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Model 415C & 415SGS Instruction Manual

 

D01669102 

 

April 2019, Revision A 

41  

8 

Maintenance and Troubleshooting 

Troubleshooting and regular maintenance procedures are described in this section. 
If more extensive maintenance or service of the instrument is required, please 
contact Fann Instrument Company. 

Consistometers can be relatively reliable and trouble free - provided they are 
serviced and maintained properly.  Instruments that are neglected and receive 
infrequent service or are subject to abuse are certain to cause trouble. Poly-paks™ 
and o-rings are important to reliable pressure sealing. If these components are free 
from debris and scratches/dents, reliable sealing will be easily achieved.   

1.

 

Inspect the pressure vessel’s o-rings after each test and wipe free of cement 
particles and other debris. Do not use sharp objects, such as screwdrivers, 
when removing the o-rings as it will likely tear or scratch the o-ring. 

2.

 

It is recommended to apply an anti-seize compound to all threads 
occasionally. Fann has done this on all required surfaces initially and re-
application should be on an “as-needed” basis. 

3.

 

The mineral oil in the reservoir should be drained and replaced when it 
becomes dirty.  To thoroughly clean the reservoir, the entire unit may be 
taken out of the instrument and the bottom removed.  Mineral oil may be 
conveniently added by pouring oil into the top of the reservoir.  The mineral 
oil supplied with the instrument has an open cup flash point of 
approximately 188°C/370°F.  

4.

 

The magnetic drive should be flushed with clean solvent periodically and 
whenever cement flows into the upper plug or particles contaminate the 
drive. If cement enters the magnetic drive, it will cause the bearings to wear 
quickly.  If the worn bearings are not replaced, it may cause the inner 
magnetic drive shaft to wear out prematurely. Worn bearings may also 
cause incorrect consistency measurement. 

8.1  Slurry Cup Bottom Removal and Reinstallation 

It is recommended that the slurry cup bottom not be removed frequently. It should 
be removed, serviced and reinstalled only when necessary such as when there is a 
leak through the slurry cup bottom. 

1.

 

Locate the wrench multi-tool and 3/8-24 bolts 

2.

 

Lock pressure vessel securely into bench mounted chain vice or suitable 
clamping mechanism. Example shown below.  

3.

 

Place “SLURRY” labeled section of tool over the slurry cup bottom notice 
the two holes in the wrench align with the two threaded holes on the plug. 

Summary of Contents for 102538946

Page 1: ...ann Instrument Company Model 415C 415 SGS HPHT Pressurized Consistometer and Cement Consistometer with Gel Strength Analyzer Instruction Manual Manual No D01669102 Revision A Instrument No 102547776 102538946 ...

Page 2: ...ered by U S Patents Fann Instrument Company reserves the right to make improvements in design construction and appearance of our products without prior notice FANN and the FANN logo are registered trademarks of Fann Instrument Company in the United States and or other countries All other trademarks mentioned in the operating instructions are the exclusive property of the respective manufacturers C...

Page 3: ... Electronic Controls 13 5 1 Hydraulic Pressure Controls 13 5 2 Pneumatic Controls 13 5 3 Electronic Controls and Displays 14 6 Using the Touchscreen Software 15 6 1 What is a touch screen and how does it work 15 6 2 Using the Touch Screen 15 6 3 What can you do with the touch screen software 15 6 4 One Key Recovery for the Computer 15 6 5 Software Upgrades 16 6 6 Using the USB Port and the Printer...

Page 4: ...lurry Cup Plug from Pressure Vessel 38 7 5 Slurry Removal 39 8 Maintenance and Troubleshooting 41 8 1 Slurry Cup Bottom Removal and Reinstallation 41 8 2 Paddle Shaft and Paddle 42 8 3 Slurry Cup Plug Disassembly and Reassembly 43 9 Warranty and Returns 48 9 1 Warranty 48 9 2 Returns 48 ...

Page 5: ...in maintaining a constant rpm The rotational force is proportional to the consistency of the cement slurry and is measured through the servo drive and customized software The consistency is indicated and displayed on a plot generated by the data acquisition system DAQ The consistency values are recorded in Bearden Units of consistency Bc Fann pressurized consistometers are equipped with a state of...

Page 6: ...conomical and powerful tool for any laboratory Critical static gel strength CSGS is the specific static gel strength of a cement in which hydrostatic pressure equilibrium is reached between the decayed hydrostatic pressure transmission of the cement column and other fluids in the annulus and the pore pressure of the formation CSGS is measured in pascals or newtons per square meter pounds force per...

