FUELCHECK - OMNTECThe process insertion fitting is a specially modified bored-through Swagelok...
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FUELCHECK ® PIPELINE BATCH CONTROL
Transcript of FUELCHECK - OMNTECThe process insertion fitting is a specially modified bored-through Swagelok...
FUELCHECK ®
PIPELINE BATCH CONTROL
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O M N T E C M F G . , I N C .
FuelCheck®
Installation & Operating Manual
Document: 600300File: 60030003162015.docx
Revised 03-16-2015
OMNTEC Mfg., Inc.1993 Pond Road
Ronkonkoma, NY 11779 USAPhone (631) 981-2001 • Fax (631) 981-2007
www.omntec.com
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Table of Contents1. System Overview........................................................................................................................52. FuelCheck® Probe......................................................................................................................7
A. Probe Construction ...................................................................................................................................................................7B. Probe Location Considerations..........................................................................................................................................8
3. FuelCheck® Controller ............................................................................................................. 11A. Controller Mounting Guidelines .......................................................................................................................................11
4. Fiberoptic Interconnect Cable................................................................................................. 17A. Precautions for working with OFS HCS Fiber ..........................................................................................................................18
5. System Installation Procedure .................................................................................................20I. Install FuelCheck Probe and Probe Junction Box.............................................................................20
A. First-time Probe Insertion Procedure..........................................................................................................................................21B. Probe Removal Procedure.............................................................................................................................................................24
II. Mount the FuelCheck Controller and Junction Boxes ......................................................................25III. Install the Fiberoptic Interconnect Cable .......................................................................................25
A. Pull Cable into Junction Boxes .....................................................................................................................................................26B. Prepare Fiberoptic Cable for Termination .................................................................................................................................26C. Termination Procedure for 200µM HCS fiber with ST Connectors .....................................................................................27Remove Fiber Buffer .................................................................................................................................................................................28Install Cable Anchor ..................................................................................................................................................................................29Install Crimp Sleeve ...................................................................................................................................................................................30Install ST Ferrule ........................................................................................................................................................................................30Cleave off the fiber end.............................................................................................................................................................................32C. Perform Loopback Test to Measure Total Optical Attenuation of the Fiberoptic Interconnect .................................33D. Shrink the adhesive heat shrink tubes .........................................................................................................................................35E. Connect the FuelCheck Probe to the Fiberoptic Interconnect Cable ...................................................................................36
NOTE: Because the fiberoptic connectors are slightly affected by moisture and large temperaturevariations, a special Stabilizer Tube has been developed to house any fiberoptic connectors
installed outdoors. ..............................................................................................................................................................................36.......................................................................................................................................................................................................................38
F. System Calibration...................................................................................................................39ACROMAG 611T/612T-500 SIGNAL CONDITIONER (LINEAR OUTPUT) CALIBRATION PROCEDURE.........39Reinstallation of Probe into Pipeline ......................................................................................................................................................41In-line calibration procedure ....................................................................................................................................................................42
6. Fluid Temperature Correction ................................................................................................43FuelCheck® System Specifications..................................................................................................45
FuelCheck® Probe ...............................................................................................................................................................................45FuelCheck® Controller ......................................................................................................................................................................45
APPENDIX A Warranty and Disclaimer........................................................................................47APPENDIX B OMEGA CN132 TEMPERATURE CONTROLLER .........................................50APPENDIX C Acromag Series 611T/612T SIGNAL CONDITIONER ...................................... 51APPENDIX D.................................................................................................................................52System Calibration Using................................................................................................................52Acromag 811T-500 SIGNAL CONDITIONER..............................................................................52
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(Non-Linear Output).......................................................................................................................52APPENDIX E Acromag BusWorks® Model 952N-4012 Modbus TCP/IP Industrial I/O
Module.............................................................................................................................................58APPENDIX F Fiberoptic Termination Kit .................................................................................... 61http://ofscatalog.specialtyphotonics.com/item/crimp-and-cleave-termination-kits/crimp-cleave-st-termination-kits/item-1298 ............................................................................................................... 61APPENDIX G .................................................................................................................................62UV Resistant Cable Additional Documentation............................................................................62APPENDIX G .................................................................................................................................63Procedure for Replacing Connectors on FuelCheck Probe ...........................................................63
Remove Fiber Buffer .................................................................................................................................................................................65Install Cable Anchor ..................................................................................................................................................................................65Install Crimp Sleeve ...................................................................................................................................................................................66Install ST Ferrule ........................................................................................................................................................................................66Cleave off the fiber end.............................................................................................................................................................................68
Before heat-shrinking the adhesive tubing on the connectors, confirm that the probe performance is within acceptabletolerances .....................................................................................................................................................................................................69Shrinking the adhesive heat shrink tubes ...............................................................................................................................................70
Table of FiguresFigure 1: FuelCheck System Architecture 5Figure 2: Principle of Operation 6Figure 3: FuelCheck Probe installed in pipeline Error! Bookmark not defined.Figure 4: Process Insertion O-Rings 8Figure 5: Suggested Probe Installation Method 9Figure 6: Standard Probe (FU-PR-24) Dimensions 10Figure 7: FuelCheck Controller 13Figure 8: FuelCheck Controller, inside view 13Figure 9: FuelCheck Controller, mounting dimensions 14Figure 10: FuelCheck Controller, wiring diagram 16Figure 11: Types of OFS 200/230µM HCS Cable 18Figure 12: FuelCheck Probe and Junction Box 20Figure 13: Insertion Valve Measurement A 21Figure 14: Mark Insertion Length (L) on Probe 21Figure 15: Installing Process Insertion Fitting 22Figure 16: Stop ring 22Figure 17: Check for Leaks 22Figure 18: Push Probe into Pipeline 23Figure 19: Probe Warning Placard 23Figure 20: Ease Probe Out of Pipeline 24Figure 21: Close Valve 24Figure 22: Remove Probe From Insertion Tool Adapter 24Figure 23: Fiberoptic Interconnect Cable 25Figure 24: NO CABLE STRIPPERS! 26Figure 25: Expose the Ripcord 26Figure 26: Pull Ripcord to Split the Jacket 27Figure 27: Cable Ready for Connectors 27Figure 28: Contents of ST Termination Kit (FU-FO-KIT) 28
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Figure 29: Contents of FU-FO-CN 28Figure 30: Strip Fiber Jacket Using Cable Stripper 28Figure 31: Remove Fiber Buffer 29Figure 32: Verify 56 mm bare fiber 29Figure 33: Install Cable Anchor 29Figure 34: Crimp Cable Anchor 30Figure 35: Install Crimp Sleeve 30Figure 36: Crimp the Crimp Sleeve Onto Cable Anchor 30Figure 37: Install ST Ferrule 30Figure 38: Crimp ST Ferrule 31Figure 39: Diamond Cleave Tool 32Figure 40: Cleave off the fiber end 32Figure 41: Install Protective Cap 33Figure 42: Route the Fiberoptic Interconnect Cable into the Heated Enclosure of the Controller 34Figure 43: Apply Optical Gel to Fiber End 34Figure 44: Attach Fiberoptic Cable to FOI Module 34Figure 45 34Figure 46: Loopback Test Configuration 35Figure 47: Expected Optical Gain (Loopback Test) 35Figure 48: Position Heat-Shrink Tubing 35Figure 49: Connectors After Heat-Shrinking 35Figure 50: Extra Cable Stored in Controller Junction Box 36Figure 51: Insert Fiber in Stopper 36Figure 52: Attach Stabilizer Tube 37Figure 53: Apply Optical Gel 37Figure 54: Connect to mating sleeve 37Figure 55: Make Up Stabilizer Tubes 37Figure 56: Secure Stabilizer Tubes with Cable Ties 38Figure 57: Extra Cable And Connector Stabilizers Stored in Probe Junction Box 38Figure 58: Acromag 611T Signal Conditioner 39Figure 59: Install Probe on Adapter 41Figure 60: Reinstall Probe Through Valve 41Figure 61: Reattach Warning Placard 41Figure 62: Fluid Temperature Normalization 44Figure 64: Contents of ST Termination Kit (FU-FO-KIT) 64Figure 65: Contents of FU-FO-CN 64Figure 66: Strip Fiber Jacket Using Cable Stripper 64Figure 67: Remove Fiber Buffer 65Figure 68: Verify 56 mm bare fiber 65Figure 69: Install Cable Anchor 65Figure 70: Crimp Cable Anchor 66Figure 71: Install Crimp Sleeve 66Figure 72: Crimp the Crimp Sleeve Onto Cable Anchor 66Figure 73: Install ST Ferrule 66Figure 74: Crimp ST Ferrule 67Figure 75: Diamond Cleave Tool 68Figure 76: Cleave off the fiber end 68Figure 77: Apply Optical Gel 69Figure 78: Position Heat-Shrink Tubing 70Figure 79: Connectors After Heat-Shrinking 70
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1. System OverviewFuelCheck® is a totally fiberoptic process refractometer system designed toprovide accurate interface discrimination in flowing pipelines at high pressures.
