Agar Corp OWM-300 Series Instruction Manual

OWM-300 Series Instruction Manual Table of Revisions Date Revision Version ER Number Description of Changes April 23, 2010 00 1 5276 Initial issue – by Sue Huffman: combined OW-301 and OW-302 into one OW-300 Manual, in addition to content review. May 11, 2010 01 5747 Add to Appendix certification information per Paul Martin – by Sue Huffman Technical Reviewer Paul Martin May 11, 2010 Reviewer Anthony Phillips May 11, 2010 Approved for Issue Steven Bates May 11, 2010 ACI-A-7.5.1-MAN-014, Rev 01 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM This page is intentionally left blank ACI-A-7.5.1-MAN-014, Rev 01 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM OW-300 Series Water Cut Meters Instruction Manual ACI-A-7.5.1-MAN-014, Rev 01 Page 1 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM OW-300 Series Water Cut Meters Instruction Manual NOTICE For personal and system safety, and for optimum product performance, make sure to thoroughly understand the contents of this manual before installing, using, or maintaining this product. This equipment is intended for use in a hazardous environment; installation must comply with local, state and national regulations, as well as safety practices for this type of equipment. Only Agar-designated personnel must install and commission this equipment or warranty is null and void. Substitutions for Agar equipment or Agar-defined practices will void certification conformance and certification warranty. For technical assistance, contacts are listed below: Agar Corporation 5150 Tacoma Drive Houston, TX 77041 Tel: 832-476-5100 (7:00 a.m. to 4:00 p.m. CST) Fax: 832-476-5299 Email: sales@Agarcorp.com http://www.Agarcorp.com Outside the United States Cayman Islands: 345-945-5242 Venezuela: 58-261-7978646 Malaysia: 603-7981-4569 (for all service calls outside U.S. operating hours) United Arab Emirates: 971-2-6811150 Indonesia: 62-21-7409206 Outside of these areas, contact your local Agar representative. Agar instruments may be protected by one or more of the following U.S. Patent Nos. 5099697; 5101163; 5101367; 5263363; 5444383; and 5461930. Foreign Patents Issued. Australia: 642436; Canada: 2066719 and 2103254; China: 91102022.5 and 90108228.7; France: 0495819; Great Britain: 523068; 0495819; and 2215061; India: 179317 and 177757; Japan: 2831462; Mexico: 174740 and 173811; Netherlands: 523068 and 0495819; Russia: 2086963; South Korea: 163605; and Taiwan: 47031. ACI-A-7.5.1-MAN-014, Rev 01 Page 2 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM Table of Contents Figures .......................................................................................................................................................................... 5 SECTION 1: Introduction .......................................................................................................................................... 9 1.1 Using This Manual .............................................................................................................................................. 9 1.2 Important Notices ................................................................................................................................................ 9 1.3 Safety Messages ................................................................................................................................................. 9 SECTION 2: OW-300 Series Water Cut Meter....................................................................................................... 10 2.1 OW-300 Description .......................................................................................................................................... 10 2.1.1 Sensor Unit (SU) .................................................................................................................................. 10 2.1.2 Data Acquisition System (DAS) ........................................................................................................... 10 2.1.3 Safety Barrier Box ................................................................................................................................ 11 2.2 OW-301 Overview ............................................................................................................................................. 12 2.3 OW-302 Overview ............................................................................................................................................. 13 SECTION 3: Unpacking and Installation ................................................................................................................ 15 3.1 Equipment Receipt ............................................................................................................................................ 15 3.2 Unpacking ......................................................................................................................................................... 15 3.3 Equipment Return ............................................................................................................................................. 15 3.4 General Installation Considerations .................................................................................................................. 15 3.5 Mechanical Installation ...................................................................................................................................... 16 3.5.1 OW-301 Mechanical Installation .......................................................................................................... 16 3.5.2 OW-302 Mechanical Installation .......................................................................................................... 20 3.5.3 OW-302 Sensor Insertion..................................................................................................................... 22 3.5.4 OW-302 Sensor Removal .................................................................................................................... 24 3.5.5 Hydrotesting ......................................................................................................................................... 25 3.5.6 ATEX Installation Safety Requirements ............................................................................................... 25 3.6 Electrical Installation ......................................................................................................................................... 27 3.6.1 System Interconnection........................................................................................................................ 27 3.6.2 Power Connection ................................................................................................................................ 27 3.6.3 Analog Outputs .................................................................................................................................... 27 3.6.4 Pulse Outputs ....................................................................................................................................... 28 3.6.5 Data Communication ............................................................................................................................ 28 3.6.6 Flow Meter Input .................................................................................................................................. 29 3.6.7 Relay Output ........................................................................................................................................ 29 3.7 OW-300 Pre-Startup Check List........................................................................................................................ 30 SECTION 4: OW-300 System Startup .................................................................................................................... 31 4.1 System Power Startup ...................................................................................................................................... 31 SECTION 5: Configuration and Operation ............................................................................................................. 33 5.1 Overview ........................................................................................................................................................... 33 5.2 Operation........................................................................................................................................................... 34 5.2.1 Connecting to the DAS......................................................................................................................... 34 5.2.2 Network Connection ............................................................................................................................. 34 5.2.3 Using VNC............................................................................................................................................ 36 5.2.4 OWM300Win® Software Start ............................................................................................................. 38 5.2.5 OWM300Win® Diagnostic Screen ....................................................................................................... 40 5.2.6 OWM300Win® Advanced Operation ................................................................................................... 41 5.2.7 OWM300Win® Configuration Screen .................................................................................................. 42 5.2.8 OWM300Win® Resonator Screen ....................................................................................................... 44 5.2.9 OWM300Win® Messages Screen ....................................................................................................... 45 ACI-A-7.5.1-MAN-014, Rev 01 Page 3 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 5.3 5.2.10 OWM300Win® Calibration Screen ...................................................................................................... 46 5.2.11 OWM300Win® Analog Output Test ..................................................................................................... 48 OW-300 Site Acceptance Test .......................................................................................................................... 48 SECTION 6: Maintenance and Procedures............................................................................................................ 49 6.1 OW-300 Series Maintenance ............................................................................................................................ 49 6.2 OW-300 Series Meter Procedures .................................................................................................................... 49 6.2.1 Returning Material to Agar Factory ...................................................................................................... 49 6.2.2 OW-300 MODBUS Register Map ........................................................................................................ 49 6.2.3 OW-300 Troubleshooting Guide .......................................................................................................... 49 6.2.4 Troubleshooting OW-300 Communication Error Procedure ................................................................ 