KAM® OWD® OIL WATER DETECTOR
Contents
1. AN OUT Can be 4 20 mA or analog voltage AN OUT DIG OUT Alarm or relay digital contact closure DIG OUT INPUT OUTPUT RS232 Consol port communication interface for calibration connection to PLC RS485 Modbus interface LED INDICATORS D1 Power D2 ZigBee wireless for communication interface D3 Bluetooth wireless for communication interface SERIAL PORT CONNECTIONS DB9 female 5 3 2 5 GND RS232RX RS232TX 1 OOOOO 9 6 OWDMANUAL 0213 21 KAM CONTROLS INC HYPERTERMINAL SOFTWARE Hyperterminal software is used during testing and calibration of the OWD Prior to beginning make sure Hyperterminal software has been installed on your PC The software is not included with your instrument but is available as a free download from numerous websites An RS232 cable for connect ing your PC to the OWD has been supplied with the OWD If your computer does not have an RS232 serial port RS232 USB adapters are readily available 1 Connect the RS232 cable to the OWD RS232 port To launch Hyperterminal click OWD icon on your desktop Name the connection OWD and hit return Fig 4 1 Deter and Focus ari icon forts connecbon Mace Lu 2 You will be promted to select a COM port If the computer has an RS232 port most likely it will be COMI If you are using an adapter like a USB to RS232 Converter the COM port will be whatever port is assigned to the adapter Click2. 42080 Sensor 1 temperature correction 10 42081 Sensor 1 temperature correction 0 10v 42082 Sensor 1 temperature correction 10 42083 Sensor 1 temperature correction O 10v 42084 Sensor 1 temperature correction 10 42085 Sensor 1 temperature correction 0 10v 42086 Sensor 1 temperature correction 10 42087 Sensor 1 temperature correction 0 10v 42088 Sensor 1 temperature correction 10 42089 Sensor 1 temperature correction O 10v 42090 Sensor 1 temperature correction 10 42091 Sensor 1 temperature correction 0 10v 42092 Sensor 1 temperature correction 10 OWDMANUAL 0213 38 KAM CONTROLS INC APPENDIX A CONTINUED MODBUS FUNCTION USE 0 0 0 0 0 0 00000 0 0 0 00 03 Holding Register continued 42093 Sensor 1 temperature correction 0 10v 42094 Sensor 1 temperature correction 10 40100 Alarm setpoint 40101 Alarm setpoint prior to change 40102 On or off alarm report 40103 On or off alarm report 40104 On or off alarm report 40105 True when value over alarm value for dead band time Reset when value below alarm value for dead band time 40106 Signal to reset transaction 40107 Water content integer 40108 ADO raw value 40109 ADI raw value 40110 Low end output at 4ma prior to change 40111 Low end output at 4ma 40112 High end output at 20ma 40113 High end output at 20ma prior to change 40114 Number of user block saves Limit to 50 000 41000 Sample period in seconds 41001 Sample period in
3. 2 If sensor is not fully enclosed inside the seal housing pull the shaft back until the probe is all the way in the seal housing and tighten the Socket Cap Screws on the locking collar This will prevent the OWD shaft from sliding and the probe from getting damaged during mounting 3 Measure the distance D1 from the outside diameter of main pipe to the end of the connection where the OWDS sensor is going to be installed FIG 3 16 4 Calculate the minimum insertion distance for the OWD Minimum insertion distance MID D1 Pipe Wall Thickness WT Gasket Thickness A See TABLE 3 16 Example for D1 16 WT 71 4 Gasket Thickness 1 8 and a 0 100 OWD sensor MID 16 1 4 1 8 3 MID 19 3 8 or 19 375 WATER RANGE A INCHES 0 10 SENSOR 0 100 SENSOR OWDMANUAL 0213 15 KAM CONTROLS INC INSTALLATION CONTINUED 5 Measure the calculated MID from the top of the Locking Collar and place a mark with a permanent marker or tape on the Shaft FIG 3 18 6 Bolt or screw the OWD sensor to the valve or designated installation location CONTROLS recommends using thread sealant and not Teflon tape for the threaded OWD 7 Open full opening valve 8 Loosen Socket Cap Screws on the locking collar 9 Push OWD sensor in until the mark is at the
4. 1 713 784 0000 Fax 1 713 784 0001 www Kam com E mail askanengineereKam com Bluetooth KAM OWD Made in USA DENSITY IN AIN2 DIG IN DIG OUT DIG IN DIG OUT GND ANA OUT GMO RS232 RX ANA OUT RS232 TX 4 20mA GND 4 20mA RS485 24V in 24V in C RS485 OWDMANUAL 0213 20 KAM CONTROLS INC INSTALLATION CONTINUED All wiring and maintenance on the KAM OWD must be done in accordance with regional and classification requirements It is the user s responsibility to understand these requirements It is also recommended that the OWD be wired with flexible wiring conduit with additional slack length in the wire to accommodate insertion removal and testing Operator s should take all possible precautions to avoid any moisture from entering the electronics enclosure The enclosure should not be left open in inclement weather or for long periods of time especially during operation as condensation will accumulate It should be tightly screwed shut and all conduits should be sealed and secured in accordance with regional and classification requirements Do not power wash the unit INPUTS 24V IN GND 24V IN Power DIG IN Pulse input discrete input for different modes of operation 0 or 5 volt DIG IN DENSITY IN OUTPUTS 4 20 mA Current output source powered 4 20 mA
