Omntec FuelCheck Installation instructions

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OMNTEC MFG., INC.
FuelCheck
®
Installation &Operating Manual
Document 600300 rev1-1.doc
Revised 11-07-2011
OMNTEC Mfg., Inc.
1993 Pond Road
Ronkonkoma, NY 11779 USA
Phone [phone] • Fax [phone]
www.innovative-sensor.com

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TABLE OF CONTENTS
System Overview _____________________________________________________________________________________________ 3
Principle of Operation _________________________________________________________________________________________ 4
FuelCheck®Probe ____________________________________________________________________________________________ 5
Probe Construction ________________________________________________________________________________________ 5
Probe Location Considerations_______________________________________________________________________________ 6
Probe Insertion and retraction________________________________________________________________________________ 7
Initial FuelCheck®SAE (standard) probe Installation ____________________________________________________________ 9
FUELCHECK®PROBE REMOVAL WITH (LINE PRESSURE < 300 PSI)__________________________________________ 13
FUELCHECK®PROBE REINSERTION with (PRESSURE <300 PSI)______________________________________________ 15
Fiberoptic Interconnect Cable __________________________________________________________________________________ 17
FuelCheck®Controller________________________________________________________________________________________ 21
System Calibration___________________________________________________________________________________________ 25
Fluid Temperature Correction __________________________________________________________________________________ 28
FuelCheck®System Specifications ______________________________________________________________________________ 30
FuelCheck®Probe________________________________________________________________________________________ 30
FuelCheck®Controller ____________________________________________________________________________________ 30
Optional Equipment Installed in Controllers with Serial Numbers______________________________________________________ 31
APPENDIX A Warranty and Disclaimer__________________________________________________________________________ 35
APPENDIX B Acromag Series 611T/612T SIGNAL CONDITIONER _________________________________________________ 37
APPENDIX C OMEGA CN132 TEMPERATURE CONTROLLER ___________________________________________________ 38
APPENDIX D Acromag BusWorks® Model 952N-4012 Modbus TCP/IP Industrial I/O Module __________________________ 39
APPENDIX E Fiberoptic Connectorizing Kit ______________________________________________________________________ 40
APPENDIX F UV Resistant Cable Additional Documentation ________________________________________________________ 41

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System Overview
FuelCheck®is a totally fiberoptic process refractometry system designed to
provide accurate interface discrimination in product pipelines.
FuelCheck®Is comprised of 3 basic components; namely:
1. FuelCheck®Probe
Part No. FU-PR-24
2. Fiberoptic interconnect cable
Part No. FU-C2-CC (conduit cable) FU-C2-DB (direct burial) FU-C2-UV (UV resistant)
3. FuelCheck®Controller
Part No. FU-CT-*I (* represents number of channels up to 3, ie. FU-CT-1I)
FuelCheck®is designed for easy installation, convenient calibration, and very low maintenance.
The following chapters will describe the principle of operation, installation considerations, and
system calibration and operation.
Figure 1
FuelCheck System Architecture
Chapter
1

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Principle of Operation
FuelCheck®is a totally fiberoptic system for measuring the index of refraction of fluids in petro-
leum pipelines.
The FuelCheck®Controller incorporates an extremely stable fiberoptic light source and detector.
This stability is provided by maintaining the source and detector circuitry at a constant tempera-
ture. Light from the infrared LED light source is coupled into the source fiber of the fiberoptic in-
terconnect cable. The FuelCheck®Probe reflects light from the source fiber to the detector fiber.
Some of the light is refracted into the fluid in which the probe lens is immersed. The amount of
light that is refracted (lost) from the lens is directly proportional to the index of refraction of the
fluid in which the probe lens is immersed. Thus, the higher the fluid’s index of refraction, the less
amount of light is returned to the detector in the FuelCheck®Controller.
5 mm
1. Sensor is a 5 mm diameter
sapphire hemisphere.
2. Optical fibers are very precisely
fused onto the flat side of the lens.
3. An LED is used to provide
constant intensity light to the lens
through either of the fibers. (LED
located in the FuelCheck
Controller, up to 2 km away from
sensor)
4. The inner surface of the lens acts
as a mirror: some of the light
reflects inside the lens; however,
some light refracts out of the lens
into whatever fluid is wetting the
lens. The amount of light lost to
refraction is directly proportional
to the refractive index of the fluid
wetting the lens.
5. Whatever light is not lost to
refraction returns to the
FuelCheck Controller via the other
fiber where its intensity is
precisely measured and converted
to a scaled value.
reflected
light
refracted
light
fiberoptic length
up to 2 km
FuelCheck
FuelCheck Operating Principle
Figure 2
Principle of Operation

