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O M N T E C M F G . , I N C .

FuelCheck® Installation &Operating Manual

Document 600300 rev1-1.doc Revised 11-07-2011

OMNTEC Mfg., Inc.

1993 Pond Road Ronkonkoma, NY 11779 USA

Phone (631) 981-2001 • Fax (631) 981-2007 www.innovative-sensor.com

2

TABLE OF CONTENTS

System Overview _____________________________________________________________________________________________ 3

Principle of Operation _________________________________________________________________________________________ 4

FuelCheck® Probe ____________________________________________________________________________________________ 5 Probe Construction ________________________________________________________________________________________ 5 Probe Location Considerations _______________________________________________________________________________ 6 Probe Insertion and retraction ________________________________________________________________________________ 7 Initial FuelCheck® SAE (standard) probe Installation ____________________________________________________________ 9 FUELCHECK® PROBE REMOVAL WITH (LINE PRESSURE < 300 PSI)__________________________________________ 13 FUELCHECK® PROBE REINSERTION with (PRESSURE <300 PSI)______________________________________________ 15

Fiberoptic Interconnect Cable __________________________________________________________________________________ 17

FuelCheck® Controller ________________________________________________________________________________________ 21

System Calibration ___________________________________________________________________________________________ 25

Fluid Temperature Correction __________________________________________________________________________________ 28

FuelCheck® System Specifications ______________________________________________________________________________ 30 FuelCheck® Probe ________________________________________________________________________________________ 30 FuelCheck® Controller ____________________________________________________________________________________ 30

Optional Equipment Installed in Controllers with Serial Numbers ______________________________________________________ 31

APPENDIX A Warranty and Disclaimer__________________________________________________________________________ 35

APPENDIX B Acromag Series 611T/612T SIGNAL CONDITIONER _________________________________________________ 37

APPENDIX C OMEGA CN132 TEMPERATURE CONTROLLER ___________________________________________________ 38

APPENDIX D Acromag BusWorks® Model 952N-4012 Modbus TCP/IP Industrial I/O Module __________________________ 39

APPENDIX E Fiberoptic Connectorizing Kit ______________________________________________________________________ 40

APPENDIX F UV Resistant Cable Additional Documentation ________________________________________________________ 41

3

System Overview FuelCheck® is a totally fiberoptic process refractometry system designed to provide accurate interface discrimination in product pipelines.

FuelCheck® Is comprised of 3 basic components; namely: 1. FuelCheck® Probe

Part No. FU-PR-24 2. Fiberoptic interconnect cable

Part No. FU-C2-CC (conduit cable) FU-C2-DB (direct burial) FU-C2-UV (UV resistant) 3. FuelCheck® Controller

Part No. FU-CT-*I (* represents number of channels up to 3, ie. FU-CT-1I)

FuelCheck® is designed for easy installation, convenient calibration, and very low maintenance. The following chapters will describe the principle of operation, installation considerations, and system calibration and operation.

Figure 1

FuelCheck System Architecture

Chapter

1

4

Principle of Operation FuelCheck® is a totally fiberoptic system for measuring the index of refraction of fluids in petro-leum pipelines.

The FuelCheck® Controller incorporates an extremely stable fiberoptic light source and detector. This stability is provided by maintaining the source and detector circuitry at a constant tempera-ture. Light from the infrared LED light source is coupled into the source fiber of the fiberoptic in-terconnect cable. The FuelCheck® Probe reflects light from the source fiber to the detector fiber. Some of the light is refracted into the fluid in which the probe lens is immersed. The amount of light that is refracted (lost) from the lens is directly proportional to the index of refraction of the fluid in which the probe lens is immersed. Thus, the higher the fluid’s index of refraction, the less amount of light is returned to the detector in the FuelCheck® Controller.

5 mm

1. Sensor is a 5 mm diameter sapphire hemisphere.

2. Optical fibers are very precisely fused onto the flat side of the lens.

3. An LED is used to provide constant intensity light to the lens through either of the fibers. (LED located in the FuelCheck Controller, up to 2 km away from sensor)

4. The inner surface of the lens acts as a mirror: some of the light reflects inside the lens; however, some light refracts out of the lens into whatever fluid is wetting the lens. The amount of light lost to refraction is directly proportional to the refractive index of the fluid wetting the lens.

5. Whatever light is not lost to refraction returns to the FuelCheck Controller via the other fiber where its intensity is precisely measured and converted to a scaled value.

reflectedlight

refractedlight

fiberoptic lengthup to 2 km

FuelCheckFuelCheck Operating Principle

Figure 2

Principle of Operation

5

FuelCheck® Probe Part No. FU-PR-24

The FuelCheck® Probe is readily installed into the pipeline through a full opening valve. Its in-stallation should ensure constant contact with fluids to ensure instantaneous and positive inter-face detection.

