KAM® OID™ OPTICAL INTERFACE DETECTOR
Contents
1. Simple Precision OID OPTICAL INTERFACE DETECTOR 08 ATEX 1027 User Manual TEL 1 713 784 0000 FAX 1 713 784 0001 OIDMANUAL0614 Email Sales Kam com KAM CONTROLS INC 3939 Ann Arbor Drive Houston Texas 77063 USA www KAM com An ISO 9001 certified company SECTION TITLE PAGE 1 Introduction 2 eAvailable Models and Mounting Options 2 e Theory of Operation 2 eFeatures B eApplications E 2 Specifications 4 eSpecifications 4 eDimensional Drawings 5 3 Installation 7 eSensor location 7 eDo s and Dont s 8 eMain Line 10 eRemoval 15 eAnalyzer Loop 14 eWiring 15 eConnecting the OID 16 4 Field Calibration 17 5 Maintenance 19 CAUTION When installing the OID M sensor in a pipeline containing petroleum products petro chemicals waste waters with the presence of pressure amp temperature and high pressure steam refer to the Pipeline Operators Health Safety and Environmental Policy Procedures to ensure safe installation KAM CONTROLS INC reserves the right to make changes to this document without notice OIDMANUAL 0614 1 KAM CONTROLS INC AVAILABLE MODELS and MOUNTING OPTIONS opening Rectractable OID M Rectractable OID OID FT Flow Through on a main pipe with on a main pipe with on a densitometer loop 2 3 4 flanged 2 MNPT seal housing with 34 or 1 MNPT seal housing THEORY OF OPERATION The OID Optical In2. GND Q INTENSITY 2 If the instrument is switched on and LEDS Fig 5 1 is NOT illuminated it indicates a problem with the power source check the voltage input and polarity 3 If LED5 is illuminated source voltage and polarity should be correct OIDMANUAL 0614 19 KAM CONTROLS INC MAINTENANCE CONTINUED 4 LED3 and LEDA Fig 5 1 should both be illuminated when the power switch on the instrument is in the ON position If LED5 is illuminated the power switch is ON and either LED3 or LEDA is off this indicates that the power supply on the OID is either damaged or there is a short in one of the circuits In this case the boards will have to repaired or replaced Please contact CONTROLS at 1 713 784 0000 for spare or replacement boards and or to arrange for repair 5 If LED5 LED3 LED4 and the power switch are all on and there is still no signal out this indicates that there may be a short in the 4 20 mA circuit In this case the boards will have to repaired or replaced Please contact KAM CON TROLS at 1 713 784 0000 for spare or replacement boards and or to arrange for repair For all other issues please contact CONTROLS at 1 713 784 0000 OIDMANUAL 0614 20 KAM CONTROLS INC
3. and signal WARNING Connecting a power source to the 4 20 mA ports on the TB will damage the OID Power Supply Board and result in failure of the unit OIDMANUAL 0614 16 KAM CONTROLS INC PRIOR TO ANY CALIBRATION MAKE SURE POWER SWITCH IS ON The KAM OID sensor is factory calibrated at the time of shipment for userspecific product interface requirements However field calibration may be required to fine tune the instrument for increased or decreased sensi tivity in specific applications INCREASE SENSITIVITY WHEN factory calibration is not sensitive enough to provide adequate resolution for interface detection and all readings are typically falling in the lower or middle portion of the OID output range Increasing sensitivity elevates the output range to provide greater interface resolution DECREASE SENSITIVITY WHEN some products exceed the maximum reading of the pre calibrated settings Products that exceed the pre set calibration readings will produce an off scale reading exceeding 20 Decreasing sensitivity lowers the output range of the OID sensor to allow all readings to fall within the 4 20 mA output ranges Caution When multiple OID sensors are being used on the same system each sensor should be calibrated equally If special calibration is applied to one unit its output will vary from those of other units measuring or monitoring like products The calibration procedure consist