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FuelCheck®Probe
Part No. FU-PR-24
The FuelCheck®Probe is readily installed into the pipeline through a full opening valve. Its in-
stallation should ensure constant contact with fluids to ensure instantaneous and positive inter-
face detection.
Probe Construction
The FuelCheck®Probe, part number FU-PR-24, is constructed of heavy-wall ½” OD stainless
steel tubing. Standard probe length is 24” giving an insertion length of 16” from the top of the
valve to the ID of the pipeline. With probe and insertion tool changes, the Probe can be made in
virtually any length so as to
accommodate almost any
installation requirement.
The maximum operating
pressure and temperature
are 1,500 PSI @ 200°F.
The materials of construc-
tion allow for use in all petro-
leum fuels with all known
additives, including MTBE.
The sapphire lens is ex-
tremely resistant to both
chemicals and abrasion.
The sensor element incor-
porates an o-ring seal with a
Teflon backup seal. The
sensor element cannot be
replaced therefore replacing
the probe will be required if
the probe is moved or
crimped at the wrong loca-
tion on the probe body. The probe incorporates a safety stop which is an 11/16” OD upset
welded onto the probe body to prevent the probe from passing through the process insertion fit-
ting.
Chapter
2
FuelCheck®Probe
process insertion fitting
insertion tool adapter
pipeline access valve
(>= 1” full-opening)
threadolet (>=2”)
flexible armor
probe body
conduit J-box
Figure 3
FuelCheck Probe installed in pipeline

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The process insertion fitting is a specially modified bored-through Swagelok tubing adapter. An
internal o-ring groove incorporating a back-up ring has been machined into the fitting to provide a
pressure seal with the probe body during process insertion and retraction. The process insertion
fitting is an integral part of the FuelCheck®probe and cannot be removed in the field.
The Insertion Tool adapter en-
ables the use of the high pressure
probe Insertion Tool in the event
that the probe must be inserted or
removed from the process at
pressures exceeding 300 PSI.
Even if the process pressure is
never expected to exceed 300
PSI, it is recommended that this
adapter be used as a safety fea-
ture so that the probe could be
removed in the event of an emer-
gency.
The top end of the probe is at-
tached to a length of 3/8” OD
stainless steel flexible conduit
(“armor”) providing protection for
the fiberoptic probe lead. Stan-
dard length is 120”. This armor is
terminated in a ½” MNPT conduit
fitting which is attached to the
probe junction box. The fiberoptic
leads are terminated with ST type
fiberoptic connectors which attach
to the fiberoptic interconnect cable
leading to the FuelCheck®Con-
troller.
A fiberglass junction box (J-Box) is
provided to protect the fiberoptic
connection between the probe and the fiberoptic interconnect cable. This J-box is normally the
terminus of a rigid or EMT conduit installed to protect the fiberoptic interconnect cable.
Probe Location Considerations
FuelCheck®probes can be installed through any full-opening valve with an inside diameter (ID)
of 1” or larger; however, several considerations should be observed in order to provide optimum
performance. It is strongly recommended that the probe be installed such that its tip not protrude
past the inside wall of the pipeline. If the probe extends into the pipeline, damage to the pipeline
and probe can result by pigging the line without removal of the probe. If the probe location is not
to be pigged, the probe can be installed into the pipeline to the desired length but fluid velocity
Figure 4
Process Insertion O-Rings