5. 3 8 Terminal fence line Typically 1 2 Miles Out station Preview In station OWD OWDMANUAL 0213 12 KAM CONTROLS INC INSTALLATION CONTINUED GENERAL INSTALLATION DO S AND DON TS Always install OWD sensors with the electronics enclosure shaded from direct sunlight DO NOT use Teflon tape on threads con necting to the OWD flow through sensor DO use liquid thread sealant OWDMANUAL 0213 13 KAM CONTROLS INC INSTALLATION CONTINUED PRIOR TO INSTALLATION Remove all the protective packaging materials and ensure that the OWD sensor was not damaged during transit REMINDER Please refer to the Installation Flow Requirements on P 9 of this manual to ensure proper sensor placement where at all possible Flow conditions must satisfy API MPMS Chapter 8 2 requirements in order to achieve accurate OWD performance In cold weather if OWD is exposed to an open environment KAM CONTROLS recommends operators insu late the OWD and if the pipeline is heated that the heating trace be extended to include the OWD If the pipeline is not going to flow for extended amount of time and the pipe is not heated then OWD should be taken out to avoid damage to the sensor probe by freezing water INITIAL CALIBRATION Though the OWD has been calibrated in the factory operators should conduct an initial calibration in process conditions This can be done in two ways Off line Prior to installation operators c
6. 42009 Trend 9 42010 Trend 10 42011 Trend 11 42012 Trend 12 42013 Trend 13 42014 Trend 14 42015 Trend 15 42016 Trend 16 42017 Trend 17 42018 Trend 18 42019 Trend 19 42020 ADO input 42021 ADI input 42022 AD2 oil water continuous input 42023 output 42024 Water content oil continuous sensor 1 42025 Water content oil continuous sensor 2 42026 Water content water continuous sensor 1 42027 Water content water continuous sensor 1 42028 Water content float 42029 Sensor 1 offset input by user 42030 Sensor 1 offset input by user 42031 Sensor 2 offset input by user 42032 Sensor 2 offset input by user 42033 Storage register for Modbus table index water value 42034 Storage register for Modbus table sensor 1 value 42035 Storage Register for Modbus table sensor 2 value 42036 Temperature voltage input 42037 Temperature value 42038 Temperature input low voltage 42039 Temperature input low value 42040 Temperature input high voltage 42041 Temperature input high value 42042 Sensor 1 temperature correction 42043 Sensor 2 temperature correction 42044 Water factor 0 00 9 99 41023 Modify Table 0 oil continuous 1 water continuous 41024 Set to 1 to signal table modification ready 42031 Storage register for Modbus table index water value 42032 Storage register for Modbus table sensor 1 value 42033 Storage register for Modbus table sensor 2 value NOOR WD OWDMANUAL 0213 40 KAM CONTROLS INC APPENDIX
7. Full opening Ball Valve Option 1 Retractable OWD Option 2 Retractable OWD on a main pipe with on a main pipe 2 3 or 4 flanged seal housing with 2 MNPT seal housing Recommended Included SMS SMS Static Mixing Spool E Static Mixing Spool Option 3 Fixed mount OWD Option 4 2 OWD flow through on a densitometer loop with sensor with integrated 1 2 3 4 1 or 2 FNPT SMS Static Mixing Spool OWDMANUAL 0213 2 KAM CONTROLS INC INTRODUCTION CONTINUED THEORY OF OPERATION Rugged easy to use and extremely accurate the Oil Water Detector is the ideal instrument for continuously monitoring water concentration in your pipeline It is designed in accordance with API ASTM ISO UL and DIN standards amongst others Especially vital in production management the sensor lets you maximize oil production versus produced water The simplicity of design and quality of engineering employed in the OWD sensor mean there are no moving parts Patented microwave sensors measure the conductivity dielectric and both the real and imaginary part of permittivity of the fluid with an extremely high degree of accuracy and measurement is fully automatic without the need for operator i
8. OK Fig 4 2 det uda For tus hens fu mb Bl ena min Lo dal Amin Phone number OWDMANUAL 0213 22 KAM CONTROLS INC KAM OWD OPERATION CONTINUED 3 Use the settings shown in Fig 4 3 and click OK COM Properties pes second Panty Cos bat Vosctoaw 4 Click on the properties icon FIG 4 4 5 Click on the settings tab FIG 4 5 6 Click on the ASCII setup button Connect Ta Sera 1 ames cee hej bel an LED ees Mende ic nes nck Rey B Da Spia aH Leadon CS EEG Tekst C AME Decker tuer ras SOC Play penne pee Erw decors ATL eta OWDMANUAL 0213 23 KAM CONTROLS INC KAM OWD OPERATION CONTINUED 7 Checkthe window for Echo Typed Characters Locally and click OK Hyperterminal is now setup for operation with the OWD ASCII Sending FI Sand line ends with line fardi J Echa typed charamen locally Line delay 0 m lseconds Character delay 0 ASCII Append line feeds to incoming line ands Force incoming data ta 7 bt ASCII af Wrap inas that exceed terminal width OWD Optimizer d dump calibrations c enter calibration enter affsel R 4 70ef range T Temperature Range 51 correction u 57 correction save calibrations i enter ip address f displays Voltages
9. and water output L Calibrate M Change Modbus Address Change WC Options Connected 40 44 Aute decr OWDMANUAL 0213 24 KAM CONTROLS INC KAM OWD OPERATION CONTINUED OWD PROMPTS d Dump Calibrations displays calibration curves c Enter Calibration this is NOT used to calibrate the OWD and is for factory use only o Enter offset allows users to enter offsets manually These should be determined by a trained technician or KAM CONTROLS representative R 4 20mA Range sets the 4 20mA range See page 29 for instructions on how to change the range s Save calibrations inputs Z Displays all sensor values L Calibrate for calibration instructions see page 28 M Change Modbus Address Factory default is 1 T u v W i These are factory settings and should NOT be input by users CAPTURING HYPERTERMINAL DATA Hyperterminal data can be captured in multiple ways Users can simply select all and then cut and paste the data into a word document Or from the OWD data screen click on Transfer Fig 4 8 Select Capture Text from the drop down menv Select and name and location for the data file and click Start When you are done capturing data click on Transfer again and select Stop Connection Description New Connection Enter a name and choose an icon for the connection leon OWDMANUAL 0213 25 KAM CONTROLS INC KAM OWD OPERATION CONTINUED HOW TO CA
