Rosemount™

Tank Gauging
System Upgrades
Contents
Simple enhancement of existing tank gauging systems 3

Modern tank gauging technology 4–5

Replacing old gauge technology 6

Hardware upgrade options 7

Retain existing antenna upgrading radar 8

Upgrading the field communication unit 9

Emulation provides easy way of upgrading old technology 10

Rosemount TankMaster Inventory Management 11

Software license key

Rosemount TankMaster Mobile Inventory Management 12

Software

Overfill prevention 13

Overfill prevention technologies 14

Wireless enables installations in locations 15

previously not possible

Tank survey 16

2
Simple enhancement of existing tank gauging systems
If you have an ageing tank gauging system
incorporating old radars or even servo
technology, you may have considered
upgrading to a new system to ensure
measurement reliability, reduce maintenance
and increase safety, but decided the project
time and cost was prohibitive. Upgrading
your existing tank gauging system with the
latest Rosemount hardware and software
can help to enhance safety, maximize
tank availability and increase operational
efficiency. Whether performing a complete
system/radar level gauge hardware
replacement or partial replacement of radar
level gauge electronics, the ability to upgrade
at your own pace and retain existing parts
and communication infrastructure helps to
reduce project complexity and cost.

Key benefits:
• Eliminate sourcing issues for obsolete parts that create • Meet the latest safety regulations by adding an
the risk of costly shutdowns independent safety layer without tank modification

• Increase measurement accuracy and reliability for • Improve worker safety and increase tank availability with
improved inventory management remote proof-testing

• Reduce the risk of an overfill with higher SIL rating • Get early warnings of roof tilting and avoid tank damage
with automated floating roof monitoring

3
Modern tank gauging technology
Emerson offers a broad range of advanced tank gauging and level measurement
technology, including non-contacting radar gauges, temperature transmitters, data
collectors and inventory management software.

Rosemount 5900S and 5900C Radar Level Gauges

Highest performance non-contacting level measurement technology for reliable tank
gauging and tank monitoring provides certified custody transfer accuracy, better
inventory management and reliable loss control data.
• Instrument accuracy ± 0.02 in. (0.5 mm) / ±0.04 in. (1 mm)
• Certified IEC 61508 SIL 2/SIL 3 capable
•A
 ntennas available for all tank types and suitable for all products, ranging from
liquefied gases to light products, heavy fuel oil and bitumen

Rosemount 5408 Level Transmitter

Non-contacting radar level transmitter for tank monitoring applications, engineered
for ease-of-use.
• ±0.08 in. (2 mm) non-contacting measurement for medium accuracy, non-inventory
grade, and difficult process applications
•S
 IL 2 capable version available for overfill prevention applications, with 4-20mA
HART® communications for direct connection to safety instrumented system

Rosemount 2410 Tank Hub

Handles the data communication between the field devices and control room, while also
providing power to field devices using the FISCO-compliant, intrinsically safe Tankbus.
• Collects and transfers data from one or multiple tanks
•C
 ommunication options include Modbus, IEC 62591 (WirelessHART® protocol) and
emulation of other vendors’ protocols
• Enables SIL certified overfill prevention

4
Rosemount 2460 System Hub
Transfers real-time tank gauging data from field devices to the Rosemount TankMaster
Inventory Management Software and the host/distributed control system.
• Ensures fast update rate
• Supports up to 64 tanks
• Provides flexible and configurable connectivity, redundancy and emulation of other
vendors’ devices.

Temperature, pressure, displays and wireless gateways

Existing temperature sensors, pressure instrumentation, graphical displays and
wireless gateways can be retained or upgraded to the latest technology including:
•R
 osemount 2240S Multi-input Temperature Transmitter for up to 16
temperature spot elements
•R
 osemount 2230 Graphical Field Display can provide local visualization for up to
10 tanks and is designed for installation in hazardous (Ex) locations
•B
 road range of pressure measurement technology to suit virtually every
application, providing unmatched reliability and improved capabilities
•E
 merson Wireless 1410S Gateway with 781S Smart Antenna helps strengthen
or add to WirelessHART® networks seamlessly; enables flexible remote antenna
locations of up to 1300 feet (400 m)

Control room software

Rosemount TankMaster Inventory Management Software collects real-time tank
gauging data and automatically calculates volume and mass for inventory and
custody transfer.
• Free upgrade to latest version of Rosemount TankMaster software
•P
 rovides operator overview, configuration, set-up and service for Rosemount Tank
Gauging Systems
•O
 ption to add Rosemount TankMaster Mobile software for quick and remote access
to tank information via standard web browsers, tablets and smartphones

5
Replacing old gauge Accuracy requirements

technology
The level of measurement accuracy required for your specific application will
determine the appropriate technology to upgrade to.