FuelCheck® Is comprised of 3 basic components; namely:1. FuelCheck® Probe
Part No. FU-PR-242. 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 sys-tem calibration and operation.
Figure 1: FuelCheck System Architecture
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A. Principle of Operation
FuelCheck® is a totally fiberoptic system for sensing changes in the index of re-fraction of fluids in petroleum 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 temperature.Light from the infrared LED light source is coupled into the source fiber of the fiberoptic interconnectcable. The FuelCheck® Probe reflects light from the source fiber to the detector fiber. Some ofthe light is refracted into the fluid in which the probe lens is immersed. The amount of light that isrefracted (lost) from the lens is directly proportional to the index of refraction of the fluid in whichthe probe lens is immersed. Thus, the higher the fluid’s index of refraction, the less amount of lightis returned to the detector in the FuelCheck® Controller.
Figure 2: Principle of Operation
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2. FuelCheck® ProbePart No. FU-PR-24
Contents: 1 FU-PR-24 with protective caps on fiberoptic connectors1 – 1 inch ANSI Class 600 Flanged Insertion Tool Adapter (RF standard)1 – safety plug for Insertion Tool Adapter (must be installed whenever probe
is removed from adapter)1 – low pressure probe insertion tool1 – Warning Placard w/ attachment wire
The FuelCheck® Probe is readily installed into the pipeline through a full opening valve. Its instal-lation should ensure constant contact with fluids to ensure instantaneous and positive interfacedetection.
A. Probe ConstructionThe FuelCheck® Probe, part number FU-PR-24, is constructed of heavy-wall ½” OD stainless steeltubing. Standard probe length is 24” giving an insertion length of 16” from the top of the valve tothe ID of the pipeline. With probe and insertion tool changes, the Probe can be made in virtuallyany length so as to accommodate almost any installation requirement. The maximum operatingpressure and temperature are 2,250 PSI @ 200°F. The materials of construction allow for use inall petroleum fuels with all known additives, including MTBE. The sapphire lens is extremely re-sistant to both chemicals and abrasion.
The sensor element incorporates an o-ring seal with a Teflon backup seal. The sensor elementcannot be replaced therefore replacing the probe will be required if the probe is moved or crimpedat the wrong location on the probe body. The probe incorporates a stop ring which is an 11/16”OD upset welded onto the probe body to prevent the probe from passing through the processinsertion fitting.
The process insertion fitting is a specially modified bored-through Swagelok tubing adapter. Aninternal o-ring groove incorporating a back-up ring has been machined into the fitting to provide apressure seal with the probe body during process insertion and retraction. The process insertionfitting is an integral part of the FuelCheck® probe and cannot be removed in the field.
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The Insertion Tool adapter enablesthe use of the high pressure probeInsertion Tool in the event that theprobe must be inserted or removedfrom the process at pressures ex-ceeding 300 PSI. Even if the pro-cess pressure is never expected toexceed 300 PSI, it is recom-mended that this adapter be usedas a safety feature so that theprobe could be removed in theevent of an emergency.
The top end of the probe is at-tached to a length of 3/8” OD stain-less steel flexible conduit (“armor”)providing protection for the fiberop-tic probe lead. Standard length is120”. This armor is terminated in a½” MNPT conduit fitting which is at-tached to the probe junction box.The fiberoptic leads are terminatedwith ST type fiberoptic connectorswhich attach to the fiberoptic inter-connect cable leading to theFuelCheck® Controller.
A fiberglass junction box (J-Box) isprovided to protect the fiberopticconnection between the probe and
the fiberoptic interconnect cable. This J-box is normally the terminus of a rigid or EMT conduitinstalled to protect the fiberoptic interconnect cable.
B. Probe Location ConsiderationsFuelCheck® probes can be installed through any full-opening valve with an inside diameter (ID) of0.75” or larger; however, several considerations should be observed in order to provide optimumperformance. It is strongly recommended that the probe be installed such that its tip not protrude
Figure 3: Process Insertion O-Rings
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past the inside wall of the pipeline. If the probe extends into the pipeline, damage to the pipelineand probe can result by pigging the line without removal of the probe.
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) willreside be of sufficient diameter and suitable loca-tion such that fluid turbulence will provide ade-quate sampling. If this fixture is too small, fluidstagnation could occur resulting in a failure of thesystem to detect the interface. It is therefore rec-ommended that the probe insertion weldolet beat least 1” in diameter so that adequate mixingtakes place thus allowing for very rapid interfacedetection. It is also important that the weldolet bitsize be as large as possible. Too often, it hasbeen observed that a large weldolet was installedbut that the hole bored through the pipeline wasvery small.
The location and orientation of the probe inser-tion weldolet is also important. Placing the probe
near an elbow in the line will provide greater turbulence and more rapid interface detection. Inser-tion of the probe in the top of the pipeline should be avoided since a vapor pocket could developin the weldolet. Insertion from 45° from vertical to the side is preferable, though care must be takento provide sufficient clearance for convenient installation and removal.
Some general recommendations for probe location and orientation are as follows:
a. Try to mount the FuelCheck probe in a location where the pipe is always full, even whenthe line is not flowing.
b. NEVER mount the FuelCheck probe in a densitometer loop.
c. Never mount the probe on the top of the pipe since vapor can get trapped there.
d. Never mount the probe on the bottom of the pipeline because the weldolet can becomefilled with dirt, rust, or other particles from the pipeline.
Figure 4: Suggested Probe Installation Method
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Figure 5: Standard Probe (FU-PR-24) Dimensions
stop ring
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3. FuelCheck® Controller
Part No. FU-CT-XI (X represent number of channels up to 3, ie. FU-CT-2I)
Contents: 1 – FU-CT-XI FuelCheck Controller with 2 – ¾” cable seals installed in bottomof unheated enclosure. Includes 1 – Acromag 611T-500 4-20 mA signal con-ditioner for each probe channel
OPTIONS: 100–240 VAC to 24 VDC 5A power supply (part# FU-CT-PS)Acromag 811T-500 signal Conditioner (for non-linear 4-20 mA output)Acromag Acromag BusWorks® Model 952N-4012 Modbus TCP/IP IndustrialI/O Module (for network interface)Dataq DI-145 10-bit DAQ with USB interface and WinDAQ Lite Software
TheFuelCheck® Controller isa high-precision optical power meterengineered specifically to provide extremelystable, sensitive and repeatable measurements for theFuelCheck®Probes.
The Controller consists of 2 attached enclosures which can either be wall-mounted or installed ina standard 19” instrument rack. FuelCheck® Controllers are available in 3 models to suit the spe-cific 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 unitshould be installed in a location out of contact with direct sunlight to avoid drastic temperaturechanges. The left enclosure is held at a constant temperature so as to provide the required thermalstability for the optoelectronic components.
A. Controller Mounting Guidelinesa. The FuelCheck Controller is designed to be mounted indoors, in a climate-controlled and non-
hazardous area. If the Controller must be installed outdoors, please consult OMNTEV TechSupport for specific instructions.
