Rosemount D Solids Scanners for Bulk Solids Inventory and Financial Reporting

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1 Rosemount D Solids Scanners for Bulk Solids Inventory and Financial Reporting 1 Introduction This technical note provides an overview of the difficulties with inventory and financial reporting of bulk solids products in storage containers, and how the Rosemount D Solids Scanner Series provides the best solution. 2 Overview Accurate volume measurement is the basis for continuous inventory and financial reporting, as well as cost-effective stock management. Measuring the volume of bulk solids is never easy because surfaces are uneven and irregular. The Rosemount D Solids Scanner Series removes the guesswork and replaces it with reliable accuracy in volume measurements. Precise inventory data allows reliable financial reporting and forecasting, and a reduction in costs associated with on-hand and safety stocks.

2 Technical Note 3 Why volume is the key measure Where solids are involved, their dramatic undulating and varying surface makes single-point level measurements in a vessel less than useful as they do not account for the variations caused by peaks and troughs in the surface area. Typically, accuracy is no better than ±10-15% when calculating the volume. New technologies are replacing traditional single-point level measurements with continuous online volume measurement, offering clear visualization of peaks and valleys of the material's surface within vessels. The introduction of 3D solids scanners provides accurate and reliable results, even when measuring uneven or sloping surfaces in dusty conditions. Matching the received data with known container dimensions allows an easy calculation of product volume, enabling the immediate and accurate listing of inventory value for end-of-month accounting and quarterly financial reports. Figure 1-1. Typical Applications for Rosemount D Solids Scanner Series 4 The Rosemount D Solids Scanners Series 4.1 Overview Rosemount 5708V non-contact 3D Solids Scanners Highly accurate readings of level and volume Provides average, minimum, and maximum level/distance measurements Appropriate for vessels up to 40 ft. (12 m) in diameter 2

3 Rosemount 5708S non-contact 3D Solids Scanners Highly accurate readings of level and volume Monitors inventory in large vessels Provides average, minimum, and maximum level/distance measurements Unlimited vessel diameter when using a system of multiple scanners Generates 3D visualization of the stored contents on a remote computer 4.2 How they are installed and configured The Rosemount 5708 Series Reference Manual (document number ) contains full instructions on installation and configuration. It is available electronically on the Rosemount pages at How they work 3D Solids Scanners The Rosemount 5708V and 5708S deliver accurate volumetric measurement of bulk solids and powders. The scanners incorporate unique dust- and vapor-penetrating technology to achieve an unrivaled degree of process measurement and inventory control, regardless of material type, product characteristics, storage type and size, or harshness of the environment. These 3D Solids Scanners from Emerson include an array of three antennas that generate low frequency acoustic signals and receive multiple echo signals from the contents of a storage container. Using these integral antennas, the unit continuously measures not only the time/distance of each echoed signal but also its direction, and generates a coordinate of the echo inside the storage container. The built-in Digital Signal Processor (DSP) digitally samples and analyzes the echoed signals and produces accurate measurements of the level and volume of the stored contents. These measurements are used to generate a 3D representation of the position and form of the material within the container for displaying on remote computer screens. 3DVision/3DMultiVision application software The 3DVision/3DMultiVision application software from Emerson provides real-time assessment of bulk solids and powders in storage containers. The application periodically supplies information, providing the essential real-time data required for critical decisions necessary for successful plant management. 3DVision works with a Rosemount 5708V and 5708S non-contact volumetric scanner providing measurement data to a Windows based computer running the programs. The program continuously collects data from the monitored vessel and generates reports. 3DMultiVision works with a multiple Rosemount 5708V and 5708S non-contact volumetric scanners, enabling a function to applied to grouped vessels across multiple sites. Data is collected from all monitored containers in all sites and geographic regions. That data is combined and merged to generate and analyze various types of reports. 3

4 Technical Note Managers and staff with the appropriate authorization levels can view this data wherever they are over a common LAN, WAN, or wireless communication. Figure 1-2. Example 3DVision Screen 4.4 How they are used Easy calculation of product volume Matching the received data with known container dimensions allows an easy calculation of product volume, enabling the immediate and accurate listing of inventory value for end-of-month accounting and quarterly financial reports. In addition, it allows for an annual or rolling inventory measurement. This is a primary requirement to prevent over- or under-purchasing of products, and eliminate complications which can occur when raising sales orders from potentially inaccurate inventory levels. Reducing on-hand inventory cost Efficient inventory management allows companies to have the right amount of stock in the right place at the right time, and ensures capital is not tied up unnecessarily. Replacing a level measurement device with the Rosemount 5708 Series 3D solids scanner can immediately save between 8% and 13% of the on-hand inventory cost. 4

5 Savings made quickly pay for cost of 3D solids scanner Based on an annual inventory carrying cost of between 25% and 52% of on-hand inventory, this translates into a significant amount of money. A Rosemount D Solids Scanner quickly pays for itself based on the reduction of annual carrying costs, typically within a year. 4.5 Safety stock management To manage inventory uncertainty and avoid fall-out from supply chain problems, most companies carry 'safety stock'. Finding the right balance is essential as the amount of safety stock an organization decides to carry can have a significant financial impact on their business. Too much safety stock increases inventory costs and, because storage times are extended, product can spoil, expire, or be damaged during handling. Conversely, too little safety stock can result in missed sales and disappointed customers, which can adversely affect the company's long-term financial success. Carrying any stock is expensive and safety stocks simply add to this burden. The costs include the following: handling the inventory obsolescence deterioration theft taxes insurance cost of money These costs can be as high as 50% of inventory value on-hand for bulk solid materials, while most organizations use 25% as an estimated figure. These higher costs are a direct result of the uncertainty generated by the inaccuracy of the level measurement of bulk solids. The highly accurate measurement data gives management the confidence to reduce safety stocks, and thereby costs. This safety stock reduction enables management to cope better with any supply chain problem. 5 Conclusion Being able to determine precisely what is in your bulk solids inventory is a vital and useful tool in ensuring accurate financial reporting. Using a Rosemount 5708V or Rosemount 5708S 3D Solids Scanner, removes the guesswork. They are a practical and cost-effective measure that can deliver significant financial benefits. 5

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