Old Rosemount and Saab radar gauges can be replaced by the Rosemount
Tank gauging radars: Tank level monitoring radars:
5900S and Rosemount 5900C Radar Level Gauges, and Rosemount 5408 Accuracy: ± 0.04 in. (1mm) / ±0.8 in. (2 mm)
Accuracy: ± 0.02 in. (0.5 mm)
Non-Contacting Radar Level Transmitters.

Rosemount 5900S
• Suitable for tank gauging with best-in-class accuracy
• The 5900S is ideally suited to replace the Rex, Pro or Saab TankRadar L/2

Rosemount 5900C
• Suitable for less demanding tank gauging applications, tank monitoring in
still-pipes, certain LPG installations and floating roof monitoring Rex Saab Pro
TankRadar L/2
• The 5900C is ideally suited to replace the Pro in most applications

Rosemount 5408U
• Suitable for tank monitoring, floating roof monitoring and difficult process
applications
• The 5408U is ideally suited to replace the Pro in most applications

Servo and displacer technology has many moving parts that are susceptible to
mechanical wear, increasing maintenance requirements and the likelihood of
failure. These devices can also be replaced by Rosemount radar level gauges
and transmitters.

5900S 5900C 5408

6
Hardware upgrade options
Full hardware upgrades
A complete upgrade of both radar gauge/transmitter
and antenna allows you to gain the full benefits of the
latest technology, including improved measurement
performance and accuracy. Existing wiring infrastructure
Play video
can be used to minimize project complexity.

Partial hardware upgrades

A partial upgrade involves the replacement of the
transmitter head, but retaining the existing antenna.
This further reduces time and cost and with no need to
open tank connections, avoids interruption to normal
operations.

7
Retain existing
antenna when
upgrading radar
If you are replacing the Rosemount TankRadar
Rex, Pro or Saab TankRadar L/2, it is possible to
perform a partial upgrade, whereby the existing
antenna is retained and only the transmitter head
is replaced. This helps to save time and cost and
reduce complexity. Installation is simple.

A range of upgrade kits are available for the

TankRadar Rex with LNG and LPG antenna:
• With new LPG seal
• With/without pressure transmitter
• With different Ex certificates

8
Upgrading the field communication unit
2160/2165/2175 Field Communication Unit
The FCU 2160 is now in a ‘supported phase’ (spare parts
only available until July 1, 2025). A tank gauging system
with Rosemount 5900 Radar Level Gauges can operate
with FCUs that utilize software version 3.D1 or later
Play video
(released November 2002).
Older FCUs need to be upgraded to the 2460 System
Hub. FCU 2165 and FCU 2175 are now obsolete and
can also be replaced with the 2460 System Hub, which
supports most of the emulation protocols available in the
FCU 2165 and FCU 2175.

9
Emulation provides an easy and cost-efficient way of
upgrading technology
Replacing a complete tank gauging system can be cost prohibitive
and impact operations. Emerson’s Rosemount 2410 Tank Hub and Rosemount
Rosemount 2460 System Hub enable new gauges to communicate Inventory software from Host/DCS TankMaster
another supplier Disconnect existing cabling.
using vendor specific communication protocols with the existing
inventory software system or old gauges to communicate with a
new inventory software system. This makes it possible to perform
easy and cost-efficient tank gauging upgrades and benefit from the
performance and reliability of modern radar gauge technology.

Rosemount
Key benefits: 2460
System Hub
• Replace old servo or radar gauges, while retaining Remove the old gauge.
existing tank management system
Gauges from another
• Replace tank management system, while retaining supplier
existing field devices Rosemount
2410 Tank
• Improve measurement accuracy and operational safety Hub
• Ability to replace one gauge at a time, with no need for
large-scale CAPEX project
• Minimal disruption to operations Rosemount
Mount the antenna.
5900S
• Enable automated floating roof monitoring

Install radar and re-connect

wiring.

10
Rosemount
TankMaster Inventory
Management
Software license key
When upgrading Rosemount TankMaster, you may need a
new license key. If existing TankMaster is version 5.B0 or
previous, the hardware key must be upgraded. If existing
TankMaster version is 6.A1 or later, there is no need to
upgrade the key and the existing key can be used.

