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fann 640, Instruction Manual

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  Model 640 & 640CC Instruction Manual

 

D01206676 

Revision A February 2016 

30  

10.

 

Remove some weight and check the CALIBRATED VALUE.  If the values 
are correct, calibration is complete.  If the values are incorrect, repeat steps 
making adjustments to Potentiometer Mechanism as required. Refer to Table 
11-1 for weight to Bc conversions for your pot-mech. 

 

Table 11-1 Consistency as a Function of Weight vs Torque*  

 

Weight (g) 

Consistency (Bc) 

0 

-4 

50 

9 

100 

22 

150 

35 

200 

48 

250 

61 

300 

74 

350 

87 

400 

100 

* Based on the equation from API Spec 10, Section 8.2T = 78.2 + 20.02 Bc 
T = Torque, g.cm 
  Bc = Bearden units of slurry consistency 

 

 

By applying additional weights between 0 and 400g and plotting 
consistency display as a function of applied weight, the linearity 
of the potentiometer mechanism may be assessed. 

 

 

 

Summary of Contents for 640

Page 1: ... 2016 Fann Instrument Company HTHP Consistometer Model 640 640CC Instruction Manual Manual No D01206676 Revision A Instrument No 102538936 Model 640 102546634 Model 640CC ...

Page 2: ... apparatus which may be covered 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...

Page 3: ... Calibrate Pressure 15 6 5 Sample Rate 15 6 6 Units 16 6 7 Archive Data 16 6 8 Edit Instrument 16 7 Test Setup 17 7 1 Temperature Control Pressure When Available 17 7 2 Hesitation Squeeze 18 7 3 Optional Parameters and Profile Saving 19 8 Start Test 20 8 1 Live Testing Screen 20 9 Stopping a Test 21 9 1 Software Upgrades 21 9 2 Using the USB Memory and Printer 21 10 Front Panel Controls 22 10 1 Hy...

Page 4: ... 3 Slurry Cup Maintenance 32 12 4 Changing the Metal O ring on the Cylinder Assembly 33 12 5 Changing Cleaning the High Pressure Filter Element 33 12 6 Replacing the Low Pressure Filter Element 34 12 7 Potentiometer Mechanism Resistor Replacement 34 12 8 Potentiometer Mechanism Spring Replacement 35 12 9 Servicing the Inner Magnetic Drive Shaft 36 12 10 Servicing the Outer Magnetic Drive Rotator 3...

Page 5: ...struction Manual D01206676 Revision A February 2016 5 List of Tables Table 4 1 Model 640 640 CC Specifications 10 Table 11 1 Consistency as a Function of Weight vs Torque 30 Table 13 1 Troubleshooting Model 640 640 CC 40 ...

Page 6: ...A predictable thickening time is desired while maintaining the other specific properties of the cement slurry The thickening time can be measured in a laboratory by testing a sample of the cement slurry in a pressurized consistometer The elapsed time between initial application of pressure and temperature on the slurry sample and occurrence of a predetermined value of consistency usually 100 Beard...

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 Safe Heating 2 2 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: ...tiometer resistor as the spring deflects under load The consistency is displayed on the plot generated by the data acquisition system The consistency values are recorded in Bearden Units of consistency Bc Bearden units are defined in API Specification 10 The consistometer is equipped with one or two devices for post test cooling of the instrument The first is an external cooling coil attached to t...

Page 10: ...m Width dual 51in 129 cm Depth 29in 72cm Weight single 1100lb 500 kg Weight dual 2050lb 930 kg Environmental Operating Temperature 32º to 105º F 0 40º C Operating Humidity 0 95 noncondensing Heater Heater Power 5000W Heater Type Internal tubular with MgO insulation Heater Control Solid state relay Drive Unit Drive Motor 1 8 Hp 93W 180 VDC Drive Speed 25 250 rpm variable Utilities Water and Air Com...

