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Model 2040 Automated HTHP Consistometer

#120-40 - Consistometer

#120-40-DAS - With Computer

Instruction Manual

Updated 3/22/2021

Ver. 1

OFI Testing Equipment, Inc.

11302 Steeplecrest Dr. · Houston, Texas · 77065 · U.S.A.

Tele: 832.320.7300 · Fax: 713.880.9886 · www.ofite.com

Summary of Contents for 120-40

Page 1: ...ter 120 40 Consistometer 120 40 DAS With Computer Instruction Manual Updated 3 22 2021 Ver 1 OFI Testing Equipment Inc 11302 Steeplecrest Dr Houston Texas 77065 U S A Tele 832 320 7300 Fax 713 880 988...

Page 2: ...arting a Test 9 Completing a Test 10 Setup 11 Software 16 General Setup 16 Setup 17 Profile Builder 19 Main Screen 21 Events 24 Calculated Values 25 Onboard Display 26 Real Time Data 27 Test Setup Tes...

Page 3: ...44 Oil Filter 45 Pressure Relief Valve Regulator 46 Troubleshooting 47 Calibration 51 Potentiometer 51 Value Chart 53 Pressure 54 Temperature 55 Appendix 56 Metal Seal Ring Installation 56 Cell Diagra...

Page 4: ...rry cup assembly A potentiometer controls an output voltage which is directly proportional to the amount of torque the cement exerts upon an API approved paddle The included software controls the inst...

Page 5: ...slurry cup stand slurry cup tool lifting tongs for heater shield and lifting tongs for potentiometer 120 103 Rupture Disk 45 000 PSI 310 MPa 120 201 Thermocouple Bath 120 203 Thermocouple Slurry Cup 1...

Page 6: ...Disk 120 510 Drive Bar 120 512 Drive Pin 120 513 Gasket for Bottom Cap 120 514 Drive Disk Set Screw 6 32 3 Stainless Steel Optional 120 40 SP Spare Parts Kit 120 001 Mineral Oil 1 Gallon Qty 2 120 10...

Page 7: ...120 602 Calibration Spring Qty 3 120 604 Potentiometer Resistor Qty 4 120 606 Potentiometer Contact Arm Qty 6 120 607 Contact Strip Qty 6 120 608 Grounding Cable 120 684 Bearing Bronze Large Qty 2 122...

Page 8: ...f the hazard and any actions which have to be taken Hot This symbol indicates that a surface may be hot to the touch Shock Hazard This symbol indicates a risk of electrical shock Note This symbol will...

Page 9: ...connection cables and mains cable Do not subject connection or mains cables to high temperatures higher than 70 C Check integrity of cables at regular intervals The unit must be powered down before an...

Page 10: ...for the next test 8 Plug the thermocouple into the port near the test cell Insert the thermocouple into the hole in the top of the cell cap and tighten the thread gland finger tight and loosen it of...

Page 11: ...s reached 150 F turn the PUMP switch off and slowly open the Pressure Release valve Never release pressure while the temperature is above 200 F 93 3 C 5 Turn the FILL DRAIN CELL switch OFF for 5 secon...

Page 12: ...upply on the back of the instrument This unit uses NPT female connectors for all supply lines 4 Connect the drain and coolant supply lines also on the back of the unit 5 The consistometer has two powe...

Page 13: ...iters or until full of oil into the reservoir Replace the cap Make sure the seal is air tight Use the sight glass on the front to check the oil level Mineral Oil 120 001 is recommended for tests up to...

Page 14: ...plecrest Dr Houston TX 77065 USA Tel 832 320 7300 Fax 713 880 9886 www ofite com 13 Onboard Display USB Port Switches Cell Pressure Scroll Wheel Thermocouple Port Cell Cap Thermocouple Storage Pressur...

Page 15: ...uctions on setting these values The Status Indicator also indicates an alarm condition If an alarm is triggered all three lights on the status indicator will blink until the alarm is acknowledged Swit...

Page 16: ...unning no pressure will be applied OFF No pressure will be applied ON The pump can be controlled by the software or onboard display in Manual mode see 33 Thermocouple The Consistometer uses two thermo...

Page 17: ...ge Devices screen appears right click the device from the list and select Set as Default Then click Done Make sure to enable the appropriate communication method for your de vice If you have connected...

Page 18: ...optional 3 On the Configuration tab set the following parameters Temperature Control The instrument has two thermocouples One is in the cement sample in the cell The other is in the heating jacket Ba...

Page 19: ...rofile are complete DAQ Rate Set the interval for data points to be recorded hh mm ss Temp Unit Choose either F Fahrenheit or C Celsius Press Unit Choose units for cell pressure psi or MPa Status Ligh...

Page 20: ...4 Each test profile has three parameters temperature pressure and motor speed For each parameter there is a series of steps Each step specifies the setpoint and other options for that parameter To ad...