4. models are mounted through a full opening ball valve you can insert or retract the probe without having to ever drain the pipe OIDMANUAL 0614 2 KAM CONTROLS INC INTRODUCTION CONTINUED FIG 1 4 KAM OID AND GRAVITY DENSITOMETER OID OUTPUT 100 90 80 70 60 50 40 30 20 10 0 API CONFIRMING OUTPUT OF A DENSITOMETER 70 FEA APPLICATIONS Detects the interface of specialty fuels such ULSD Batching No moving parts e Interface detection Measurement is fully automatic Product transmix management Lens cleans in place e Product downgrade management Insertable retractable and flow through Pipeline automation models available Chemicals interface e Output signal can be sent to a SCADA PLC s or to a Central Control Room Clear oil interface Insertable model installs without having to drain Quality control the pipe OIDMANUAL 0614 3 KAM CONTROLS INC Media Material Power Output Communication Port Fluid temperature Electronics temp Pressure ratings Mounting EX enclosure Shaft length Pipe size Weight OIDMANUAL 0614 Refined products Wetted 5 316 stainless steel 12 24 VDC 15 Watts max Max current is 1275 mA Q 12V and 637 mA Q 24V 4 20 mA RS485 factory use only 40 to 160 F 40 to 70 C 40 to 160 F 40 to 70 C ANSI 150 300 600 900 3 4 and 1 MNPT 2 MNPT Sea
5. nuts should never be over tightened Their major function is to apply light pressure on the chevron packing to ensure a seal between the seal housing body and the insertion shaft REMOVING THE OID SENSOR FIG 3 10 1 Toremove the OID sensor first disconnect all electrical connections to the OID enclosure 2 Make sure that the line pressure is below 100 psi Then slowly and with caution loosen the Socket Cap Screws on the Lock Down Collar Socket Cap Screws NOTE Once the Socket Cap Screws have been loosened the OID shaft may push out from the line If pressure in the line is above 100 psi it may do so with enough force to cause bodily injury or damage to the instrument 3 Slide the OID sensor upward until it stops and the probe rests inside the seal housing FIG 3 10 4 Next close the Full opening Ball Valve tightly The OID sensor may now be unbolted from the sys tem OIDMANUAL 0614 13 KAM CONTROLS INC INSTALLATION CONTINUED ANALYZER LOOP INSTALLA TION KAM CONTROLS recommends this installation for 3 4 amp 1 MNPT OID sensors We recommend using thread sealant and not teflon tape the OID sensor threads CAUTION DO NOT USE THE ENCLOSURE TO TIGHTEN OR LOOSEN THE OID THIS CAN CAUSE THE PROBE TO COME UNDONE AND THE FIBER CABLE TO BREAK Please refer to Do s and Don ts on pages 8 9 FIG 3 11 3 4 and 1 MNPT OID sensors should be installed according to FI
6. G 3 10 The OID sen sor should be installed in an analyzer loop in such a fashion that the flow sweeps across the probe lens rather than rushing directly at the probe The reason for this is to 1 obtain a credible reading of the product pipeline interface 2 keep the lens of the probe clean and abrasion free If the OID is installed with the product rushing directly at the probe particles in the pipeline can scratch the lens causing abrasions and resulting in a non credible reading You do not need to measure for insertion distance on the fast loop models OIDMANUAL 0614 14 KAM CONTROLS INC INSTALLATION CONTINUED WIRING FIG 3 12 OFFSE Kam Controls Incorporated 3939 Ann Arbor Drive Houston Tx 77063 Tel 1 713 784 0000 Fax 1 713 784 0000 E mail AskAnEngineer Kam com www Kam com 2 nN RB e NI S8 LNO 68754 SHO 1 NI 98754 Os ALISNALNI POWER OUT V 4 20 mA Current output source powered GND 4 20 mA COMMUNICATION INTERFACE factory use only RS485 OUT Communication port CAUTION When electronics enclosure is open be ex RS485 OUT tremely careful to avoid any contact with interior fiber RS485 IN optic connections Failure to do so could result in the OID 85485 IN malfunctioning OIDMANUAL 0614 15 KAM CONTROLS INC INSTALLATION CONTINUED CON