10. seconds prior to change 41002 Alarm dead band intervalue timer 41003 Alarm dead band start time 41004 Alarm dead band current time 41005 Alarm intervalue timer 41006 Alarm start time 41007 Alarm current time 41008 Array of time of alarms 41009 Array of time of alarms 41010 Array of time of alarms 41011 Value at time of alarm 41012 Value at time of alarm 41013 Value at time of alarm Reset when value below alarm value for dead band time 41014 Amount of measured material 41015 Material less water 41016 Average water 41017 Transaction intervalue timer 41018 Transaction start time 41019 Sample period in second 41020 Sample start time 41021 Sample current time 41022 Mode oil continuous water continuous 41023 Modify Table O oil continuous 1 water continuous 41024 Set to 1 to signal table modification ready Reset to 1 to indicate not ready 41025 Set to 1 to signal write UB 41026 Modify sensor 1 TempCorf 1 Modify sensor 2 TempCorf 2 41027 Set to 0 19 to indicate temperature curve modification ready Reset to 1 to indicate not ready 41028 Temperature value input by user 41030 41049 Temperature table temperatures 42000 Trend 0 OWDMANUAL 0213 39 KAM CONTROLS INC APPENDIX A CONTINUED MODBUS FUNCTION USE 0 0 0 0 0 0 0 00 03 Holding Register continued 42001 Trend 42002 Trend 42003 Trend 42004 Trend 42005 Trend 42006 Trend 42007 Trend 42008 Trend 8
11. should be installed in accordance with API MPMS Chapter 8 Section 2 Table 1 For Low Range 0 5 Water in Oil OWD s the sensor must be installed in the vertical down flow with a minimum flow velocity of 4 feet per second A KAM SMS Static Mixing Spool is required if the flow velocity is between 4 and 7 feet per second FIG 3 1 For OWD s operating in the Oil Continuous Phase the sensor must be installed in the vertical down flow A KAM SMS Static Mixing Spool is required if the flow velocity is between 4 and 7 feet per second FIG 3 1 For KAM OWD s operating in the Water Continuous Phase the sensor must be installed in the vertical up flow A KAM SMS Static Mixing Spool is required if the flow velocity is between 4 and 7 feet per second FIG 3 2 In situations where the flow velocity is less that 4 feet per second KAM CONTROLS recommends the installation of a KAM ML Measurement Loop incorporating suction and injection nozzles a pump and the OWD on a separate loop ensuring a homogenous high velocity flow across the measurement sensor FIG 3 3 The KAM OWD may be installed horizontally when the minimum flow velocity is above 10 feet per second SUCTION KAM SMS ii STATIC MIXING ja INJECTION L cz LOW RANGE AND dh _ OIL CONTINUOUS i PHASE OPERATION a EN y WATER C
12. 0213 10 KAM CONTROLS INC INSTALLATION CONTINUED In a refinery feedstock application KAM CONTROLS recommends that the OWD sensor be installed far enough in advance of the Refinery Unit to give time to take corrective action in instances where the OWD senses unacceptable high water levels FIG 3 6 SMS STATIC MIXING SPOOL CAT CRACKER BOILER For ideal performance in desalter applications the desalter tank should incorporate a progressive series of 8 sample lines each with its own draw off valve and flow through OWDS sensor plus an additional OWD sensor located on the outgoing oil line FIG 3 7 SAMPLE LINES DRAW OFF FLOW THROUGH VALVES OWD SENSORS OWDMANUAL 0213 n KAM CONTROLS INC INSTALLATION CONTINUED For optimal batch detection Kam Controls recommends that you install the in station OWD sensor at the first accessible pipeline location inside the terminal fence line upstream of the interface cut valve s This allows the operator ample time to open close the cut valves prior to the arrival of the product interface KAM Controls also strongly recommends that you utilize a preview or out station 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
13. 2 41013 41014 41015 41016 41017 41018 41019 36 Alarm setpoint Alarm setpoint prior to change On or off alarm report On or off alarm report On or off alarm report True when value over alarm value for dead band time Reset when value below alarm value for dead band time Signal to reset transaction Water content integer ADO raw value ADI raw value Low end output at 4ma prior to change Low end output at 4ma High end output at 20ma High end output at 20ma prior to change Number of user block saves Limit to 50 000 Sample period in seconds Sample period in seconds prior to change Alarm dead band inter value timer Alarm dead band start time Alarm dead band current time Alarm inter value timer Alarm start time Alarm current time Array of time of alarms Array of time of alarms Array of time of alarms Value at time of alarm Value at time of alarm Value at time of alarm Reset when value below alarm value for dead band time Amount of measured material Material less water Average water Transaction intervalue timer Transaction start time Sample period in second KAM CONTROLS INC APPENDIX A CONTINUED MODBUS FUNCTION USE 0 0 0 00 0 00 000 03 Holding Register continued 41020 Sample start time 41021 Sample current time 41022 Mode oil continuous water continuous 41023 Modify table O oil continuous 1 water continuous 41024 Set to 1 to signal table modification ready Reset