Page 21: ...e time hh mm ss into the Time Box The maximum temperature setpoint allowed is 600 F 315 6 C The unit allows pressure setpoints up to 40 000 psi 275 8 MPa The units of measure will be the same as enter...

Page 22: ...320 7300 Fax 713 880 9886 www ofite com 21 The software has a set of five tabs Each tab shows different information The Info tab shows the test information The Profile tab shows a graph of the Test P...

Page 23: ...11302 Steeplecrest Dr Houston TX 77065 USA Tel 832 320 7300 Fax 713 880 9886 www ofite com 22 The Chart tab shows a graph of the current test conditions The Log Data tab shows the data for the current...

Page 24: ...OFITE 11302 Steeplecrest Dr Houston TX 77065 USA Tel 832 320 7300 Fax 713 880 9886 www ofite com 23 The Events Cal Values tab shows any calculated values or events that have been triggered...

Page 25: ...gth Transition Time Expansion 2 Enter the Value you want to test for For example if your Signal is Tem perature then a Value of 100 represents 100 3 Enter the time in seconds you want the Signal to be...

Page 26: ...a Calculation At Time Calculate the value of the Signal at a specific test time Time When Calculate the time when the Signal reaches a specified value Signal Min Calculate the minimum Signal value fo...

Page 27: ...s it possible to run the instrument without an external computer The display can be operated either as a touch screen or with the control wheel To operate the display with the Control Wheel 1 Turn the...

Page 28: ...fite com 27 The Real Time Data screen is the default screen When the display has been idle for more than 2 minutes it will automatically revert to this screen Here you can see the current test paramet...

Page 29: ...g 2 Enter a consistency value in Bc for each threshold Signal LED G Y When the consistency reaches this level the green and yellow lights will come on Signal LED Y When the consistency reaches this le...

Page 30: ...re up to the target in a set number of minutes Enter the ramp time and target Step This will increase the temperature or pressure up to the target as fast as possible Enter the target temperature or p...

Page 31: ...een the onboard display can calibrate the pressure transducer thermocouple and potentiometer It can also perform a Drag Check 1 Select the system Pressure Temperature Consitency to calibrate 2 Follow...

Page 32: ...s two thermocouples One is in the cement sample in the cell The other is in the heating jacket Bath Use this option to determine which thermocouple will be used to control the temperature Sample is re...

Page 33: ...e status of the inserted drive a Green The drive is inserted and supported b Amber The drive is inserted and supported but low on free space c Red The drive is inserted but not supported Make sure the...

Page 34: ...MOTOR must be set to MANUAL 1 On the left hand side of the screen choose Temperature Pressure or Motor 2 Enter the setpoint in the box 3 Select SET when done When setting the temperature with Manual...

Page 35: ...al board Before pressing the Start Test button be sure to configure your test parameters on the Test Setup screen see page 29 or in the PC software see page 19 Also note when saving settings in the on...

Page 36: ...er 120 502 1 1 With the slurry cup disassembled examine the threads on the inside of the sleeve The end with the larger set of threads is the top 2 Coat the top and bottom threads of the slurry cup wi...

Page 37: ...o the o ring and base surface Screw the base onto the cup and tighten with the slurry cup tool The slurry cup should contain enough cement slurry that it leaks out of the hole in the center of the bas...

Page 38: ...age with the contacts on the inside of the test cell The slurry cup and potentiometer both have two holes near the top for the lift tongs provided Use the lift tongs to easily lower the slurry cup and...

Page 39: ...LING PUMP and POT VOLTS switches to AUTO 12 Load the test a If you will be using the software to run the test select a Test Profile and click the Start Test button on the Main Screen see page 21 b If...

Page 40: ...ver release pressure while the temperature is above 190 F If the pump switch is in the automatic position the consistometer will maintain pressure above 5 000 PSI as long as the temperature above 190...

Page 41: ...e cell and clean off any excess cement that has accumulated on the shaft It is recommended that you periodically flush the test cell with mineral oil to clean out any contaminants that may have collec...

Page 42: ...eath the test cell before beginning another test Filters The instrument has an air filter and an air dryer Both are located inside the cabinet on the left hand side see photo on page 44 Periodically c...

Page 43: ...s Contact Arm Shaft Bearing Retainer Calibration Spring Resistor Set Screws 2 To install a new resistor a Remove the four small screws holding the shaft bearing retainer to the potentiometer assembly...

Page 44: ...the contact arm and the shaft bearing retainer b Carefully lift the calibration spring from the potentiometer assembly c Install the new spring When properly installed it should tighten when the cent...

Page 45: ...rupture disk to prevent damage due to over pressurization If the pressure inside the cell exceeds 45 000 50 000 PSI the disk will rupture and release the pressure If this happens the cell cannot be pr...