Page 7: ...to avoid undesirable consequences MANDATORY ACTION Gives directions that if not observed could result in loss of data or in damage to equipment WARNING Describes an unsafe condition or practice that if not corrected could result in personal injury or threat to health ELECTRICITY WARNING Alerts the operator that there is risk of electric shock HOT SURFACE Alerts the operator that there is a hot sur...

Page 8: ...shut off the compressed air supply to the machine and carefully relieve air pressure from the machine 2 2 Safe Heating Before opening the pressure chamber use the cooling system to lower the temperature to at least 120 F 49 C The machine uses domestic water as coolant Shut off the domestic water supply before servicing NEVER operate the heater on an empty chamber The heater element will quickly ov...

Page 9: ...eight 15 in 38 cm Width single 26 in 67 cm Depth 15 in 38 cm Weight single 150 lb 68 kg Environmental Operating Temperature 32º to 105º F 0 40º C Operating Humidity 0 95 noncondensing Heater Heater Power 1500W Utilities Water and Air Compressed Air 80 150 psig 5 4 10 2 bar Must be water separated and filtered Cooling Water Pressure 100 psig 6 8 bar maximum Must be filtered and sediment free Utilit...

Page 10: ...ld damage copper stainless steel plastic or Teflon 4 1 1 Connecting the Drain Line Connect the drain line to the connector labeled Coolant Drain on the rear panel of the instrument The drain system must be capable of handling hot water up to 212 ºF 100 ºC or brief surges of up to 400 º F 204 º C steam for short periods of time during initial cooling of the instrument If two or more RP Consistomete...

Page 11: ...ntrol box These connections include a 15 pin SVGA cable USB and AC 120 240VAC power The touchscreen power should be powered by the instrument and not into a separate power source prevent electrical ground loops If a printer is included with the instrument it may be connected to the rear of the control box Connect the USB connector on the printer cable to an available USB port on the control box Th...

Page 12: ...at the jumper cable 4 3 Pressure Vessel Installation The pressure vessel is shipped separately from the instrument locate the pressure vessel assembly and the motor drive assembly The pressure vessel is installed into the heater block by carefully sliding it in from the top A thermocouple is contained inside the instrument The thermocouple must be inserted into the bottom sidewall of the pressure ...

Page 13: ...d be opened following the test procedure to vent pressure from the slurry vessel Use caution when opening this valve when the slurry is still very hot 150ºF Opening the valve will cause oil and possibly cement to vent from the pressure vessel into a supplied plastic container on the back of the instrument If the test pressure is exceedingly high then slowly open the valve to release pressure to a ...

Page 14: ...POWER controls electrical power to the entire instrument Nothing else is operable if this switch is not on including the touchscreen software The touch screen is used to control temperature and motor speed display a plot of consistency and temperature as a function of elapsed time and perform various operations A thermocouple is plugged into the THERMOCOUPLE connector located on the middle wall in...

Page 15: ...interface to the instrument All instrument operations are accessed and controlled through the touch screen This consistometer is a leap forward in design because it is the first time that mechanical control has been eliminated from the point of view of the operating technician Filling and draining the pressure vessel with oil heating and cooling pressurizing and depressurizing and rotational speed...

Page 16: ... delete it and restore Old exe to the original However we recommend you only upgrade your system with the expressed permission of a Fann engineer 6 6 Using the USB Port and the Printer The instrument is equipped with a Universal Serial Bus USB port on the front panel that allows the use of a USB memory stick for mobile storage The memory stick is a flash disk that can be connected to the USB port ...

Page 17: ... your instrument The cooling button is located on the main screen and is operated by selecting it to turn it on Select again to turn off The cooling button is connected to a solenoid valve which is connected to the cooling input located on the back of the instrument Typically water is used at house pressure and temperature However you may also connect a circulating chiller If cooling is turned on ...

Page 18: ...9 Revision A 18 6 8 Instrument Setup Figure 6 2 Software Screenshot The instrument setup button takes the user to the instrument setup screen shown From this screen the user may perform a variety of operations and change options 6 8 1 Calibrating Temperature ...

Page 19: ...bration signal changes When the low data point has been entered press the SAVE LOW VALUE button The user can now enter the high data point on the calibrator and then again on the touchscreen as before The raw value should be different for the low and high data points or there will be a computation error After the high data point has been established press the SAVE HIGH VALUE button We recommend us...

Page 20: ...e calibration signal changes When the low data point has been entered press the SAVE LOW VALUE button The user can now enter the high data point on the calibrator and then again on the touchscreen as before The raw value should be different for the low and high data points or there will be a computation error After the high data point has been established press the SAVE HIGH VALUE button We recomm...

