullage dipping is preferred
- but requires a stable [UR]
(should not be influenced by Hydrostatic Deformation)

Honeywell Proprietary
Slide 13
Accurate Level Gauging
Hydrostatic Deformation
• Hydrostatic Deformation causes
– Movement of [UR] UR?
– Ullage dipping assumes fixed [UR],
thus causing error in the obtained innage level [INN]

• Ullage dipping is allowed under the conditions that:

– Influence of Hydrostatic Deformation is neglect able low

or
– Using a support pipe to stabilize [UR]
or ULL
– Automatic Hydrostatic Deformation correction in level gauge (basic
feature in all Enraf gauges).

Honeywell Proprietary
Slide 14
Accurate Level Gauging
Stable [UR] with Support pipe
UR
• To obtain a stable [UR] the support pipe must not be fixed
– On the tank roof it can be fixed on the lowest
– On the tank bottom ring of the tank which is stable
– On the tank shell because of the tank foundation

• Other requirements for the support pipe

– Diameter: min. 2” for manual dipping;
min. 6” for level gauge;
– Bottom end provided with dip plate;
– Free of rust, welding joints or other irregularities,
should be straight and vertical;
– Provided with sufficient holes:
- diameter approx. 25 mm (1”) A A
- pitch approx. 300 mm (1 ‘)

cross section A-A

Honeywell Proprietary
Slide 15
Accurate Level Gauging
Hydrostatic Deformation correction
• Required when gauge nozzle is fixed to the roof
– Roof moves with level changes
– Movement is not linear, but is “linearized”,
correction acc. to OIML recommendation ISO 7507-1
• INC = INN – (INN-HL)HF
– INC is innage level after Hydr. Def. correction
HL is Hydrostatic deformation Level
HF is Hydrostatic deformation Factor INN
INC
– Set DE to C to show INC on display and host

Level
Error X
12
X HF = 0.75 mm/m
8 HL = 4 m
X
HF
X
4
X
X
0 X
4 8 12 16 20
Level
HL

Honeywell Proprietary
Slide 16
Accurate Level Gauging
Tank Capacity Table TCT
• Fixed or Floating roof tanks are build up in several rings, with
– Each ring having his own shell thickness and diameter;
– Each ring being cylindrical, thus linear Ln ,Vn
• First a raw TCT is obtained via the “dry method”: Ring n
– From each ring the inner diameters are measured
physically (using laser-lines from tank center) Dn0
Ln-1 ,Vn-1
– From the known ring heights the volume of each
ring is calculated resulting in a preliminary table
– All other additional volumes are taken into account:
- inlet(s) and outlet(s) L3 ,V3 D40
- objects in tank like heating coils, mixers etc. D31
• The final TCT is specified by adding corrections for: Ring 3
– Hydrostatic Deformation mathematical corrections D30
- at operating temperature and product density L2 ,V2 D21
- deviations at other temperatures and product densities
– Roof weight corrections by specifying roof weight and Ring 2
forbidden zone (take off and support levels) L1 ,V1 D20
– Specifying uncertainties and D11
tank construction details Ring 1
∇V
D10
L0 ,V0
Tank zero
Foundation

Honeywell Proprietary
Slide 17
Accurate Level Gauging
Tank Capacity Table TCT (example)

Automatic Volume calculations

Volume at level L = A0 +A1*(L-H1) Tank 4567: cylindrical tank with floating roof:
shell temp. 15 °C and liquid density 840 kg/m3
H1 (mm) H2 (mm) A0 (l) A1 (l/mm)
0 110 *** ***
Deviations:
110 410 64 859 490.511
Product density: A change in density of less than 250
410 860 212 016 490.860 kg/m3 cause a change of volume of max. 0.05 %
860 423 903
Shell temperature: changes in volume as a result of
860 1 400 *** *** different shell temperature t can be corrected with the
1 400 5 030 697 666 490.316 following formula:
5 030 7 500 2 477 510 489.913 Vt = V * {1 + α (t – 15)} with α = thermal expansion
7 500 12 690 3 687 593 489.586 coefficient.
12 690 13 310 6 228 542 489.488
13 310 6 532 025 Roof: Weight 9344 kg
Take of 1395 mm
Support 865 mm
Enraf volume calculation at measured level (mm)
TOV = A0n-1 + (Level – H1n)* (A0n - A0n-1)/(H1n - H1n-1)