49 6.2.5 XPe CF Creation Procedure ................................................................................................................ 49 6.2.6 OW-300 Analog Output Calibration Procedure .................................................................................... 49 6.2.7 Upgrade Software on OW-300 Procedure ........................................................................................... 49 6.2.8 Import Sensor Puck Settings Procedure .............................................................................................. 49 6.2.9 Puck Power Management Update Procedure...................................................................................... 50 6.2.10 Procedure to Replace U-Cup Seal in OW-302 Seal Housing .............................................................. 50 6.2.11 Data Collection for Automatic Zero Shift Calibration Procedure .......................................................... 50 6.2.12 Logging Diagnostic Data from an OW-300 Procedure ........................................................................ 50 6.2.13 Export Sensor Puck Settings Procedure .............................................................................................. 50 6.2.14 OW-300 Site Acceptance Test (SAT) Procedure and Check List........................................................ 50 6.2.15 OW-300 Pre Startup Check List ........................................................................................................... 50 6.2.16 Cabling for OW-300 Series Meters ...................................................................................................... 50 6.2.17 Field Temperature Calibration Procedure ............................................................................................ 50 6.2.18 Detailed Instructions to Connect to the DAS via VNC ......................................................................... 50 SECTION 7: Diagnostics and Troubleshooting ...................................................................................................... 51 7.1 Recommended OWM Tool Kit .......................................................................................................................... 51 7.1.1 Hand Tools ........................................................................................................................................... 51 7.1.2 Test Equipment .................................................................................................................................... 51 7.2 OWM 300 Troubleshooting Guide..................................................................................................................... 52 7.3 Troubleshooting “OWM Communication Error”................................................................................................. 52 APPENDIX A: Guides and Procedures APPENDIX B: Drawings and Diagrams APPENDIX C: Certifications ACI-A-7.5.1-MAN-014, Rev 01 Page 4 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM Figures 2-1 OW-301 L Configuration and U Configuration 2-2 OW-302 with Insertion Tool and without Insertion Tool 3-1 OW-301 System L-Shape Assembly Mounting Arrangement (Built-in RTD) 3-2 OW-301 System Arrangement (External RTD Option) 3-3 OW-301 System U-Shape Assembly Mounting Arrangement 3-4 OW-302 System with Insertion Tool Mounting Arrangement 3-5 OW-302 System before Insertion 3-6 OW-302 System after Insertion 3-7 TB2 Terminal Legend 3-8 Analog Outputs 3-9 Pulse Outputs 3-10 Flow Meter Input 3-11 Alarm Relay 3-12 Customer Wiring Connections to DAS 4-1 TB2 Terminal 5-1 OW-300 Enclosure Closed 5-2 OW-300 Enclosure Open 5-3 OW-300 Data Acquisition System (DAS) 5-4 Network Connection Socket 5-5 Internet Protocol (TCP/IP) Properties Screen 5-6 Local Area Connection Status Screen 5-7 UltraVNC Icon 5-8 UltraVNC Viewer Connection 5-9 OWM300Win® Summary Screen 5-10 OWM300Win® Shortcut Icon 5-11 OK Message 5-12 Fail Message 5-13 OWM300Win® Diagnostic Screen 5-14 Login Dialog Box 5-15 OWM300Win® Configuration Screen 5-16 OWM300Win® Resonator Screen 5-17 OWM300Win® Messages Screen 5-18 OWM300Win® Calibration Screen 5-19 Air Calibration Dialog Box 5-20 Epsilon Values on the Diagnostic Screen 5-21 External Temperature 5-22 High Frequency Oil Continuous Corrected Value (In KHz) ACI-A-7.5.1-MAN-014, Rev 01 Page 5 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM Glossary Accuracy Qualitative expression for the closeness of the agreement between the result of a measurement and the true value of the quantity subject to measurement. Air Air is used interchangeably with the word gas when discussing the ID-201. Any gas will give the same raw signal as air. Antenna The part of the probe that emits the signal which is used to make the measurement of the percent water. Antennas come in different configurations: bare, coated and with guards for various applications. Coriolis Force Force applied on an object or fluid moving in a curved path when the object moves simultaneously in the direction of the curvature radius. Coriolis Meter Unit used for density measurement and mass flow. Current Loop 4 to 20mA current loop to power and transmit data. DAS Data Acquisition System. Emulsion Colloidal mixture of two immiscible fluids, one being dispersed in the other in the form of fine droplets. Error of Measurement Result of measurement minus the true value of the quantity subject to measurement. Flow regime The physical geometry exhibited by a multiphase flow in a conduit; for example, liquid occupying the bottom of the conduit with the gas phase flowing above, or a liquid phase with bubbles of gas. Fluid A substance readily assuming the shape of the container in which it is placed; e.g. oil, gas, water or mixtures of these. Gas Hydrocarbons in the gaseous state at the prevailing temperature and pressure. Gas-liquid-ratio (GLR) The gas volume flow rate, relative to the total liquid volume flow rate (oil and water), all volumes converted to volumes at standard pressure and temperatures. Gas-oil-ratio (GOR) The gas volume flow rate, relative to the oil volume flow rate, both converted to volumes at standard pressure and temperatures. Gas Volume Fraction (GVF) The gas volume flow rate, relative to the multiphase volume flow rate, at the pressure and temperature prevailing in that section. The GVF is normally expressed as a percentage. Hold-up The cross-section area locally occupied by one of the phases of a multiphase flow, relative to the cross-sectional area of the conduit at the same local position expressed as a percentage. Homogeneous Multiphase Flow A multiphase flow in which all phases are evenly distributed over the cross-section of a closed conduit; i.e. the composition is the same at all points. ID Interface Detector. Mass Flow Rate The mass of fluid flowing through the cross-section of a conduit in unit time. Microwave Electromagnetic radiation having wavelength between 300 mm to 10 mm (1GHz to 30 GHz). MPFM Multiphase Flow Meter. Multiphase Flow Two or more phases flowing simultaneously in a conduit; this document deals in particular with multiphase flows of oil, gas and water. ACI-A-7.5.1-MAN-014, Rev 01 Page 6 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM Multiphase Flow Meter A device for measuring the flow rates of oil, gas and water of a multiphase flow through a cross-section of a conduit. Multiphase Flow Rate The total amount of the two or three phases of a multiphase flow flowing through the cross-section of a conduit in unit time. The multiphase flow rate should be specified as multiphase volume flow rate or multiphase mass flow rate. Oil Hydrocarbons in the liquid state at the prevailing temperature and pressure conditions. OWM Oil/Water Monitor. Oil-continuous Multiphase Flow A multiphase flow of oil/gas/water characterized in that the water is distributed as water droplets surrounded by oil. Electrically, the mixture acts as an insulator. PAMS Phase Amplitude Measurement System. PCB Printed Circuit Board. Permittivity Measure of a medium’s ability to be electrically polarized when exposed to an electric field. It is a frequency-dependent complex quantity whose imaginary part corresponds to dielectric losses. Phase In multiphase flow measurement, “phase” is used in the sense of one constituent in a mixture of several. In particular, the term refers to oil, gas or water in a mixture of any number of the three. Phase Flow Rate The amount of one phase of a multiphase flow flowing through the cross-section of a conduit in unit time. The phase flow rate may be specified as phase volume flow rate or as phase mass flow rate. Phase Velocity The velocity of one phase of a multiphase flow at a cross-section of a conduit. It may also be defined by the relationship (Superficial phase velocity x Phase area fraction). Phase Volume Fraction The phase volume flow rate of one of the phases of a multiphase flow, relative to the multiphase volume flow rate. Pressure Transducer A device that measures the absolute and differential pressure. Probe The unit which contains the antenna and transmitter that is mounted into the process being monitored. PS Power Supply/Signal Conditioner used to power the ID or OW probe and receive its “raw signal” and condition it to a customer-usable output. Puck Type of PCB assembly, so called because of its round shape and resemblance to a puck used in ice hockey. It provides a raw signal to the PS for conditioning. Raw Signal The DC current or voltage signal, from a transmitter, that is sent to the PS for conditioning into a customer-usable output. Repeatability Closeness of the agreement between the results of successive measurements of the same quantity carried out under the same measurement conditions (same procedure, observer and instrument, and repeated over a short time). Reproducibility Closeness of the agreement between the results of successive measurements of the same quantity carried out under changed measurement conditions. RDC Remote Data Controller. SBC Single-Board Computer. Slip Ratio The ratio between two phase velocities. ACI-A-7.5.1-MAN-014, Rev 01 Page 7 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM Slip Velocity The phase velocity difference between two phases. Superficial Phase Velocity The flow velocity of one phase of a multiphase flow, assuming that the phase occupies the whole conduit by itself. It may also be defined by the relationship (Phase volume flow rate/Pipe cross-section). Uncertainty Parameter associated with a measurement characterizing the dispersion of the values that could reasonably be attributed to the quantity being measured. Velocity Profile The mean velocity distribution of a fluid at a cross-section of a conduit. The velocity profile may be visualized by means of a two- or three-dimensional graph. VNC Remote communication software. Void Fraction The cross-sectional area locally occupied by the gas phase of a multiphase flow, relative to the cross-sectional area of the conduit at the same local position. Volume Flow Rate The volume of fluid flowing through the cross-section of a conduit in unit time at the pressure and temperature prevailing in that section. Watchdog Timer Failsafe device to restart after system errors. Water-Continuous Multiphase Flow A multiphase flow of oil/gas/water characterized in that the oil is distributed as oil droplets surrounded by water. Electrically, the mixture acts as a conductor. Water Cut (WC) The water volume flow rate, relative to the total liquid volume flow rate (oil and water), both converted to volumes at standard pressure and temperature. The WC is normally expressed as a percentage. Water-in-Liquid Ratio (WLR) The water volume flow rate, relative to the total liquid volume flow rate (oil and water), at the pressure and temperature prevailing in that section. ACI-A-7.5.1-MAN-014, Rev 01 Page 8 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM SECTION 1: 1.1 Introduction Using This Manual This manual provides instructions, specifications and other important information for installation, operation, maintenance and troubleshooting procedures. Section 2: Contains a description of the instrumentation, along with component breakdown and principles of operation. Section 3: Contains information about receiving and unpacking equipment; instructions for returning equipment; considerations for installation; and mechanical and electrical installation instructions. Section 4: Contains basic calibration information for system start-up. Section 5: Contains configuration and operational instruction. Section 6: Contains maintenance schedules and technical procedures. Section 7: Contains troubleshooting techniques, diagnostic information and checks for error messages or alarms. 