Page 21: ...er pulley 7 Attach the 50g hook weight 8 Add additional 50g for total of 100g to the hook weight 9 Start the motor On the touchscreen in the box labeled LOW DATA POINT input 9 on the touchpad Select SAVE LOW VALUE Turn motor off Do not allow cord to become jammed in motor 10 Add an additional 500g for a total of 600g to the load 11 Start the motor On the touchscreen inside the box labeled HIGH DAT...

Page 22: ...l Strength Calibration Procedure The gel strength meter which indicates static gel strength development should be calibrated by using the consistency mechanism calibrator This device applies a known torque to the motor mechanism allowing the Static Gel Strength equivalent to be resolved on the PC Calibration of the gel strength is described in the example below CementLab automatically adjusts moto...

Page 23: ...on string make sure there is not excessive movement Wait 10 minutes to allow the motor to warm up 12 On the touchscreen inside the box labeled HIGH DATA POINT input 600 on the touchpad Wait a moment for stabilization and select SAVE HIGH VALUE 13 On the bottom of the screen ensure that the CALIBRATED VALUE is reading 600g 25 and press SAVE 14 Remove the weight and the string calibration is finishe...

Page 24: ...02 April 2019 Revision A 24 Figure 6 5 Software Screenshot 6 8 5 Print Report A copy of the calibration time and date for temperature pressure and consistency may be exported to an attached printer or saved as a jpg file An example is shown below ...

Page 25: ...s and always on If a test is started while cooling is still activated the test will not heat even if it is programmed to heat In other words cooling must be deactivated if a test is to be started even if it is still in automatic mode 6 8 7 Sample Rate This button allows the user to select a sampling rate for taking data Rate is given in number of seconds between samples To save data space and achi...

Page 26: ...ccessible from the instrument To permanently delete these files the user must go to their stored location and delete them manually The default location for Fann test files is C Fann Tests This folder also stores the actual test parameters so any test deleted cannot be run again without reprogramming TEST SETUP 6 8 10 Auto Export This button allows users to store test files in a completely differen...

Page 27: ...ontrol Temperature is automatically controlled by programing a temperature ramp into the software To create a new temperature profile either select that button or just above select the graph with the red temperature line The program temperature screen is shown below Enter desired set point values by touching the SET POINT parameter box and entering the values on the keypad Time to set point is sel...

Page 28: ...ramp is displayed for confirmation Press ACCEPT to save ramp or CANCEL to exit without saving as shown Figure 6 9 Software Screenshot 6 9 2 GEL Hesitation Squeeze On units equipped with the gel strength and hesitation squeeze options those are accessed using the button labeled GEL Hesitation Squeeze Pressing this button will bring up the screen shown ...

Page 29: ...ents that have been programmed for 999 minutes At least two segments must be programmed to function correctly A preview of the schedule will be shown for approval as shown Here the first segment was started in Bc mode for 45 minutes then STOP mode for 20 minutes and then GEL mode for the remainder of the time which is typically programmed as 999 minutes Typically an SGS test is programmed per API ...

Page 30: ...omplete Select view test and select the test file to be chosen Then select the PRINTING tab on the left hand side and sample properties can be seen and values edited accordingly Figure 6 11 Software Screenshot 6 9 4 Alarms Consistency and time alarms can be added to and deleted from a test setup These alarms produce audible alerts and are displayed in the test printout An example of programmed ala...

Page 31: ... In other words your testing temperature will need to be controlled downwards below ambient temperature Effectively what happens is that the cooling solenoid is being opened and closed to allow more cooling fluid to flow through the heating jacket This also stops any heater input Below ambient tests necessitate that you connect a suitable cooling fluid properly chilled for the capacity required Fa...

Page 32: ...ame This will be the test file name and will be stored in the tests folder located on the C drive An example is shown Choose a descriptive test name and select save Once you have performed this action the software is ready and programmed for that specific test The next action would be to start test If a test setup is not performed prior to starting a test the previous test file will continue to be...

Page 33: ...alarm values entered in test setup that are printed with each plot In addition to the automatic consistency shutdown there is a timed shutdown It is necessary to select the number of hours from the drop down box that is required for a timed shutdown SGS alarms greater than 600 lbf 100 ft2 may allow the test to show the break of the SGS bond to the slurry cup causing the graph to fluctuate down to ...

Page 34: ...es The color of the curve may also be edited using the Color box These custom settings are shown 6 12 3 Data Tab The data tab displays the test file name and date recorded at the top of the screen The data tab also displays all data for each sample point including time HH MM SS consistency Bc Gel lb 100ft2 if option is equipped on the instrument Temperature units optional and Pressure units option...

Page 35: ... Be certain the thermocouple is fully seated and reliably in place Failure to verify this configuration may result in either a temperature run away or a test error and a stop Refer to the following section Thermocouple Retainer for those pressure vessels with threaded ports 8 Mix the slurry and fill the slurry cup with paddle in place Fill to approximately just above the paddle 9 Install slurry cu...