Honeywell Proprietary
Slide 18
Accurate Level Gauging
Tank Capacity Table TCT (example)
Manual Volume calculations
From (cm) Untill (cm) 1 (mm) 2 (mm) 3 (mm) 4 (mm) 5 (mm) 6 (mm) 7 (mm) 8 (mm) 9 (mm)
0 11 *** *** *** *** *** *** *** *** ***
11 41 491 981 1472 1962 2453 2943 3434 3924 4415
41 86 491 982 1473 1963 2454 2945 3436 3927 4418
86 1 40 *** *** *** *** *** **** **** **** ****
1 40 5 03 490 981 1471 1961 2452 2942 3432 3923 4413
5 03 7 50 490 980 1470 1960 2450 2939 3429 3919 4413
7 50 12 69 490 979 1569 1958 2448 2938 3427 3917 4406
12 69 13 31 489 979 1468 1958 2447 2937 3426 3916 4405

Level (cm) Vol. (l) Level (cm) Vol. (l)

Level (cm) Vol. (l)
9 ***
31 162 946
1 311 6 434 124 Tank table:
10 *** 1 312 6 439 019
11 64 859 32 167 851 1 313 6 443 914
12 69 763 33 172 755 1 314 6 448 809 Volume as function of the
13 74 668 34 177 661 1 315 6 453 704
14 79 572 35 182 568 1 316 6 458 599 average innage level.
15 84 476 36 187 475 1 317 6 463 494
16 89 381 37 192 381 1 318 6 468 389
17 94 285 38 197 289 1 319 6 473 284
18 99 189 39 202 198 1 320 6 478 179
19 104 094 40 207 107 1 321 6 483 074
20 108 998 1 300 6 380 280 1 322 6 487 969
` 21 113 902 1 301 6 385 174 1 323 6 492 864
22 118 807 1 302 6 290 069 1 324 6 497 759
23 123 711 1 303 6 394 964 1 325 6 502 654
24 128 616 1 304 6 399 859 1 326 6 507 549
25 133 520 1 305 6 404 754 1 327 6 512 444
26 138 424 1 306 6 409 649 1 328 6 517 339
27 143 329 1 307 6 414 544 1 329 6 522 234
28 148 233 1 308 6 419 439 1 330 6 527 130
29 153 138 1 309 6 424 334 1 331 6 532 025
30 158 042 1 310 6 429 229 (end of table)

Honeywell Proprietary
Slide 19
 Accurate Level Gauging
Volume calculation with Floating Roof
• Calculations zones:
1. Level ≥Roof Take Off level
Calculation with Roof weight correction
2. Level between Roof Support – Roof Take Off
No Go Zone, No volume calculation
(calculation not accurate)
3. Level ≤ Roof Support level
Calculation without Roof weight correction Lm Measured Level
LR Real Level

Volume calculation at measured level Strap Ln Vn

TOV = (Lm – Ln)* (Vn - Vn-1)/(Ln - Ln-1)

Floating roof with adj. roof supporting legs
Volume after Roof weight correction:
GOV = TOV – (Roof weight / density) Strap Ln-1 Vn-1

Roof Take Off

Roof Support No Go zone

Ref. plate
Tank Zero

Honeywell Proprietary
Slide 20
 [Link]

Tank Inventory Calculations

By: Chan Sitaram

Senior Training Officer

21
Honeywell Proprietary
Document control number
 Tank Inventory Calculations
Observed Volumes TOV/GOV

• TOV = Total Observed Volume or “Total”

Ln ,Vn
– Volume at measured innage level
– Linear interpolation in TCT

• GOV = Gross Observed Volume or “Gross”

– BSW = Base Sediment and Water
- also referred as “Water” L3 ,V3
- volume at measured water interface
calculated from the TCT
Level
TOV
L2 ,V2
– GOV = TOV – Water
- corrected for: GOV
- roof weight (floating roof tanks only) INN
L1 ,V1
- tank shell temperature (if required)

Water
L0 ,V0
Tank zero BSW

Honeywell Proprietary
Slide 22
 Tank Inventory Calculations Dn0
Reference Volumes GSV
• GSV = Gross Standard Volume or “Net”
– GOV is “Volume at actual temperature”
Ln ,Vn
– GSV is “Volume at reference temperature”
• GSV = GOV * VCF
– VCF = Volume Correction Factor
- VCF is the relative change in volume if
product temperature is changed from
TACT (actual temperature) to
L3 ,V3
TREF (reference temperature).

Level
– VCF is derived (calculated) from TOV
ASTM/API tables or other formulas. L2 ,V2

– VCF >1 if TREF > TACT GOV INN

VCF = 1 if TREF = TACT L1 ,V1
VCF < 1 if TREF < TACT.