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and fluid density should be considered to insure any type of harmful harmonics are produced
(Call ISS Ltd for harmonic calculation if required).
When the probe is to be installed flush with the ID of the pipeline so as to accommodate pigging,
several factors must be considered. First, it is recommended that the fixture (i.e., weldolet) in
which the tip of the probe (i.e., the sensor element) will reside be of sufficient diameter and suit-
able location such that fluid turbulence will provide adequate sampling. If this fixture is too small,
fluid stagnation could occur resulting in a failure of the system to detect the interface. It is there-
fore recommended that the probe inser-
tion weldolet be at least 1” in diameter
so that adequate mixing takes place
thus allowing for very rapid interface
detection. It is also important that the
weldolet bit size be as large as possi-
ble. Too often, it has been observed
that a large weldolet was installed but
that the hole bored through the pipeline
was very small.
The location and orientation of the
probe insertion weldolet is also impor-
tant. Placing the probe near an elbow
in the line will provide greater turbu-
lence and more rapid interface detec-
tion. Insertion of the probe in the top of
the pipeline should be avoided since a
vapor pocket could develop in the wel-
dolet. Insertion from 45° from vertical to the side is preferable, though care must be taken to
provide sufficient clearance for convenient installation and removal.
Some general recommendations for probe location and orientation are as follows:
1. Try to mount the FuelCheck probe in a location where the pipe is always full, even when
the line is not flowing.
2. NEVER mount the FuelCheck probe on a densitometer loop.
3. Never mount the probe on the top of the pipe since vapor can get trapped there.
4. Never mount the probe on the bottom of the pipeline because the threadolet can become
filled with dirt, rust, or other particles from the pipeline.
Probe Insertion and retraction
The FuelCheck®Probe has been designed to be safely inserted into and retracted from the
process. These instructions must be followed to prevent injury and damage to the equipment.
Figure 5
Suggested Probe Installation Method

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Appropriate safety equipment should always be used (i.e., safety glasses, and fire-retardant
clothing).
The probe should always be installed in close proximity to a reliable pressure gauge or the pres-
sure must be known when performing these operations. When installing a FuelCheck®Probe
for the first time, the following procedures must be followed. It is imperative that all client safety
procedures be followed explicitly, and that engineering specifications (i.e., threaded connection
compounds, sealants, tightening torque, etc.) be strictly adhered to. Probe installation, removal,
insertion, retraction, etc. should only be undertaken by qualified and authorized personnel.
These procedures require 2 people to perform the operation.
Note - Probe Insertion and Retraction instructions included in this manual are for low (<300 PSI)
and high pressure (>300 PSI) applications. Select correct procedure for operation desired. Each
procedure has its on tools and operating instructions and will require special training before per-
forming operation.
Figure 6
Low Pressure Insertion

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Initial FuelCheck®SAE (standard) probe Installation
Low Pressure Installation
IMPORTANT: Note line pressure. If over 300 PSI (2000 kPa) follow instructions for high-
pressure installation.
NOTE - Make Initial measurement “A” before starting to install probe into pipeline.
1. Use Teflon tape or required sealing compo-
nents on the Insertion Tool Adapter and in-
stall Adapter on the Valve. Measure precise
length from pipeline to the to top of Insertion
Tool Adapter (Figure 3). Record this length
as measurement “A”.
2. Use ½ of the wall thickness on the pipeline to
ensure the tip of the probe is not intruding
into the pipeline. Calculate and record Probe
o-ring groove
machined into fitting
sensor element
safety stop
access valve
Insertion Tool Adapter
ENLARGED
CUTAWAY
Process Insertion Fitting
SAE/MS STRAIGHT THREAD
Insertion Tool
Adapter
Valve
A
Figure 7
Probe Alignment
Figure 8
Insertion Valve measurement