Page 46: ...e filter element from inside the housing 4 Clean the filter element with compressed air This will blow out any dirt and debris 5 Carefully place the filter element back inside the housing 6 Screw the...

Page 47: ...037 which controls the air pressure to the pressure relief valve This regulator comes calibrated and requires no adjustment unless a part within this system has been replaced If the user must gain acc...

Page 48: ...The unit is not heating The heater switch is not on The heater circuit breaker has tripped The Solid State Relay SSR is bad The unit is running on bat tery backup Turn the heater switch on Check and r...

Page 49: ...ake sure the cooling switch is set to Auto or On Make sure the Heat switch is Off Make sure the cooling lines are free from obstructions The cooling solenoid is not functioning Contact OFITE Replace t...

Page 50: ...et to Drain Not enough oil in the reservoir No air supplied to the unit Air filter is full of water The air filter is full of water Air solenoid is damaged Replace the cell cap o ring Trace the tubing...

Page 51: ...edge is flat and level Use an emery cloth to clean the upper and lower edge of the resistor Replace the contact pin Contact OFITE Tighten the potentiometer shaft Tighten the drive bar The consistency...

Page 52: ...he calibration stand Place the stand on the edge of the Consistometer and plug it into the port on the underside of the control panel Potentiometer Calibration Stand Weight in Groove Calibration Stand...

Page 53: ...of the calibration stand to settle the weights and stabilize the potentiometer When adding weights remember that the hook weighs 50 grams Therefore to test the potentiometer at 200g you only need to...

Page 54: ...n Value Chart Torque Equivalent g cm Mass of Reference Weights g 0 1 g Slurry Consistency Bc 5 260 50 9 520 100 22 780 150 35 1 040 200 48 1 300 250 61 1 560 300 74 1 820 350 87 2 080 400 100 a For a...

Page 55: ...at least yearly or whenever the pressure transducer has been replaced 1 Connect a calibrated pressure gauge to the thermocouple port in the cell cap 2 Start the calibration procedure a For onboard co...

Page 56: ...The thermocouple will require calibration quarterly or if it is replaced 1 Place the thermocouple in a dry block calibrator 2 Start the calibration procedure a For onboard control touch Calibrate and...

Page 57: ...st enough to prevent the cell from leaking If the o ring is over crushed the upper surface of the o ring will be level with the inside lip This will prevent the mandrel from making a good seal and kee...

Page 58: ...l the cell with oil and perform a pressure test Manually increase the pressure in steps of 5 000 PSI up to 25 000 PSI Hold the pressure at each step for 10 minutes to ensure that the cell is not leaki...

Page 59: ...nal check to make on the cell o ring will be to physically check and make sure the upper surface of the o ring sticks up above the o ring ledge around the entire circumference of the cell If the o rin...

Page 60: ...Ring 120 40 704 Heater Shield 120 35 057 Heater Assembly 120 212 Mag Drive Table 120 147 017 Cell Body 120 40 701S Handle 120 00 112 Metal O ring 120 401 Metal O ring for Mag Drive 120 147 014 Cell St...

Page 61: ...515 Diaphragm Retaining Ring 120 508 Paddle Pin 120 503 Sleeve 120 501 Base 120 516 Drive Pin 120 512 Pivot Bearing 120 504 Drive Bar 120 510 Drive Disk Set Screw 120 514 Paddle Shaft 120 520 Molded D...

Page 62: ...Drive Disk 120 509 Locking Ring 120 517 Diaphragm Support 120 515 Diaphragm Retaining Ring 120 508 Paddle Pin 120 503 Sleeve 120 501 Base 120 516 Drive Pin 120 512 Pivot Bearing 120 504 Drive Bar 120...

Page 63: ...618 Pivot Arm 120 615 Spring 120 602 Spring Adjuster Stand Assembly 120 617 Resistor 120 604 Contact Spring Yellow 120 605 3 Contact Strip 120 607 Body 120 603 4 Bearing 120 620 7 1 WHS Nut 4 40 3 16...

Page 64: ...the consistometer 2 Loosen the three set screws on the bottom of the potentiometer 3 Locate the spring holder on the top of the potentiometer It may be positioned beneath the shaft bearing retainer Pu...

Page 65: ...it could be that the fuse for the main power supply is blown or that the main circuit breaker has tripped 1 Check the breaker switches and make sure they are in the on position 2 Open the fuses holde...

Page 66: ...ram Files x86 folder 3 Locate the HTHP Consistometer folder and select it 4 Hold down the CTRL key and then hit C Then hold down the CTRL key and hit V This will create a duplicate of the folder calle...

Page 67: ...ny losses or damages that occur as a result of Improper installation or maintenance of the products Misuse Neglect Adjustment by non authorized sources Improper environment Excessive or inadequate hea...

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