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b. Since the standard signal output from the Controller is analog (4-20 mA), the Controller shouldbe located close to the PLC or computer to which it will be connected. If optional signal condi-tioners (i.e., serial or Ethernet output) are used, there will be more flexibility in mounting loca-tion.
c. The Controller is sized such that it may be installed into a standard 19” instrument rack; how-ever, it may also be wall or cabinet mounted if desired. Please refer to Figure 8 for mountingdimensions.
d. Locate controller at eye level, where it is easily accessible.
e. Locate the controller in a dry area (avoid sweating or leaking pipes and areas where rain canenter).
f. Locate the controller in areas where temperatures will stay between 50ºF – 90ºF (10ºC - 30ºC)and not exposed to direct sunlight.
g. Allow 6" clearance on the top and sides of the controller for air circulation.
h. Make certain that there is sufficient clearance for opening the controller door.
i. Allow for sufficient clearance around the controller for conduit access. All conduits will enter thecontroller through the ¾” knockouts in the bottom of the enclosure.
j. Avoid installing in corners.
k. Avoid swinging doors that can bang into the controller.
If the enclosure is installed indoors in a climate-controlled environment, the 100°F (38°C) defaultprogrammed temperature can be used. If the enclosure must be installed outdoors, it MUST bemounted 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 temperaturecontroller be reprogrammed to approximately 20°F (11°C) above the maximum ambient tempera-ture. Please follow the directions in Appendix C for reprogramming the Omega CN132 Tempera-ture Controller.
After powering up the Controller, approximately 1 hour is required for the temperature inside thisenclosure to stabilize; thus, do not open it as instability in the probe readings will result.
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Figure 6: FuelCheck Controller
Figure 7: FuelCheck Controller, inside view
1 1.2
1 9.4 - 4 2 .7
- 2 9 .4
10 0.0
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Figure 8: FuelCheck Controller, mounting dimensions
Figure 9: Conduit fittings and enclosure depth
11.00”12.00”
16.00”
18.00”
8.00”
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Figure 10: Horizontal clearance required to open enclosures
32.00”
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Figure 11: FuelCheck Controller, wiring diagram
SHEET:
OF:
INFORMATION CONTAINED ON THESE PRINTSIS THE PROPERITY OF OMNTEC Mfg. Inc. AND ANYPERSON REVEALING THE CONTENTS OF THESEPRINTS IN ANY MANNER TO ANY UNAUTHORIZEDPERSON WITHOUT WRITTEN CONSENT FROMOMNTEC 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
ZS3
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
- 4-20BRN/J
CDBM DISPLAYB
VIO/ABLK/A
WHT/A
BLU/A
BLK/A
24 VDCINPUT
ON OFF
S1F1
2A SBTP1 TP2
A B
SUPPLIES 5 VDCPOWER 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
952EN811T611T 952EN811T611TTB1111213141516
TB3363534333231
TB4464544434241
TB2212223242526
TB3363534333231
TB4
TB1111213141516
TB2212223242526
TB3363534333231TB4464544434241
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
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4. Fiberoptic Interconnect Cable
The fiberoptic interconnect cable is used to provide a stable optical connection between the Probeand the FuelCheck® Controller.
OPTIONS: Conduit Cable (Part No. FU-C2-CC)Outdoor UV Resistant Cable (Part No. FU-C2-UV)Direct Burial Cable (Part. No. FU-C2-DB)ST Termination Kit (Part No. FU-FO-KIT)Fiberoptic Cable Installation Kit (Part No. FU-FO-CIK), includes:
1 – Probe Junction Box with 2 – ¾” conduit adapters installed.2 – Fiberoptic mating sleeves (Part No. FU-FO-MS)4 – 2.5mm ST Connector assemblies (Part No. FU-FO-CN), includes:
2” length of ¼” adhesive heat shrink tubing (strain relief)Cable anchorCrimp sleeveST ferruleProtective cap
1 – Fiberoptic connector stabilizer assembly (FU-FO-STB)2 – connector stabilizer tubes4 – slotted rubber stoppers1 – support tube (long)2 – cable ties
1 – Vial optical index-matching gel (FU-FO-GEL)
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Figure 12: Types of OFS 200/230µM HCS Cable
A. Precautions for working with OFS HCS FiberIf the fiberoptic interconnect cable is to be installed into a rigid or EMT conduit, the inexpensiveconduit cable (FU-C2-CC) may be employed. The specifications for this cable are shown in thetable in Figure 10.
When installing the fiber, several rules must be followed to avoid damaging it.
a. Do not pull the fiber around sharp obstructions which may cut the fiber.
b. Never step on the fiber.
c. Do not kink the fiber when installing it: make certain to unspool the fiber rather than allowing itto spin off the end of the spool, which can result in twists and kinks in the fiber.
d. Do not exceed the maximum pulling stress of the fiberoptic cable. On long runs, it is recom-mended that a suitable lubricant be employed, and that intermediate pull boxes be used.
e. Do not subceed the minimum bend radius (see table in Figure 10).
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f. Do not install when the temperature is below -20°C (-4°F).
g. IMPORTANT: In areas where winter temperatures are extremely cold, precautions mustbe taken to prevent water from entering conduit runs as the force exerted by ice for-mation can seriously damage the conduit cable (FU-C2-CC). If such precautions aren’tfeasible or practical, use of the PE jacketed outdoor cable (FU-C2-UV) should be con-sidered.
h. On short fiber runs to be undertaken inside conduit deemed to be in good condition and notcontaining any other cables, the fiberoptic cable can be supplied pre-terminated. It is recom-mended that the conduit run be carefully measured and that sufficient excess be allowed foreasy connection to the FuelCheck® Controller.
i. If the fiberoptic connectors are to be installed after the fiber is pulled into the conduit, it is im-perative that sufficient excess (~3 m, ~10 ft.) be left on each end so that the connectors can beattached conveniently and subsequent re-termination can be performed if the connectors be-come damaged..
j. The procedures for installing the fiberoptic connectors require training by OMNTEC as thesemethods are unique to this cable and connector type.
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5. System Installation ProcedureI. Install FuelCheck Probe and Probe Junction Box
IMPORTANT: Note line pressure. If over 300 PSI (2000 kPa) follow instructions for high-pressure installation in the IOM supplied with the High Pressure Insertion Tool.
Figure 13: FuelCheck Probe and Junction Box
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A. First-time Probe Insertion Procedure
1. Use Teflon tape or required sealing components onthe Insertion Tool Adapter and permanently installinto the Valve. The Insertion Tool Adapter shouldnever be removed from the Valve as this will changethe Probe’s insertion distance into the pipeline.
2. Measure precise length from pipeline to the top of In-sertion Tool Adapter (Figure 12). Record this lengthas measurement “A”.
3. Calculate and record Probe Insertion Length (L) asfollows:
L = A + ½ pipe wall thickness
4. Clean and lubricate exposed probe body using light machine oil or a grease to avoid damagingo-ring seals.
5. Hand-tighten the hex nut on the Process Insertion Fitting. Slide the Process Insertion Fittingup 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 InsertionFitting. Make a mark on probe body at the top of the hex cap (Figure 13) using an indeliblemarker.
Need new picture
Insertion ToolAdapter
Valve
A
Figure 14: Insertion Valve Measurement A
Figure 15: Mark Insertion Length (L) on Probe
L
Mark probe bodyhere
stop ring
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6. Again, clean and reapply lubricant to the exposed probe body as needed. Slide the ProcessInsertion Fitting completely down the Probe Body until it reaches the stop ring, then installprobe into the Insertion Tool Adapter.
7. Use a backup wrench to prevent the Insertion ToolAdapter from turning while tightening the Process Inser-tion Fitting, (Figure 14). Remember, this is an o-ringstraight-thread fitting so don’t over tighten.
8. Pull upward on the probe to ensure the stop ring is against the bottom ofthe Process Insertion Fitting.
Pull Up-ward
Figure 16: Installing Process Insertion FittingInto Insertion Tool Adapter
Figure 17: Stop ring
Figure 18: Check forLeaks
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9. Open valve slowly and check for leaks. Do not stand over theprobe while opening the valve.
10. Using low-pressure probe insertion handle, push probe into pipe-line (figure 17) until indelible mark is aligned with top of the Pro-cess Insertion Fitting. Tighten Hex nut on the fitting exactly 1¼turns to permanently swage the tubing ferrule onto the probebody.