Page 11: ...locations The air and water inlet connections may be made with either metal or plastic tubing It is recommended that the water drain lines be made from metal since this line may carry very hot water and steam from time to time Electrical connections are made using the twist lock receptacle on the rear of the instrument A 50 A female plug is supplied with each dual consistometer and a 30 A female p...

Page 12: ...ment If the instrument is equipped with auxiliary standalone temperature controllers they must be removed from their shipping containers and installed into the sleeves in the front panel Simply slide the controllers into the sleeves and snap them into place In order to protect the internal mechanisms of the pressure gauges the needles are fixed in place with a screw and a small metal bracket This ...

Page 13: ...ted to an A C power outlet One is supplied on the back of the instrument for this Refer to the printer documentation for power requirements A USB flash drive may also be connected to the control box in lieu of a printer Test data may be uploaded to the USB drive and then transferred to a PC for archival storage Refer to section 9 2 for more information on printer and USB drive An optional keyboard...

Page 14: ...ns screwdrivers etc should not be used as they may damage the touch surface A pen like touch stylus has been included in your accessories to use if desired The purpose of the touch screen is to provide the user with a single interface to the instrument Temperature control motor control instrument setup and current test data are accessed through the touch screen This eliminates the need to individu...

Page 15: ...orrect temperature value for the Low Data Point using the touchpad at the right The raw value is the signal read directly off the I O hardware and it should change as the 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 ...

Page 16: ...folder Note that the program will ask for the storage location and the user may browse to any available drive or folder Once the files are copied from the consistometer to the memory stick the files remain on the consistometer and will still be accessible from the instrument To permanently delete these files the user must go to their stored location and delete them manually The default location fo...

Page 17: ...by touching the SET POINT parameter box and entering the values on the keypad Time to set point is selected by touching the TIME parameter box and entering a time in minutes on the touch pad The final segment should always be a SOAK segment where the temperature equals the final test temperature and the time equals SOAK This guarantees the instrument will maintain final temperature for the remaind...

Page 18: ...r Speed Bc select the empty box under Run Time and enter the hesitation start time in minutes using the touch pad a right The Start Time is the elapsed time from the beginning of the test to the first hesitation squeeze start Select Next Ramp to enter first stop The screen will re initialize and you can select STOP for motor speed and enter desired amount of time for STOP segment in Run Time box S...

Page 19: ...e Customer menu by pressing NEW next to the Customer menu and inputting a customer name The customer can then be selected from the drop down Customer menu box The entire profile of any test can be easily saved and recalled by selecting SAVE PROFILE after the profile has been completely configured To recall a saved profile simply select it from the SAVED PROFILES drop down menu and press OK Custome...

Page 20: ...tom header and footer segments of the printed plot Pressing the EXIT button returns the user to the RUN TIME MENU shown below Temperature control may be toggled between AUTO and MANUAL AUTO is recommended Note that establishing a set point significantly different from the current temperature may cause large overshoots in temperature set point If manual temperature control is required it is recomme...

Page 21: ...es Generally the only file that needs to be upgraded is CementLab exe It is located in the C Program Files FANN folder If it is necessary to install an updated CementLab exe file it may be copied from the USB memory stick It may also be copied over a network if the instrument is connected to one To copy the file from a memory stick put the new file on the memory stick rename the old CementLab exe ...

Page 22: ...nd SI units The pressure gauge displays pressure in both English and SI units The PRESSURE gauge is used to display the pressure inside the pressure vessel The PRESSURE RELEASE valve is used to release pressure from the pressurized cylinder The PRESSURE RELEASE valve must also be fully opened to remove oil from the cylinder If it is necessary to fill only one pressure vessel of a dual consistomete...

Page 23: ... an airline may be blocked or the compressor may be insufficient to deliver the volume of air required The air pressure REGULATOR is used to control the air pressure to the air driven hydraulic pump Higher hydraulic pressures require higher air pressures To adjust the pressure of the air supplied to the pump pull the knob on the regulator out to unlock it Turn the regulator knob clockwise to incre...