14. A CONTINUED MODBUS FUNCTION USE 0 00000000 00 04 Input Register Reads individual 0x30001 0x30002 Float value of 0 calibrated values of 0x30003 0x30004 Float value of ADC 1 each ADC input 0x30005 0x30006 Float value of ADC 2 0x30007 0 30008 Float value of ADC 3 0x30009 0x30010 Float value of ADC 4 0x30011 0x30012 Float value of ADC 5 0x30013 0x30014 Float value of ADC 6 0x30015 0x30016 Float value of ADC 7 0x30017 0x30018 Float value of ADC 8 0x30019 0x30020 Float value of ADC 9 0x30021 0x30022 Float value of ADC 10 OWDMANUAL 0213 41 KAM CONTROLS INC
15. Kam Controls Incorporated simple precision CE PTB 08 ATEX 1026 API COMPLIANT An ISO 9001 certified company User Manual OWDMANUAL 0213 TEL 1 713 784 0000 CONTROLS INC FAX 1 713 784 0001 3939 Ann Arbor Drive Houston Texas 77063 USA www KAM com Email Sales Kam com SECTION APPENDIX A CAUTION When installing the OWD sensor a pipeline containing petroleum products petrochemicals 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 TITLE Introduction Available Models and Mounting Options e Theory of Operation Features Applications Specifications Specifications Dimensional Drawings Installation Installation Flow Requirements Locations Applications General Do s and Don t s Main Line Fast Loop Wiring OWD Operation Hyperterminal Software Calibration Changing the Range Modbus Interface Maintenance Cleaning Inspection e Troubleshooting Antenna Replacement Modbus Registers ensure safe installation KAM CONTROLS INC reserves the right to make changes to this document without notice OWDMANUAL 0213 i m an RK 35 AVAILABLE MODELS and MOUNTING OPTIONS Recommended KAM SMS Recommended KAM SMS Static Mixing Spool LI Static Mixing Spool
16. LIBRATE THE KAMP OWD USING BRINE AND DRY OIL Though the OWD has been calibrated in the factory it should be calibrated in process conditions prior to use This can be done using 100 brine produced water and 100 dry oil in buckets as outlined below or it can be done with online sampling For the brine dry oil method in addition to fluid samples operators will need appropriate tools for the extraction of the OWD an RS232 cable supplied or an RS232 USB adapter and a PC equipped with Hyperterminal software 1 If the OWD has been installed remove from the line according to the instructions on page 16 for insertable models and page 18 for models installed on fast loops and ML Measurement Loops Clean the OWD sensor according the guidelines on page 28 of this manual 2 Restore power to the OWD and connect to a PC via 232 or RS232 USB adapter Initiate Hyperterminal setup For information on setting up Hyperterminal software see page 22 3 Let the OWD sensor warm up for 20 minutes 4 Insert the sensor in a bucket with brine produced water Probe should remain in brine until a stabilized tem perature is observed Readings should show 100 water in the Hyperterminal As all water in crude oil has salt the OWD sensor has already been calibrated for salt water You will not get an accurate reading if you use fresh water for testing It should also show 20mA if the mA range is calibrated for 0 100 which you can measure at the output te
17. ONTINUOUS PHASE OPERATION The KAM ML Measurement Loop utilizes a pump to draw a representative flow from the main line into a circulation loop incorporating a KAM SMS KAM OWD The loop flow is injected back into STATIC MIXING the main pipeline upstream of the suction site creating mixing and homogeneity prior to suction A homogenous flow of 10 13 fps is maintained at the sensor head for the most accurate measurement at all times OWDMANUAL 0213 9 KAM CONTROLS INC INSTALLATION CONTINUED EFFECTS OF ENTRAINED GAS If entrained gas is constant its affect is factored out If entrained gas is introduced or removed after OWD calibration it will shift water cut measurement by approximately 1 2 for every 1 change in gas levels RECOMMENDED LOCATION BY APPLICATION In separator applications KAM CONTROLS recommends that the OWD sensor should be installed immediately downstream of the Separator Dump Valve in a vertical section of the pipe with the flow travelling downward If possible it should also be downstream of a SMS Static Mixing Spool or a KAM SMP Static Mixing Plate FIG 3 4 SEPARATOR KAM SMS STATIC MIXING SPOOL A second installation option for this application is in a horizontal pipe immediately downstream of the Separator Dump Valve in an OWD spool integrated with a KAM static mixer FIG 3 5 SMS STATIC MIXING SPOOL OWDMANUAL
18. WD and if the pipeline is heated that the heating trace be extended to include the OWD If the pipeline is not going to flow for extended amount of time and the pipe is not heated then OWD should be taken out to avoid damage to the sensor probe by freezing water The KAM OWD must be installed in accordance with API MPMS Chapter 8 2 Table 1 Please ensure that the flow in the analyzer loop represents the main pipe flow The analyzer loop flow velocity must be equal to or greater than the maximum main line flow velocity If your installation utilizes a pump to pump the fluid through the OWDS cell CONTROLS recommends that the pump be installed upstream of the OWD sensor to create mixing KAM CONTROLS also recommends installing a small SMS Static Mixing Spool at the OWD cell inlet FIG 3 21 The Inlet and outlet of the OWD Cell are 12 34 1 or 2 FNPT Additional sizes including metric are available KAM CONTROLS recommends using liquid thread sealant and not Teflon tape for the threads to reduce the chances of the threads galling Refer to FIGURE 3 20 for vertical installation and FIGURE 3 22 for horizontal installation INITIAL CALIBRATION Though the OWD has been calibrated in the factory operators should conduct an initial calibration in process conditions This can be done in two ways Off line Prior to installation operators can go through the procedures for off line calibration outlined on page 26 of t