WARNING!!: This is a critical step! If the tubing ferrule is notPERMANENTLY swaged onto the probe body, the process pressurecould force the probe out of the fitting, and the resulting impactcould shear off the stop ring thus allowing the probe to come outof the pipeline. The stop ring is intended only to prevent the userfrom accidentally pulling the probe out of the process insertion fit-ting during installation and removal from the pipeline. Also, theProbe Insertion Tool MUST NOT be removed from the probe untilthe Swagelok nut is completely tightened or the access valve isclosed.
11. Again, check entire fixture for leaks and attach Warning Placard (Figure 18) to valve handleand probe body using cable tie.
Figure 20: Probe Warning Placard
Figure 19: Push Probeinto Pipeline
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12. Install fiberoptic junction box in close proximity to the probe as shown in Figure 3.
13. Connect the probe’s armored shield conduit to one of the conduit holes on the junction box.
B. Probe Removal Procedure
14. 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 lowpressure insertion handle to probe. Hold inward force on handle without standing inline with the probe axis.
15. Remove the Warning Placard.
16. Safe probe removal requires 2 people. One person must hold the insertion handlewhile the other person loosens the Process Insertion Fitting nut while holding abackup wrench on the Insertion Tool Adapter.
17. When the Process Insertion Fitting Nut is free, the person holding the probe han-dle should allow the process pressure to gradually allow the probe to be retracteduntil the stop ring comes to rest against the insertion fitting (probe fully retracted).
18. Close the valve slowly and completely.
19. Place a backup wrench on the Insertion Tool Adapter. Remove theProcess Insertion Fitting from the Insertion Tool Adapter taking carenot to spill any process fluid. The use of hydrocarbon absorbing pad-ding is suggested to prevent environmental contamination. Be sure todispose of contaminated padding properly.
20. Make sure the threads in the top of the Insertion Tool Adapter areclean, then install the Safety Plug to keep out dirt and provide a backupin case the valve leaks.
Figure 21: Ease ProbeOut of Pipeline
Figure 22: Close Valve
Figure 23: Remove Probe FromInsertion Tool Adapter
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II. Mount the FuelCheck Controller and Junction Boxes
21. Refer to the Controller Mounting Guidelines shown on p. 9.
22. Always use a level, and be sure to use proper mounting hardware based on where the con-troller will installed.
23. Input power is 24VDC, minimum 5A service, apply to terminal block as shown in Figure 9.
24. Mount the Probe Junction Box within 2m of the FuelCheck Probe
25. Mount the Controller Junction Box within 2m of the FuelCheck Controller.
III. Install the Fiberoptic Interconnect Cable
Figure 24: Fiberoptic Interconnect Cable
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A. Pull Cable into Junction Boxes26. Install the fiberoptic interconnect cable between the Probe Junction Box and the Controller
using standard cable pull techniques. Do not expose the cable to bend radii less than or pulltension greater than the values shown in Figure 10.
27. Be sure to leave at least 3m (10 ft.) of excess fiber at each end for ease of termination.
B. Prepare Fiberoptic Cable for Termination28. NOTE: all OFS PE jacked cables (FU-C2-UV and FU-C2-DB)
have an integral ripcord to facilitate removal of the outer PEjacket. NEVER circumcise the cable with a cable stripper asthis will almost certainly penetrate the individual optical fiberjackets and damage the fiber!
29. Carefully use a sharp knife to remove the first ~5 cm (~2 in.) ofjacket to expose the red jacket removal ripcord.
Figure 25: NO CABLE STRIPPERS!
Figure 26: Expose the Ripcord
27
30. After the red ripcord is exposed, grasp the end of the cablefirmly with one hand while pulling downward on the ripcord withpliers to split open the cable. Expose ~30 cm (1 ft.).
31. Remove all cable fillers, strength mem-bers and wrappers. DO NOT cut off theripcord so that additional cable jacketcan easily be removed if necessary. Thecable is now ready to be terminated.
C. Termination Procedure for 200µM HCS fiber with ST ConnectorsNOTE: This procedure is specific to this fiber type, and OMNTEC training is required.
NOTE: This procedure requires the following tools and components:
A. FU-FO-KIT ST Termination Kit OFS TK-7-200 ST (DT03732-32)
Figure 27: Pull Ripcord to Split the Jacket
Figure 28: Cable Ready for Connectors
28
B. FU-FO-CN ST Connector Set OFS BP05065-13 + shrink tube
32. Slide the adhesive heat shrink tubing onto the cable, and move it up out of the way
33. Mark the cable 63 mm (2-1/2”) fromthe end with a marker. Using the1.6mm hole on the Cable Strippertool, use a quick squeeze-and-re-lease action to remove the 64mm ofouter jacket.
Remove Fiber BufferNote: Be careful while handling theFIBER STRIPPER. Handle as a pre-cision device and do not strike on hard surfaces or drop. Be sure to clean blades frequentlyusing small bristle brush supplied.
Figure 29: Contents of ST Termination Kit (FU-FO-KIT) Figure 30: Contents of FU-FO-CN
Figure 31: Strip Fiber Jacket Using Cable Stripper
29
IMPORTANT: Pull straight when stripping the fiber buffer. The HCS cladding can be damagedif fiber is not pulled straight.
34. Separate buffered fiber from yellow aramid yarn by pulling backalong the cable.
35. Insert the buffered fiber through the guide tube of the FIBERSTRIPPER until the cable outer jacket bottoms out in the tube.
NOTE: If unable to insert buffered fiber through guide tube, trimtip of the fiber using scissors. If a short length of cable is being ter-minated, wrap the cable around your finger to prevent fiber and ar-amid yarn from pulling out of cable jacket.
36. Holding cable securely, squeeze handles to cut buffer and PULLSTRAIGHT to remove buffer.
37. Inspect HCS cladding for damage from improper buffer stripping.[i.e. white dusty stripe]
NOTE: If damage is visible cut off the damaged fiber and repeatthe procedure from Step 33: Strip Cable Outer Jacket.
38. Verify proper buffer strip length to be 56 mm (2-3/16”).
Install Cable Anchor39. Pull aramid yarn strands back over stripped fiber.
NOTE: Avoid touching fiber as oils from fingers may affect subsequentcrimp performance.
40. Holding aramid yarn and fiber at very top. Feed the fiber and thearamid yarn through the CABLE ANCHOR. Bottom out the anchoron the cable outer jacket using a clockwise turning motion. [i.e.screw the anchor onto the cable outer jacket if necessary]
Figure 32: Remove Fiber Buffer
Figure 33: Verify 56 mm bare fiber
Figure 34: Install Cable Anchor
30
41. Position anchor in CRIMP TOOL, such that the end of the anchoraligns with the edge of the crimp die. Squeeze crimp tool handlestogether until it clicks, then releases.
Install Crimp Sleeve42. Divide the aramid yarn into approxi-
mately two equal halves. Fold bothhalves of the aramid yarn back overthe cable anchor. Be sure the fiber iscentered in the cable anchor.
43. Slide the CRIMP SLEEVE over thecable anchor and aramid yarn until itbottoms out on the cable anchor.
44. Position the crimp sleeve in the CRIMP TOOL such that:
• The back edge of the crimp sleeve isaligned with the edge of the crimp nest.
• The aramid yarn halves are posi-tioned over the jaws.
45. Squeeze the crimp tool together untilit clicks, then releases.
Install ST Ferrule46. Feed fiber through hole in rear of FERRULE.
47. Slide the ST ferrule down the fiber and into the crimp sleeve.Push the ferrule firmly until it bottoms out in the crimp sleeve.
48. Make sure the ST ferrule is fully seated in the crimp sleeve.
49. Position the back of the ST COUPLING NUT against the side ofthe crimp die set stamped ‘ST’ as shown.
Figure 35: Crimp Cable Anchor
Figure 36: Install Crimp Sleeve
Figure 37: Crimp the Crimp Sleeve Onto Cable Anchor
Figure 38: Install ST Ferrule
31
NOTE: THE FOLLOWING STEP IS CRITICAL AND OFTEN OVERLOOKED,WHICH WILL RESULT IN A LOOSE CONNECTOR!
