AGAR CORPORATION

INSTRUCTION MANUAL FOR

MODEL OW-101 & OW-102

WATER-IN-OIL MONITORS
WITH THE PS-203 REV. B LINEARIZER
FOR LOW WATER-CONTENT RANGES
USING THE REV. H TRANSMITTER

1.0 DESCRIPTION
2.0 OUTPUT OPTIONS
3.0 INSTALLATION
4.0 CALIBRATION
5.0 TROUBLESHOOTING
6.0 PROCEDURES FOR RETURNING MATERIAL
7.0 ADDENDUM: DRAWINGS AND DIAGRAMS

MODEL:

SERIAL #:

EDITED: February, 1995

1.0 DESCRIPTION

The Agar Oil/Water monitor system consists of an Agar Model OW-101 or OW-102 detector and a
power supply/signal conditioner, Agar Model PS-203 Rev B.

The monitor uses the principle of energy absorption to detect the water content of an oil/water
emulsion flowing through the monitor, over the complete range of 0-100%. The oil/water monitor
uses a high frequency signal and produces a DC output current proportional to the absorption of the
signal, by the fluid which is moving past the antenna.

The power supply/signal conditioner provides power to and accepts the non-linear, unscaled, "raw
signal" from the OW instrument. The power supply is energy limited to avoid the need for a safety
barrier when the intrinsically safe probe is used in a hazardous location.

The output of the OW-101/OW-102 is linearized with the use of two EPROMs [programmable I.C.
"chips"], which contain the calibration data (which is unique to that particular instrument). The
linearized signal is then converted to a standard 4-20 mA output, which is proportional to the water
content of the fluid being measured.

2.0 OUTPUT OPTIONS

2.1 LN/420: Linearized 4 to 20 mA output (corresponding to water content) into a maximum load
of 400 Ohms. The Agar PS-203 powers the loop; therefore, the receiving device (load) must
not supply energy.

2.2 LN/420/RL as above; also includes SPDT (Form C) relay (dry contacts). Adjustable setpoint,
rated 2 Amps @ 115 VAC. Failsafe mode selectable by jumpers.

2.3 LN/420/RL/PN as above; also includes a 3-way electro-pneumatic solenoid valve that can
operate either normally open or normally closed; includes manual override and exhaust speed
control. It can be supplied with air, nitrogen or natural gas, 75 psi maximum. Process
connections are ¼" FNPT. The valve has a maximum capacity of 9 SCFM, a port size of 3/32",
and requires no special filtration. The standard valve is fitted with Buna-N seals and is
explosion-proof.

2.4 LN/420/DD same as 2.1, but with an LCD (digital) display of the water content.

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3.0 INSTALLATION

In order to successfully measure the water content over the full range of 0-100% water, the oil/water
emulsion must be well-mixed and reasonably homogeneous. Because oil and water usually differ in
density, high water content, low velocities and gravity will allow stratification, where the water
settles to the bottom of long horizontal piping runs.

The velocity in the pipe should not be less than 5 feet per second (or the equivalent) and should be
maintained as nearly constant as is feasible, particularly when in the water-continuous phase, in order
to attain the maximum accuracy from the instrument. This minimum velocity will avoid laminar flow
(and thus the possibility of stratification) through turbulence that ensures adequate mixing. The
maximum flow rate desired is 7 feet per second, or is limited by the allowable pressure loss in the
system without degassing occurring, whichever is less.

If, due to low velocities, it is impractical to obtain turbulent mixing, the use of a static (in-line) mixer
should be considered. Care must be taken again with the pressure loss caused by the mixer and the
possibility of degassing.

The presence of gas in the emulsion will be interpreted as oil by the instrument. If the fluid cannot be
effectively degassed, the water concentration reading will have an error proportional to the gas
content.

Generally, emulsions with low water cuts are quite stable and the aforementioned considerations only
become critical when the water content exceeds 40 to 60% water (by volume).

Because the method of installation for the Model OW-101 is totally different than for the OW-102,
the two instruments will be addressed separately.