Probe Construction The FuelCheck® Probe, part number FU-PR-24, is constructed of heavy-wall ½” OD stainless steel tubing. Standard probe length is 24” giving an insertion length of 16” from the top of the valve to the ID of the pipeline. With probe and insertion tool changes, the Probe can be made in virtually any length so as to accommodate almost any installation requirement. The maximum operating pressure and temperature are 1,500 PSI @ 200°F. The materials of construc-tion allow for use in all petro-leum fuels with all known additives, including MTBE. The sapphire lens is ex-tremely resistant to both chemicals and abrasion.

The sensor element incor-porates an o-ring seal with a Teflon backup seal. The sensor element cannot be replaced therefore replacing the probe will be required if the probe is moved or crimped at the wrong loca-tion on the probe body. The probe incorporates a safety stop which is an 11/16” OD upset welded onto the probe body to prevent the probe from passing through the process insertion fit-ting.

Chapter

2

FuelCheck® Probe

process insertion fitting

insertion tool adapter

pipeline access valve(>= 1” full-opening)

threadolet (>=2”)

flexible armor

probe body

conduit J-box

Figure 3

FuelCheck Probe installed in pipeline

6

The process insertion fitting is a specially modified bored-through Swagelok tubing adapter. An internal o-ring groove incorporating a back-up ring has been machined into the fitting to provide a pressure seal with the probe body during process insertion and retraction. The process insertion fitting is an integral part of the FuelCheck® probe and cannot be removed in the field.

The Insertion Tool adapter en-ables the use of the high pressure probe Insertion Tool in the event that the probe must be inserted or removed from the process at pressures exceeding 300 PSI. Even if the process pressure is never expected to exceed 300 PSI, it is recommended that this adapter be used as a safety fea-ture so that the probe could be removed in the event of an emer-gency.

The top end of the probe is at-tached to a length of 3/8” OD stainless steel flexible conduit (“armor”) providing protection for the fiberoptic probe lead. Stan-dard length is 120”. This armor is terminated in a ½” MNPT conduit fitting which is attached to the probe junction box. The fiberoptic leads are terminated with ST type fiberoptic connectors which attach to the fiberoptic interconnect cable leading to the FuelCheck® Con-troller.

A fiberglass junction box (J-Box) is provided to protect the fiberoptic

connection between the probe and the fiberoptic interconnect cable. This J-box is normally the terminus of a rigid or EMT conduit installed to protect the fiberoptic interconnect cable.

Probe Location Considerations FuelCheck® probes can be installed through any full-opening valve with an inside diameter (ID) of 1” or larger; however, several considerations should be observed in order to provide optimum performance. It is strongly recommended that the probe be installed such that its tip not protrude past the inside wall of the pipeline. If the probe extends into the pipeline, damage to the pipeline and probe can result by pigging the line without removal of the probe. If the probe location is not to be pigged, the probe can be installed into the pipeline to the desired length but fluid velocity

Figure 4

Process Insertion O-Rings

7

and fluid density should be considered to insure any type of harmful harmonics are produced (Call ISS Ltd for harmonic calculation if required).

When the probe is to be installed flush with the ID of the pipeline so as to accommodate pigging, several factors must be considered. First, it is recommended that the fixture (i.e., weldolet) in which the tip of the probe (i.e., the sensor element) will reside be of sufficient diameter and suit-able location such that fluid turbulence will provide adequate sampling. If this fixture is too small, fluid stagnation could occur resulting in a failure of the system to detect the interface. It is there-

fore recommended that the probe inser-tion weldolet be at least 1” in diameter so that adequate mixing takes place thus allowing for very rapid interface detection. It is also important that the weldolet bit size be as large as possi-ble. Too often, it has been observed that a large weldolet was installed but that the hole bored through the pipeline was very small.

The location and orientation of the probe insertion weldolet is also impor-tant. Placing the probe near an elbow in the line will provide greater turbu-lence and more rapid interface detec-tion. Insertion of the probe in the top of the pipeline should be avoided since a vapor pocket could develop in the wel-

dolet. Insertion from 45° from vertical to the side is preferable, though care must be taken to provide sufficient clearance for convenient installation and removal.

Some general recommendations for probe location and orientation are as follows:

1. Try to mount the FuelCheck probe in a location where the pipe is always full, even when the line is not flowing.

2. NEVER mount the FuelCheck probe on a densitometer loop.

3. Never mount the probe on the top of the pipe since vapor can get trapped there.

4. Never mount the probe on the bottom of the pipeline because the threadolet can become filled with dirt, rust, or other particles from the pipeline.

Probe Insertion and retraction The FuelCheck® Probe has been designed to be safely inserted into and retracted from the process. These instructions must be followed to prevent injury and damage to the equipment.

Figure 5

Suggested Probe Installation Method

8

Appropriate safety equipment should always be used (i.e., safety glasses, and fire-retardant clothing).

The probe should always be installed in close proximity to a reliable pressure gauge or the pres-sure must be known when performing these operations. When installing a FuelCheck® Probe for the first time, the following procedures must be followed. It is imperative that all client safety procedures be followed explicitly, and that engineering specifications (i.e., threaded connection compounds, sealants, tightening torque, etc.) be strictly adhered to. Probe installation, removal, insertion, retraction, etc. should only be undertaken by qualified and authorized personnel. These procedures require 2 people to perform the operation.