19. an go through the procedures for off line calibration outlined on page 26 of this manual This method requires samples of 100 produced water and dry oil or oil with a known percentage of water On line After installation operators can follow calibration procedures for in line calibration outlined on page 26 of this manual This method requires accurate sampling and sample processing MAIN LINE INSTALLATION The OWD sensor should be installed according to FIG 3 13 A full opening ball valve is used to isolate the OWDS sensor from the pipeline during installation or removal The seal housing of the OWD sensor allows the probe to be inserted and removed from the pipe under pressure and flow conditions It is the user s responsibility to ensure that the OWD sensor be placed at the most representative point within the flow profile see location recommendations above The OWD sensor should be inserted so that the window of the probe is located in the center of the diameter of the pipeline Locking Collar 1 Socket Cap Screw Seal Housing gt Full opening Ball Valve ME Note If line pressure exceeds 100 psi use a KAM IT Insertion Tool when installing removing the KAM OWD sensor OWDMANUAL 0213 14 KAM CONTROLS INC INSTALLATION CONTINUED l Prior to mounting verify that the tip of the sensor is all the way inside the seal housing FIGS 3 14 3 15
20. e new Antennas into the Seal Holder The Antennas need to extend 175 180 from the top of the Seal Holder FIG 5 8A Slide the new 2 004 O rings on the Antennas FIG 5 8B A Slide Seal Holder Covers behind the 2 004 O rings Make sure the use the Seal Holder Cover with the larger center hole with the Coated Antenna FIG 5 8B Add a small amount of grease to the 2 004 O rings Push the 2 004 O rings inside Seal Holder using Seal Holder Covers FIG 5 8C 175 180 Z 7 A 2 009 O ring e 2 004 4 Seal Holder Cover 7 Add small amount of grease to the 2 009 O rings 8 Insert Seal Holder Antenna assembly into the Sensor Body FIG 5 9 OWDMANUAL 0213 33 KAM CONTROLS INC MAINTENANCE CONTINUED 9 Place Sensor Cover onto the Sensor Body Be careful to ensure that the holes for the RTD are in alignment 10 Add a small amount of Loctite to the 4 4 40 Screws and install them into the Sensor Body holding the Cover in place FIG 5 10 11 Push Bottom Cover back into place Make sure holes align with the Antennas 12 Add Loctite to all 4 6 32 Screws and install them into the Sensor Body securing the Bottom Cover FIG 5 11 6 32 Screw OWDMANUAL 0213 34 CONTROLS INC MAINTENANCE CONTINUED 13 Connect the Cables to the Sensor with the SMA connectors NOTE Do not add Loctite to the SMA Connectors They should be finger tigh
21. ennas that could affect measurement Check the condition of both antennas 2 If there is debris clogging the sensor or coating the antennas in any way this is most likely the cause of any measurement anomalies Once the OWD has been cleaned it can be reinstalled It does not need recalibration 3 there is no evidence of debris OWD must be tested in order to determine the cause of the measurement error This requires samples of 100 6 brine produced water and dry oil or oil with a known low percent age of water an RS232 cable supplied or an RS232 USB adapter and a PC equipped with Hyperterminal software 4 Connect the OWD to a PC via RS232 or RS232 USB adapter and turn the power on Initiate Hvperterminal setup For information on setting up Hyperterminal software see page 22 5 Let the OWD sensor warm up for 20 minutes 6 Insert the sensor in a bucket with brine produced water Probe should remain in brine until a stabilized tem perature is observed As all water in crude oil has salt the OWD sensor has already been calibrated for salt water You will not get an accurate reading if you use fresh water for testing OWDMANUAL 0213 28 KAM CONTROLS INC MAINTENANCE CONTINUED 7 Capture and save screen data according to instructions outlined on page 25 8 Thoroughly clean and dry the probe 9 Insert the OWD sensor into a bucket or a jar filled with a sample of dry oil In order to accurately test the OWD sens
22. f the shelf lengths are 12 24 and 36 609 6mm 762mm 914 4mm Yo to 48 15mm to 1200mm from 20 lbs 9kg The OWD must be installed in accordance with MPMS Chapter 8 Section 2 Table 1 If entrained gas is constant its effect is factored out If entrained gas is introduced or removed after OWD calibration it will shift water cut measurement by approximately 1 2 for every 1 change in gas levels OWDMANUAL 0213 4 KAM CONTROLS INC SPECIFICATIONS CONTINUED DIMENSIONAL DRAWINGS Seal Housing Z Electronics Enclosure Shaft Length 5 290 296 i INCHES Shaft Lengths are available in 5 increments 114 Standard sizes are 24 30 36 48 and 60 609 6mm 762mm 914 4mm 1219mm 1524mm OWDMANUAL 0213 5 KAM CONTROLS INC SPECIFICATIONS CONTINUED ON AB Q OW THRO cus mm INCHES MM ABLE 2 8 D 0 ABLE 2 9 OW THROUGH D 0 cues T INCHES 25 70 of 575 T il 2 jw 75 ss se