1.2 Important Notices Notes of significance in this manual will be offset as follows: NOTE Standard materials for this equipment are stainless steel, Teflon®, Vitron and Aflas. Other materials may have been used at the customer’s request. 1.3 Safety Messages Instructions and procedures in this manual require special precautions to ensure safety of the personnel performing the operations. Please pay attention to boxes with the warning signal, example follows: WARNING MESSAGE!!! Explosions could result in death or serious injury: Do not open in hazardous atmosphere. ACI-A-7.5.1-MAN-014, Rev 01 Page 9 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM SECTION 2: 2.1 OW-300 Series Water Cut Meter OW-300 Description The AGAR OW-300 series water cut meter is a third-generation of oil/water analyzers designed to measure the volumetric concentration of water in the oil stream in the low water cut (WC) range. The principle of OW-300 operation is based on measuring the complex permittivity properties of the flow stream using the energy absorption of multiple high frequency wave method. The fluid permittivity is a unique monotonic function of WC and the instrument uses the permittivity to calculate WC. OW-300 measures the volumetric water concentration over the low water cut range in the oil continuous phase. The instrument provides temperature compensation of the reading. The energy absorption of multiple high-frequency wave method allows compensation for the effect of changing hydrocarbon composition (different types of crude oils) and for water salinity. The accuracy of the OW-300 measurement is not affected by changing salinity, density, viscosity, temperature or velocity of the components being analyzed. The OW-300 is available in two models: the OW-301, a spool-type configuration; and the OW-302, an insertion-type assembly. The OW-300 instrument consists of three sub-systems: the Sensor Unit; the Data Acquisition System; and the Safety Barrier Box. 2.1.1 Sensor Unit (SU) The SU consists of: • A Probe/Antenna with or without an open guard • An Enclosure with the Sensor Transmitter - Measuring Electronics Board (MEB) • A Seal Housing (SH) for the OW-302 or a Spool for the OW-301 The antenna assembly consists of an antenna, a cylindrical open guard and a cylindrical shaft where coaxial feeder to the antenna is mounted together with the platinum RTD (temperature sensor). The enclosure with the sensor transmitter (MEB) is mounted on the top of the antenna. For the OW-302, the seal housing provides a sealed connection to the isolation valve mounted on the pipeline nozzle. The OW-300 antenna is intrinsically safe. The Measuring Electronics Board (MEB) generates multiple high-frequency signals that are transmitted to the antenna. The antenna radiates high-frequency signals into the measured fluid that is surrounding it, and the reflected signals from the measured fluid are transmitted back to the MEB where the voltage and frequency of multiple high-frequency signals are measured The fluid’s complex permittivity is calculated from this measurement. 2.1.2 Data Acquisition System (DAS) After all corrections (i.e. temperature, water salinity, and crude oil pattern recognition) the value of water cut is calculated in the Data Acquisition System (DAS). The DAS is a single-board computer that receives frequency and voltages data from the MEB, and with software modeling, calculates the water concentration of the fluid in the sensor. The DAS can be remotely mounted from the field sensor. The OW-300 has a flow meter input channel available that can be a pulse input or a 4-20 mA input to obtain liquid flow rates as outputs from the water cut meter. The DAS has (6) six 4-20 mA output channels that represent the water concentration, temperature, oil flow rate, water flow rate and liquid flow rate. By integrating the flow rate from a flow meter over time, and measuring the water concentration, the DAS calculates the liquid flow totals for oil and water. The DAS can communicate to a distributed control system (DCS) or other user equipment using MODBUS through an RS-232, RS-422 or RS-485 serial communication channel or HART through a 4-20mA analog channel. Status, process temperature, water concentration, liquid flow rate, oil flow totals ACI-A-7.5.1-MAN-014, Rev 01 Page 10 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM and water flow totals are the DAS outputs provided. User configurable parameters for field calibration of the sensor, setting flow parameters (meter K factor, units, ranges, etc.) are accessible. For convenience, the DAS has LCD screen which has four lines and shows the current status of the system as seen below. PARAMETERS 11:23:07 Water cut 1.2% Status: No warning messages • • • 2.1.3 The first line shows the current time in a 24 hour format. The second line shows the current water cut or “air” if the sensor is in air or “fault” if there is a problem with the sensor. The last two lines show any warning messages. Safety Barrier Box The barrier box in an explosion-proof enclosure made with intrinsically-safe connections. It contains a power barrier, and a serial communication barrier. Barriers ensure the connections from the DAS to the sensor remain intrinsically safe. ACI-A-7.5.1-MAN-014, Rev 01 Page 11 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 2.2 OW-301 Overview The AGAR OW-301 is a spool-piece design water cut meter available for 1” to 4” flow lines. The sensor should be mounted in a location where the fluid will be well-mixed (normal recommendation is vertical flow upwards). The spool piece is available in an “L” or “U” shaped design, or a straight inline design. In addition, the OW-301 has stable performance in common pipelines where the fluid composition can change regularly. Figure 2-1. OW-301 L-Configuration and U-Configuration OW-301 Physical Dimensions Electric Enclosure Diameter 6” Length 12” Spool Design for 1” to 4” pipeline sizes Flange Rating 150#; 300#; 600#; 900#; 1500# consult factory for others Maximum Pressure Rating 5000psi Shipping Weight Approximately 25lbs. for 2” ANSI 150# ACI-A-7.5.1-MAN-014, Rev 01 Page 12 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 2.3 OW-302 Overview The AGAR OW-302 has a patented seal housing that connects to a full-port isolation valve, which allows installation and retraction of the sensor while the pipeline is in service and under pressure. The OW-302 probe is inserted through the valve and nozzle into the flow lines 6” and larger. An insertion tool is available (and recommended) for insertion into high pressure lines. The sensor has a blow-out preventer to ensure that the sensor cannot be extracted past the seal housing. The OW-302 probe is mounted perpendicular to the flow in a vertical section with ascending flow at a point where the fluids are well-mixed to ensure proper measurement. Figure 2-2. OW-302 Meter with Insertion Tool and Without Insertion Tool ACI-A-7.5.1-MAN-014, Rev 01 Page 13 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM OW-302 Physical Dimensions Electric Enclosure Diameter 6” Length 12” Probe Outside Diameter Shaft 1.25” Sensor 1.8” Probe Length Active length: 6” to 12” to match the diameter of the pipe. Overall length is determined by the pipe diameter, nozzle, and valve size with standard lengths. Insertion Design For 6” and larger pipeline sizes; process connection minimum 2” full-port ball or gate isolation valve; and 2” schedule 80 or larger ID nozzle. Flange Rating 150#; 300#; 600#; 900#; 1500# consult factory for others Maximum Pressure Rating 5000psi Shipping Weight Approximately 25lbs. for 2” ANSI 150# Insertion Tool Recommended for OW-302 when operating pressure is over 60psi and flange rating is 600# or less. ACI-A-7.5.1-MAN-014, Rev 01 Page 14 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM SECTION 3: 3.1 Unpacking and Installation Equipment Receipt When equipment is received, inspect the outside of the packaging for damage incurred during shipment. If external damage exists, the local carrier should be notified at once concerning their liability. A report should be submitted to: Agar Corporation, Inc. 5150 Tacoma Drive Houston, TX 77041, USA Tel: 832-476-5100 Fax: 832-476-5299 sales@Agarcorp.com 3.2 Unpacking Before proceeding to unpack the items, please insure that the crates are positioned with the correct side up. Remove the envelope containing the packing list. Remove the lid. Unpack the box and inspect for damaged or missing parts that might have occurred during shipment. Remove the straps securing the meter body and the screws securing the meter ends to the crate. The meter can be lifted with a strap under the flange assembly of the meter. Move the unit with a lift. When moving the unit, ensure that it is secured from moving sideways and falling. Do not drop or tip the meter. Refer to the packing list for information as to what is supplied with the order. In the event any item is missing from the shipment, contact your Agar representative. The unit’s work order number will be requested at this time. 3.3 Equipment Return If, for any reason, an assembly or part must be returned, a Return Materials Authorization (RMA) number must be obtained from the manufacturer prior to shipment. To be able to process return goods quickly and efficiently, it is important to provide essential information about the nature of the problem. Do not return any assembly or part without a Return Materials Authorization (RMA) number. RMA numbers can be obtained from the Agar Service Coordinator. When requesting an RMA, please have the unit's work order number, a description of the problem, and a serial number for each part or piece of equipment being returned. Return instructions will be sent with the RMA # information. See APPENDIX A for return shipment procedures, ACI-A-7.5.4-FRM-001: Return Material to Agar Factory. 