Note - Probe Insertion and Retraction instructions included in this manual are for low (<300 PSI) and high pressure (>300 PSI) applications. Select correct procedure for operation desired. Each procedure has its on tools and operating instructions and will require special training before per-forming operation.

Figure 6

Low Pressure Insertion

9

Initial FuelCheck® SAE (standard) probe Installation

Low Pressure Installation

IMPORTANT: Note line pressure. If over 300 PSI (2000 kPa) follow instructions for high-pressure installation.

NOTE - Make Initial measurement “A” before starting to install probe into pipeline.

1. Use Teflon tape or required sealing compo-nents on the Insertion Tool Adapter and in-stall Adapter on the Valve. Measure precise length from pipeline to the to top of Insertion Tool Adapter (Figure 3). Record this length as measurement “A”.

2. Use ½ of the wall thickness on the pipeline to ensure the tip of the probe is not intruding into the pipeline. Calculate and record Probe

o-ring groovemachined into fitting

sensor element

safety stop

access valve

Insertion Tool Adapter

ENLARGEDCUTAWAY

Process Insertion Fitting

SAE/MS STRAIGHT THREAD

Insertion Tool Adapter

Valve

A

Figure 7

Probe Alignment

Figure 8

Insertion Valve measurement

10

Insertion Length (L) as follows:

L = A + ½ wall thickness

3. Clean and lubricate exposed probe body using light machine oil or a grease to avoid damag-ing o-ring seals.

4. Tighten the Hex cap on the Process Insertion Fitting. Move the Process Insertion Fitting up the probe body until the exact distance calculated in Step 2 is reached. This distance L, will be from the bottom of the probe body to the bottom of the Hex nut on the Process Insertion Fitting. Make a mark on probe body at the top of the hex cap (Figure 4) using an indelible marker.

5. Apply a lubricant to the probe body. Slide the Process Insertion Fitting down the Probe Body until it touches the safety stop and install in the Insertion Tool Adapter.

6. Secure the Insertion Tool Adapter from turning while tightening the Process Insertion Fitting, (Figure 5).

Figure 6

Need new picture

L

Mark probe body here

Figure 9

Marking Insertion Length on Probe

Figure 10

Tightening the process insertion fitting

11

7. Verify Process Insertion Fitting is snug against safety stop by pulling upward on the probe body.

8. Open valve slowly and check for leaks.

9. Using low-pressure probe insertion handle, push probe into pipeline (figure 6) until indelible mark is aligned with top of the Process Insertion Fitting. Tighten Hex nut on the fitting exactly 1¼ turns.

Figure 9

Pull Upward

Figure 11

Safety stop

Figure 12

Check for leaks

Figure 13

Push probe into pipeline

12

10. Again, check entire fixture for leaks and attach Warning Placard (Figure 9) to valve handle and probe body using cable tie.

WARNINGWARNING•DO NOT CLOSE VALVE

•DO NOT LOOSEN FITTINGSFuelCheck™ Probe installed through valve

please refer to FuelCheck™ Operating Manualbefore attempting to remove FuelCheck™ Probe

Figure 14

Warning Placard

13

FUELCHECK® PROBE REMOVAL WITH (LINE PRESSURE < 300 PSI)

Positively ascertain line pressure is less than 300 PSI or 2000 KPA.

NOTE: At 300 PSI, the upward force on the probe will be about 60 lb. Attach low pressure inser-tion handle to probe. Hold inward force on handle without standing in line with the probe axis.

1. Another person must loosen the Process Insertion Fitting nut while holding a backup wrench on the process inser-tion fitting.

2. When the Process Insertion Fitting Nut is free, the person holding the probe handle should allow the process pres-sure to gradually allow the probe to be retracted until the safety stop comes to rest against the insertion fitting (probe fully retracted).

3. Close the valve slowly and completely.

Figure 17

Loosen fitting

Figure 15

Ease probe out

Figure 16

Close valve

14

4. Place a backup wrench on the Insertion Tool Adapter. Remove the Process Insertion Fitting from the Insertion Tool Adapter taking care not to spill any process fluid. The use of hydrocarbon absorbing padding is suggested to prevent environmental contamination. Be sure to dispose of contaminated padding properly.

Figure 18

Remove probe

15

FUELCHECK® PROBE REINSERTION with (PRESSURE <300 PSI)

Positively ascertain line pressure is less than 300 PSI or 2000 KPA.

1. Make sure probe is fully retracted (safety stop against bottom of insertion fitting). Install probe onto Process Insertion Fitting and tighten insertion fitting to valve. Make sure Swagelok nut is hand-tight.