7. ION CONTINUED Minimum Output Range Adjustment OIDMANUAL 0614 O E O Kam 44 6 6 4 20mA 4 20mA RTN Im cus RS485 OUT RS485 OUT RS485 IN GND INTENSITY Maximum Output Range Adjustment KAM CONTROLS INC CLEANING AND INSPECTION Under normal operation the KAM OID should not require cleaning unless pipeline usage is limited to a small num ber of products Gasoline products or jet fuel in the pipeline will clean the OID without removal To remove any oil residues for visual inspection use a clean cloth with oil solvent or part washer Preferred solvents include any petroleum solvent such as mineral spirits xylene toluene gasoline or diesel Do not use WD40 or other chemicals If you have a question regarding cleaning solvents please contact KAM CONTROLS directly at 1 713 784 0000 or email AskAnEngineerGKam com TROUBLESHOOTING If there is no signal output from the OID please follow the steps below 1 Please double check that the instrument is switched on Fig 5 1 FIG 5 1 LED5 ON OFF SWITCH 4 20mA 4 20mA RTN T cus RS485 OUT RS485 OUT RS485 IN O Q E mail AskAnEngineer Kam com 3939 Ann Arbor Drive www Kam com Houston Tx 77063 Tel 1 713 784 0000 Fax 1713 784 0000 2 E O Kam R amp M85 IN
8. NECTINGTHE OID 1 Proper Grounding of the OID sensor Grounding the OID sensor through the 4 20 mA signal out and power lines is not adequate to protect the OID sensor against power surges To ground the OID sensor connect the chassis ground on the OID board labeled CHS on the OID Terminal Block FIG 3 13 to the green grounding screw on the OID explosion proof box using 16 AWG braided wire Insure that the box is connected to Earth ground either through the pipeline or appropriate low impedance buried grounding structure NOTE CHS is isolated from GND Grounding CHS to pipeline through the grounding screw will not short OID GND to the pipeline 2 connect the power for the OID sensor first check both wires from the source for polarity and voltage then label appropriately 3 Connect positive wire to V FIG 3 13 4 Connect negative wire to GND on TB Terminal Block FIG 3 13 5 Check voltage and polarity at TB then turn OID on FIG 3 13 ON OFF Switch 4 20mA 4 20mA RTN cus RS485 OUT Chassis Ground RS485 OUT RS485 IN x Q Controls 3939 Ann Arbor Drive OQR E 06 R485 IN V GND Power Supply 999999999 INTENSITY EXTERNAL FUSES Power Amp slow fuse Current loop 750 mA MAXIMUM CURRENT LOOP RESISTANCE 500 Ohm Recommended Wire Shielded twisted pair wire is recommended for both power
9. also strongly recommends that you utilize a preview or out station OID sensor This lets the operator decide how to optimize each batch cut prior to actually making the batch cut at the in station and gives the operator more confidence in their decisions as well as the time to identify and resolve any issues that may arise during a critical interface FIG 3 1 RECOMMENDED OID LOCATIONS TO TANK OUT STATION PREVIEW TYPICALLY IN STATION CUT 1 2MILES OID CUTVALVES T 1 6 3 2km T 56 lt b gt INCOMING OID TO TANK TERMINAL FENCE LINE PRIORTO INSTALLATION Remove all the protective packaging materials including the red cap placed at the tip of the sensor probe En sure that the OID sensor was not damaged during transit CAUTION Do not stand the OID sensor on the probe end or allow the probe to hit the ground or any hard surface under any circumstances This will damage the lens and the OID M sensor will not work properly OIDMANUAL 0614 7 KAM CONTROLS INC INSTALLATION CONTINUED INSTALLATION DO S AND OIDMANUAL 0614 DO NOT install the fast loop OID sensor in a straight portion of pipe It needs to be mounted off the bend opposite the pump DO NOT install the OID M sensor with the lens facing directly into the flow If the product has particulate matter in the fluid like sand this will sandblast the lens and c
10. asuring the distance from the edge of the Valve or female connection to the top of the Seal Housing body and subtracting that distance from 5 25 FIG 3 7 FIG 3 7 Measuring points p If the measured distance from the top of the valve to the top of the seal housing body is 4 75 you would calculate the threaded depth TD by subtracting 4 65 from 5 25 5 25 4 65 0 6 In this case the threaded depth TD would be 6 For example You are now ready to calculate TID TID D1 Pipe Wall Thickness TD 25 Example for D1 19 Pipe WT 3 8 and TD 6 TID 19 375 6 25 TID 18 525 11 Use the calculated TID and mark a second line on the shaft measuring from first mark FIG 3 8 FIG 3 8 First mark sn Second mark OIDMANUAL 0614 12 CONTROLS INC INSTALLATION CONTINUED 12 If you have an OID with a Flanged Seal Housing may now attach it to the valve on the pipeline 13 Slowly open Full opening Ball Valve and check for leaks 14 Loosen Socket Head Screw on the Locking Collar 15 Push the OID in until the Second Mark is at the top edge of the Locking Collar FIG 3 9 FIG 3 9 QO Second Mark 10 Re tighten the Socket Cap Screws 11 Tighten the Hex Nuts on the top of the Locking Collar one half turn These