3.4 General Installation Considerations • Stray magnetic or electric fields of high intensity may disturb the operation of the meter. A large electric motor or transformer placed in the vicinity of the meter may produce a magnetic field large enough to affect the meter. • Good standard practice suggests that it is important to avoid locating the meter near such sources of interference and to avoid passing the signal cable over or near cables carrying high AC voltages or large currents. • Make sure to remove the protective covering from the flow meter flanges before installation. ACI-A-7.5.1-MAN-014, Rev 01 Page 15 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM • 3.5 All required grounding should be performed before the instrument is put into operation. Mechanical Installation As the OW-300 comes in two particular designs – spool-piece and insertion type – thus, mechanical installation is contingent on the instrument type. 3.5.1 OW-301 Mechanical Installation The OW-301 sensor is designed to be installed in pipelines 1” to 4” diameter. The mounting arrangement is shown in Figures 3-1, 3-2 and 3-3. The piping must be able to support the weight of the instrument. Add bracing as appropriate. All process connections and instrument dimensions are shown in the set of customer drawings provided with the unit. A homogeneous flow must be maintained through the instrument to obtain the specified accuracy. For OW-301 mechanical installation, consider the following factors: • If practical, install the OW-301 downstream of a pump or choke to ensure a well-mixed flow stream. • If practical, install the instrument in a vertical pipe run, upwards flow direction preferred. • If practical, install a static mixer upstream of the meter. Figure 3-1 shows a blind TEE upstream of the meter as a static mixer. • The liquid stream must be free of gas. Entrained gas will affect the water cut measurement. (Gas will lower the water cut reading). • Use the Pitot Tube (13) and Sampling Valve (14) to take fluid samples for the analysis. ACI-A-7.5.1-MAN-014, Rev 01 Page 16 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 1 - FLANGE A - Flow in 2 - FLANGE B – Flow out 3 - SPOOL SUB-ASSEMBLY 4 - SWAGELOK COMPRESSION FITTING 5 - SENSOR TRANSMITTER 7 - CABLE TO DAS AND POWER SUPPLY (1”NPT) 10 - PROBE SHAFT 11 - PROBE ANTENNA 12 - SPOOL FLANGE COVER FLOW OUT 13 – SAMPLE PORT 14 - SAMPLING VALVE 15 - BLIND TEE STATIC MIXER FLOW IN Figure 3-1. OW-301 System L-Shape Assembly Mounting Arrangement [Built-In RTD] ACI-A-7.5.1-MAN-014, Rev 01 Page 17 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 1 - FLANGE A - FLOW IN 2 - FLANGE B – FLOW OUT 3 - SPOOL SUB-ASSEMBLY 4 - COMPRESSION FITTING NUT 5 - SENSOR TRANSMITTER 6 - JUNCTION BOX 7 - CABLE TO DAS AND POWER SUPPLY (1”NPT) 8 - RTD CABLE 9 - RTD ENCLOSURE 10 - PROBE SHAFT 11 - PROBE ANTENNA FLOW OUT FLOW IN Figure 3-2. OW-301 System Mounting Arrangement [External RTD Option] ACI-A-7.5.1-MAN-014, Rev 01 Page 18 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 1 - FLANGE A - FLOW IN 2 - FLANGE B – FLOW OUT 3 - SPOOL SUB-ASSEMBLY 4 - COMPRESSION FITTING NUT 5 - SENSOR TRANSMITTER 7 - CABLE TO DAS AND POWER SUPPLY (1”NPT) 10 - PROBE SHAFT 12 - SPOOL FLANGE COVER FLOW IN FLOW OUT Figure 3-3. OW-301 System U-Shape Assembly Mounting Arrangement ACI-A-7.5.1-MAN-014, Rev 01 Page 19 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 3.5.2 OW-302 Mechanical Installation The OW–302 sensor is designed to be inserted in 6” or larger pipelines. When mounted with an isolation ball valve, the shaft of the retractable sensor probe is sealed against loss of fluids. The valve may be opened and the probe extended into the process stream without depressurizing the pipeline. Once in service, the probe may be retracted for inspection or relocation without depressurizing the pipeline. The OW-302 assembly is engineered for installation on a 2” nozzle with probe insertion through a 2” nominal, full-port valve. Larger size isolation valves and nozzle piping may be specified. The mounting arrangement is shown in Figure 3-4. The piping must be able to support the weight of the instrument. Add bracing as appropriate. All process connections and instrument dimensions are shown in the set of customer drawings provided with the unit. A homogeneous flow must be maintained through the instrument to obtain the specified accuracy. 3.5.2.1 OW-302 Installation Considerations For OW-302 mechanical installation, consider the following factors: • If practical, install the OW-302 downstream of a pump or choke to ensure a well-mixed flow stream. • If practical, install the instrument in a vertical pipe run, upwards flow direction preferred. • Provide at least 6 ft (2 meters) straight piping upstream from the meter. • The liquid stream must be free of gas. Entrained gas will affect the water concentration measurement. (Gas will lower the water cut reading). • Flow through the OW-302 may be in either direction. Ensure proper clearances are provided around the instrument for installation and maintenance. NOTE: Verify the isolation ball valve is 2” FULL-PORT or larger, prior to installation. If the pipeline has been “hot-tapped”, ensure that the actual opening in the pipe is in accordance with system as designed. ACI-A-7.5.1-MAN-014, Rev 01 Page 20 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 1 - PIPE LINE 2 - PIPE NOZZLE 3 - ISOLATION VALVE 4 - SEAL HOUSING SUB-ASSEMBLY 5 - PROBE/ANTENNA 6 - INSERTION HANDLE 7 - SENSOR TRANSMITTER 8 - CABLE TO DAS AND POWER SUPPLY 9 - DRAIN VALVE 10 - CHAIN SUPPORT 11 - SAFETY CHAIN 12 - INSERTION TOOL SUB-ASSEMBLY 13 - COMPRESSION FITTING NUT Figure 3-4. OW-302 System with Insertion Tool Mounting Arrangement ACI-A-7.5.1-MAN-014, Rev 01 Page 21 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM Pipe Diameter LS Fully Withdrawn L Figure 3-5. OW-302 System before Insertion L LS Fully Inserted 6.925 REF LA LV LP Figure 3-6. OW-302 System after Insertion 3.5.3 OW-302 Sensor Insertion Insert the OW-302 sensor using the following steps, with numbering references to Figure 3.4. A. Verify the sensor is fully retracted into the seal housing. B. Verify the compression-fitting nut (13) on the top of the seal housing is secured (hand-tight plus ¼ to ½ turn by wrench), so the probe is secure (cannot slip axially) in the seal housing. WARNING MESSAGE!!! CAUTION: Do not over-tighten the nut. The ferrules may become permanently seated onto the shaft body, making insertion and retraction impossible. C. Find the probe length L from the set of customer drawings provided with the unit to calculate La: La = L - Lv – Lp. Mark the length of La on the shaft (5). D. Lift the instrument into alignment with an appropriate forklift or crane and attach the flanged seal housing (4) to the isolation valve (3). Bolt the flanged seal housing (4) of the meter to the isolation valve (3). ACI-A-7.5.1-MAN-014, Rev 01 Page 22 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM E. Ensure the drain valve (9) on the seal housing (4) is closed, and the safety chain (11) is hooked with minimal slack. F. Crack open the isolation valve (3) to allow the liquid pressures to equalize on both sides of the valve. Visually check for leaks; if none are found, fully open the isolation valve. G. For low-pressure installation with no insertion tool, loosen the compression fitting nut (9) on the top of seal housing (6) slightly, slowly slide probe by hand in the “INSERTION” direction to extend the probe through the isolation valve and into the pipeline, then go to step “J”. WARNING MESSAGE!!! CAUTION: Reconnect the safety chain (8) for every 3” of travel to eliminate slack and reduce the risk of injury to personnel. H. For pressures above 50psi, an insertion tool may be provided (and is recommended) to assist in installation of the probe section. For standard insertion tool, continue with step “I”. I. When using the standard insertion tool, loosen the compression fitting nut (13) on the top of seal housing (4) slightly, and then rotate the hand-wheel of insertion mechanism (6) slowly in the “INSERTION” direction to insert the probe through the isolation valve and into the pipeline. WARNING MESSAGE!!! CAUTION: Reconnect the safety chain (11) for every 3” of travel to eliminate slack and reduce the risk of injury to personnel. J. Stop insertion at marked position on the shaft (5). K. Reconnect the safety chain (11) with a minimum amount of slack; the chain should be straight for better protection. WARNING MESSAGE!!! CAUTION: The safety chain (11) should be as straight as possible with the probe in the fully inserted position to reduce the risk of injury to personnel. L. Hand-tighten the compression fitting nut (13) and then tighten it with a wrench approximately ¼ to ½ turn (just enough to keep the probe from being forced out of the pipe by the maximum operating pressure). M. For insertion tool installation, reverse the hand-wheel of insertion mechanism a little to release cable stress. N. Optional: Remove or secure the isolation valve lever (3) or hand-wheel to prevent accidental damage to the OW-302 probe. ACI-A-7.5.1-MAN-014, Rev 01 Page 23 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM WARNING MESSAGE!!! CAUTION: If the pipeline is pressurized, exercise utmost caution when inserting the OW-302. The instrument is designed where the probe (5) must be assembled into the seal housing (4) from the end facing process pressure. As a result, there is a mechanical stop that prevents the probe (5) from been ejected completely from the seal housing (4); however, the line pressure will tend to force the probe (5) to the fully retracted position when the compression fitting nut (13) is loosened. WARNING MESSAGE!!! CAUTION! Serious personal injury could result if the OW-302 were allowed to be forcibly retracted without proper restraint by the safety chain (11) or cranking mechanism – insertion handle (6). The moving portion of the instrument can strike any installer standing in the path of the probe (5) and sensor transmitter (7). WARNING MESSAGE!!! CAUTION! DO NOT STAND IN THE PATH OF THE PROBE during insertion or retraction. If these procedures or cautionary notes are not completely clear, contact the Application Department at Agar before attempting to install or remove the OW-302. 3.5.4 OW-302 Sensor Removal The removal procedure for the OW-302 sensor is the same as the insertion procedure with a few steps reversed. The same CAUTIONS that were applicable to insertion apply equally to removal. Remove the OW-302 sensor using the following steps, with numbering references to Figure 3.4. NOTE: the safety chain should always be attached for protection. Loosen the chain whenever the chain is tight. A. Ensure the safety chain (11) is secure. B. Loosen the compression fitting nut (13). C. For no insertion tool, insert the probe slightly by hand and go to step “E”. D. When using the standard insertion tool, rotate the insertion tool hand crank in the “INSERTION” direction until the safety chain (11) is slack enough to be disconnected from the probe (5). E. Hand-tighten the compression fitting nut (13) to hold the probe (5) in place. F. Remove the safety chain (11) from the quick link and reattach it with six (6) inches of slack. NOTE: The safety chain should always be attached for protection. It can only be detached when the compression fitting nut is holding the probe secure. ACI-A-7.5.1-MAN-014, Rev 01 Page 24 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM G. For no insertion tool, hold the probe by hand and loosen the compression fitting nut; retract by hand and repeat steps E & F until probe is fully retracted into the seal housing, then proceed to step “J”. H. If using the insertion tool, loosen the compression fitting nut (13) again and rotate the insertion tool hand crank (6) in the “RETRACTION” direction until the probe (5) is retracted with enough slack still in the safety chain (11) to repeat steps E & F. I. Repeat steps E, F and H until the probe comes to a positive stop inside the seal housing (4); this will be the blowout preventer seating against the compression fitting. J. Tighten the compression fitting nut (13) to hold the probe in place. K. Close the isolation valve (3) completely. If there is any resistance from the ball valve closing, STOP, and open the isolation valve; make sure the probe is fully retracted. NOTE: Prepare to use a container to catch fluid trapped inside the seal housing. Remember the same pressure that is in the line is trapped in the seal housing. Hold the container around the drain valve on the seal housing and open it slowly to allow the pressure and fluids to drain from the seal housing. L. Ensure the isolation valve (3) is not leaking fluids from the line into the seal housing (4) and then remove the OW-302 from the isolation valve (3) using an appropriate forklift or crane. M. Install a proper-sized blind flange on the Isolation valve (3). NOTE: Do not remove probe from the seal housing unless it is absolutely necessary. 