3.1 OW-101 (IN-LINE MONITOR)

The OW-101 is an in-line device (spool-piece) suitable for 1", 1½", 2" or 3" pipelines, and is
available in either threaded (NPT) or flanged (to customer's specification) versions. Flanged units are
available in both "L" and "S" pattern designs. Because the OW-101 is an in-line instrument, the line
must be taken out-of-service (or bypassed temporarily) for installation of the instrument.

Vertical piping eliminates the effects of stratification. It is therefore best to install the OW-101 so
that its antenna is in a vertical position, rather than a horizontal one.

For typical well-testing applications, it is also preferable to install the OW-101 in an inverted
position. This will allow the oil (which is ordinarily at the end of the dump cycle) to gravitate back
into the separator, while water will be allowed to settle near the bottom of the piping. This helps to
prevent a thick, paraffinic coating on the antenna, particularly in areas where the ambient temperature
varies widely from summer to winter. Refer to the Well-testing bulletins and drawings in Section 7
for additional information.

The actual pressure drop for standard OW-101 models is shown on graphs in Section #7, however, it

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is typically in the one to three psi range.

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3.2 OW-102 (INSERTION PROBE)

The OW-102 is an insertion type instrument for 4" to 60" pipelines. The Agar seal housing allows
insertion and removal from a pressurized flowline.

Before inserting the OW-102 into the pipeline, verify that the flow is turbulent (Reynolds number
greater than 4000 or a flow rate between 5 and 7 ft./sec.).

The seal housing is available in either threaded (NPT) or flanged (to the customer's specification)
versions, and should be mated with a 2" (or larger) full-port ball valve, which provides isolation from
the pressurized flowline. The valve is mounted on the pipeline via a threaded coupling or flanged
nozzle. Refer to the installation drawing in Section #7.

As an alternate, a full-bore plug or gate valve can be used. However, caution must be taken with gate
valves, because gate valves referred to as "full port" do not always mean that the gate clears the port
completely. Therefore, this should be verified prior to installation. Also, it is easier to damage the
probe with a gate valve should it be inadvertently closed without the probe having been fully
retracted.

NOTE: If the pipeline has been "hot-tapped", ensure that the actual opening in the pipe is of
sufficient diameter to allow insertion of the OW-102. (Refer to the dimensional drawing in Section 7
for details.)

INSERTION:

1. Decrease the line pressure to 80 PSI (or less).

2. NOTE: Instructions for installation and removal of OW-102 from the seal housing are in the
drawing section of this manual.
With the OW-102 installed (and fully retracted) into the seal housing, verify that the
compression fitting nut on the top of the seal housing is hand-tight plus ¼ to ½ turn, so that the
probe is secure (can't slip through) in the seal housing.
CAUTION: Do not overtighten the nut as the ferrules will become permanently seated onto
the probe body, making insertion and retraction impossible.
3. Attach the seal housing to the isolation valve. Position the reference mark (X) near the top of
the probe body (shaft) so that it faces upstream, or into the flow. (It may be necessary to loosen
the compression fitting nut temporarily; re-tighten after positioning the reference mark.)
4. Ensure that the sample valve on the seal housing is closed.
5. Slowly open the isolation valve to allow the pressures to equalize, then check for leaks. If no
leaks are found, open the isolation valve fully.
6. CAUTION: If the pipeline is pressurized, exercise utmost caution when inserting the OW-
102. The seal housing is designed so that the instrument must be installed from the process
end; while the OW-102 cannot be ejected completely from the seal housing, the line pressure
will force it to the fully retracted position when the nut is loosened. It may be necessary to have
two or more persons work together to restrain the OW-102 against the line pressure until the
safety chain is attached and the nut is tightened. Serious personal injury could result if the
OW-102 were allowed to forcibly retract (without proper restraint), striking the installer who

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 stood in the path of the instrument. Contact the Applications Department at Agar before
attempting to install or remove the OW-102 if further information is needed. For high-
pressure applications, an insertion and retraction tool is available from Agar
Corporation.