Water
L0 ,V0
Tank zero BSW

Honeywell Proprietary
Slide 23
 Tank Inventory Calculations
Volume Correction Factor VCF
• For Hydrocarbons VCF is calculated from
API/ASTM tables, e.g. ASTM 53, 54 DOBS DREF
– ASTM 53: automatic density (DOBS)
(For not pressurized tanks) ASTM-53
– ASTM 54: manual density (DREF) VCF
TPROD
GSV (Ref. Volume)
VCF =
GOV(Observed Volume) TREF P-CODE

DOBS (density at prod. temp. TPROD) DREF TCF

VCF =
DREF (density at ref. temp. TREF) ASTM-54
VCF
TPROD
P-CODE: A for Crude
B for Refined products TREF P-CODE
C for special products
D for Lubricants
E for light Hydrocarbons (LPG)

Honeywell Proprietary
Slide 24
 Tank Inventory Calculations
Final Reference Volumes GSV-NSV-TGSV
• NSV = Net Standard Volume is the reference volume without Sed. & Water
NSV = GSV*(100-S&W%)/100
– S&W% is obtained by product analyzing.
• TGSV = Total Gross Standard Volume is the reference volume including “vapor as
liquid”. The calculation is based on:
– Vapor to Liquid method
– Molecular structure method.

TGSV

GSV None GSV

NSV

Honeywell Proprietary
Slide 25
 Tank Inventory Calculations
Mass Calculations DREF of DOBS (HTG/HIMS)

• Mass can be calculated using:

– Reference Density DREF (dip or sampled density)
– Observed Density DOBS (Hydrostatic density, using Smart Pressure Transmitters)

• DREF from Dipped or Sampled Density :

– Mass in vacuum: Mass = DREF * GSV (TGSV or NSV if available)
– Mass in air: Mass = (DREF-DAIR) * GSV (TGSV or NSV is available)

• DOBS from Hydrostatic pressure (HTG or HIMS)

– Mass in vacuum: Mass = DOBS * GOV
– Mass in air: Mass = (DOBS-DAIR) * GOV

Honeywell Proprietary
Slide 26
 Tank Inventory Calculations
Overview Inventory Calculations

Observed Volume Reference Volume

Views
TOV GOV GSV NSV TGSV Mass

TCF VCF
VOL BSW Calculations S&W GasVol

TCT TCT ASTM or API Corrections *DREF

Field Data S&W%.

Prod. Level Water Level Prod. Temp. Sampled Dens Vapor Temp. Vapor Press.

TOV = Total Observed Volume

GOV = Gross Observed Volume, corrected for:
- tank shell temp. and/or
TCT = Total Capacity Table ASTM = American Standard of Testing Materials - roof weight.
BSW = Base Sediment and Water API = American Petrol Institute GSV = Gross Standard Volume
TCF = Thermal Expansion Coefficient GasVol = Volume of vapor as liquid NSV = Net Standard Volume
VCF = Volume Correction Factor DREF = Density at reference temperature TGSV = Total Gross Standard Volume

Honeywell Proprietary
Slide 27
 Tank Inventory Calculations
Operational Inventory Data

Shell capacity = utmost maximum volume what the tank can have.
Shell capacity
High TOV = Safe fill (usually the high alarm of the tank). High TOV
Available room = the empty room of the tank at this moment.

TOV = Total Observed Volume at actual level.

Available room
GOV = Gross Observed Volume (TOV - Water).

Available GOV = the transferable product from the tank .

Low TOV = the low stop of product transfer in normal operation

(usually the low alarm of the tank). TOV Level
Water = the amount of “sediment and water” in the tank.

BSW = Base sediment and water. Available GOV

GOV

Low TOV

Water
BSW

Honeywell Proprietary
Slide 28
 Tank Inventory Systems
Sampling or Standpipe for
Aspects of Automatic Tank Gauging Manual Dip level gauge Thermo well

STATIC QUANTITY ASSESSMENT Shell capacity

Overfill Prot.
Shell capacity = utmost maximum volume what the tank can hold. High TOV

Overfill Prot. = Automatic Overfill trip independent from tank inventory system.

High TOV = Safe fill (usually the gauged high alarm of the tank).
Available room
Available room = the empty room in the tank at this moment.

TOV = Total Observed Volume at actual level.

GOV = Gross Observed Volume (TOV - Water).

TOV Level
Available GOV = the transferable product from the tank .

Low TOV = the low stop of product transfer in normal operation

Available GOV
(usually the low alarm of the tank).
GOV / GSV
S&W% = Sediment and Water mixed with product S&W%
Water = the amount of “sediment and water” in the tank. Low TOV
BSW = Base sediment and water.
Water
BSW

Honeywell Proprietary
Slide 29
 [Link]

Questions
Accurate Level Gauging
Tank Inventory Calculations

By: Chan Sitaram

Senior Training Officer

30
Honeywell Proprietary
Document control number