3.5.5 Hydrotesting Prior to initial operation of the system, the OW-300 instrument and the manifold should be tested to the pressure integrity of new piping and to eliminate leaks. The hydrostatic leak test shall be conducted in accordance with ANSI/ASME B31.3 with a test pressure of no less than 1 ½ times the design pressure at design temperature. The holding time for the leak test should be at least 10 min. Joints and connections should be examined for leaks. The pressure test is intended to uncover any damage that might have occurred during shipping. NOTE: Check the instrument nameplate for the design pressure and temperature of your specific instrument. 3.5.6 ATEX Installation Safety Requirements When an aluminum enclosure is used for the sensor electronics (puck) and it is installed in a Zone 0 environment, all exposed aluminum surfaces are covered with a durable coating and the apparatus must be mounted in such a manner as to remove the risk of sparks caused by friction or impact. Please refer to EN60079-0:2006 clause 8.1.2. A single run of Type B intrinsically-safe cable connecting the sensor electronics and the DAS must be effectively protected from damage, for example, by running the cable in conduit. Please refer to EN60079-14:2003 clause 12.2.2.8. The medium around the probe must not be potentially explosive or outside the pressure, temperature and oxygen limits listed in EN60079-0:2006 clause 1. ACI-A-7.5.1-MAN-014, Rev 01 Page 25 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM When Zener barriers are used, the barrier must be connected via a high-integrity connection using 2 an insulated conductor equivalent to a 4mm copper conductor, and the impedance from the point of connection to the barrier must be less than 1 ohm. The user must perform a risk assessment in accordance with the requirements of clause 10 of EN60079-25:2004 and install lightning arrestors if deemed necessary. The programming connections must not be used by the user or when in a hazardous area. See Drawing EEX0017 in the APPENDIX B for System Certification Requirements. A CANBUS interface and the RS-232 interface may not be connected at the same time. The ATEX markings, certification number and terminal parameters will be tag-displayed upon the hockey puck enclosure, DAS enclosure and barrier enclosure similar to the tag model below. ACI-A-7.5.1-MAN-014, Rev 01 Page 26 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 3.6 Electrical Installation WARNING MESSAGE!!! CAUTION! Opening the DAS or barrier explosion-proof enclosures in hazardous areas may cause an explosion. Follow local codes and regulations for maintenance work of electrical equipment in hazardous areas. Do not remove enclosure covers in explosive atmospheres when the circuit is live. Electrical connections should be made according to the local code of practice, for example; BS5345 in Europe or article 500 of the NEC (NFPA 70) in USA. Connections to explosion-proof enclosures should be made through rigid conduit or approved cable glands. Available entries are equipped with close-up plugs; these can be removed to allow attachment of the conduit/cable system. 3.6.1 System Interconnection The OW-300 consists of three main sub-systems: the DAS, the sensor probe with the sensor transmitter (MEB), and a safety barrier box. The DAS is electrically connected to the MEB via safety barriers that are installed inside an explosion-proof (EXD) enclosure (barrier box). The barriers are connected to the sensor transmitter via an intrinsically safe cable that provides the power and RS-232 communication between the DAS and the sensor transmitter. The DAS is connected to the barrier box through an EXD cable. The maximum cable length allowed between the DAS and the barrier box is 50 ft, and between the barrier box and the sensor is 50 ft. -- totaling 100 ft. See “Cabling for the OW-300 Series Meters” in APPENDIX A. Since the cable between the barrier box and the sensor is providing intrinsically safe signals, the cable parameters must follow the OW-300 ATEX certification. Follow the supplied customer-wiring diagram for the interconnection between the DAS and sensor. See the Communication/Power Terminal Enclosure drawing in APPENDIX B for location of the terminals. 3.6.2 Power Connection Prior to connecting power to the OWM DAS, verify the instrument nameplate to ensure the supplied voltage matches instrument requirements. Connect power to the power supply terminal TB2 as shown in the Customer Wiring Diagram in APPENDIX B (refer to Figure 3-7 and Figure 4-1). The cable can be 12 to 18 AWG. Figure 3-7. TB2 Terminal Legend 3.6.3 Analog Outputs Six (6) 4-20 mA output channels are available on the DAS (see Figure 3-12 #2). The outputs can be configured as any of the following options: % water cut, temperature, oil flow rate, water flow rate ACI-A-7.5.1-MAN-014, Rev 01 Page 27 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM and total liquid flow rate. The flow rates are only available when a flow meter is connected to the OW-300. A twisted pair, 18 AWG cable should be used to connect to the equipment. All the analog output channels provided are active which means that no power is required. See the Customer Wiring Diagram in APPENDIX B for the analog output connections. Figure 3-8. Analog Outputs 3.6.4 Pulse Outputs Three isolated pulse output channels are available from the DAS (see Figure 3-12 #5). The outputs are configured to provide pulse outputs for Total Liquid, Total Water, and Total Oil Volumes. If DO2+/- output channels are wired, contact an Agar service technician to access them. See the Customer Wiring Diagram in APPENDIX B for more information. Figure 3-9. Pulse Outputs 3.6.5 Data Communication The OW-300 instrument provides a port for data communications between the instrument and a PLC or DCS via MODBUS or HART protocols. Please note: MODBUS is a serial communications protocol published by Modicon in 1979 for use with its programmable logic controllers (PLCs). It has become a default standard communications protocol in industry, and is now the most commonly available means of connecting industrial electronic devices. The main reasons for the extensive use of MODBUS over other communications protocols are: • It is openly published and royalty-free • Relatively easy industrial network to deploy • It moves raw bits or words without placing many restrictions on vendors MODBUS allows for communication between many devices connected to the same network, for example, a system that measures temperature and humidity, and then communicates the results to a computer. MODBUS is often used to connect a supervisory computer with a remote terminal unit (RTU) in supervisory control and data acquisition (SCADA, LabVIEW) systems. Versions of the MODBUS protocol exist for serial port and Ethernet. For serial connections, two variants exist, with different representations of numerical data and slightly different protocol details. MODBUS RTU is a compact, binary representation of the data. MODBUS ASCII is human-readable, and more verbose. Both of these variants use serial communication. The RTU format follows the commands/data with a cyclic redundancy check ACI-A-7.5.1-MAN-014, Rev 01 Page 28 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM checksum, while the ASCII format uses a longitudinal redundancy check checksum. Nodes configured for the RTU variant will not communicate with nodes set for ASCII, nor the reverse. The HART Communications Protocol (Highway-Addressable Remote Transducer Protocol) is an early implementation of Fieldbus, a digital industrial automation protocol. Its claim to fame is that it can communicate over legacy 4-20 mA analog instrumentation wiring, sharing the pair of wires used by the older system. According to some, due to the huge installed base of 4-20 mA systems throughout the world, the HART Protocol is one of the most popular industrial protocols today. For this reason, RS-232 and RS422/485 serial channels are provided for communication between the SBC and customer equipment (see Figure 3-12 #1). RS-232 communication can generally be transmitted up to ~ 50 feet/15m and RS422/485 until 4000 feet/1200m. See the MODBUS Register Map in APPENDIX A and the Customer Wiring Diagram in APPENDIX B. 3.6.6 Flow Meter Input A flow meter can be connected to the OW-300 using an analog input channel or a pulse input channel. 3.6.6.1 Analog Flow Input When connecting a flow meter to the OWM through an analog input channel, connect to the analog input terminal block on channel 3 (see Figure 3-13 #4). It will accept a 4 to 20 mA analog signal. See Customer Wiring Diagram for flow meter input connections in APPENDIX B. 3.6.6.2 Pulse Flow Input When connecting a flow meter to the OWM through the pulse input channel, it will accept a 0.1 to 24 volts pulse input. The pulse input is capable of measuring input frequencies up to 2,000 Hz (see Figure 3-12 #3). Figure 3-10. Flow Meter Input 3.6.7 Relay Output One single-pole double-throw SPDT relay output channel is available from the DAS (see Figure 3-12 #6). It is configured as water cut set point alarm. See the Customer Wiring Diagram in APPENDIX B. Figure 3-11. Alarm Relay ACI-A-7.5.1-MAN-014, Rev 01 Page 29 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 6 2 4 1 5 3 Figure 3-12. Customer Wiring Connections to DAS 1 – Data Communication 2 – Analog Outputs 3 – Flow Meter Input 4 – Analog Flow Inputs 5 – Pulse Flow Outputs 6 – Relay Outputs 3.7 OW-300 Pre-Startup Check List After electrical and mechanical installation, and prior to starting the OW-300, complete the Pre-Startup Check List, ACI-A-7.5.2-FRM-016. ACI-A-7.5.1-MAN-014, Rev 01 Page 30 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM SECTION 4: 4.1 OW-300 System Startup System Power Startup After performing the installation described in SECTION 3, the OW-300 is ready for startup. WARNING MESSAGE!!! CAUTION! Opening the DAS or barrier explosion-proof enclosures in hazardous areas may cause an explosion. Follow local codes and regulations for maintenance work of electrical equipment in hazardous areas. Do not remove enclosure covers in explosive atmospheres when the circuit is live. Before applying power to the meter, check the following: • Open the fuses on TB2 