23. g Register continued 42038 Temperature input low voltage 42039 Temperature input low value 42040 Temperature input high voltage 42041 Temperature input high value 42042 Sensor 1 temperature correction 42043 Sensor 2 temperature correction 42044 Water factor 0 00 9 99 42045 Sensor 1 temperature correction 0 10v 42046 Sensor 1 temperature correction 10 42047 Sensor 1 temperature correction 0 10v 42048 Sensor 1 temperature correction 10 42049 Sensor 1 temperature correction 0 10v 42050 Sensor 1 temperature correction 10 42051 Sensor 1 temperature correction O 10v 42052 Sensor 1 temperature correction 10 42053 Sensor 1 temperature correction 0 10v 42054 Sensor 1 temperature correction 10 42055 Sensor 1 temperature correction 0 10v 42056 Sensor 1 temperature correction 10 42057 Sensor 1 temperature correction 0 10v 42058 Sensor 1 temperature correction 10 42059 Sensor 1 temperature correction O 10v 42060 Sensor 1 temperature correction 10 42061 Sensor 1 temperature correction 0 10v 42062 Sensor 1 temperature correction 10 42063 Sensor 1 temperature correction O 10v 42064 Sensor 1 temperature correction 10 42065 42066 42067 42068 42069 42070 42071 42072 42073 42074 42075 Sensor 1 temperature correction 0 10v 42076 Sensor 1 temperature correction 10 42077 Sensor 1 temperature correction 0 10v 42078 Sensor 1 temperature correction 10 42079 Sensor 1 temperature correction 0 10
24. hich color cable goes to which antenna For example Red cable goes to green antenna 5 Loosen and unscrew completely the SMA Connectors using the 5 16 Allen Wrench 6 Pull to remove the RTD DO NOT pull from the wires FIG 5 2 7 Unscrew the 4 4 40 Screws on the top of the sensor using the Phillips Screwdriver Size 0 FIG 5 3 4 40 Screws 209 8 Remove the Cover from Sensor FIG 5 4 9 Remove the 4 Set Screws at the bottom of the Sensor using the 1 16 Allen Wrench Be sure to insert wrench fully or screws will strip FIG 5 5 10 Push the Bottom Cover from the inside of the Sensor until it is completely free FIG 5 5 6 32 x 4 Set Screw 1 PEST OWDMANUAL 0213 31 KAM CONTROLS INC MAINTENANCE CONTINUED 11 Pushing from the bottom remove the Antennas FIG 5 6 12 Remove the Antennas from the PEEK Seal Holders by turning them counterclockwise FIG 5 7 13 Slide the Seal Holder Covers off the Antennas FIG 5 7 NOTE The Seal Holder Cover for the Coated and Uncoated Antennas are different The cover for the Coated Antenna has a larger hole 14 Remove the 2 009 and 2 004 O rings from the Seal Holder FIG 5 7 Seal Holder Seal Holder Cover 2 009 O ring 4 15 Clean Sensor Body with parts washer and let it dry OWDMANUAL 0213 32 KAM CONTROLS INC MAINTENANCE CONTINUED REASSEMBLY Install the new 2 009 O rings on the Seal Holder FIG 5 8A N Screw th
25. his manual This method requires samples of 100 produced water and dry oil or oil with a known percentage of water On line After installation operators can follow calibration procedures for in line calibration outlined on page 26 of this manual This method requires accurate sampling and sample processing OWDMANUAL 0213 17 KAM CONTROLS INC INSTALLATION CONTINUED REMOVING THE OWD SENSOR FROM ANALYZER LOOPS AND ML MEASUREMENT LOOPS To remove the sensor first shut off power to the instrument Discontinue flow in loop fram the main line and drain fluid from loop The probe can removed from the housing by removing screws connecting probe and shaft to flanged probe housing or OWD cell The probe can then be lifted from the cell for testing inspection cali bration purposes Removal should be conducted in accordance with all regional and Class requirements OWDMANUAL 0213 18 KAM CONTROLS INC INSTALLATION CONTINUED FAST LOOP INSTALLATION DO S AND DON TS Always install OWD flow through sensors with the flow of the fast loop moving from top to bottom through the OWD cell OWDMANUAL 0213 19 KAM CONTROLS INC INSTALLATION CONTINUED WIRING Kam Controls Incorporated 3939 Ann Arbor Drive Houston TX 77063 USA
26. k through a 2 3 4 hot tap the OWD sensor helps you avoid costly drainage the need for a bypass loop or having to cut a section in the pipe All wetted parts are ma chined from 316 stainless steel Shaft lengths from 1 to 3 feet are available with off the shelf lengths coming in 12 24 and 36 Metric and custom lengths are available Range water in oil 5 0 10 0 30 0 40 0 100 Accuracy at listed range 0 05 0 10 0 30 0 40 1 00 OWDMANUAL 0213 3 KAM CONTROLS INC 1 Material Fluid temperature Power requirements Accuracy Repeatabilitv Resolution Minimum water detection Outputs Mounting Pressure ratings Flow conditions Sensor dimensions EX enclosures Shaft length Pipe Size Weight Crude oil refined products and chemicals Wetted parts 316 stainless steel To 300 F 149 C High temp model available to 600 F 315 C 24 VDC 1 amp at 24 watts 1 of full range 0 01 0 01 100 Selectable 4 20 mA with adjustable range or 0 5 VDC Alarm relay RS232 RSA85 Yo 34 1 or 2 FNPT flow through Other sizes including metric are available 2 MNPT seal housing 2 3 or 4 flanged seal housing ANSI 150 300 600 900 1500 2500 Well mixed in accordance with API MPMS Chapter 8 Section 2 Table 1 1 5 x 7 38mmh x 178mm Sensor electronics 3 x 6 x 3 76mm x 152mm x 7 mm 12 to 36 305mm to 914 4mm Of