Loosen the nut slightly and push the probe through the isolation valve and into the pipeline,
slightly beyond the desired insertion depth. Attach the safety chain to the "S" hook below the
junction box. Use the link of the chain that makes the chain as nearly taut as possible. Allow
the probe to retract under the line pressure (or retract it manually if the line is not pressurized)
so that the safety chain is tight. DO NOT allow your finger, hand or arm to be trapped in or
under the chain and injured.
7. Hand-tighten the compression fitting nut, then tighten with a wrench approximately ¼ turn
(just enough to keep the probe from being forced out of the pipe by the maximum operating
pressure.)
8. Resume normal operating pressure.
9. (Optional) Remove or secure the isolation valve lever or handwheel to prevent accidental
damage to the OW-102.

REMOVAL:

Basically, removal follows the reverse sequence of insertion. The same cautions which were
applicable to insertion apply to removal. Please read the foregoing section carefully. If any
questions arise, contact the Applications Department at Agar before attempting removal. For high-
pressure applications, an insertion and retraction tool is available from Agar Corporation.

1. Reduce the line pressure to 80 PSI (or less).

2. Loosen the compression fitting nut on the top of the seal housing slightly.
3. Push the probe into the line to detach the safety chain and slowly allow the line pressure to
push the probe outward until it is fully retracted. Exercise utmost caution when restraining the
probe during retraction. DO NOT stand in the path of the probe.
4. Tighten the compression fitting nut so that it is hand-tight plus ¼ to ½ turn, then close the
isolation valve completely.
5. NOTE: Be prepared to collect the fluid which is trapped inside the seal housing. Open the
sample valve slightly, to "bleed" the pressure from the seal housing.
6. After verifying that the isolation valve is not leaking, remove the seal housing and OW-102
from the isolation valve. Install a plug or blind flange (as applicable) onto the isolation valve.
7. Resume normal operating pressure.

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3.3 DETECTOR WIRING

The detectors are intrinsically safe and the power supply/signal conditioner is available in an
explosion proof box suitable for hazardous locations, Division 1, Class 1, groups C and D.
Class 2 groups F and G.

Connect a 3 conductor cable 18 AWG to the detector and run cable through conduit to the
power supply/signal conditioner. Shielded cable is not required. Do not run power wires in
the same conduit as the signal wires.

Refer to the wiring diagram in the drawing section in the rear of this manual. The terminals on
the barrier strip of the detector are identified as follows:

R Factory wired for RTD. (Do not remove.)

R Factory wired for RTD. (Do not remove.)
T Factory wired.
I Raw signal from detector (mADC).
- 15 VDC power supply from PS-203 negative or common.
+ 15 VDC power supply from PS-203 positive voltage.

3.4 POWER SUPPLY/SIGNAL CONDITIONER WIRING:

Refer to the wiring diagram in Section 7 of this manual for details concerning hook-up to the
terminal blocks on the PS-203.

The terminals on the barrier strip TB2 located on the low-voltage side of the PS-203 are
identified as follows:

SIN Raw signal from the transmitter.

DET- DC supply to the transmitter, negative.
DET+ DC supply to the transmitter, positive.
O/P- 4 to 20 mA output signal, negative.
O/P+ 4 to 20 mA output signal, positive.

NOTE: The PS-203 is designed to supply the power for the 4-20 mA output loop. Therefore,
the receiving device (load) must not supply energy to the loop.

The terminals located on the power end of the PS-203 are identified as follows:

N (-) Supplied power source neutral or negative.

L (+) Supplied power source line or positive.
GND Earth ground
L1 Normally closed relay contact connected to L(+) through fuse (F2)
L2 Normally open relay contact connected to L(+) through fuse (F2)
NC Relay "dry" contact--normally closed
COM Relay "dry" contact--common

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 NO Relay "dry" contact--normally open

Use 18 AWG wire to connect the power supply to the power source.

The power input and optional relay output wiring should enter the enclosure through the
hole(s) nearest to TB1 terminal block. The low-voltage wires (to the OW-102 and the 4-20 mA
output circuit) should enter the enclosure through the hole(s) nearest the TB2 terminal block on
the PS-203.

4.0 CALIBRATION

The OW-102 and its same-serialized (including the suffix number, if applicable) transmitter PCB (or
"hockey puck") are calibrated together, as a single unit. The PS-203 is calibrated, and its EPROMs
are programmed according to the data that was recorded when the OW-102 was calibrated at the
factory.