Page 36: ...he motor assembly onto the slurry cup plug and tighten the associated set screws to prevent it from being dislodged or wobble 17 Press START TEST 18 Activate AUTO SHUTDOWN and select desired shutdown value Be careful not to over pressure the cylinder As the heat increases during a test so does the pressure Pressure is not released automatically and requires that the pressure be monitored and adjus...

Page 37: ...xtreme care in removing the slurry head as the two metals will be more prone to seizing Slurry head and or pressure vessel damage can be avoided by allowing the two temperatures to equalize somewhat before removal of slurry head 7 3 Thermocouple Retainer On some pressure vessels the bottom has a threaded thermocouple retainer which must be used correctly to help prevent the thermocouple probe from...

Page 38: ... head to dislodge from the cup 5 Slowly apply increasing air pressure to move head The head may eject with a pop or gently ease out of the slurry cup The cap will stop the head from coming completely off the cup 6 Undo the head removal nipple and remove the slurry cup cap 7 Remove the head from the cup using caution 8 If the head does not come loose it may be necessary to reinstall the slurry cup ...

Page 39: ... until slurry is sufficiently hardened to allow removal in one piece 2 Place slurry cup in a vise with slurry above waste container or table 3 Remove the paddle retaining bolt from bottom plug 4 Insert cement removal bolt Long brass bolt similar to the paddle retaining bolt 5 Continue to screw in the cement removal plug until the slurry is easy to pull out by hand ...

Page 40: ...m plug 4 Insert slurry ejection bolt Ejection bolt should have air fitting Schrader valve inserted into center hole 5 Using hand driven air pump apply pressure to the cement plug using caution to properly secure cement plug when it exits the slurry cup Use safety gear not limited to eye face hand and foot protection 6 Cleanup slurry cup with soap and water There is no need to remove bottom plug un...

Page 41: ... in the reservoir should be drained and replaced when it becomes dirty To thoroughly clean the reservoir the entire unit may be taken out of the instrument and the bottom removed Mineral oil may be conveniently added by pouring oil into the top of the reservoir The mineral oil supplied with the instrument has an open cup flash point of approximately 188 C 370 F 4 The magnetic drive should be flush...

Page 42: ... ring and reinstall it If o ring is too difficult to install try heating the o ring in warm water to soften it Be careful not to burn yourself A moderate amount of warming will soften the o ring enough to make installation easier 9 Use wrench to re install the slurry cup plug Confirm the use of anti seize and red grease Bottom of the slurry cup plug must be fully flush with the bottom of the press...

Page 43: ...e slurry cup plug Take care to not spill any oil Typically this can be done over a spill catch or sink 4 Remove the ball bearing and upper bearing retainer 5 Remove the inner mag drive assembly by rotating counter clockwise and gently pulling up The Poly pak fits very tight around the shaft and will want to roll on itself unless an unscrewing action is used 6 Remove ball bearing 7 Insert retainer ...

Page 44: ...ve to prevent spinning 5 Gently anti seize the outer threads of the slurry cup plug where the outer magnetic drive housing threads onto it 6 Replace the nut and plug onto the outer mag drive 7 Place upper bearing retainer and bearing correctly into the outer mag drive housing Orient the mag drive housing so they do not fall out 8 Fill the outer mag drive 1 3 full with mineral oil 9 Without spillin...

Page 45: ...sel has trapped air Bleed all air from lines by manually pushing oil through tubing Oil reservoir is empty Fill reservoir with oil Faulty pump check valve Clean and or overhaul pump outlet check valve No air supplied to air operated valve if so equipped Check air lines leading to valve Check valve solenoid valve Restore air supply Pump builds and maintains pressure to a certain level then stops If...

Page 46: ...cuit in thermocouple Replace thermocouple Open circuit in thermocouple circuitry Check thermocouple circuitry for open circuits or loose connections Temperature is overshooting The instrument is optimized for higher temperature operation and may have difficulty at temperatures just above ambient Program a dual ramp instead of one single ramp Also check the supplied voltage to the machine as higher...

Page 47: ...415SGS Instruction Manual D01669102 April 2019 Revision A 47 Symptom Cause Remedy started Then close the nut Add oil if necessary Or disassemble the slurry cup plug and reassemble following maintenance guidelines ...

Page 48: ...in its catalogs literature or brochures of materials used in the manufacture of its products Fann reserves the right to substitute other materials without notice Fann does not warrant in any way equipment products and material not manufactured by Fann and such will be sold only with the warranties if any that are given by the manufacturer thereof Fann will only pass through to Customer the warrant...

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