27. lly homogenous sample from the pipeline close to the sensor location on the pipeline and at the same time type L for calibration in the Hyperterminal and hit ENTER A Water prompt will appear OWDMANUAL 0213 26 KAM CONTROLS INC KAM OWD OPERATION CONTINUED 3 Determine water percentage in sample using a KAM Karl Fischer Moisture Analyzer recommended or ap propriate method Enter the determined sample water percentage into Hyperterminal prompt and hit ENTER 4 Type S then hit ENTER to save 5 The KAM OWD is now calibrated This process can be repeated if the sample taken was a bad sample or the percent of water obtained from the sample taken was not accurate HOW TO CHANGE THE HIGH LOW 4 20 mA RANGE l To enter or change the desired range for the OWD sensor type R and hit ENTER Prompts will appear for the low and then the high ends of the range 2 After entering both type S to save The range has been set and the Hyperterminal will return to the OWD Optimizer prompt menu SETTING UP A MODBUS INTERFACE 1 To set Modbus variables type M and hit ENTER 2 The prompt is for an ID for the slave device This ID MUST BE UNIQUE from any other Modbus device connected and a value between 1 255 SYSTEM SETTINGS Modbus Baudrate 9600 Protocol is RTU Modbus See APPENDIX A for designated MODBUS Registers OWDMANUAL 0213 27 KAM CONTROLS INC 11 H CLEANING AND INSPECTION If probe is re
28. moved from the line for inspection NEVER use sharp or metallic objects such as a knife or screw driver to clean the antenna especially the Teflon coated antenna Do NOT power wash the unit Instead 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 WDAO or other chemicals If you have a question regarding cleaning solvents please contact KAM CONTROLS directly at 1 713 784 0000 or email AskAnEngineer amp Kam com During inspection ensure that there are no foreign objects stuck in the probe or attached to the antennas and that the Teflon coating is completely intact without any chips or scratches TROUBLESHOOTING IF OWD data begins to differ slightly or gradually from sampling data and falls outside of acceptable accuracies this is most likely caused by drift The OWD should be recalibrated using the on line recalibration procedure out lined on page 26 IF OWD data suddenly veers from historical norms or sampling data it needs to be removed from the line and inspected using the steps outlined below 1 Remove the OWD from the line according to the instructions on page 16 for insertable models and page 18 for models installed on fast loops and ML Measurement Loops Clean the OWD sensor according the guide lines above and check for any debris in the probe or on the ant
29. ntervention or supervision The output signal can be sent to Flow Computers SCADA PLC s or to a Central Control Room for logging or display on chart recorders or monitors The KAM sensor also uses internal references to auto calibrate for drift caused by temperature changes of the electronics the aging of the electronics components fluid pressure and fluid temperature The KAM OWD flow through model can be used in an analyzer densitometer loop for process optimization where an accurate determination of water concentration is important and it is vital to optimizing the desalinization process Placed on the desalter sample line or on each sample line the KAM OWD flow through model provides real time information about your desalter performance To ensure the highest degree of accuracy the flow must be homogenous Installed upstream of your OWD sensor the patented KAM SMP Static Mixing Plate or KAM SMS Static Mixing Spool create a fully homogenous mixture in your pipeline In low velocity situations the use of a KAM ML Measurement Loop may be required in order to create a homogenous flow for measurement Proper calibration also key to complete accuracy can be achieved in the field with the PKF Portable Karl Fischer Moisture Analyzer Data from the PKF analyzer can then be entered into the OWDS sensor via IR port or corrected via RS232 at the flow computer Because it can be inserted into your pipe or tan
30. or you must use oil that does not have any water in it or which has a known low percentage of water 10 Capture and save screen data according to instructions outlined on page 25 11 Captured data should be sent to the CONTROLS factory for analysis or analyzed by a CONTROLS trained technician The technician will then advise the operator on the next steps OWDMANUAL 0213 29 KAM CONTROLS INC MAINTENANCE CONTI ANTENNA REPLACEMENT TOOLS REQUIRED 1 Phillips Screwdriver Size 2 1 16 Allen Wrench 3 5 64 Allen Wrench 4 5 16 Allen Wrench MATERIALS REQUIRED 1 Uncoated Antenna 2 Coated Antenna 3 2 2 004 O rings 4 2 2 009 O rings 5 Medium Strength Loctite DISASSEMBLY Contact KAM CONTROLS at 1 713 784 0000 Fax to 1 713 784 0001 or email Sales amp Kam com Ask for Part Number OWD ANT 1 Remove all 6 8 32 Set Screws using the 5 64 Allen Wrench Make sure that the wrench in fully inserted or the Set Screws will strip FIG 5 1 A rds Box Lid 8 32 Set Screws 2 Unscrew lid to round junction box FIG 5 1 and ensure that cables are somewhat slack If not untie loosen the cables prior to pulling probe away from housing 3 Slowly pull Probe away from Housing to gain access to the SMA connectors Do not pull too hard or too far as the wires can be damaged FIG 5 2 OWDMANUAL 0213 30 CONTROLS INC MAINTENANCE CONTINUED 4 Make a note of w
31. r 4 vs 7 OWDMANUAL 0213 6 KAM CONTROLS INC SPECIFICATIONS CONTINUED FIG 2 10 2 OWD FLOW THROUGH SENSOR FOR 0 10096 WATER SS ER UAE o H NSION BETON A 425 108 jD 1452 5 368 13_ BEN NE sas OWDMANUAL 0213 7 KAM CONTROLS INC SPECIFICATIONS CONTINUED 2 150 300 or 600 weld neck flanges SS316 both ends 15 DIMENSION RANGE size INCHES 4 7 16 gt o il ma 725 104 22 2 3008 2 6008 22 OWDMANUAL 0213 2 sch seamless pipe SS316 55316 12 sample valve with 12 pitot probe 8 KAM CONTROLS INC INSTALLATION FLOW REQUIREMENTS PLEASE NOTE In all KAM OWD Installations the user should insure that the KAM OWD is installed in a turbulent flow with the Reynolds Number above 2000 Additionally all KAM OWD s