11
Rosemount
TankMaster Mobile
Inventory Management
Software
Existing users of Rosemount TankMaster can easily add
TankMaster Mobile, which provides instant access, via
smartphones, tablets and computers, to all tank and
inventory information from anywhere, at any time.
This helps to improve operational efficiency, operator
productivity and collaboration throughout the supply chain.

Play video

12
 Overfill prevention
Automatic Overfill Prevention System (AOPS) Automatic Tank Gauging (ATG) Robust overfill prevention systems that comply with industry
safety standards are essential to reduce risk in process vessels

Overfill

Level
Rosemount and bulk liquid storage tanks. Emerson has a comprehensive
Safety portfolio of certified products, including continuous level
Instrumented SIL 2 2240S with
Multiple Point
System (SIS) Rosemount 5900S Temperature measurement and point level detection devices, to support
2-in-1 Radar your vision for preventing overfills, and keeping people
Level Gauge Rosemount 2230
Graphical Field and the environment safe. A 2-in-1 radar level gauge helps
Display
to simplifying installations by enabling both inventory
measurements and overfill prevention to be performed by a
single device that requires just one tank opening.

Selecting the right overfill prevention solution is not easy.

You need to ask a number of questions, including:
SIL 2 Relay and/or • Do you need a continuous level device or point detection?
4-20 mA Analog Signal
• What is the media you are measuring?
• What kind of tank is it and what is its size?
• Do I have enough tank openings to add overfill prevention or
will the tank require modification?
Rosemount 2410 Rosemount 2410
Tank Hub Tank Hub

Our team of experts can advise you and guide you through
TankMaster Inventory
Management Software selecting the solution that best meets your needs.
Connection to
TankMaster
(optional)

Rosemount 2460 Rosemount 2460

System Hub System Hub

Includes Visual & Audible Level Alert High

and Level Alarm High-High (optional)

13
Overfill prevention technologies
Continuous Measurement Solutions Point Level Detection Solutions
Rosemount 5900S Radar Level Gauge Rosemount 2140:SIS Level Detector – Vibrating Fork
For bulk storage applications. 2-in-1 functionality enables combined basic Next generation point level overfill prevention with smart diagnostics and
process control and overfill application in a single device. remote functionality.

Rosemount 5900C Radar Level Gauge Rosemount 2130 Level Switch – Vibrating Fork
For continuous surveillance in bulk storage applications. Flexible switch, suitable for more challenging conditions.

Rosemount 5408/5408:SIS Level Transmitter Rosemount 2120 Level Switch – Vibrating Fork
Non-contacting radar level transmitter for tank monitoring applications, Simple, cost-effective and flexible switch, suitable for most liquid types.
delivering reliable measurement of both liquid and solid materials. Engineered
for ease-of-use.

Rosemount 5300 Level Transmitter – Guided Wave Radar

Market-leading guided wave radar with state-of-the-art reliability and safety
features, plus powerful built-in diagnostics.

14
Wireless enables
installations in locations
previously not possible
Wireless technology is used widely within the process industry and
Emerson’s WirelessHART® networks and wireless tank gauging systems
enable applications that were previously not viable, by removing the
need for new costly and complex cable infrastructure to be installed.

Key benefits:
• Reduce installation time and costs
• Eliminate the need for new cabling over long distances
•G
 et online monitoring data from previously unreachable tanks

Suitable for non-SIS overfill

protection layers
Although the use of wireless
technology is not permitted within
safety instrumented systems (SIS),
the API 2350 standard related to the
safety of large tanks, deems digital
wireless networks as an acceptable
means of deploying non-SIS overfill
protection layers.

15
Tank survey
Emerson’s engineering and applications team can review
your existing tank gauging solution and provide an overview
of potential adjustments and improvements to ensure
greater system availability, performance and safety.

Commissioning and start-up service

Emerson’s lifecycle services provides commissioning and
start-up services tailored to Rosemount tank gauging
products and systems. Our team will perform standardized
procedures that follow best practices aimed at increasing
plant performance.
• Experienced and certified technicians will commission
Rosemount products
• Mechanical and electrical installation is validated to ensure
Rosemount products operate correctly
• Product performance is verified under operating conditions
• Emerson start-up and commissioning services extends the
warranty period from one to three years

16
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