Page 24: ... primary electrical electronic controls may include the POWER HEATER MOTOR and TIMER switches the pump controls and motor speed adjustments The primary display is the touch screen These controls are discussed in detail below The switch labeled POWER controls electrical power to the entire instrument Nothing else is operable if this switch is not on If available switches labeled HEATER and MOTOR ca...

Page 25: ...pressure control option is installed the unit will be equipped with a three position switch labeled ON OFF and AUTO When the switch is in the OFF position the pump will not run When the switch is in the ON position the pump will run until turned to the OFF position When the switch is in the AUTO position the pump will be turned on and off by the pressure control software This completes our tour of...

Page 26: ...e slurry cup and the potentiometer mechanism pot mech into the pressure vessel and engage the slurry cup to the cup table The motor may be turned on now or at any time using the software selector switch It is not necessary to pound the lid closed with a sledgehammer 7 Close the lid on the pressure vessel Insert the thermocouple but do not tighten thermocouple fitting 8 Turn FILL DRAIN switch to FI...

Page 27: ...en the cylinder is cool enough remove the slurry from the slurry cup before it sets and becomes too hard Press the cement plug out from bottom to top Slurry cups are tapered with the large end at the top This makes it easier to press the cement plug out of the slurry cup Calibration 11 3 The potentiometer mechanism thermocouple and pressure transducer optional should be recalibrated on a regular b...

Page 28: ...alibrator 5 Enter the same temperature value into the LOW VALUE box in CementLab 6 Select SAVE LOW VALUE 7 On the calibrator input 220C or 400F 8 Enter the same number into the HIGH VALUE box in CementLab 9 Select SAVE HIGH VALUE 10 On the calibrator enter 100C or 200F 11 Verify the calibration is reading the same value on the touchscreen 12 Select SAVE or DONE and Exit Calibration screen Pressure...

Page 29: ...ibration of the potentiometer mechanism is described in the example below 1 Set the calibrator near the front edge of the consistometer 2 Install the potentiometer mechanism to be calibrated on the holder Insert the wedge into the open slot nearest the potentiometer ground spring 3 Wind the cord around the potentiometer mechanism frame and over the pulley Place the hanger weight hook in the loop o...

Page 30: ...le 11 1 for weight to Bc conversions for your pot mech Table 11 1 Consistency as a Function of Weight vs Torque Weight g Consistency Bc 0 4 50 9 100 22 150 35 200 48 250 61 300 74 350 87 400 100 Based on the equation from API Spec 10 Section 8 2T 78 2 20 02 Bc T Torque g cm Bc Bearden units of slurry consistency By applying additional weights between 0 and 400g and plotting consistency display as ...

Page 31: ... a friction reducing PTFE coating by the factory to help prevent thread seizing and galling However it is still recommended to apply a molybdenum disulfide anti seize compound to the threads periodically If the transfer of the oil from the pressure vessel to the reservoir is slow the filter needs to be cleaned or replaced 3 The high pressure filter is located in the 3 8 inch stainless steel pressu...

Page 32: ...plastic reservoir otherwise it will run dry and leave the air side of the pump un lubricated perhaps leading to premature failure of the pump Do not pour the lubricating oil into the filter bowl by mistake Potentiometer Mechanism Pot Mech Maintenance 12 2 1 Check upper and lower bearings for smooth friction free operation If bearing operation is not smooth clean or replace the bearings If the bear...

Page 33: ... the Metal O ring on the Cylinder Assembly 12 4 Pry the old o ring out using a plastic or soft metal tool so as not to damage the sealing surfaces 1 Coat the new o ring with a light coating of grease 2 Press the new o ring into the seal groove using your fingers Do not bend or scratch the new o ring 3 Place the plug in the pressure vessel and thread in place until the seal shaft contacts the new o...