and apply power to the meter as describe in section 3.6.2. Check that the voltage is within +/-10% (refer to Figure 4-1) of the nominal specified voltage stated on the meter tag. Figure 4-1. TB2 Terminal • Make sure the OW-300 communication wires and power between the sensor electronics and the DAS is terminated properly. • Make sure the customer output wires are terminated properly. • Measure resistance on the system input and make sure it is above 100 ohms. ACI-A-7.5.1-MAN-014, Rev 01 Page 31 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM • Close the power fuses terminal and verify that the system is starting up. The green and red LEDs on the SBC computer will start flashing and the meter display will show the Agar logo, status messages, and process data numbers. (System boot takes around 1 to 2 minutes). If the LCD shows no error messages and the time is updating, the unit is ready for initial verification. The DAS will receive data from the sensor transmitter (MEB) and will calculate the water concentration and the stream temperature. The DAS will also receive the flow meter pulse or analog input and will calculate the flow rate and volume totals (when flow meter input is provided to the OW-300). The user configurable parameters will need to be set for proper flow meter input, flow rate scaling, total volume output scaling, and for % water cut relay set point. Configuration and Operation will be covered in greater detail in SECTION 5 of this manual. ACI-A-7.5.1-MAN-014, Rev 01 Page 32 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM SECTION 5: 5.1 Configuration and Operation Overview The OW-300 series water cut meter represents a new generation of embedded Windows-based meter from Agar Corporation Inc. The meters consist of a probe with a sensor (often referred to as a “puck” for its resemblance to a hockey puck) mounted on top and a cable leading to a Data Acquisition System (DAS). The probe is inserted into the process fluid and the sensor takes basic raw measurements and sends them back to the DAS for processing. The DAS takes data from the sensor and uses it to calculate very accurate water cut (WC). The DAS can also take inputs from flow meters and can calculate flow information. Figure 5-1. OW-300 Enclosure Closed Figure 5-2. OW-300 Enclosure Open Standard outputs from the DAS include water cut, stream temperature, oil flow rate, water flow rate, total flow rate, oil total volume, water total volume and total liquid volume. The outputs are available via industry standard 4-20mA analog output, HART and MODBUS. In addition, the system provides an alarm relay and three relays for additional alarms or flow output. ACI-A-7.5.1-MAN-014, Rev 01 Page 33 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM SBC MPC555 Interface Board Figure 5-3. OW-300 Data Acquisition System (DAS) 5.2 Operation 5.2.1 Connecting to the DAS All operation and configuration is conducted via OWM300Win®.software running on the DAS. There are two ways to access the software. One is by opening the DAS enclosure and attaching a keyboard and monitor directly to the Single Board Computer (SBC). The other is by connecting an external computer to the DAS via a standard network and using a VNC software client. 5.2.2 Network Connection In order to connect to the DAS via the network, a network connection must be established. A standard RJ-45 network socket is located inside the communication enclosure on the side of the DAS enclosure (see Figure 5-4). ACI-A-7.5.1-MAN-014, Rev 01 Page 34 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM Reset Button COM 1 and 2 Ethernet Figure 5-4. Network Connection Socket The PC should be configured as a DHCP client (set to “obtain an IP address automatically”) as shown Figure 5-5; it is the most common configuration for PCs in a network environment. Figure 5-5. Internet Protocol (TCP/IP) Properties Screen ACI-A-7.5.1-MAN-014, Rev 01 Page 35 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM There is a DHCP server running on the DAS that will provide a proper network address. Connect a standard network cable from the PC to the RJ-45 connector on the DAS and wait for the PC to establish a connection. Once the connection is established, an IP address on the 192.168.239.xxx network will appear. Verify this by looking at the current network settings as shown in Figure 5-6. Figure 5-6. Local Area Connection Status Screen For advanced troubleshooting situations, there is also a second network port available on the DAS. It is located on the SBC inside of the DAS enclosure. The second connection can be used to connect the DAS to a customer’s network. This port is configured to obtain an IP address automatically FROM THE CUSTOMER. Once the DAS is established on the customer’s network, it may be possible to access the DAS via the VNC Viewer from any workstation on the customer’s network or even from the Internet. This enables Agar’s home office to provide direct support through the Internet. See Detailed Instructions for Connecting to the DAS via VNC, form ACI-A7.5.1-PRO-070 in APPENDIX A or check with your network administrator for connection of a DAS to the Internet. For further information on networking and network configuration, please contact Agar tech support or your network administrator. 5.2.3 Using VNC VNC is software that is used to remotely access the desktop (display, keyboard and mouse) of another computer on a network. It is similar to other remote-access programs: PCAnywhere® or GoToMyPC®. The VNC server is installed on the DAS and a VNC viewer is required to connect to the DAS. VNC Viewer may be downloaded for free from the Agar website: http://www.Agarcorp.com/ or the UltraVNC website: http://www.uvnc.com/. VNC is an open standard and there are a number of free viewers available on the Internet. There are viewers available for Windows, MAC, Linux, and others. Agar recommends the use of UltraVNC Viewer. Once the network connection has been established, VNC Viewer can be started by clicking on the UltraVNC Viewer Icon (Figure 5-7). Figure 5-7. UltraVNC Icon ACI-A-7.5.1-MAN-014, Rev 01 Page 36 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM Click the UltraVNC Viewer and the connection dialog box should appear as in Figure 5-8. Figure 5-8. UltraVNC Viewer Connection The IP address of the DAS is 192.168.239.1. Enter this address in the VNC Server space and click the “connect” button. After a moment, the password dialog will come up. The password is: welcome. The DAS desktop should appear on screen and you should be able to control the keyboard and mouse from your PC. To avoid confusion and get the best display possible, Agar recommends turning off the UltraVNC toolbar and maximizing the VNC Window to fill the entire display. For further information on using VNC, contact Agar technical support or read the VNC documentation available on the Internet. ACI-A-7.5.1-MAN-014, Rev 01 Page 37 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 5.2.4 OWM300Win® Software Start Once connected to the SBC on the DAS; either by a direct connection of keyboard, mouse and monitor or through VNC on a network connection, the OWM300Win® application should appear as shown in Figure 5-9. 1 2 3 4 5 6 Figure 5-9. OWM300Win® Summary Screen If the application is not running, start it up by clicking a shortcut on the desktop as shown in Figure 5-10. Figure 5-10. OWM300Win® Shortcut Icon The OWM300Win® Summary Screen shows a summary of the status of the system and all of the vital system information (see Figure 5-9). The numbered boxes indicate key elements. 1 – The Button Bar is used to navigate to the various different screens of the application. 2 – The Software Revision of the OWM300Win® application. Use this when reporting any software problems to Agar. 3 – The Current Time in 24 hour format. 4 – The Command Buttons. On each screen this area will have the command buttons relevant to the screen currently displayed. On the summary screen the “Login” and “Clear Totals” command buttons can be found. ACI-A-7.5.1-MAN-014, Rev 01 Page 38 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 5 – The Measurement Summary. The top portion shows the measured water cut and stream and instrument temperature. The bottom shows both flow rate and flow total information. 6 – The System Status Message. Here any system warning messages are displayed. In this example, the “Water Cut Alarm 2” is active indicating that the current water cut is above or below the level configured for alarm 2. If everything is OK and there are no problems the message will read “No Warning Messages”. One of two messages (see Figures 5-11 and 5-12) may flash quickly on the screen then disappear. Figure 5-11. OK Message Figure 5-12. Fail Message The fail message indicates the OWM300Win® application is having trouble communicating with the sensor puck. The OK message indicates that the communication has been properly established. When starting the OWM300Win® application it is normal for the fail/OK messages to blink a couple of times while communication is being established. If repeated fail/OK messages occur after more than a minute, contact Agar for support. ACI-A-7.5.1-MAN-014, Rev 01 Page 39 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 5.2.5 OWM300Win® Diagnostic Screen From the Summary Screen, click the Diagnostic button to show the diagnostic screen. 1 3 4 5 2 6 Figure 5-13. OWM300Win® Diagnostic Screen The OWM300Win® Diagnostic Screen shows a summary of the status of the system and all of the vital system information (see Figure 5-13). The numbered boxes indicate key elements. 1 – Polling Activity Indication. The first number here is the amount of time in seconds since the last raw measurement data packet was received from the sensor puck. The second number indicates the average time between packets. The first number should count up to about the value of the second number then start over at zero. This indicates that a measurement data packet was received. If the first number is just counting up and not resetting to zero, there is a problem. 2 – Diagnostic Data Area. In this area all of the raw data from the sensor can be seen as well as some numbers from other data sources and some from calculations. The numbers on this screen should update each time a data packet is received from the sensor puck. 3 – Firmware Revision Number. This is the version number of the software on the sensor puck. Please include this number anytime when reporting problems with the system. 4 – Puck Serial Number. This is the serial number of the sensor puck. Include this number anytime reporting problems with the system. 5 – Line Save Button. This button is used to record all of the information displayed on the diagnostic display into a file that can be used for diagnostic and calibration purposes. The blank below the button indicates the status of the line save operation. When the button is ACI-A-7.5.1-MAN-014, Rev 01 Page 40 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM clicked, a file name must be provided. If choosing an existing file, the new data will be appended to the end. When reporting problems, Agar support may ask for a Line Save and file to be sent back to Agar for analysis. 6 – Autopoll Check Box. This is used for diagnostic purposes. It provides and option for the OWM300Win® application to temporarily suspend communication with the puck in order to freeze the current values on the diagnostic display. PLEASE LEAVE THIS CHECKED AT ALL TIMES! 