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Omntec FuelCheck Installation & Operating Manual

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Summary of Contents for Omntec FuelCheck

  • Page 1 ® ®...
  • Page 2 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...

  • Page 3: Table Of Contents

    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 ®...

  • Page 4: System Overview

    Part No. FU-CT-*I (* represents number of channels up to 3, ie. FU-CT-1I) ® is designed for easy installation, convenient calibration, and very low maintenance. FuelCheck The following chapters will describe the principle of operation, installation considerations, and system calibration and operation. Figure 1 FuelCheck System Architecture...

  • Page 5: Principle Of Operation

    (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. FuelCheck Operating Principle FuelCheck 1.

  • Page 6: Fuelcheck ® Probe

    Figure 3 the probe is moved or FuelCheck Probe installed in pipeline 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.

  • Page 7: Probe Location Considerations

    The process insertion ® fitting is an integral part of the FuelCheck probe and cannot be removed in the field. The Insertion Tool adapter en-...

  • Page 8: Probe Insertion And Retraction

    Some general recommendations for probe location and orientation are as follows: Try to mount the FuelCheck probe in a location where the pipe is always full, even when the line is not flowing.
  • Page 9 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...

  • Page 10: Initial Fuelcheck ® Sae (Standard) Probe Installation

    ® 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. SAE/MS STRAIGHT THREAD...
  • Page 11 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.
  • Page 12 7. Verify Process Insertion Fitting is snug against safety stop by pulling upward on the probe body. Pull Upward Figure 11 Safety stop 8. Open valve slowly and check for leaks. Figure 12 Figure 9 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.
  • Page 13 10. Again, check entire fixture for leaks and attach Warning Placard (Figure 9) to valve handle and probe body using cable tie. WARNING WARNING •DO NOT CLOSE VALVE •DO NOT LOOSEN FITTINGS FuelCheck™ Probe installed through valve please refer to FuelCheck™ Operating Manual before attempting to remove FuelCheck™ Probe Figure 14 Warning Placard...

  • Page 14: Fuelcheck Probe Removal With (Line Pressure < 300 Psi)

    ® 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.
  • Page 15 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.

  • Page 16: Fuelcheck Probe Reinsertion With (Pressure <300 Psi)

    ® 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.
  • Page 17 7. Reattach Warning Placard to valve han- dle and probe body using cable tie. •DO NOT CLOSE VALVE •DO NOT LOOSEN FITTINGS FuelCheck™ Probe installed through valve please refer to FuelCheck™ Operating Manual before attempting to remove FuelCheck™ Probe Figure 23 Reattach warning placard...

  • Page 18: Fiberoptic Interconnect Cable

    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.
  • Page 19 Spread open the slit and place the stopper over the fiberoptic interconnect cable and the ® probe cable as shown. Attach the ST mating sleeve to the ST connector on FuelCheck the interconnect cable. Figure 24 Insert fiber in stopper b) Attach stabilizer tube to stopper as shown leaving the connector protruding from the end.
  • Page 20 d) Connect the probe’s ST connector to the mating sleeve. Figure 27 Attach mating sleeve to FO connectors 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.
  • Page 21 Cable Construction Conduit Cable UV resistant Direct Burial (PVC jacketed) (PE jacketed) (steel armored) Part No. FU-C2-CC FU-C2-UV FU-C2-DB Fiber Core Diameter (µm) Attenuation @ 850 nrn (dB/km) <6 <6 <6 Subchannel Diameter (mm) Outer Cable Diameter (mm) 3.5x6.0 Cable Weight (kg/km) Outer Jacket Material Polyethylene Polyethylene...

  • Page 22: Fuelcheck ® Controller

    ® 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;...
  • Page 23 10 0. 0 1 1.2 - 2 9 . 4 1 9.4 - 4 2 . 7 Figure 31 FuelCheck Control, front view Figure 32 FuelCheck Controller, inside view...
  • Page 24 11.5" 19.5" 2.25" 6.0" Figure 33 FuelCheck Controller, mounting dimensions...
  • Page 25 PIN 1 - ORG/K (+24 VDC) PIN 2 - BLK/K (-24 VDC) PIN 3 - RED/F (+24 VDC Switched) INFORMATION CONTAINED ON THESE PRINTS IS THE PROPERITY OF OMNTEC Mfg. Inc. AND ANY PERSON REVEALING THE CONTENTS OF THESE 24 VDC A Output...

  • Page 26: System Calibration

    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-...
  • Page 27 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.
  • Page 28 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.

  • Page 29: 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: = V+(0.01374(60-T))
  • Page 30 FuelCheck ® Fluid Temperature Normalization fluid temp., °F 87OCT 87OCT60 Normalization to 60°F 92OCT 92OCT60 =V+(0.01374*(60-T)) 93OCT 93OCT60 where: JETA JETA60 = corrected voltage LSDiesel LSDiesel60 V = FuelCheck ™ output voltage T = fluid temperature, °F Figure 35 Fluid Temperature Normalization...

  • Page 31: Fuelcheck ® System Specifications

    Chapter 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”...

  • Page 32: Optional Equipment Installed In Controllers With Serial Numbers

    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 Diagram FuelCheck® Controller Serial No. xxxxxx (single channel Modbus TCP/IP) 0 - 10VDC PIN 42...
  • Page 33 Simplified I/O Diagram FuelCheck® Controller Serial No. xxxxxx (two channel Modbus TCP/IP) 0 - 10VDC PIN 45 PIN 46 CHANNEL B PIN 44 PIN 45 PIN 42 PIN 44 CHANNEL A PIN 41 PIN 43 ACROMAG ACROMAG -10VDC - +10VDC...
  • Page 35 APPENDICES...

  • Page 36: Appendix A Warranty And Disclaimer

    APPENDIX A Warranty and Disclaimer...
  • Page 37 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.

  • Page 38: Appendix B Acromag Series 611T/612T Signal Conditioner

    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...

  • Page 39: Appendix Comega Cn132 Temperature Controller

    APPENDIX C OMEGA CN132 TEMPERATURE CONTROLLER NOTE: for most up-to-date manual, please refer to: http://www.omega.com/Manuals/manualpdf/M1638.pdf...

  • Page 40: Appendix D Acromag Busworks® Model 952N-4012 Modbus Tcp/Ip Industrial I/O Module

    APPENDIX D Acromag BusWorks® Model 952N-4012 Modbus TCP/IP Industrial I/O Module NOTE: for most up-to-date manual, please refer to: http://www.acromag.com/PDF/951_952EN_759a.pdf...

  • Page 41: Appendix E Fiberoptic Connectorizing Kit

    APPENDIX E Fiberoptic Connectorizing Kit Part No. FU-FO-KIT NOTE: for most up-to-date manual, please refer to: http://ofscatalog.specialtyphotonics.com/item/crimp-and-cleave-termination-kits-and-connectors/crimp-cleave- termination-kits-st-connectors/item-1298?&bc=0|1103#...

  • Page 42: Appendix F Uv Resistant Cable Additional Documentation

    APPENDIX F UV Resistant Cable Additional 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- cables/ac02602-10?&plpver=10&origin=keyword&by=prod&filter=0#...

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