2. Open valve slowly and fully. Again, carefully check for leaks and repair as needed.

3. Clean and lubricate exposed probe body with light ma-chine oil or a grease to avoid damaging o-ring seals.

4. When certain of a no-leak status, attach low-pressure probe insertion handle to probe. Push probe into pipeline.

Figure 19

Attach probe

Figure 20

Open valve Lubricate probe

Figure 21

Insert probe into pipeline

16

5. Tighten Hex nut until snug.

6. Again, check entire fixture for leaks.

7. Reattach Warning Placard to valve han-dle and probe body using cable tie.

Figure 18

Figure 22

Tighten SwagelokCheck for leaks

WARNINGWARNING•DO NOT CLOSE VALVE

•DO NOT LOOSEN FITTINGSFuelCheck™ Probe installed through valve

please refer to FuelCheck™ Operating Manualbefore attempting to remove FuelCheck™ Probe

Figure 23

Reattach warning placard

17

Fiberoptic Interconnect Cable Part No. FU-C2-CC (conduit cable) FU-C2-DB (direct burial) FU-C2-UV (UV resistant)

The fiberoptic interconnect cable is used to provide a stable optical connection between the Probe and the FuelCheck® Controller

If the fiberoptic interconnect cable is to be installed into a rigid or EMT conduit, the inexpensive zipcord fiberoptic cable may be employed. The specifications for this cable are shown on the fol-lowing page.

When installing the fiber, several rules must be followed to avoid damaging it.

1. Do not pull the fiber around sharp obstructions which may cut the fiber…

2. Never step on the fiber.

3. Do not kink the fiber when installing it: make certain to unspool the fiber rather than allowing it to spin off the end of the spool, which can result in twists and kinks in the fiber.

4. Do not exceed the maximum pulling stress of the fiberoptic cable. On long runs, it is recom-mended that a suitable lubricant be employed.

5. Do not exceed the minimum bend radius (~ 1”).

6. Do not install when the temperature is below -20°F.

7. IMPORTANT: In areas where winter temperatures are extremely cold, precautions must be taken to prevent water from entering conduit runs as the force exerted by ice formation can seriously damage the fiberoptic cable. If such precautions aren’t feasi-ble or practical, use of the PE jacked fiberoptic cable should be strongly considered.

8. On short fiber runs to be undertaken inside conduit deemed to be in good condition and not containing any other cables, the fiberoptic cable can be supplied pre-connectorized. It is rec-ommended that the conduit run be carefully measured and that sufficient excess be allowed for easy connection to the FuelCheck® Controller.

Chapter

3

18

9. If the fiberoptic connectors are to be installed after the fiber is pulled into the conduit, it is im-perative that sufficient excess (<10 ft) be left on each end so that the connectors can be at-tached conveniently.

10. The procedures for installation of the fiberoptic connectors on the fiberoptic cable is specific to the cable type and the connector type, and must be performed by a trained technician. These instructions assume the fiberoptic cable has already been performed.

11. Due to possible wide temperature changes, a stabilizer is required over the connectors and mating sleeve located in the probe conduit j-box. The following steps will perform this re-quirement..

a) Spread open the slit and place the stopper over the fiberoptic interconnect cable and the FuelCheck® probe cable as shown. Attach the ST mating sleeve to the ST connector on the interconnect cable.

b) Attach stabilizer tube to stopper as shown leaving the connector protruding from the end.

c) Apply a small dab of optical gel to the tips of the Probe ST connector by dipping it into the optical gel container. Be careful not to allow any dirt to get into the gel.

Figure 24

Insert fiber in stopper

Figure 25

Attach Stabilizer Tube

Figure 26

Apply optical gel

FU-FO-CN (fiberoptic connector)

FU-FO-MS (fiberoptic mating sleeve)

19

d) Connect the probe’s ST connector to the mating sleeve.

e) Draw the stabilizer tube assemble together by carefully pulling the interconnect cable fiber through the holes in the stopper. Make sure the stoppers are snug in the stabilizer tube and the fibers are straight.

f) Complete steps a thru e on the second set of ST connectors.

g) Using the cable ties secure the longer tube to the shorter tubes. The longer tube is used as a support to eliminate excessive force being applied to the fiber. Place the three tubes in the junction box and coil fiber to fit, while watching bend radius.

Figure 27

Attach mating sleeve to FO connectors

Figure 28

Make up stabilizer tubes

Figure 29

Secure stabilizer tubes with cable ties

20

Cable Construction Conduit Cable (PVC jacketed)

UV resistant (PE jacketed)

Direct Burial (steel armored)

Part No. FU-C2-CC FU-C2-UV FU-C2-DB

Fiber Core Diameter (µm) 200 200 200

Attenuation @ 850 nrn (dB/km) <6 <6 <6

Subchannel Diameter (mm) 2.5 2.5 2.5

Outer Cable Diameter (mm) 3.5x6.0 8 13

Cable Weight (kg/km) 20 45 135

Outer Jacket Material PVC Polyethylene Polyethylene

Standard Jacket Color Orange Black Black

Maximum Short-Term Pull Tension (lbs/N) 155 309 475

Maximum Long-Term Tension (lbs/N) 110 155 340

Break Strength (lbs/N) 400 530 1350

Minimum Bend Radius (mm) 25 50 130

Operating Temperature (°C) -40 - +80 -40 - +80 -40 - +80

Storage Temperature (°C) -40 - +80 -40 - +80 -40 - +80

aramid yarn

(strength member)

ETFE buffer

200/230 µm

optical fiber

PVC jacket

PVC outer jacket

simplex

subunit

filler filler filler filler

simplex

subunit

simplex

subunit

strength

member

(monofilament)

HDPE jacketsteel braid

Figure 30

Types of Fiberoptic Cable

21

FuelCheck® Controller Part No. FU-CT-*I (* represent number of channels up to 3, ie. FU-CT-1I)

The FuelCheck® Controller is engineered specifically to provide extremely stable, sensitive and repeatable measurements for the FuelCheck® Probes.