11. l Housing 2 3 or 4 Flanged Seal Housing 3 x 6 x 3 76 mm x 152 mm x 76 mm 12 to 60 Off the shelf lengths are 24 30 36 48 and 60 610 mm to 1524 mm Off the shelf 610 mm 762 mm 914 4 mm 1219 mm 1524 mm 3 4 to 48 20 mm to 1200 mm from 10 Ibs 4 5 kg 4 KAM CONTROLS INC SPECIFICATIONS CONTINUED DIMENSIONAL DRAWINGS FIG 2 10ID SENSOR with FLANGED SL C Shaft Diameter Seal Housing Ts FNPT Shaft Length 5 Oo TABLE 2 2 FLANGE SIZE AND CLASS SL Lom 9 5 0 HEGE Ros Ros Ros TABLE 2 3 DIMENSIONS n INCHES Shaft Lengths are available in 5 12 7 1 443 mm increments Standard sizes are 24 30 36 48 60 610 mm 762 mm 914 4 mm 1219 mm 1524 mm OIDMANUAL 0614 5 KAM CONTROLS INC SPECIFICATIONS CONTINUED FIG 2 4 FLOW THROUGH OID for ANA TABLE 2 5 34 MNPT DIMEN TABLE 2 6 1 MNPT DIMEN pee pow 4 53 B OIDMANUAL 0614 6 KAM CONTROLS INC LOCATION For optimal batch detection KAM CONTROLS recommends that you install the in station OID sensor at the first accessible pipeline location inside the terminal fence line upstream of the interface cut valve s This al lows the operator ample time to open close the cut valves prior to the arrival of the product interface KAM CONTROLS
12. ould cause premature failure DO NOT attempt to screw the OID sensor either in or out by hand Always use a 1 1 4 or 1 3 8 wrench on the wrench flat below the electronics enclosure KAM CONTROLS INC INSTALLATION CONTINUED INSTALLATION DO S AND Minimum 8 20 3 cm OIDMANUAL 0614 DO NOT use teflon tape on the OID sensor threads DO use liquid thread sealant DO install the OID sensor with a minimum of 8 or 200mm be tween the lens and the nearest flat surface DO install the sensor with a sun shade if the electronics are directly exposed to sunlight KAM CONTROLS INC INSTALLATION CONTINUED PRIOR TO INSTALLATION Remove all the protective packaging materials and ensure that the OID sensor was not damaged during transit MAIN LINE INSTALLATION 3 2 OID INSTALLED ON MAIN PIPE The KAM OID sensor should be installed according to FIG 3 2 KAM CONTROLS recommends installing the OID M sensor at a 2 or 10 o clock position to ensure the tip of the probe remains in the fluid A full opening ball valve is used to isolate the OID sensor from the pipeline during installation or removal The seal housing of the OID sensor allows the optical probe to be inserted and removed from the pipe under pressure lt and flow conditions It is the user s responsibility to ensure that the OID sensor is placed at the mos
13. ousing and tighten the socket cap screws on the locking collar This will prevent the the OID shaft from sliding and the probe from getting dam aged during mounting 6 Measure the distance D1 from the outside diameter of main pipe to the end of the connection where the OID sensor is going to be installed FIG 3 5 FIG 3 5 7 Calculate the insertion distance for Flanged Seal Housing If you have a MNPT Seal Housing proceed to step 9 Total Insertion Distance TID D1 Pipe Wall Thickness Seal Thickness 1 4 Example for D1 19 Pipe WT 3 8 and Seal Thickness is 1 8 TID 19 3 8 1 8 1 4 or TID 19 375 125 25 TID 19 1 4 or 19 25 8 Use the calculated TID and mark a second line on the shaft measuring from first mark FIG 3 6 FIG 3 6 9 Bolt or screw the OID sensor to the valve or designated installation location CONTROLS recommends using thread sealant and not Teflon tape for the threaded OID Skip to Step 12 OID with Flanged Seal Housing only OIDMANUAL 0614 11 KAM CONTROLS INC INSTALLATION CONTINUED 10 Calculate the Insertion distance for 2 MNPT Seal Housing TID cannot be calculated until the Seal Housing is screwed into place If you have not already done so please screw your OID sensor into place now You must then measure the Threaded Depth TD into the Valve or connection in order to calculate TID You can do this by me