5.2.6 OWM300Win® Advanced Operation From time to time it may be necessary to access some advanced features of the system. To access the advanced features, it will be necessary to LOGIN to the system. On the Summary screen, find the login button. When clicked, the login dialog will appear as shown in Figure 5-14. Figure 5-14. Login Dialog Box There are three user levels: • Level 1 – The default level gives access to the Summary screen and the Diagnostic screen. There is no need to login to see these screens. • Level 2 – The guest level gives additional access to the Configuration screen, the Messages screen and the Calibration screen. The user name is guest and the password is guest. • Level 3 – The admin level gives additional access to the Resonator screen. Contact Agar for user names and passwords to access the various advanced user levels. Once logged in to an advanced user level, additional buttons will appear in the button bar allowing access to the advanced screens. Also, additional buttons and fields may appear on various screens depending on the user level. ACI-A-7.5.1-MAN-014, Rev 01 Page 41 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 5.2.7 OWM300Win® Configuration Screen 8 6 1 11 2 7 3 4 9 5 10 12 Figure 5-15. OWM300Win® Configuration Screen The Configuration screen contains the entire configuration for the OW-300 system (see Figure 515). The numbered boxes indicate key elements. 1 - COM Port Setup Box – used to define which com port each external device is attached to. If the external device is not present, set its com port to -1. • OW-300 Com Port is where the sensor puck is connected. This is usually Com 3 or Com 4. • LCD is always attached to Com 2. • Loop Com Port is used for the Agar calibration loop and should be set at -1. • RDC Com Port is used for an Agar RDC module and is not applicable to standard water cut measurements. NOTE: The MiniDAS has support for HART or RS-485/422 on Com 1. Either MODBUS or HART may be assigned on com 1, but not both. • MODBUS Com Port is used to define which port is used for MODBUS communications. • HART Com Port is used to define which port is used for HART communications. ACI-A-7.5.1-MAN-014, Rev 01 Page 42 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 2 - Temperature Units Box – allows the meter to be configured to present all temperatures in either Celsius or Fahrenheit. 3 - Water cut Analog Out Box – allows selection of the range of the 4 to 20mA analog output when used to express the water cut within the instrument’s range. The lower limit does not have to be zero, and the range can be backwards, as in 0% = 20mA and 10% = 4mA. 4 - Stream Temp Analog Out Box – allows selection of the range of the 4 to 20mA analog output when used to express the stream temperature. The lower limit does not have to be zero, and the range can be backwards, as in 4mA = 100° and 20mA = -10°. The temperature units are expressed in the units configured in the Temperature Units Box. 5 - Flow Meter Pulse Output Box – allows selection of the units for the flow meter output. Each pulse output from the meter represents one K factor volume of the specified units has been measured. Polarity of the output pulse may also be selected. 6 - Flow Meter Input Box – allows selection of the type of flow meter input connected to the OW-300 meter and configure the units of the input. Select either 4 to 20mA analog input or select pulse input. If selecting the 4-20mA analog input which represents a flow rate input, use the drop down box to define the volume and time units of the flow meter and enter the flow rate represented by a 4mA signal and the flow rate represented by a 20mA signal. If selecting the pulse input, which represents a volume per pulse input, use the drop down box to select the volume units of the flow meter and enter the K factor to adjust the volume per pulse. 7 - Flow Rate Output Box – allows configuration of the flow rate analog output. Use the drop down boxes to set the volume units and time units for the flow rate output. Then enter the flow rate represented by a 4mA output and the flow rate represented by a 20mA output. 8 - Analog Output Assignment Box – The OW-300 meter has six 4-20mA analog outputs. Use the drop down boxes to assign any of the following outputs to any analog output. The same output value may be assigned to more than one analog output. • Water Cut • Stream Temperature • Oil Flow Rate • Water Flow Rate • Total Flow Rate • Percent Oil 9 - Water cut Alarm 1 and 2 Boxes – The OW-300 has two water cut alarms. Each of the alarms can be set to activate when the water cut is above or below a given value. In addition, the water cut alarms can be set activate when there is a system error. 10 - Alarm Relay Box – The alarm relay is a dry contact mechanical relay. It can be configured to activate on system alarms or the water cut alarms. The polarity of the alarm relay can also be defined. 11 - Opto Relay Output Assignment Box – The OW-300 meter has 3 solid state optically isolated relays. Use these drop down boxes to assign any of the following outputs to any one of the relays. The same output value may be assigned to more than one relay. • Oil Total • Water Total • Liquid Total ACI-A-7.5.1-MAN-014, Rev 01 Page 43 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM • • • • Water Cut Alarm 1 Water Cut Alarm 2 Sensor Power Management Not assigned 12 - Logging Box – There are two types of log files that can be continuously generated (versus a specific line save activated from the diagnostic display). Do NOT leave either one of these log files enabled for a long period of time. They WILL completely fill the meter’s drive space. 5.2.8 • The APLog file represents a log of the raw data packet from the sensor puck. This data is used during the factory oven calibration. • Fast mode data is a log file that is generated when the sensor puck is put into a special fast data acquisition mode. This is used for a special application and is not applicable to standard water cut meter operation. OWM300Win® Resonator Screen Figure 5-16. OWM300Win® Resonator Screen The Resonator screen as shown in Figure 5-16 is used to configure the sensor puck. These values should only be changed by an Agar factory-trained technician. THIS CAN CAUSE THE SYSTEM TO STOP FUNCTIONING BY ENTERING THE WRONG VALUES INTO THIS SCREEN. This screen is useful to a trained technician to troubleshoot measurement problems or to modify the puck measurements. ACI-A-7.5.1-MAN-014, Rev 01 Page 44 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 5.2.9 OWM300Win® Messages Screen Figure 5-17. OWM300Win® Messages Screen The Messages screen has two parts as shown in Figure 5-17. The top portion shows a running log of system messages. These messages are also written to the error log file, “ErrorLogFile.txt”. Any error codes reported by the puck or other system errors or warnings are listed here. The bottom portion of the screen is a communication log. It shows a log of communication messages going back and forth between the DAS and the sensor puck. ACI-A-7.5.1-MAN-014, Rev 01 Page 45 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 5.2.10 OWM300Win® Calibration Screen Figure 5-18. OWM300Win® Calibration Screen The Calibration screen as shown in Figure 5-14 allows field calibration and testing of the OW-300 unit. The OW-300 meter is factory calibrated. However, due to the wide variation in the properties of various oils and waters, the zero and span may need to be adjusted for specific fluids. A full field calibration begins with setting the Air Reference. Make sure that the sensor is in air and click the Air Calibration button. The display will change to the diagnostic display and a dialog will appear as shown in Figure 5-19. Figure 5-19. Air Calibration Dialog Box ACI-A-7.5.1-MAN-014, Rev 01 Page 46 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM Figure 5-20. Epsilon Values on the Diagnostic Screen All of the Epsilon Values on the diagnostic screen should be showing 1.0 ± 0.002. If so click the OK button on the “accept the air calibration”, if not click CANCEL and try again. Setting the Zero can be done in one of two ways. Both methods require that the probe is placed in dry oil (or very nearly dry). Setting the Zero Method 1: If the water cut of the fluid being measured is known, make sure the “Use Manual Calibration” is unchecked and fill in the Oil Calibration field with the actual water cut of the oil, and then click the Oil Calibration button. This will cause the meter to calculate the epsilon of the dry oil. A typical epsilon for dry oil is around 2.0 to 2.4. A dialog popup will appear that shows the epsilon calculated for the dry oil. If it seems like a reasonable number (1.7 to 2.8), then click OK; if not, then click CANCEL and try again. Setting the Zero Method 2: If the water cut of the fluid being measured is NOT known, take a sample of the process fluid. The sample should be taken from a sample port as close to the OW sensor as possible. NOTE: Do not use the drain valve on the seal housing to take samples. While the sample is being taken, go to the diagnostic screen and write down the External Temperature and the High Frequency Corrected Oil Continuous Value. Have the sample analyzed for water content only; disregard any sediment. Figure 5-21. External Temperature Figure 5-22. High Frequency Oil Continuous Corrected Value (In KHz) When the water cut sample information comes back, go to the calibration screen and make sure the Use Manual Calibration is checked. Fill in the Oil Calibration field with the water cut from the lab and fill in the recorded External Temperature and Frequency Value. NOTE: make sure to enter the frequency in Hz. ACI-A-7.5.1-MAN-014, Rev 01 Page 47 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM Click the Oil Calibration button. This will cause the meter to calculate the epsilon of the dry oil at the time the sample was taken. A typical epsilon for dry oil is around 2.0 to 2.4. A dialog popup will appear that shows the epsilon calculated for the dry oil. If it seems like a reasonable number (1.7 to 2.8), then click OK; if not, then click CANCEL and try again. Setting the span can be done in one of two ways. Both methods require the probe is set in the flowing process with water cut near the top limit of the process. Setting the Span Method 1: If the water cut of the fluid being measured is known, then simply fill in the known water cut in the Span Calibration blank and click the Span Calibration button. A dialog box will be presented showing the span calibration number. Ideally it would be 1.0. If the number looks reasonable (0.9 to 1.1), then click OK: otherwise, click CANCEL and try again. Setting the Span Method 2: If the water cut of the fluid being measured is NOT known, make sure the number in the Span Correction Oil Continuous Low Cut blank is 1.0. Then write down the meter’s water cut value. Then take a sample of the process fluid and send it to the lab for analysis. Once the lab returns the water cut percentage in the sample, use the formula below to calculate the correction factor: Enter the calculated correction factor into the Span Correction Oil Continuous Low Cut blank. Then click the Save Span Correction button. A dialog will pop up confirming the new value. Click OK to save the new value. 