Note: Linearization of the "raw" signal from the transmitter is accomplished with the use of two
EPROMS (U6 and U7) located on the PS-203 signal conditioner circuit board. The serial
number (work order number) of these EPROMS must match the serial number on
all parts of the instrument.

The EPROMS must be installed correctly, with the notch in each of the I. C. "chips" nearest the
outside edge of the PS-203. The "A" chip must be mounted in the U7 socket; the "B" chip in the U6
socket.

4.1 FIELD SET-UP/USE OF THE CALIBRATION RECORD AND DATA SHEET:

Each AGAR system comes with a calibration record and calibration data sheet that are unique to that
instrument, transmitter and signal conditioner board. For field calibration, they should be matched
together according to the work order number found on each transmitter, signal conditioner and
calibration record. These sheets have special significance as follows:

DATA SHEET:

This sheet gives the raw mADC reading that should be obtained from the probe with the antenna in
air and with the antenna short circuited to ground.

The values represent the absolute maximum and minimum outputs that each particular transmitter
can generate and should not change appreciably throughout the life of the transmitter.

This sheet also shows a table of raw mADC values at intervals over the probe's entire range of
calibration. The values are the "raw signal" output of the transmitter itself, and are not to be
confused with the 4-20 mA output of the signal conditioner. This table is generated in the calibration
lab, in order to define the unique response of each probe to water and hydrocarbon.

NOTE: The actual field values may be slightly different, due to the nature of the actual process fluids

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encountered in the field.

CALIBRATION RECORD:

This sheet records the settings of each adjustment of the PS-203 when it left the AGAR production
facility. The readings given in the shop calibration section A through H are to be used in the field to
ensure that each instrument is fully functional and set according to factory specifications.

Instructions are given in each column on checking and adjustments, as well as any special
instructions (notes) needed for the given measurements. The PS-203 may be checked out according
to this record prior to calibration and start-up.

Once the instrument is installed and calibrated, some of these readings will be changed (such as zero
suppression voltage and span resistances). For this reason, one column of the record is reserved for
recording the final settings after field calibration. Refer to the drawing in section 7 for measurement
locations and follow the steps on the calibration record.

4.2 FIELD CALIBRATION

PS-203 REV. B - LOW RANGES ONLY (OW-101 & OW-102)

READ THIS ENTIRE SECTION BEFORE PROCEEDING

Using the CALIBRATION RECORD sheet in this manual, check all the "Factory" settings and verify
that they are correct. Use the test points listed on the sheet and any conditions necessary for proper
measurements (ie: "power off"). Refer to drawing 5212 for the locations of test points and
potentiometers. If you can not obtain these factory settings, check and make sure you have the
system wired correctly and you are on the correct test points and are meeting all required conditions.

After verifying the factory settings, use one of the following methods to calibrate to actual process
fluids.

If the calibration record is not available, proceed with the following steps.

1. Connect a mA meter (multimeter in the mA mode) to test points TP6 (+) and TP11 (-). While
depressing SW7, adjust R33 (Potentiometer) to obtain a reading of 3.9 mA.

2. Connected to the same test points, while depressing SW5, adjust R29 (Potentiometer) to obtain
a reading of 20.1 mA.

(Refer to the drawing in section #7 for the location of test points and potentiometers.)

These two parameters are set at the factory. These first two steps are to insure that they have
not been changed. These must be set properly for correct output.

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4.2.1 OW-101 ZERO SETTING

Isolate the OW in the line and fill the probe with dry process oil (refer to Drawing #4725).
Use oil with no water or with a know low water content.

With a mA meter connected to test points TP6 (+) and TP11 (-), adjust R22
(Potentiometer) to obtain a reading of 4 mA (for 0% water) or a reading that reflects the
water content of the oil used. If a digital display is used, it should reflect the water content
of the oil used.

NOTE: The output reading can be calculated easily as no matter what the range the OW
is, the lowest point of the range will be a 4 mA output, and the highest point of the range
will be a 20 mA output. The water content of the oil will be a linear output between these
two readings.