14. s of increasing the gain or reducing the gain as needed to increase or reduce sensitivity LED light output settings are pre set at the factory and should not be adjusted REQUIRED TOOLS VOLT METER SMALL FLATHEAD SCREWDRIVER CHANGINGTHE HIGH END OF OUTPUT RANGE 1 Determine which product produces the highest current output 2 Connect a volt meter across 4 20 mA terminals When the highest output product is flowing increase the gain by turning GAIN FIG 4 1 counterclockwise or decrease by turning clockwise As you are turning look at your volt meter and stop when it reads 18 4 mA or 80 of scale CHANGINGTHE LOW END In most cases products with the minimum current output are clear and readings will be consistent with factory calibration Only recalibrate the low end of the range in situations when there will be no clear product in the pipeline 1 Determine which product produces the lowest current output 2 Connecta volt meter across 4 20 mA terminals When the lowest output product is flowing increase or de crease the gain by turning OFFSET As you are turning OFFSET look at your volt meter and stop when it reads 72 mA or 2096 of scale SEE FIG 4 1 Once the low end of the output range has been reset output sensitivity can be further refined by resetting the high end of the output range again FOR ALL OTHERTYPES OF ADJUSTMENTS CALL CONTROLS INC 1 713 784 0000 OIDMANUAL 0614 17 KAM CONTROLS INC FIELD CALIBRAT
15. t lt S representative point within the flow profile The OID sensor should be inserted so that the tip of the probe is located 1 4 above the inner wall of the pipeline This ensures that the probe is not damaged when pigging the pipeline Socket Cap Screw NOTE If line pressure exceeds 100 psi use a KAM IT Insertion Tool when installing removing the OID sensor Prior to mounting the OID sensor on the Full opening Ball Valve you must determine the insertion length required 1 Lay the OID sensor on the ground or a table 2 Loosen Socket Cap Screws on the locking collar This will allow the OID shaft to slide through the seal housing Mark here 3 Push the OID shaft though the seal housing until the OID probe sits flush with the end of the seal housing or seal housing flange FIG 3 3 and 3 4 Remove red protection cap on the tip of the probe if it has not been removed FIG 3 4 4 Place a mark with a sharpie or a permanent marker on the shaft at the edge of the locking Xe here collar Do not use anything sharp to mark the shaft as this will create grooves that will damage the O rings in the seal housing OIDMANUAL 0614 10 KAM CONTROLS INC INSTALLATION CONTINUED b Pull shaft back until the probe is all the way in the seal h
16. terface Detector has been the preferred sensor for interface detection between refined products since its inception in 1995 Literally like eyes in the pipe it provides accurate real time data on product interface and quality That data allows operators to monitor interface in real time making the most advantageous cut and significantly reducing product downgrade and or transmix The simplicity of design and quality of engineering employed in the OID sensor mean there are no moving parts The OID is comprised of an optical probe inserted into the fluid flow and connected via fiber optic cable to the related transmit and receive electronics which are housed within an explosion proof enclosure on the atmospheric end of the sensor During operation light from the light source in the explosion proof enclosure travels via the fiber optics cable to the process fluid Unabsorbed light returns via the fiber optics cable to a photodetector in the explosion proof enclosure The resulting information regarding the absorption fluorescence and refractive properties of the fluid is then turned into an analog signal or optical signature Measurement is fully automatic without the need for operator intervention or supervision The output signal can be sent to a SCADA PLCs or to a Central Control Room for logging or display on chart recorders monitors The OID sensor can be installed in an analyzer loop or in the main line Because main line
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