Page 34: ... AIR EXHAUST valve 3 Locate the blue low pressure oil filter housing 4 Remove the nut on the top of the filter housing The filter bowl and filter element will come off 5 Replace the filter element with a new element 6 Inspect the gasket and replace if necessary 7 Replace the bowl and filter element and install the nut It may appear that the filter element is too long but the element will be compre...

Page 35: ...y adjust slider by bending it up or down 7 Replace shaft bearing retainer and check the potentiometer mechanism with a calibrating device Potentiometer Mechanism Spring Replacement 12 8 The spring should wind tighter when the slider is moved in the counter clockwise direction 1 Remove shaft bearing retainer and potentiometer Slider 2 Remove old spring 3 Install new spring 4 Replace potentiometer s...

Page 36: ...gh the top of the pressure vessel 2 Unscrew the cup table from the magnet shaft assembly 3 Press the roll pin out of the thrust ring and remove the thrust ring Take care not to bend the shaft Replace the thrust ring if badly worn 4 The upper bronze bearing may now be removed Replace if badly worn 5 Remove the snap ring Replace is corroded or damaged The carbon bearing or the 3 0073 1 Bronze Bearin...

Page 37: ... the retaining ring and slide the bearing out Inspect for excessive runout or rough operation and replace if necessary 4 Removal of the inner magnet sleeve is usually not necessary and is not recommended 5 Assembly is the reverse of disassembly Removal of the Magnetic Drive Housing 12 11 Make certain that the power to the instrument is disconnected before servicing the magnetic drive rotator The r...

Page 38: ...embly 5 Assembly is the opposite of disassembly Heater Replacement 12 12 Heater should be replaced if a hole burns through the sheath or if the heater fails to heat The replacement steps are listed below Make certain that the power to the instrument is disconnected before servicing the heater Severe shock or electrocution could occur if contact is made with a live heater circuit 1 Remove the upper...

Page 39: ...s 10 Clean the bottom of the pressure vessel and the heater holes before installing new heater Assembly is the reverse of assembly A deep socket or a piece of 3 8 inch tubing may be placed over the heater terminals and used as punch to loosen the heater ferrules With the heater gaskets removed from the heater insure that the heater is bent so that it drops through the heater holes with minimal eff...

Page 40: ... ring sealing surfaces and or seal shaft are worn pitted or scratched Lap o ring sealing surfaces Pump strokes but little or no pressure is obtained Valve open severe leak blown rupture disc Locate problem and correct Pressure vessel has trapped air Open thermocouple connector slightly and release trapped air Oil reservoir is empty Fill reservoir with oil OIL SUPPLY valve is closed dual consistome...

Page 41: ...sel or heater spreaders missing Bend heater to sit flush with bore of vessel and add heater spreaders Magnet drive bearings are worn Check bearings on inner magnet shaft and replace if necessary Missing pin on slurry cup base Replace pin or base Slurry cup will not turn Magnetic drive severely contaminated with cement Remove magnetic drive plug and inner magnet shaft and clean magnetic drive thoro...

Page 42: ...f the potentiometer resistor If it is greater than 200Ω replace the resistor Broken or corroded potentiometer connecting strips Replace Broken severely worn or corroded contact springs Inspect and replace if necessary Broken or corroded ground pin Check electrical continuity between ground pin and cylinder If continuity does not exist replace ground pin Faulty CONSISTENCY SPAN potentiometer Check ...

Page 43: ...e circuitry Check thermocouple circuitry for open circuits or loose connections Correct if necessary Oil comes out pump muffler Pump may or may not stroke AIR TO CYLINDER valve has been opened while cylinder is pressurized flooding the airlines and pump pneumatic side with oil Remove air lines and drain oil Remove pump and disassemble pump pneumatic side to remove oil If contamination is not too s...

Page 44: ...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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