50. Rotate the STconnector sothat its key is ori-ented in thecrimp die set asshown.
51. SqueezeCRIMP TOOLhandles to-gether until thetool releases.
Figure 39: Crimp ST Ferrule
32
Cleave off the fiber endBEFORE YOU START:
a. Make sure the appropriate STcleave tool positioner plate is be-ing used.
b. Make sure the appropriate col-ored tension spring is being used:200 µm = Green.
c. Refer to Figure 37 for a diagramof the CLEAVE TOOL.
d. Be very careful while handling theCLEAVE TOOL. Handle as a del-icate precision device and do notstrike on hard surfaces or drop.
e. Keep the cleave tool clean andfree from oils. Gripper pads, dia-mond blade and anvil should becleaned after every 50 cleaves.Clean with ‘Tech Spec LensCleaner’, which is available sepa-rately from Edmund ScientificCompany, Barrington, NJ.
f. Do not use alcohol to clean the di-amond blade or the gripper pads.Alcohol will chemically react withthe gripper pads and ruin them.
g. Do not insert metal tools near thediamond blade, as it is fragile andmay chip.
52. Holding the CLEAVING TOOL in a horizontal position, grip the han-dle while leaving your index finger free to actuate trigger.
53. Place the ferrule into the hole of the positioner plate until it is fullyinserted.
NOTE: It is critical that the connector is fully inserted in the posi-tioner plate. Failure to do so, may cause poor cleave quality and/ordamage to the diamond blade.
54. Release the connector in the tool.
Figure 40: Diamond Cleave Tool
Figure 41: Cleave off the fiber end
X
33
NOTE: Do not hold onto the connector during the cleave process as doing so may cause poorcleave quality.
55. Using index finger, SLOWLY and GENTLY depress trigger to perform the cleave process. Thecleave process is complete when the fiber snaps away from the connector. Do not releasetrigger!
56. Before releasing the trigger, remove the connector from the cleavetool and grasp the top of the scrap fiber while releasing the trigger.Gently remove the scrap fiber while keeping it away from the dia-mond blade.
57. Dispose of scrap fiber safely.
58. Install protective cap onto connector to protect cleaved fiber sur-face.
C. Perform Loopback Test to Measure Total Optical Attenuation of theFiberoptic Interconnect
NOTE: FuelCheck® is an intensity-based optical sensor system. This means that the light source,fiberoptic interconnect cable and all of its connectors, and the light detector must be absolutelystable in order for the system to function properly. This test will measure the sum of the attenuationof the fiberoptic interconnect cable and its 4 ST connectors, as well as the stability of the connect-ors. Its primary goal is to make sure all 4 connectors were installed correctly. If this test fails (themeasured attenuation is too high) then connector(s) must be replaced.
59. Route the Fiberoptic Interconnect Cable into the heated enclosure of the FuelCheck Connectthe ST Connectors to the FOI Module in the FuelCheck Controller as shown in Figure 40. Coilup extra fiberoptic cable in the Controller Junction Box.
Figure 42: Install Protective Cap
34
Figure 43: Route the Fiberoptic Interconnect Cable into the Heated Enclosure of the Controller
60. Apply a small dab of optical gel to the tips of the Control-ler ST connectors by dipping them into the optical gelcontainer. Be careful not to allow any dirt to get into thegel.
61. Connect Fiberoptic Interconnect Cable’s ST Connectorsto FOI module. This is a very tight space, so be carefulnot to kink the fiber or subceed the minimum bend ra-dius. Then, power up the Controller, switch it on, andwait for temperature in heated enclosure to reach pro-grammed temperature.
Figure 44: Apply Optical Gel to Fiber End
Figure 45: Attach Fiberoptic Cable to FOI Module
35
62. At the Probe Junction Box, use a Mating Sleeve to jointhe 2 ends of the Fiberoptic Interconnect Cable asshown in Figure 44. This will enable you to measure thetotal attenuation of the entire Fiberoptic Interconnect in-cluding the cable and its 4 ST connectors. This will con-firm that the cable is in good condition and that the con-nectors were installed properly.
63. Observe the Optical Gain output on the Controller. If the output is ≥ -10dBm, then it’s likely you did a good job of installing the connectors. Astandard FuelCheck® fiberoptic interconnect will include 4 ST connectors.Because a properly installed ST connector has an attenuation of ~1 dB,and the HCS fiber has an attenuation of <6 dB/km, then the values in Fig-ure 49 would serve as a guideline for overall attenuation.
64. Once you have established the overall attenuation is acceptable, havesomeone gently pull and wiggle each connector in turn while you are ob-serving the Optical Gain. If the reading remains stable, then you can as-sume the connectors are crimped tightly, and you can then proceed withheat-shrinking.
D. Shrink the adhesive heat shrink tubes65. Slide the adhesive shrink-wrap tubes over the crimp
sleeves as shown in Figure 50.
66. Carefully shrink the tubing using a heat gun until the tub-ing is tight around both the fiber jacket and the connectoras shown in Figure 51.
Distancefrom
Probe toController,
m
Approx-imate
OpticalGain,dBm
10 -4
100 -6
1,000 -16
2,000 -28
Figure 48: Expected OpticalGain (Loopback Test)
Figure 49: Position Heat-Shrink Tubing
Figure 50: Connectors After Heat-Shrinking
Figure 47: Loopback Test Configuration
36
67. Allow the connectors to cool, then repeat steps 60 – 62 to ensure the heat-shrinking operationsdidn’t damage the connectors. If the Optical Gain remains the same and constant, you arenow ready to attach the Fiberoptic Interconnect Cable to the FuelCheck Probe.
68. At the Controller, disconnect the fiberoptic connectorsfrom the FOI Module, and pass the terminated end intoone of the cable seals in the bottom of the ControllerJunction Box and then out through the other cable seal.Then, neatly coil the extra fiberoptic cable into a ~20 cm(8”) diameter coil and secure with cable ties. Then placethe coil into the Controller Junction Box as shown in Fig-ure 52.
E. Connect the FuelCheck Probe to the Fiberoptic Interconnect CableNOTE: Because the fiberoptic connectors are slightly affected by moisture and large temperature variations, a specialStabilizer Tube has been developed to house any fiberoptic connectors installed outdoors.
69. Insert the probe fiberoptic connectors through the threaded adapted in the bottom of the ProbeJunction Box, then screw in the fitting on the end of the probe armor.
70. Spread open the slit and place the stopper over the fi-beroptic interconnect cable and the probe cable asshown. Attach the ST mating sleeve to the ST con-nector on the interconnect cable.
71. Attach stabilizer tube to stopper as shown leaving the connector protruding from the end
INSERT PHOTO SHOWING CONTROLLERJUNCTION BOX WITH EXTRA CABLE
COILED AND TIE-WRAPPED.
Figure 51: Extra Cable Stored in Controller Junc-tion Box
Figure 52: Insert Fiber in Stopper
37
Figure 53: Attach Stabilizer Tube
72. Apply a small dab of optical gel to the tips of the ProbeST connector by dipping it into the optical gel container.Be careful not to allow any dirt to get into the gel.
73. Connect the probe's ST connector to themating sleeve.
74. Draw the stabilizer tube assemble togetherby carefully pulling the interconnect cablefiber through the holes in the stopper. Make sure the stoppers are snug in the stabilizer tubeand the fibers are straight.
75. Complete steps 68 – 72 for the other cable.
.
Figure 54: Apply Optical Gel
Figure 56: Make Up Stabilizer Tubes
Figure 55: Connect to mating sleeve
38
76. Using the cable ties, secure the longer tube to the shorter tubes. The longer tube is used asa support to eliminate excessive force being applied to the fiber.
77. Neatly coil the extra cable into a ~20cm (8”) diametercoil and secure with cable ties. Neatly place the cablecoil with connectors secured inside the stabilizer tubesinto the Probe Junction Box and secure, taking care notto subceed the cable bend radius.
Figure 57: Secure Stabilizer Tubes with Cable Ties
INSERT PHOTO SHOWING PROBEJUNCTION BOX WITH EXTRA CABLE
COILED AND TIE-WRAPPED, ANDCONNECTORS IN STABILIZER TUBES.
Figure 58: Extra Cable And Connector StabilizersStored in Probe Junction Box
39
F. System CalibrationBefore the FuelCheck Probe is reinstalled into the pipeline, thesignal conditioner in the Controller must be calibrated so that thespan of its analog output will coincide with the optical gain of theFuelCheck Probe when immersed in products in the pipeline.Since the refractive indices of these products will be slightly dif-ferent at static, ambient conditions compared to flowing condi-tions in the pipeline, this “static calibration” may need to be re-fined once the probe is in pipeline operation.