32. rminal Regardless of readings the sensor should be recalibrated 5 Enter 1 on the Hyperterminal interface and hit ENTER A Water prompt will appear Enter 100 Hit ENTER Type s then ENTER to save 6 Remove probe from brine and thoroughly clean and dry the probe 7 Insert the OWD sensor into a bucket or a jar filled with a sample of dry oil In order to accurately test the OWD sensor you must use oil that does not have any water in it or which has a known low percentage of water The water percentage reading in the Hyperterminal should show 0 or reflect the known water percentage 8 Enter 1 on the Hyperterminal interface A Water prompt will appear Enter or the known percentage of water Hit ENTER Type s then ENTER to save 9 The OWD has now been calibrated to process conditions and can be installed ON LINE CALIBRATION OF THE OWD PLEASE NOTE The following calibration steps should only be conducted during initial installation with process conditions when process conditions have changed or when OWD readings indicate a slight drift off acceptable accuracies You will need an RS232 cable supplied or an RS232 USB adapter a PC equipped with Hyperterminal software and a means for collected and measuring samples 1 Connect PC to the OWD sensor via supplied RS232 serial port or RS232 USB adapter Launch Hyperterminal and hit ENTER For Hyperterminal setup see page 22 2 Take an accurate fu
33. t and then turned 1 16 of a turn with the 5 16 Wrench 14 Ensure that the proper Cable colors are connected to the proper Antenna colors per previous notes 15 Insert the RTD into Sensor Body FIG 5 12 SMA Connectors 16 Push Sensor back into place 17 Align the window so that it will directly face the direction of the flow FIG 5 13 18 Add Loctite to all 6 8 32 Set Screws and install them back in Sensor FIG 5 14 8 32 Set Screws IL lt OWDMANUAL 0213 35 KAM CONTROLS INC 01 Discrete Coil Status 02 Discrete Input Status 03 Holding Register OWDMANUAL 0213 Reads output coil status digital outputs Reads state of individual digital inputs Reads and writes to the DAC channels 0 3 Takes a converted float value from 2 unsigned int values and updates the DAC output values in Volts O 1OVDC 0x00001 0x00016 Digital outputs 0 15 0x10001 0x10024 Digital inputs 0 23 0x40001 0x40002 Float value for DAC O 0 40003 0x40004 Float value for DAC 1 0x40005 0x40006 Float value for DAC 2 0x40007 0x40008 Float value for DAC 0 40100 40999 16 bit values 41000 41999 32 bit values 42000 44999 Float values 45000 47299 Modbus registers 40100 40101 40102 40103 40104 40105 40106 40107 40108 40109 40110 40111 40112 40113 40114 41000 41001 41002 41003 41004 41005 41006 41007 41008 41009 41010 41011 4101
34. to 1 to indicate not ready 41025 Set to 1 to signal write UB 41026 Modify 1 TempCorf 1 Modify sensor2 TempCorf 2 41027 Set to 0 19 to indicate temperature curve modification ready Reset to 1 to indicate not ready 41028 Temperature value input by user 41029 41030 41049 Temperature table temperatures 42000 Trend 0 42001 Trend 1 42002 Trend 2 42003 Trend 3 42004 Trend 4 42005 Trend 5 42006 Trend 6 42007 Trend 7 42008 Trend 8 42009 Trend 9 42010 Trend 10 42011 Trend 11 42012 Trend 12 42013 Trend 13 42014 Trend 14 42015 Trend 15 42016 Trend 16 42017 Trend 17 42018 Trend 18 42019 Trend 19 42020 ADO input 42021 ADI input 42022 AD2 oil water continuous input 42023 output 42024 Water content oil continuous sensor 1 42025 Water content oil continuous sensor 2 42026 Water content water continuous sensor 1 42027 Water content water continuous sensor 2 42028 Water content float 42029 Sensor 1 offset input by user 42030 Sensor 1 offset input by user 42031 Sensor 2 offset input by user 42032 Sensor 2 offset input by user 42033 Storage register for Modbus table index water value 42034 Storage register for Modbus table sensor 1 value 42035 Storage register for Modbus table sensor 2 value 42036 AD3 temperature voltage input 42037 Temperature value input OWDMANUAL 0213 37 KAM CONTROLS INC APPENDIX A CONTINUED MODBUS FUNCTION USE 0 0 0 0 0 00 0 000 03 Holdin
35. top edge of the locking collar Ensure that OWD flow indicator is aligned with pipeline flow direction FIG 3 19 EN _ 10 Re tighten the Socket Cap Screws 11 Tighten the hex nuts holding down the Locking Collar one half turn Fig 3 19 These 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 OWD SENSOR To remove the OWD sensor first shut off power to the instrument Loosen the Socket Cap Screw the Lock Down Collar Slide the OWD sensor upward until the probe rests inside the seal housing Next close the Full opening Ball Valve tightly Drain oil from valve if possible The OWD sensor may now be unbolted from the system Note If line pressure exceeds 100 psi use a Insertion Tool when installing removing KAM OWD sensor Removal should be conducted in accordance with all regional and Class requirements OWDMANUAL 0213 16 KAM CONTROLS INC INSTALLATION CONTINUED FAST LOOP INSTALLATION PRIOR TO INSTALLATION Remove all the protective packaging materials and ensure that the OWD sensor was not damaged during transit In cold weather if OWD is exposed to an open environment KAM CONTROLS recommends operators insulate the O
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