The Controller consists of 2 attached enclosures which can either be wall-mounted or installed in a standard 19” instrument rack. FuelCheck® Controllers are available in 3 models to suit the specific application; namely, 1 channel, 2 channel, and 3 channel. The 2 channel model (part# FU-CT-2I) is shown in the manual.

The drawing below illustrates the principal components and layout of the Controller. The unit should be installed in a location out of contact with direct sunlight to avoid drastic temperature changes. The left enclosure is held at a constant temperatureso as to provide the required ther-mal stability for the optoelectronic components.

If the enclosure is installed indoors in a climate-controlled environment, the 100°F (38°C) default programmed temperature can be used. If the enclosure must be installed outdoors, it MUST be mounted so that it will not be exposed to direct sunlight as constant temperature cannot be main-tained if solar radiation is involved. If mounted outdoors, it is recommended that the temperature controller be reprogrammed to approximately 20°F (11°C) above the maximum ambient tem-perature. Please follow the directions in Appendix C for reprogramming the Omega CN132 Temperature Controller.

After powering up the Controller, approximately 1 hour is required for the temperature inside this enclosure to stabilize; thus, do not open it as instability in the probe readings will result.

Chapter

4

22

1 1.2

1 9.4 - 42 .7

- 29 .4

10 0.0

Figure 31

FuelCheck Control, front view

Figure 32

FuelCheck Controller, inside view

23

19.5"

11.5"

6.0"2.25"

2.5

"

Figure 33

FuelCheck Controller, mounting dimensions

24

SHEET:

OF:

INFORMATION CONTAINED ON THESE PRINTSIS THE PROPERITY OF OMNTEC Mfg. Inc. AND ANY PERSON REVEALING THE CONTENTS OF THESE PRINTS IN ANY MANNER TO ANY UNAUTHORIZED PERSON WITHOUT WRITTEN CONSENT FROM OMNTEC WILL BE SUBJECT TO PROSECUTION

notes

DRAWING NO.

SCALE

FILE NAME

OMNTEC Mfg. Inc. 1993 POND Rd. Ronkonkoma, NY 11779

L

K

F

I

E

D

A

DC

-DC

CO

NV

ER

TE

R

ZS

3

2405

+24v ORG+24v ORG

-24V BLK

-24V BLK

TB331-ORG/K32-BLK/KTB442-YEL/E41-BLK/E

TB1N/CTB 226-BRN/C25-WHT/H

1 2 3 41 2 3 4 5 - BLK /K

+ ORG/SWITCH

A Output4/20 mA

J

RED/L

ORG/K/L

GRY/D

BLK/D+24V

+24V TOHEATER

FROM TEMPCONTROLLER

1 2 3 4 5 6 7 8Y R G B O B / / R L R LM M Y K G K / / / / F F K K

TEMP CONTROLLER1-2 Thermocouple3-4 Signal to SCR7-8 24VDC Pwr

4/20 +GRN/H

- 4-20 BRN/J

CDBM DISPLAYB

VIO/ABLK/A

WHT/A

BLU/A

BLK/A

24 VDCINPUT

ON OFF

S1F1

2A SBTP1 TP2

A B

SUPPLIES 5 VDC POWER FOROPTICAL CKT.

CONNECTOR FOROPTICAL CKTS

PIN 1 - BLU/B (DBM)PIN 2 - BLK/B (DBM)PIN 3 - VIO/B (DBM)PIN 4 - BLK/B (DBM)PIN 5 - WHT/B (DBM)PIN 6 - YEL/E (+OUTPUT)PIN 7 - BLK/E (-OUTPUT)PIN 8 - N/CPIN 9 - BLK/I (- 5 VDC)PIN 10 - RED/I (+5 VDC)

CONNECTORS FORHEATER CKTS

PIN 1 - ORG/K (+24 VDC)PIN 2 - BLK/K (-24 VDC)PIN 3 - RED/F (+24 VDC Switched)

FIBER OPTICAL CABLETHRU THIS PORT

COLOR CODE ABV.