ACROMAG 611T/612T-500 SIGNAL CONDITIONER (LINEAR OUTPUT)CALIBRATION PROCEDURE
a. If the Acromag 811T (non-linear output) signal conditioner isbeing used, please follow the calibration procedure in Appen-dix G.
b. If the output is to be routed to a TCP/IP network using theAcromag BusWorks® Model 952N-4012 Modbus TCP/IP In-dustrial I/O Module, instructions can be found in Appendix H.
After the connectors have been installed on the fiberoptic inter-connect fiber and connected to the FuelCheck® Controller andProbe, the attenuation reading on the Optical Gain meter lo-cated on the front of the Controller should read greater than -20dBm with the Probe in air. Typical readings in air are -5 dBm to-10 dBm. If the reading is less than -20 dBm contact TechnicalSupport at OMNTEC for assistance. If it is suspected that theST Connectors on the Probe have become damaged, please re-fer to the procedure in Appendix for replacing them.
The system calibration is performed in 2 separate steps: A) pre-liminary calibration using samples in bottles, and B) final in-linecalibration using known fluids in the pipeline. The preliminarycalibration is performed to simply ensure the sensor readingswill be “in-scale” when the pipeline is running. The final in-linecalibration is performed to optimize the output levels so that allthe pipeline products can be observed on the HMI trend.
When performing the preliminary calibration, obtain samples oftwo fluids which will fall on each end of the calibration scale.Example: if the pipeline is transferring gasoline and diesel, thelowest octane gasoline will be the fluid for the low set point andthe diesel will be used for the high set point. When using something other than gasoline anddiesel, the fluid which has the dBm reading closest to -30 dBm will be used for the LOW setpoint.
78. Ensure Controller is powered on and the temperature has stabilized.
Figure 59: Acromag 611T SignalConditioner
40
79. Connect a multimeter to the + and – input test points. These are located on the panel con-taining the on/off switch and the Fuse.
80. Select the fluid setpoints within the 4-20 mA range. As an example, we will select 8 mA forregular gasoline (usually the lightest pipeline product) and 16 mA for diesel (usually the heav-iest pipeline product). The set point can be set to any desired ratio to meet your desiredpresentation on the display being used. CAUTION: Do not use a sharp object for depressingthe calibration buttons on the signal conditioner. Use blunt objects and apply pressure grad-ually until you feel a tactile change or see the visual change in the LEDs.
81. Press the MODE button. When depressed, the RUN indicator will turn off and the CH 1 indi-cator will start flashing. The Signal Conditioner is ready to begin the setup.
82. Clean the lens on the probe using a cotton swab and glass cleaner.
83. Place the probe in the fluid to be used as the High set point, making sure the signal is stableby observing the dBm display, it may be necessary to agitate the probe in the fluid to makesure the sensor is properly wetted. When the signal is stable record the voltage and nextpress the up ▲ or down ▼ arrows to select the desired output current shown on the 4-20 mAdisplay, example: 16 mA for Diesel.
84. When the correct current value is reached, press the SET button. When the button is pressedthe ST indicator will flash indicating the value was set.
85. Press MODE button and the CH 1 indicator will turn on solid.
86. Place the probe in the fluid determined for the Low set point, making sure the signal is stableby observing the dBm display. When the signal is stable record the voltage and next pressthe up ▲ or down ▼ arrows to select the desired output current shown on the 4-20 mA displayselected for the fluid being used, example being 8 mA for Gasoline.
87. When the current is set press the SET button. When the button is pressed the ST indicatorwill flash indicating the value was set.
88. Press MODE button and the CH 1 indicator will turn off and the RUN indicator will turn green.
89. Check the Current indicator and the value should be reading 8 mA. Insert the probe in theDiesel and the indicator should read 16 mA. If the values are not correct repeat the abovesteps again.
90. This is a preliminary calibration because the values can be different with the fluid under pres-sure in the pipeline and the refractive index may change between different batches.
41
Reinstallation of Probe into Pipeline
Positively ascertain line pressure is less than 300 psi (2 MPa) before proceeding.
91. Make certain valve is fully closed.
92. Slowly loosen Safety Plug, making sure valve isn’t leaking. Re-move the Safety Plug and store.
93. Make sure probe is fully retracted (stop ring against bottom ofinsertion fitting). Install probe onto Insertion Tool Adapter andtighten insertion fitting to adapter. Make sure Swagelok nut isonly hand-tight.
94. Open valve slowly and fully. Again, carefully check for leaks and repair as needed.
95. When certain of a no-leak status, attach low-pressureprobe insertion handle to probe. Push probe into pipe-line.
96. Tighten Swagelok nut until snug.
97. Again, check entire fixture for leaks.
98. Reattach Warning Placard.
Figure 60: Install Probe on Adapter
Figure 61: Reinstall Probe Through Valve
Figure 62: Reattach Warning Placard
42
In-line calibration procedure
99. Press the MODE button and the RUN indicator will go off and the CH 1 indicator will startflashing. 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 thegasoline under pressure in the Pipeline.
100. Press the MODE button again and the RUN indicator will turn green and the current displayshould be indicating 8 mA.
101. When the fluid in the Pipeline changes to Diesel, perform the same operation but do thesetup when the CH 1 indicator is flashing for the High setting. This can be done whenever thefluid changes in the Pipeline and the reading may require a change.
43
6. Fluid Temperature CorrectionFor certain applications, it may be advantageous to normalize the refractive index output to stand-ard temperature (60°F).
During the development of FuelCheck, a series of flow loop measurements was made at variousfluid 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 intoa 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, VV60 FOI output corrected to 60°F, VS60 signal conditioner output corrected to 60°F, mAS signal conditioner output, mAVmax photoelectric output at maximum signal conditioner output, VVmin photoelectric output at minimum signal conditioner output, VT fluid temperature, °F
As an example, let us assume that a signal conditioner is being used to convert the photoelectricoutput voltage to a 4-20 mA current, and that it is calibrated so that a -1.03 to -4.22 photoelectricvoltage range is translated to a 4-20 mA signal. Presently, the signal conditioner output is 11.3mA, and the fluid temperature is 104°F.
S 11.3 mAVmax -4.22 VVmin -1.03 VT 104°F
S60 =(11.3*(-4.22--1.03)+(0.22*(60-104)))/(-4.22--1.03)S60 = 14.3 mA
Chapter
6
44
Figure 63: Fluid Temperature Normalization
FuelCheck ® Fluid Temperature Normalization
-1
0
1
2
3
4
20 40 60 80 100 120
fluid temp., °F
outp
ut v
olta
ge
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
45
FuelCheck® System SpecificationsFuelCheck® Probe
Part No. FU-PR-24Sensor type: dual reflection critical angle fiberoptic refractometerFiber type: duplex 200/230 µm HCPFiberoptic connector type: ST crimp and cleaveMaximum fiber length: 2 km (~7,500 ft)Probe construction: ½” OD X 0.095” WT TV9426 304 stainless tubingStandard connection: 1” MNPT to access valveMax. 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 insertionhandle
FuelCheck® ControllerPart 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-4XConduit connections: 2 - ½” female connectors on 3.75” centers (bottom of enclosure)Power requirement: 24 VDC standard, AC optionalOperating temperature: 50°F - 130°F (do not mount in direct sunlight, requires sunshade if
mounted outdoors)Signal output: 4-20 ma with user-adjustable zero, span, and polarity
normal polarity proportional to refractive index and specific gravityreverse polarity proportional to °API.
Chapter
7
46
APPENDICES
Chapter
8
47
APPENDIX AWarranty and Disclaimer
48
WARRANTY & DISCLAIMER
OMNTEC Mfg., Inc. ("OMNTEC") warrants its products ('Product' or 'Products') to conform to its own specifications and to be free ofdefects in materials and workmanship under normal use for a period of twelve (12) months from the date of manufacture. Within the warrantyperiod, OMNTEC will repair or replace, at its option, all or any part of the warranted product. OMNTEC will not be responsible for disman-tling and/or reinstallation charges. In order to exercise the warranty, the User (‘‘User’,’Installer’’' or 'Consumer') must be given a ReturnMaterial 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 TOFOLLOW INSTALLATION AND OPERATING INSTRUCTIONS, ALTERATION, ABUSE, ACCIDENT OR TAMPERING, AND/ORREPAIR BY ANYONE OTIIER THAN OMNTEC Mfg., Inc..