For example:

If the range of the OW is 0 to 10%, the 0% output will be 4 mA and the 10% output will
be 20 mA. Each percent reading will be equal to:

20 mA - 4 mA
Top of Range - Bottom of Range

20 mA - 4 mA
10 - 0

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10

1.6 mA

Starting at 4 mA, add 1.6 mA for each 1% of water content. Therefore, 5% would equal 4
mA plus (1.6 mA x 5), or 12 mA.

SPAN SETTING
Connected to the test points TP6 and TP11 as above, flow normal process fluid through
the OW-101. Record the reading while taking a sample of the fluid flowing through the
OW.

Have the sample analyzed for water content.

Calculate the difference between the output reading and the actual water content of the
sample. With the mA meter connected as above (TP6 (+) and TP11 (-)), adjust R19 OC
for this calculated difference from the present reading.

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 For example: If the reading taken was 10% water and the sample shows 11% water,
increase the present output by 1%. If present reading is 8%, increase it to 9%.

4.2.2 ALTERNATE METHOD, USING A DC mA CURRENT GENERATOR

Set the 4 mA (zero %) output as in Step 4.2.1.

With normal process fluid flowing through the OW and a mA meter connected to test
points TP14 (+) and TP11 (-), while depressing SW7, record the reading while taking
a sample of the fluid flowing through the OW.

Have the fluid analyzed for water content.

Disconnect the OW wiring from "DET +", "DET-" and "SIN" on the terminal block,
TB2. Connect a DC mA current generator to the "SIN" (+) and "DET-" (-) points on
the terminal block. Input the current measured while taking the sample. Connect a
mA meter to test points TP6 (+) and TP11 (-), adjust R19 OC for a reading that
reflects the water content shown by the analysis.

Again, if a digital display is being used, the water content shown on the display can
be used for the adjustments.

4.2.3 OW-102

The OW-102 can be calibrated in the pipeline in the same manner as the OW-101 (above)
or it may be calibrated externally in a container large enough for the entire antenna and
guard, and part of the probe body to be covered by the fluid, without the antenna or guard
touching any part of the container.

The "ZERO" setting should be done as above with a dry process oil with a 0% water
content or a known low water content, in the container.

The "SPAN" setting can be done in a container using a well mixed, non-separating
emulsion of know water content. If one is not available, do the calibration in-line with
normal flowing process, as in "SPAN" setting above. The samples may be drawn from the
valve on the OW-102 seal housing.

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NOTE: RELAY TRIP VOLTAGE:

If your unit is supplied with the option of an adjustable set point relay, the PS-203 provides a linear
voltage ranging between 0 and 5 VDC. This voltage is normally provided directly proportional to
water content.

(When requested, the voltage can be provided inversely proportional to the water content. This must
be specially specified when ordering the instrument).

The relay trip voltage is set between 0 and 5 Volts.

To set the relay to trip at 15% water content of a 0 to 20% water content instrument, use the
following formula:

Install Equation Editor and double-

click here to view equation.

where:

RTV = Relay trip voltage, VDC

PCT = Water concentration of desired trip point (percent)
U = Upper range (maximum water content percentage)

In our example:

Install Equation Editor and double-

click here to view equation.

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5.0 TROUBLESHOOTING

Percent water display is blank or no output signal:

No power to the PS-203.
Fuse F1 on PS-203 is blown.
The EPROMs are installed incorrectly.
The PS-203 has failed.

Percent water display reads 0.0 / Output always 4.0 mA:

Wiring from transmitter to PS-203 is incorrect.
Probe is in dry oil.
Probe is in air.
Transmitter is not connected.
DET+ voltage to transmitter has failed.
Banana plugs of transmitter are not firmly in antenna jacks.
Ground wire in PS-203 has failed.
Calibration is incorrect.
PS-203 has failed.

Percent water display always reads 100% / output always 20ma

Wiring from transmitter to PS-203 is incorrect.
Probe is in water.
Antenna is shorted. See note #1 below.
Rainwater entering the transmitter housing.
Banana plug of transmitter is grounded.
Calibration is incorrect.
EPROMs are installed incorrectly.
PS-203 has failed.