BLU = BLUEBRO = BROWNGRN = GREENGRY = GRAYORG = ORANGERED = REDBLK = BLACKVIO = VIOLETWHT = WHITEYEL = YELLOW

- GRN + WHT / C /J

RED/ABLK/A

YEL/ABLK/A

G H

ORG/KBLK/K

1

2

3

4

JUMPER1-2 BLK/K3-4 ORG/K

TB331-ORG/K32-BLK/KTB443-BRN/C41-WHT/H

TB222-YEL/E26-BLK/E

J

TB331-ORG/K32-BLK/K36-BRN/C33-WHT/HTB4N/C

TB112-YEL/E16-BLK-E

J

952EN811T611T952EN811T611T

TB1

111213141516

TB3

363534333231

TB4

464544434241

TB2

212223242526

TB3

363534333231

TB4

TB1

111213141516

TB2

212223242526

TB3

363534333231

TB4

464544434241

464544434241

FuelCheck Wiring

THERMOCOUPLE YEL/MRED/M

A = FOI CABLEB= DBM DISPLAYC= 4/20ma DISPLAYD= TEMPERATURE CONTROLLERE= SWITCH ASSEMBLYF= SCRG= 24V TERMINAL BLOCKH=4/20 TERMINAL BLOCKI= DC-DCJ= SIGNAL CONDITIONERSK= 24V TERMINAL BLOCKL= HEATER CABLEM= THERMOCOUPLE

Figure 34

FuelCheck Controller, wiring diagram

25

System Calibration ACROMAG 611T/612T-500 SIGNAL CONDITIONER CALIBRATION PROCEDURE

After the connectors have been installed on the fiberoptic interconnect fiber and connected to the FuelCheck® Controller and Probe, the attenuation reading on the Optical Gain meter located on the front of the Controller should read greater than -20 dBm with the Probe in air. Typical readings in air are -5 dBm to -10 dBm. If the reading is less than -20 dBm contact Technical Support at OMNTEC for assistance. The system calibration is performed in 2 separate steps: A) prelimi-nary calibration using samples in bottles, and B) final in-line calibra-tion using known fluids in the pipeline. The preliminary calibration is performed to simply ensure the sensor readings will be “in-scale” when the pipeline is running. The final in-line calibration is performed to optimize the output levels so that all the pipeline products When performing the preliminary calibration, obtain samples of two fluids which will fall on each end of the calibration scale. Example: if the pipeline is transferring gasoline and diesel, the lowest octane gasoline will be the fluid for the low set point and the diesel will be used for the high set point. When using something other than gaso-line and diesel, the fluid which has the dBm reading closest to -30 dBm will be used for the LOW set point. 1. Turn system power on, allowing time for temperature to stabilize at

the programmed enclosure temperature (default =100°F ).

2. Connect the multimeter to the + and – input test points. These are located on the panel containing the on/off switch and the Fuse.

3. Select the fluid set points within the 4-20 mA range. As an example, we will select 8 mA for gasoline and 16 mA for diesel. The set point can be set to any desired ratio to meet your desired presentation on the display being used. CAUTION: Do not use a sharp object for depressing the calibration buttons on the signal conditioner. Use blunt objects and apply pressure gradually until you feel a tactile change or see the visual change in the LED’s.

Chapter

5

Acromag RUN

ST

CH 1 2

MODE

SET

26

4. Press the MODE button. When depressed, the RUN indicator will turn off and the CH 1

indicator will start flashing. The Signal Conditioner is ready to begin the setup. 5. Place the probe in the fluid to be used as the High set point, making sure the signal is

stable by observing the dBm display, it may be necessary to agitate the probe in the fluid to make sure the sensor is properly wetted. When the signal is stable record the voltage and next press the up ▲ or down ▼ arrows to select the desired output current shown on the 4-20 mA display, example: 16 mA for Diesel.

6. When the correct current value is reached, press the SET button. When the button is

pressed the ST indicator will flash indicating the value was set. 7. Press MODE button and the CH 1 indicator will turn on solid. 8. Place the probe in the fluid determined for the Low set point, making sure the signal is

stable by observing the dBm display. When the signal is stable record the voltage and next press the up ▲ or down ▼ arrows to select the desired output current shown on the 4-20 mA display selected for the fluid being used, example being 8 mA for Gasoline.

9. When the current is set press the SET button. When the button is pressed the ST indica-

tor will flash indicating the value was set. 10. Press MODE button and the CH 1 indicator will turn off and the RUN indicator will turn

green. 11. Check the Current indicator and the value should be reading 8 mA. Insert the probe in

the Diesel and the indicator should read 16 mA. If the values are not correct repeat the above steps again.

This is a preliminary calibration because the values can be different with the fluid under pressure in the pipeline and the refractive index may change between different batches. Install the probe in the pipeline following the instructions in Chapter 3. Make sure accurate insertion measurements are made because once the Swagelok fitting is tightened, the set-ting is permanent. View the mA display and determine if the reading is correct. Example: Gasoline is in the pipeline and the mA reading is 7.4 mA. A low calibration can be performed at this time to correct the reading to 8 mA. 1. Press the MODE button and the RUN indicator will go off and the CH 1 indicator will start

flashing. Press the MODE button the second time and the CH 1 indicator will remain steady. The Signal Conditioner is ready for the Low setup to be performed. Using the up ▲ and down ▼ arrows, set the Current for 8 mA and press SET. The Low value has been reset for the gasoline under pressure in the Pipeline.

2. Press the MODE button again and the RUN indicator will turn green and the current dis-

play should be indicating 8 mA.

27

When the fluid in the Pipeline changes to Diesel, perform the same operation but do the se-tup when the CH 1 indicator is flashing for the High setting. This can be done whenever the fluid changes in the Pipeline and the reading may require a change.