THIS WARRANTY IS EXCLUSIVE AND EXPRESSLY IN LIEU OF ALL OTIIER WARRANTIES, OBLIGATIONS OR LIABILITIESWIIETIIER WRITTEN, ORAL, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCIIANTABILITY OR FITNESS FOR APARTICULAR PURPOSE. OMNTEC Mfg., Inc. WILL NOT BE LIABLE TO ANYONE FOR ANY CONSEQUENTIAL OR INCIDENTALDAMAGES 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 extendthis warranty. This warranty will apply to OMNTEC Products only. All other products, accessories or attachments used in conjunction withOMNTEC 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 attachments ofother 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 contamination,environmental contamination and/or fire. It does not insure or guarantees that there will be no death, personal damage and/or damage toproperty as a result. OMNTEC does not claim that the Product may not be compromised and/or circumvented, or that the Product willprevent any death, personal and/or bodily injury and/or damage to property resulting from overfill, environmental contamination, fire orotherwise, 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, regardlessof cause or origin, OMNTEC maximum liability will not in any case exceed the purchase price of the Product, which will be fixed as liquidateddamages 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 Productand systems tests at a minimum of once per week. Changes in environmental conditions, electric or electronic disruptions and/or tampering,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 necessaryprecautions for the safety and protection of lives and property wherever OMNTEC are installed. OMNTEC strongly advises the User toalways 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.
49
50
APPENDIX BOMEGA CN132
TEMPERATURE CONTROLLER
NOTE: for most up-to-date Omega manual, please refer to:http://www.omega.com/Manuals/manualpdf/M1638.pdf
51
APPENDIX CAcromag Series 611T/612T
SIGNAL CONDITIONER
NOTE: for most up-to-date Acromag manual and data sheets, please refer to:http://www.acromag.com/catalog/433
52
APPENDIX DSystem Calibration Using
Acromag 811T-500 SIGNAL CONDITIONER
(Non-Linear Output)
NOTE: for most up-to-date Acromag manual and data sheets, please refer to:http://www.acromag.com/catalog/452
53
The Acromag 811T-500 is a special order signal conditioner and is only used when adjustable scaling is notavailable in the HMI software or display system being used to view the fluid interface of two similar fluids.
When the connectors have been installed on the interconnect fiber and connected to the FuelCheck® Control-ler and Probe, the attenuation reading on the dBm meter located on the front of the Controller should read lessthan -20 dBm with the Probe in air. If the reading is over -20 dBm contact Technical Support at OMNTEC forassistance.
1. To perform a calibration, voltage readings in the three fluids will need to be recorded. Obtainsamples of the fluids to be used in the preliminary calibration. Connect a multimeter across thesignal conditioner “A” + and – input test points. These are located on the panel containing theon/off switch and the fuse.
2. Place the “A” probe in one of the fluids. Make sure the signal is stable by observing the dBmdisplay, it may be necessary to agitate the probe in the fluid to make sure the sensor is wettedwell. Record the voltage, dBm reading and the type of fluid being measured. Repeat the testseveral times to verify correct readings.
3. Perform step 2 for the other two fluids, recording the voltage, dBm reading, and the type of fluidbeing measured.
Note: The FuelCheck manual will contain a CD containing an EXCEL program to be used tocalculate the voltage values for the 4 and 20 ma values and also the % of input values.
4. The following screen will be shown when this program is running. (THE VALUES ARE ANEXAMPLE)
IntelliPack Configuration Calculations with Set Points of 8 & 16 mA
Output Cur-rent Input Measured Values Voltage Values Calculated Val-
ues for Input %Values forOutput %
4ma Calculated Value -3.285 0.0% 0.0%8ma Input measured voltage for diesel -2.450 25.0% 25.0%
12ma Input measured voltage for gasoline Oct 2 -0.930 70.5% 50.0%16ma Input measured voltage for gasoline Oct 1 -0.780 75.0% 75.0%20ma Calculated Value 0.055 100.0% 100.0%
5. Input the measured voltage into the cells in GREY. The 4 and 20 ma and Input % values willbe calculated to use in the IntelliPack Configuration software program.
6. Move the Multimeter to Probe “B” jacks and repeat steps 2 thru 5 for the B Channel.
When the voltage measurements have been made and recorded the two signal conditioners canbe configured.
Install the IntelliPack Configuration Software Program (Model 5030-881) following setup in-structions in the transmitter configuration manual.
Connect adapter to serial port, serial port adapter, and to the RJ11 connection on the front ofthe Module.
54
7. Start the program by clicking on the IntelliPack program icon to boot the Configuration Pro-gram. The following screen will be shown. The display gives the menus for File, Module, andSettings.
8. Click on “C” Settings and select the communication port which is connected to the IntelliPackmodule.
9. The IntelliPack has had an initial configuration. Select “B” Module and click the Upload Con-figuration option. This will upload the configuration from the signal conditioner to the PC.
10.When the upload has been completed the following screen will be displayed. In the Gen-eral screen there is options for Comments, Location and Tag name. Input 1 Range willset for the +/-6V DC, and the Output 1 Range set for 4-20mA. The Mode can be set fornormal or reversed. This will make the 4-20mA output reverse for the same input signal.The Input 1 Range will be set for +/-6VDC. This range will cover almost any productsthe probe can detect.
55
11.Select the Xmtr Configuration option. The following screen will be displayed.
12.Click on Linearizer and the default will be displayed. Change the number of Breakpointsfrom 25 to 5. The display will change to the one below.
56
13. Input the values from the EXCEL Spreadsheet. The value for the 0% output will be inputas the most negative value. Change the Input % and Output % to the calculated values.This will set the value displayed to be 25% of the overall scale of the 4 to 20mA scale.
14. Click on Show Graph and a Graph of Current Output to Voltage Input will be shown.
15.Click on Module and select Download Configuration. This will download all of the in-formation into the signal conditioner.
16. Click on Test , This screen will give you a real time presentation of the input and outputof the signal conditioner. This will be useful to determine if the calibration is valid.
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17.Check the voltage levels during the next several pipeline batch changes and ifthere is a noticeable change between the original calibration numbers and theone’s observed in the pipeline, repeat the calibration.
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APPENDIX EAcromag BusWorks® Model 952N-4012
Modbus TCP/IP Industrial I/O Module
NOTE: for most up-to-date Acromag manual, please refer to:
http://www.acromag.com/catalog/318/Ethernet_Network_I_O/Ethernet_I_OModules/Multi-Func-tion_I_O/951EN___952EN
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The Acromag BusWorks® Model 952N-4012 Modbus TCP/IP Industrial I/O Modules is used toprovide network output for the FuelCheck System. This module provides a scaled 4-20 mA out-put, with corresponding MODBUS registers accessible via TCP/IP.
Shown below is a simplified I/O diagram
NOTE: The analog inputs for this module are fixed at 0-10 VDC, and the analog outputsare fixed at 4-20 mA. DO NOT attempt to calibrate any of the analog inputs or outputs onthe Acromag 952N-4012. All analog calibrations should be made in the Acromag 611T or612T modules. Please refer to Chapter 5 for instructions!
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The only user setup required for the Acromag 952EN-4012 are in the Network ConfigurationPage. Please see the menus below:
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APPENDIX FFiberoptic Termination Kit
Part No. FU-FO-KIT
NOTE: for most up-to-date OFS manual, please refer to:
http://ofscatalog.specialtyphotonics.com/item/crimp-and-cleave-termination-kits/crimp-cleave-st-termina-tion-kits/item-1298
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APPENDIX G
UV Resistant CableAdditional Documentation
Part No. FU-C2-UV
NOTE: for most up-to-date manual, please refer to:
http://ofscatalog.specialtyphotonics.com/item/all-categories/-mm-based-construction-200-m-hcs-step-index-ca-bles/ac02602-10?&plpver=10&origin=keyword&by=prod&filter=0#
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APPENDIX G
Procedure for Replacing Connectorson FuelCheck Probe
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NOTE: This procedure is for replacing the ST connectors on the FuelCheck Probe (FU-PR-24 should they become damaged.
