KAM Oid™ Optical Interface Detector: User Manual
KAM Oid™ Optical Interface Detector: User Manual
User Manual
OIDMANUAL-1213
TEL +1 713 784 0000
FAX +1 713 784 0001 KAM CONTROLS, INC.
Email [email protected] 3939 Ann Arbor Drive
Houston, Texas 77063 USA
www.KAM.com
TABLE OF CONTENTS
2 Specifications 4
•Specifications 4
•Dimensional Drawings 5
3 Installation 7
•Sensor location 7
•Do's and Dont's 8
•Main Line 10
•Removal 13
•Analyzer Loop 14
•Wiring 15
•Connecting the OID 16
4 Field Calibration 17
5 Maintenance 19
CAUTION:
KAM CONTROLS, INC. reserves the right to make changes to this document without notice.
THEORY OF OPERATION
The KAM® OID™ Optical Interface 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 or monitors.
The KAM® OID™ sensor can be installed in an analyzer loop or in the main line. Because main-line models
are mounted through a full-opening ball valve, you can insert or retract the probe without having to ever
drain the pipe.
OIDMANUAL 1213 2 KAM CONTROLS, INC.
INTRODUCTION CONTINUED
FIG. 1-4 KAM® OID™ AND API GRAVITY/DENSITOMETER
FEATURES APPLICATIONS
Power: 12–24 VDC 15 Watts max (Max current is 1275 mA @ 12V and 637 mA @ 24V)
Output: 4-20 mA
Shaft length: 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)
SPECIFICATIONS CONTINUED
DIMENSIONAL DRAWINGS
E
C (Shaft Diameter)
Seal Housing
B
A D
¾" FNPT
Shaft Length ± .5"
F
E
D
C
B
A G
¾" or 1"
H
MNPT
¾" FNPT
TABLE 2-5 ¾" MNPT DIMENSIONS TABLE 2-6 1" MNPT DIMENSIONS
INCHES MM INCHES MM
A .3 8 A .3 8
B .5 13 B .5 13
C 1.4 36 C 1.45 37
D 2.25 57 D 2.4 61
E 6.75 171 E 6.75 171
F 7 178 F 7 178
G 4.53 115 G 4.53 115
H 1.2 30 H 1.3 33
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 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
TERMINAL FENCE
may arise during a critical interface.
TO TANK
TO TANK
INCOMING
OID
TO TANK
PRIOR TO INSTALLATION
Remove all the protective packaging materials including the red cap placed at the tip of the sensor probe.
Ensure 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™ sensor will not work properly.
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.
P P
FLOW
FLOW
FLOW FLOW
DO NOT install
the OID™
sensor with the
lens facing directly
into the flow. If
the product has
particulate
matter in the fluid,
P like sand, this will P
sandblast the lens
and could cause
FLOW premature failure. FLOW
FLOW FLOW
DO NOT attempt
to screw the OID™
sensor either in
I
I
or out by hand.
Always use a
1 1/4" or 1 3/8"
wrench on the
wrench flat below
P the electronics
P
enclosure.
FLOW FLOW
FLOW FLOW
DO install the
OID™ sensor with
a minimum of 8"
or 200mm be-
tween the lens and
the nearest flat
surface.
Minimum 8" P
(20.3 cm)
FLOW
FLOW
DO install the
OID™ sensor with
a sun shade if the
electronics are
directly exposed
to sunlight.
PRIOR TO INSTALLATION
Remove all the protective packaging materials, and ensure that the OID™ sensor was not damaged during transit.
5. Pull 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 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
D1
D1
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
TID
First Mark
Second Mark
9. Bolt or screw the OID™ sensor to the valve or designated installation location.
(KAM CONTROLS recommends using thread sealant and not Teflon tape for the threaded OID™). Skip to Step
12 (OID with Flanged Seal Housing only).
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 measuring 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
For example:
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".