28

Fluid Temperature Correction For certain applications, it may be advantageous to normalize the refractive index output to stan-dard temperature (60°F).

During the development of FuelCheck, a series of flow loop measurements was made at various fluid temperatures. From the experimental data, the following conclusion can be made:

V60 = V+(0.01374(60-T))

In most instances, a signal conditioner is employed to convert the bipolar photoelectric voltage into a standard voltage or current. In this case, the following scaling corrections can be made:

S60 = (S(Vmax-Vmin)+(0.22(60-T)))/(Vmax-Vmin)

where:

V FOI output, V V60 FOI output corrected to 60°F, V S60 signal conditioner output corrected to 60°F, mA S signal conditioner output, mA Vmax photoelectric output at maximum signal conditioner output, V Vmin photoelectric output at minimum signal conditioner output, V T fluid temperature, °F

As an example, let us assume that a signal conditioner is being used to convert the photoelectric output voltage to a 4-20 mA current, and that it is calibrated so that a -1.03 to -4.22 photoelectric voltage range is translated to a 4-20 mA signal. Presently, the signal conditioner output is 11.3 mA, and the fluid temperature is 104°F.

S 11.3 mA Vmax -4.22 V Vmin -1.03 V T 104°F S60 =(11.3*(-4.22--1.03)+(0.22*(60-104)))/(-4.22--1.03) S60 = 14.3 mA

Chapter

6

29

FuelCheck ® Fluid Temperature Normalization

-1

0

1

2

3

4

20 40 60 80 100 120

fluid temp., °F

ou

tpu

t vo

ltag

e

87OCT 87OCT60

92OCT 92OCT60

93OCT 93OCT60

JETA JETA60

LSDiesel LSDiesel60

Normalization to 60°F

V60=V+(0.01374*(60-T))

where:

V60 = corrected voltage

V = FuelCheck ™ output voltage T = fluid temperature, °F

60

Figure 35

Fluid Temperature Normalization

30

FuelCheck® System Specifications FuelCheck® Probe

Part No. FU-PR-24

Sensor type: dual reflection critical angle fiberoptic refractometer

Fiber type: duplex 200/230 µm HCP

Fiberoptic connector type: ST crimp and cleave

Maximum fiber length: 2 km (~7,500 ft)

Probe construction: ½” OD X 0.095” WT TV9426 304 stainless tubing

Standard connection: 1” MNPT to access valve

Max. operating pressure: 1,500 PSI (10.3 MPa)

Max. probe insertion/removal pressure: 1,500 PSI (10.3 MPa) with optional high-pressure in-sertion tool, 300 PSI (2.1 MPa) with standard insertion handle

FuelCheck® Controller

Part No. FU-CT-*I (* represents number of channels up to 3, ie. FU-CT-1I)

Enclosure size: 2 - tandem mounted 8”W X 10”H X 6.63” Total width 19.5”

Enclosure type fiberglass NEMA-4X

Conduit connections: 2 - ½” female connectors on 3.75” centers (bottom of enclosure)

Power requirement: 24 VDC standard, AC optional

Operating temperature: 50°F - 130°F (do not mount in direct sunlight, requires sunshade)

Signal output: 4 - 20 ma with user-adjustable zero, span, and polarity normal polarity proportional to refractive index and specific gravity reverse polarity proportional to °API.

Chapter

7

31

Optional Equipment Installed in Controllers with Serial Numbers These units have been optionally equipped with the Acromag BusWorks® Model 952N-4012 Modbus TCP/IP Industrial I/O Modules. This module provide a scaled 4-20 mA output, with cor-responding MODBUS registers accessible via TCP/IP.

Shown below is a simplified I/O diagram

Simplified I/O DiagramFuelCheck® Controller Serial No. xxxxxx

(single channel Modbus TCP/IP)

FOIMODULE

ACROMAG611T-0500

ACROMAG952EN-4012-10VDC - +10VDC

TB

4T

B1

TB

1T

B1

0 - 10VDC

PIN 12PIN 16

PIN 42PIN 41

PIN 44PIN 43

PIN 25PIN 26

RJ-45ETHERNETMODBUS TCP/IP(see Appendix D)

4 – 20mA

NOTE: The analog inputs for this module are fixed at 0-10 VDC, and the analog outputs are fixed at 4-20 mA. DO NOT attempt to calibrate any of the analog inputs or outputs on the Acromag 952N-4012. All analog calibrations should be made in the Acromag 611T or 612T modules. Please refer to Chapter 5 for instructions!