NOTE: This procedure requires the following tools and components:
G. FU-FO-KIT ST Termination Kit OFS TK-7-200 ST (DT03732-32)
H. 2 - FU-FO-CN ST Connector Set OFS BP05065-13 + shrink tube
1. Slide the adhesive heat shrink tubing onto the cable, and move it up out of the way
2. Mark the cable 63 mm (2-1/2”) fromthe end with a marker. Using the1.6mm hole on the Cable Strippertool, use a quick squeeze-and-re-lease action to remove the 64mm ofouter jacket.
Figure 65: Contents of FU-FO-CN
Figure 66: Strip Fiber Jacket Using Cable Stripper
Figure 64: Contents of ST Termination Kit (FU-FO-KIT)
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Remove Fiber BufferNote: Be careful while handling the FIBER STRIPPER. Handle as a precision device and donot strike on hard surfaces or drop. Be sure to clean blades frequently using small bristle brushsupplied.
IMPORTANT: Pull straight when stripping the fiber buffer. The HCS cladding can be damagedif fiber is not pulled straight.
3. Separate buffered fiber from yellow aramid yarn by pulling backalong the cable.
4. Insert the buffered fiber through the guide tube of the FIBERSTRIPPER until the cable outer jacket bottoms out in the tube.
NOTE: If unable to insert buffered fiber through guide tube, trimtip of the fiber using scissors. If a short length of cable is being ter-minated, wrap the cable around your finger to prevent fiber and ar-amid yarn from pulling out of cable jacket.
5. Holding cable securely, squeeze handles to cut buffer and PULLSTRAIGHT to remove buffer.
6. Inspect HCS cladding for damage from improper buffer stripping.[i.e. white dusty stripe]
NOTE: If damage is visible cut off the damaged fiber and repeatthe procedure from Step 33: Strip Cable Outer Jacket.
7. Verify proper buffer strip length to be 56 mm (2-3/16”).
Install Cable Anchor8. Pull aramid yarn strands back over stripped fiber.
NOTE: Avoid touching fiber as oils from fingers may affect subsequentcrimp performance.
9. Holding aramid yarn and fiber at very top. Feed the fiber and thearamid yarn through the CABLE ANCHOR. Bottom out the anchoron the cable outer jacket using a clockwise turning motion. [i.e.screw the anchor onto the cable outer jacket if necessary]
Figure 67: Remove Fiber Buffer
Figure 68: Verify 56 mm bare fiber
Figure 69: Install Cable Anchor
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10. Position anchor in CRIMP TOOL, such that the end of the anchoraligns with the edge of the crimp die. Squeeze crimp tool handlestogether until it clicks, then releases.
Install Crimp Sleeve11. Divide the aramid yarn into approxi-
mately two equal halves. Fold bothhalves of the aramid yarn back overthe cable anchor. Be sure the fiber iscentered in the cable anchor.
12. Slide the CRIMP SLEEVE over thecable anchor and aramid yarn until itbottoms out on the cable anchor.
13. Position the crimp sleeve in the CRIMP TOOL such that:
• The back edge of the crimp sleeve isaligned with the edge of the crimp nest.
• The aramid yarn halves are posi-tioned over the jaws.
14. Squeeze the crimp tool together untilit clicks, then releases.
Install ST Ferrule15. Feed fiber through hole in rear of FERRULE.
16. Slide the ST ferrule down the fiber and into the crimp sleeve.Push the ferrule firmly until it bottoms out in the crimp sleeve.
17. Make sure the ST ferrule is fully seated in the crimp sleeve.
18. Position the back of the ST COUPLING NUT against the side ofthe crimp die set stamped ‘ST’ as shown.
Figure 70: Crimp Cable Anchor
Figure 71: Install Crimp Sleeve
Figure 72: Crimp the Crimp Sleeve Onto Cable Anchor
Figure 73: Install ST Ferrule
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NOTE: THE FOLLOWING STEP IS CRITICAL AND OFTEN OVERLOOKED,WHICH WILL RESULT IN A LOOSE CONNECTOR!
19. Rotate the STconnector sothat its key is ori-ented in thecrimp die set asshown.
20. SqueezeCRIMP TOOLhandles to-gether until thetool releases.
Figure 74: Crimp ST Ferrule
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Cleave off the fiber endBEFORE YOU START:
h. Make sure the appropriate STcleave tool positioner plate is be-ing used.
i. Make sure the appropriate col-ored tension spring is being used:200 µm = Green.
j. Refer to Figure 37 for a diagramof the CLEAVE TOOL.
k. Be very careful while handling theCLEAVE TOOL. Handle as a del-icate precision device and do notstrike on hard surfaces or drop.
l. Keep the cleave tool clean andfree from oils. Gripper pads, dia-mond blade and anvil should becleaned after every 50 cleaves.Clean with ‘Tech Spec LensCleaner’, which is available sepa-rately from Edmund ScientificCompany, Barrington, NJ.
m. Do not use alcohol to clean the di-amond blade or the gripper pads.Alcohol will chemically react withthe gripper pads and ruin them.
n. Do not insert metal tools near thediamond blade, as it is fragile andmay chip.
21. Holding the CLEAVING TOOL in a horizontal position, grip the handle while leaving your indexfinger free to actuate trigger.
22. Place the ferrule into the hole of the positioner plate until it is fullyinserted.
NOTE: It is critical that the connector is fully inserted in the posi-tioner plate. Failure to do so, may cause poor cleave quality and/ordamage to the diamond blade.
23. Release the connector in the tool.
Figure 75: Diamond Cleave Tool
Figure 76: Cleave off the fiber end
X
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NOTE: Do not hold onto the connector during the cleave process as doing so may cause poorcleave quality.
24. Using index finger, SLOWLY and GENTLY depress trigger to perform the cleave process. Thecleave process is complete when the fiber snaps away from the connector. Do not releasetrigger!
25. Before releasing the trigger, remove the connector from the cleave tool and grasp the top ofthe scrap fiber while releasing the trigger. Gently remove the scrap fiber while keeping it awayfrom the diamond blade. Dispose of scrap fiber safely.
26. Repeat Steps 1-25 for the other probe fiber.
27. Perform a Loop-Back test of the Fiberoptic Interconnect Cable (between the Controller andthe Probe by following Steps 57-62 starting on Page 28 to confirm that it is within tolerancesbefore proceeding.
Before heat-shrinking the adhesive tubing on the connectors, confirm thatthe probe performance is within acceptable tolerances
28. Clean the lens on the probe using a cotton swab and glass cleaner.
29. Apply a small dab of optical gel to the tips of the ProbeST connector by dipping it into the optical gel container.Be careful not to allow any dirt to get into the gel.
30. Connect the probe to the fiberoptic interconnect cable using 2 mating sleeves.
31. The Probe reading in AIR should be no less than 4 dB less than the cable attenuation meas-ured in the Loop-Back test in Step 27 above. For example, if the Loop-Back test yielded anOptical Gain reading of -4 dBm, then the probe reading in AIR should be no lower than -8dBm.
32. Dip the probe into Diesel (or the heaviest product transported in the pipeline) and observe theOptical Gain. The reading in Diesel should be no less than 35 dB less than the Loop-Backreading. For example, if the Loop-Back test yielded a reading of -4 dBm, then the probe read-ing should be no lower than -39 dBm.
Figure 77: Apply Optical Gel
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33. If the Probe readings are less than these values, then the Probe must be replaced. If thereadings are acceptable then proceed with heat-shrinking.
Shrinking the adhesive heat shrink tubes
34. Slide the adhesive shrink-wrap tubes over the crimpsleeves as shown in Figure 50.
35. Carefully shrink the tubing using a heat gun until the tub-ing is tight around both the fiber jacket and the connectoras shown in Figure 51.
36. Repeat Steps 31-32 above to ensure the heat-shrinking operation didn’t change the readings.
Figure 78: Position Heat-Shrink Tubing
Figure 79: Connectors After Heat-Shrinking