11. Use the calculated TID and mark a second line on the shaft, measuring from first mark. FIG. 3-8.
FIG. 3-8
TID
First mark
Second mark
12. If you have an OID™ with a Flanged Seal Housing, you may now attach it to the valve on the pipeline.
13. Slowly open Full-opening Ball Valve and check for leaks.
15. Push the OID™ in until the Second Mark is at the top edge of the Locking Collar. FIG. 3-9.
FIG. 3-9
Second Mark
11. Tighten the Hex Nuts on the top of the Locking Collar one half turn. These 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.
KAM CONTROLS recommends this installation for 3/4" & 1" MNPT OID™ sensors.
We recommend using thread sealant and not teflon tape for 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
KAM 3/4" and 1" MNPT OID™ sensors should be
installed according to FIG. 3-10. The OID™ sensor
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 Flow
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.
Flow
WIRING
FIG. 3-12
OFFSET GAIN
Kam
Controls
Incorporated
3939 Ann Arbor Drive
Houston, Tx 77063
Tel + 1 713 784 0000
Fax + 1 713 784 0000
OFF
E-mail [email protected]
www.Kam.com
ON
RS485 OUT +
RS485 OUT –
4-20mA RTN
RS485 IN +
RS485 IN –
4-20mA (+)
GND
CHS
V+
INTENSITY
P5
PMT
GAIN
POWER OUTPUTS
RS485 OUT (+) Communication port CAUTION: When electronics enclosure is open, be
RS485 OUT (–) extremely careful to avoid any contact with interior fiber
RS485 IN (–) optic connections. Failure to do so could result in the OID
RS485 IN (+) malfunctioning.
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™ Termi-
nal 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-imped-
ance 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. To connect the power for the OID™ sensor, first check both wires from the source for polarity and
voltage, then label appropriately.*
FIG. 3-13
OFF ON
ON/OFF Switch
4-20mA (+)
GAIN
4-20mA RTN
Incorporated
RS485 OUT +
Controls
RS485 OUT –
Houston, Tx 77063
www.Kam.com
Kam
RS485 IN –
RS485 IN +
OFFSET
V+
Power Supply
GND
P5
PMT
GAIN
INTENSITY
*Recommended Wire: Shielded twisted pair wire is recommended for both power 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.
The KAM® OID™ sensor is factory calibrated at the time of shipment for user-specific, product-interface
requirements. However, field calibration may be required to fine-tune the instrument for increased or decreased
sensitivity 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 KAM® OID™ output range. Increasing sensitivity elevates the output
range to provide greater interface resolution.
Caution: When multiple KAM® 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 consists 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.
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.
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.
2. Connect a volt meter across 4-20 mA terminals. When the lowest output product is flowing, increase or
decrease the gain by turning OFFSET. As you are turning OFFSET, look at your volt meter and stop when it
reads 7.2 mA or 20% 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 OTHER TYPES OF ADJUSTMENTS CALL KAM CONTROLS, INC. +1 713 784 0000.
OFF ON
4-20mA (+)
GAIN
4-20mA RTN
Incorporated
CHS
E-mail [email protected]
RS485 OUT +
Controls
Houston, Tx 77063
www.Kam.com
Kam
RS485 IN –
RS485 IN +
OFFSET
Minimum Output
V+
Range Adjustment
GND
P5
PMT
GAIN Maximum Output
Range Adjustment
INTENSITY
Under normal operation, the KAM OID should not require cleaning, unless pipeline usage is limited to a small
number 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: [email protected]
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
LED3 LED5
ON/OFF SWITCH
LED5
OFF ON
4-20mA (+)
LED3
4-20mA RTN
Incorporated
CHS
E-mail [email protected]
RS485 OUT +
Controls
RS485 OUT –
Houston, Tx 77063
www.Kam.com
Kam
RS485 IN –
RS485 IN +
LED4
OFFSET
V+
GND
P5
PMT
GAIN
INTENSITY
LED4
2. If the instrument is switched on and LED5 (Fig. 5-1) is NOT illuminated, it indicates a problem with the power
source: check the voltage input and polarity.
4. LED3 and LED4 (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 LED4 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 KAM 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 CONTROLS at +1 713 784 0000 for spare or replacement boards and/or to arrange for repair.
For all other issues, please contact KAM CONTROLS at +1 713 784 0000.