Percent water display is incorrect. / Output is incorrect:

Verify transmitter range is correct.
Verify signal conditioner range is correct.
Wiring between transmitter and signal conditioner is incorrect.
Calibration is incorrect.
Curve select voltage is incorrect.
The span resistances are incorrect.
The EPROMs are installed incorrectly.
The EPROMs do not match the transmitter serial number.
The PS-203 has failed.
Rainwater has entered the transmitter housing.
Gas or air in the lines.
Flow rate is out of the specified range.

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5.1 HOW TO TAKE "RAW SIGNAL" READINGS

The raw signal is the DC current that is fed from the OW instrument into the PS-203, before the
signal is conditioned, processed, linearized, and converted to a standard format output. This signal is
an invaluable tool for troubleshooting, and for diagnosing calibration difficulties. It may be measured
at the OW instrument, or at the PS-203, whichever is more convenient. To troubleshoot suspected
"hockey puck" transmitter malfunctions, it will be necessary to perform tests by subjecting the puck
itself to certain specific conditions. Since the raw signal is measured in DC milliamperes (mA), a
zero reading could be the result of a blown fuse in the mA meter. If in doubt, test the fuse.

5.1.1 RAW SIGNAL READINGS AT THE PS-203

The raw signal may be measured at the PS-203 by connecting a DC mA meter to test points TP11 (-)
and TP14 (+), and pressing SW7. Raw signal readings would usually be taken with the instrument in
air, and process fluids at either end of its measurement range, as available.

5.1.2 RAW SIGNAL READINGS AT THE "HOCKEY PUCK"/HOCKEY PUCK TESTS

The raw signal may be measured at the transmitter "hockey puck" as follows: remove the puck (pull
it straight out); disconnect the wire connected to the "I" terminal; insert the probes of the DC mA
meter into the test points on the top of the puck. Readings are taken under the following conditions:

1. Air unplugged: nothing touching either of the banana plugs on the puck

2. Short circuit: the two banana plugs touching the bare metal on the threads of the junction
box (or a screwdriver, for example.)

3. Air (plugged in): re-install the puck into the OW instrument, antenna in air

4. Process fluids: puck installed, antenna in process fluids at either end of the measurement
range of the instrument, as available.
NOTE: Water-continuous fluids must be flowing during the measurement.

* Re-connect the "I" wire after completing the tests.

5.2 ANTENNA TEST

With the OW-101/OW-102 it is possible to verify the condition of the antenna by using an
ohmmeter. Remove the transmitter PCB and read resistance between the antenna jack and the metal
enclosure (ground). The resistance should be greater than 20 MΩ (20,000,000 ohms). Failure of the
antenna "O" rings could cause process fluid to create a short circuit between the antenna and ground.
Physical damage to the antenna coating will cause a very low resistance reading when the antenna is
in water or brine.

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6.0 PROCEDURE FOR RETURNING MATERIALS TO AGAR

If the equipment is not operating as required, before returning, contact your agent or the Agar
Corporation Applications Department. It is possible to diagnose and resolve most difficulties
without removing the instrument.

Agar Corp.: TEL: (713) 464-4451

* After the voice-mail system answers, press ZERO and ask to speak with an
Applications Technician.
FAX: (713) 464-7741

BEFORE CALLING:

1. Re-check the wiring.

2. Read the troubleshooting section on the previous page and make a note of the voltage and raw
current readings.
3. Obtain the serial number and model number of the instrument. These are stamped on the metal
tags which are attached to the probe junction box, and the power supply enclosure.

The Applications Technician will require the above information in order to provide instructions for
returning materials.

The Applications Technician will determine whether on-site service is required, or which
components of the unit need to be returned.

A returned materials authorization (RMA) number will be issued. Together with return address for
identification purposes, all material returned (either under warranty or for repair) must be
accompanied by:

1. RMA number issued by the AGAR technician. (Material not bearing this number on the
outside of the package will be returned unopened.)

2. An order authorizing us to:

a. Inspect and advise for further instructions.

b. Inspect, repair and advise for instructions.
c. Inspect, repair and return.

3. A Material Safety Data Sheet (MSDS) for all substances with which the instrument has been in
contact.

Please provide a contact name, address and phone/fax number on all returned goods.

On-site service by an AGAR technician can also be arranged by the Applications department.

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7.0 ADDENDUM: DRAWINGS AND DIAGRAMS

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