5.2.11 OWM300Win® Analog Output Test The analog output test box is used to output a known value on the 4-20mA analog outputs. This is often used to test the meter connection to the control system. To activate the analog output test place a check in the Analog Out Test check box on the Calibration Screen, and then simply select the current level to output from the list. Once the analog output test is done, make sure to uncheck the Analog Out Test check box. 5.3 OW-300 Site Acceptance Test After OW-300 installation, network connection, calibration and configuration, a Site Acceptance Test (SAT) should be completed according to the procedure outlined in ACI-A-8.2.4-PRO-069 using form ACI-A-8.2.4FRM-059, OW-300 Site Acceptance Test Check List. ACI-A-7.5.1-MAN-014, Rev 01 Page 48 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM SECTION 6: 6.1 Maintenance and Procedures OW-300 Series Maintenance The OW-301 and OW-302 do not require scheduled maintenance; rather, occasional updates and calibration are required for software and components. See Procedures in Section 5.2 and APPENDIX A. 6.2 OW-300 Series Meter Procedures Agar has developed step-by-step procedures to provide clear instruction for installing and upgrading software, calibrating equipment components, and other procedures the operator or technician routinely face. The complete procedures are located in APPENDIX A. Listed here are brief descriptions of the procedures. If the procedure is not listed here or on the APPENDIX A cover sheet, it does not mean there is not a defined procedure; ask technical support for additional procedural information or clarification of printed procedures to be added to this manual. 6.2.1 Returning Material to Agar Factory This objective of this form and procedure is to give clear instruction for returning materials to Agar for replacement or repair. See form ACI-A-7.5.4-FRM-001. 6.2.2 OW-300 MODBUS Register Map This is a document containing MODBUS register variable data. See form ACI-A-7.5.1-DOC-023. 6.2.3 OW-300 Troubleshooting Guide This is a document containing error descriptions and possible solutions for troubleshooting the OW300 meter. See form ACI-A-7.5.1-DOC-027. 6.2.4 Troubleshooting OW-300 Communication Error Procedure The objective of this procedure is to provide clear instruction, with pictures, for troubleshooting the OW-300 Communication Error. See form ACI-A-7.5.1-PRO-058. 6.2.5 XPe CF Creation Procedure The objective of this procedure is to provide clear instructions for installing the XP embedded Operating System (XPe) on a compact flash (CF) for the OW-300 series meter. See form ACI-A7.5.1-PRO-059. 6.2.6 OW-300 Analog Output Calibration Procedure The objective of this procedure is to provide clear instruction for calibrating the Analog Output for OW-300 series meters. See form ACI-A-7.5.1-PRO-60. 6.2.7 Upgrade Software on OW-300 Procedure The objective of this procedure is to provide clear instruction, with pictures, for updating the software for OW-300 series meters. See form ACI-A-7.5.1-PRO-061. 6.2.8 Import Sensor Puck Settings Procedure The objective of this procedure is to provide clear instruction, with pictures, for importing OW-300 sensor puck settings, from a file sent by Agar to the operator, into an OW-300 sensor puck by attaching a Notebook PC with USB puck dongle or file transfer using VNC. See form ACI-A-7.5.1PRO-62. ACI-A-7.5.1-MAN-014, Rev 01 Page 49 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 6.2.9 Puck Power Management Update Procedure The objective of this procedure is to provide clear instructions for updating the Puck Power Management by modifying wiring to DAS, upgrading OWM300Win® software and reconfiguring the DAS. See form ACI-A-7.5.1-PRO-63. 6.2.10 Procedure to Replace U-Cup Seal in OW-302 Seal Housing The objective of this procedure is to provide clear instructions for replacing a U-Cup seal in the OW-302 seal housing. See form ACI-A-7.5.1-PRO-068. 6.2.11 Data Collection for Automatic Zero Shift Calibration Procedure The objective of this step-by-step procedure is to provide clear instructions for verifying and setting data collection parameters for OW-300 unit to enable operators to make accurate automatic zero shift calibration. See form ACI-A-7.5.1-PRO-072. 6.2.12 Logging Diagnostic Data from an OW-300 Procedure The objective of this step-by-step procedure is to provide clear instructions for setting diagnostic data parameters for OW-300 unit to enable operators to make accurate calibrations. See form ACIA-7.5.1-PRO-073. 6.2.13 Export Sensor Puck Settings Procedure The objective of this procedure is to provide clear instruction, with pictures, for exporting sensor puck settings from an OW-300 sensor puck by attaching a Notebook PC with USB puck dongle or file transfer using VNC. See form ACI-A-7.5.1-PRO-074. 6.2.14 OW-300 Site Acceptance Test (SAT) Procedure and Check List The objective of the Site Acceptance Test (SAT) is to ensure that the system is installed and functioning properly in preparation for site acceptance by the end-user. See forms ACI-A-8.2.4PRO-069, OW-300 Site Acceptance (SAT) Procedure and ACI-A-8.2.4-FRM-059, OW-300 Site Acceptance Test (SAT) Check List. 6.2.15 OW-300 Pre Startup Check List The objective of this checklist is to effectively manage startup of the OW-300. See form ACI-A7.5.2-FRM-016, OW-300 Pre Startup Check List. 6.2.16 Cabling for OW-300 Series Meters This document provides detailed cabling information for the OW-300 Series Meter. See form ACI-A7.5.1-DOC-031. 6.2.17 Field Temperature Calibration Procedure The objective of this procedure is to provide step-by-step instructions for calibrating temperature on the OW-300 meter. See form ACI-A-7.5.1-PRO-069. 6.2.18 Detailed Instructions to Connect to the DAS via VNC The objective of this procedure is to provide step-by-step instruction, with pictures, for connecting to the DAS via a VNC software client. See form ACI-A-7.5.1-PRO-070 ACI-A-7.5.1-MAN-014, Rev 01 Page 50 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM SECTION 7: 7.1 Diagnostics and Troubleshooting Recommended OWM Tool Kit 7.1.1 Hand Tools • • • • • • • • • • • 7.1.2 Flat blade screw driver (2.5mm) Philips blade screwdrivers (#1) and (#3) Wire stripper/cutter th 3/16 T handle hex wrench nd 5/32 T handle hex wrench ¾ box wrench th 7/16 box wrench ½ box wrench ¼ nut driver th 5/16 RF cable torque wrench Hex key set: inch and metric (including 10mm) Test Equipment • • • Digital multi-meter 4-20mA loop calibrator Laptop/PC with Ethernet port and either a native serial port or a USB-to-serial adapter o USB puck dongle (OW300) o Ethernet cable (OW300) o Null modem serial cable (OW-200 and MPFM) o 232/485 serial converter o USB/serial HART modem o 375 HART Sim software o Ultra VNC Viewer (OW300) o OWMWin® (OW-200) o AMAIN and CALIBRAT software (OW-200 and MPFM) o MODBUS test software o USB floppy drive (OW-300) o USB CF card reader o TWO CF CARDS PRE-CONFIGURED WITH OWM300 OR OW200 IMAGES RESPECTIVE OF UNIT TO BE SERVICED ACI-A-7.5.1-MAN-014, Rev 01 Page 51 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM 7.2 OWM 300 Troubleshooting Guide In response to technical difficulties in the field, Agar technical support has created a grid of common symptoms and solutions for troubleshooting the OW-300. See the OW-300 Troubleshooting Guide, ACI-A-7.5.1-DOC-027 in APPENDIX A. 7.3 Troubleshooting “OWM Communication Error” On an OW-300 water cut meter, the operator may receive an error message: “OWM Communication Error”. Most of the time, this error can be traced to wiring problems. To troubleshoot, the operator must trace and verify the wiring from the DAS through the barrier enclosure to the OW-300 sensor. A step-by-step procedure has been developed to aid in troubleshooting this error message. The procedure should be followed with power applied to the DAS and all of the wiring from DAS to barrier to sensor connected. See “OWM Communication Error” Troubleshooting Procedures, ACI-A-PRO-058 in APPENDIX A. See wiring diagrams DASO4076-CD (for the DAS1000 style interface board) or DASO4088-CD (for the new DAS1019 style interface board) in APPENDIX B. ACI-A-7.5.1-MAN-014, Rev 01 Page 52 of 52 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM APPENDIX A: Guides and Procedures ACI-A-7.5.4-FRM-001, Return Material to Agar Factory ACI-A-7.5.2-FRM-016, OW-300 Pre-Startup Check List ACI-A-7.5.1-DOC-023 OW-300 MODBUS Register Map ACI-A-7.5.1-DOC-027, OW-300 Troubleshooting Guide ACI-A-8.2.4-PRO-069, OW-300 Site Acceptance Test (SAT) ACI-A-8.2.4-FRM-059, OW-300 Site Acceptance Test (SAT) Check List ACI-A-7.5.1-PRO-058, “OWM Communication Error” Troubleshooting Procedures ACI-A-7.5.1-PRO-059, XPe CF Field Installation Procedure ACI-A-7.5.1-PRO-060, OW-300 Analog Output Calibration Procedure ACI-A-7.5.1-PRO-061, Upgrade OW-300 Software Procedure ACI-A-7.5.1-PRO-062, Import Sensor Puck Settings Procedure ACI-A-7.5.1-PRO-063, Puck Power Management Update Procedure ACI-A-7.5.1-PRO-068, Procedure to Replace U-Cup Seal in OW-302 Seal Housing ACI-A-7.5.1-PRO-072, Data Collection for Automatic Zero Shift Calibration Procedure ACI-A-7.5.1-PRO-073, Logging Diagnostic Data from OW-300 Procedure ACI-A-7.5.1-PRO-074, Export Sensor Puck Settings Procedure ACI-A-7.5.1-DOC-031, Cabling for OW-300 Series Meters ACI-A-7.5.1-PRO-069, OW-300 Field Temperature Calibration Procedure ACI-A-7.5.1-PRO-070, Detailed Instructions to Connect the DAS via VNC ACI-A-7.5.1-MAN-014, Rev 01 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM This page is intentionally left blank. ACI-A-7.5.1-MAN-014, Rev 01 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM APPENDIX B: Drawings & Diagrams ACI-A-7.5.1-MAN-014, Rev 01 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM This page is intentionally left blank. ACI-A-7.5.1-MAN-014, Rev 01 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM APPENDIX C: Certifications ACI-A-7.5.1-MAN-014, Rev 01 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM This page is intentionally left blank. ACI-A-7.5.1-MAN-014, Rev 01 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM Agar Locations USA Agar Corporation, Inc. (ACI) 5150 Tacoma Drive Houston, TX 77041 Tel: +1 832-476-5100 Fax: +1832-476-5299 ACI@Agarcorp.com CANADA Agar Canada Corp. (ACC) th 708 11 Ave SW Ste. 243 Calgary, Alberta T2R 0EA Tel: +1 403-718-9880 Fax: +1403-450-8350 ACC@Agarcorp.com MAYLAYSIA AgarCorp SDN. BHD. (ACSB) st 168-1 Floor Main Road Salak South 57100 Kuala Lumpur Tel: +603-7980-7069 Fax: +603-7980-5369 ACSB@Agarcorp.com ABU DHABI Agar Corporation Ltd. Abu Dhabi (ACAD) 1505, Three Sails Tower Corniche, Khalidiya Abu Dhabi, UAE Tel: +971-2681-1150 Fax: +971-2681-1779 ACAD@Agarcorp.com VENEZUELA Agarcorp de Venezuela C.A. (ADV) Av. 77, Edif. 5 de Julio, Piso 4, Oficina D-4, Sector Tierra Negra, Zona Postal 4002, Maracaibo, Edo. Zulia, Venezuela Tel/Fax: +58 261 324 5789 ADV@Agarcorp.com INDONESIA PT Agar Indonesia (PTAI) Jalan Teratai CB-17 Ciputat Baru, Ciputat Tangerang 15413 Tel: +6221-7409206 Fax: +6221-7424757 PTAI@Agarcorp.com User Survey Please tell us how we’re doing. Visit this website and complete a survey. http://www.Agarcorp.com/CustomerSatisfactionSurvey/ ACI-A-7.5.1-MAN-014, Rev 01 OW-300 Series Instruction Manual ©2010 Agar Corp. Inc. Proprietary and confidential information. Electronic versions of this document are uncontrolled except when accessed directly from Agar Corporation Inc. document control database. Printed versions are uncontrolled. User must verify correct revision before use. Agar Corporation, Inc. - Accessed By Bill Wilk On 11/16/2010 1:12 PM