Chapter

8

32

Simplified I/O DiagramFuelCheck® Controller Serial No. xxxxxx

(two channel Modbus TCP/IP)

FOIMODULE

A

ACROMAG612T-0500

ACROMAG952EN-4012-10VDC - +10VDC

TB

4

TB

1 TB

2T

B1

0 - 10VDC

PIN 12PIN 16

PIN 45PIN 44PIN 42PIN 41



RJ-45ETHERNETMODBUS TCP/IP(see Appendix D)

4 – 20mA

FOIMODULE

BT

B2 PIN 22

PIN 26

CHANNEL A

CHANNEL B

CHANNEL B

CHANNEL A

The only user setup required for the Acromag 952EN-4012 are in the Network Configuration Page. Please see the menus below:

34

APPENDICES

35

APPENDIX A Warranty and Disclaimer

36

WARRANTY & DISCLAIMER OMNTEC Mfg., Inc. ("OMNTEC") warrants its products ('Product' or 'Products') to conform to its own specifications and to be free of defects in materials and workmanship under normal use for a period of twelve (12) months from the date of manufacture. Within the war-ranty period, OMNTEC will repair or replace, at its option, all or any part of the warranted product. OMNTEC will not be responsible for dismantling and/or reinstallation charges. In order to exercise the warranty, the User (‘‘User’,’Installer’’' or 'Consumer') must be given a Return Material Authorization ("RMA") Number by OMNTEC. Details of shipment will be arranged at that time. THIS WARRANTY IS VOIDED, AND DOES NOT APPLY, IN INSTANCES OF IMPROPER INSTALLATION, MISUSE, FAILURE TO FOLLOW INSTALLATION AND OPERATING INSTRUCTIONS, ALTERATION, ABUSE, ACCIDENT OR TAMPERING, AND/OR REPAIR BY ANYONE OTIIER THAN OMNTEC Mfg., Inc.. THIS WARRANTY IS EXCLUSIVE AND EXPRESSLY IN LIEU OF ALL OTIIER WARRANTIES, OBLIGATIONS OR LIABILITIES WIIETIIER WRITTEN, ORAL, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCIIANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. OMNTEC Mfg., Inc. WILL NOT BE LIABLE TO ANYONE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR BREACII OF THIS WARRANTY OR ANY OTHER WARRANTIES. This warranty will not be modified, varied or extended. OMNTEC does not authorize any person to act on its behalf to modify, vary or extend this warranty. This warranty will apply to OMNTEC Products only. All other products, accessories or attachments used in conjunc-tion with OMNTEC equipment, including batteries, will be covered solely by their own warranty, if any. OMNTEC will not be liable for any direct, incidental or consequential damage or loss whatsoever caused by the malfunction of Product due to products, accessories or attach-ments of other manufacturers, including batteries, used in conjunction with OMNTEC. This warranty does not warrant the replacement of batteries that are used to power OMNTEC. The User recognizes that a properly installed and maintained system may only reduce the risk of events such as overfill, product contamina-tion, environmental contamination and/or fire. It does not insure or guarantees that there will be no death, personal damage and/or damage to property as a result. OMNTEC does not claim that the Product may not be compromised and/or circumvented, or that the Product will prevent any death, personal and/or bodily injury and/or damage to property resulting from overfill, environmental contamination, fire or otherwise, or that the Product will in all cases provide adequate warning or protection. OMNTEC shall have no liability for any death, injury or damage, however incurred, based on a claim that OMNTEC failed to function. However, if OMNTEC is held liable, directly or indirectly, for any loss or damage arising under this limited warranty or otherwise, regardless of cause or origin, OMNTEC maximum liability will not in any case exceed the purchase price of the Product, which will be fixed as liqui-dated damages and not as a penalty and will be the complete and exclusive remedy against OMNTEC. WARNING: The User should follow all installation, operation and maintenance instructions. The User is strongly advised to conduct Prod-uct and systems tests at a minimum of once per week. Changes in environmental conditions, electric or electronic disruptions and/or tam-pering, may cause the Product not to perform as expected. WARNING: OMNTEC warrants its Products to the User. The User is responsible for exercising all due prudence and taking necessary precautions for the safety and protection of lives and property wherever OMNTEC are installed. OMNTEC strongly advises the User to always program Products to be supervised. Users are warned that unsupervised devices are subject to undetected failure due to malfunction, battery failure, tampering or changes in environment.

§ 2007 OMNTEC MFG., INC.

37

APPENDIX B Acromag Series 611T/612T

SIGNAL CONDITIONER

NOTE: for most up-to-date manual, please refer to:

http://www.acromag.com/PDF/611T_612T_602g.pdf

38

APPENDIX C OMEGA CN132

TEMPERATURE CONTROLLER


http://www.omega.com/Manuals/manualpdf/M1638.pdf

39

APPENDIX D Acromag BusWorks® Model 952N-4012

Modbus TCP/IP Industrial I/O Module


http://www.acromag.com/PDF/951_952EN_759a.pdf

40

APPENDIX E Fiberoptic Connectorizing Kit

Part No. FU-FO-KIT


http://ofscatalog.specialtyphotonics.com/item/crimp-and-cleave-termination-kits-and-connectors/crimp-cleave-termination-kits-st-connectors/item-1298?&bc=0|1103#

41

APPENDIX F UV Resistant Cable

Additional Documentation

Part No. FU-C2-UV


http://ofscatalog.specialtyphotonics.com/item/all-categories/-mm-based-construction-200-m-hcs-step-index-cables/ac02602-10?&plpver=10&origin=keyword&by=prod&filter=0#

fuelcheck - omntec

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