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User Manual - Rohrback Cosasco Systems

1. A DD This information furnished withest warranty expressed or implied except that it is accurate te the beat knowledge of Bayer Corporation data on this sheet relates only te the apecific material designated herein Bayer Corperation assumes no legal reaponsibility for use or reliance upon these dala Fraduct Code 9404 MSDS Page Approval date 11 08 95 Last page
2. The vapors of thionyl chloride are strong irritants to tha eyes and respiratory tract Symptoms of exposure include a borning senaalion in the eyes and violent coughing In contact with humid hy regen chloride HCl and aulfur dioxide 502 are predeced which are themselves irritating Significant overexposure to thiemyl chloride vapors and ils related decomposition products which could ercur if a person is trapped or aprayed may cause delayed pulmonary edema CHROMIC EFFECTS EKPUBSURE Chronic owerexpozure to thionyl chloride can cause sywptoms of non ibretic lung imjury similar te other irritating vapors CARCINOGENICITY 2555552255555 This is not listed by IARC or regulated as carcinogen by OSHA MEDICAL CONDITIONS AGGRAVATED BY EXPUSURE 3 Asthma other respiratery disorders bramzhitis breachisl hyperresetivity skim allargieu EXPOSURE 5 Refar to Section Yi EMERGENCT AND FIRST AID PROCEDURES FIRST AID 5 Immediately flush eyes with remming water for at least 15 minutes To assure thorough flughimg of ali eye tissue the eyelids should be held spart during irrigation Fermament eye injury can occur particularly if rinsing is delayed Immediately refer to physician preferably an oye specialist for medical tr
3. CHEF f ae N d SON MildvOv ZZS OL 951 304 Q3 43534 4 DCMSm 532 14 FIOKNMOG 304 Figure 1 2 DHT Carrying Case Layout INTRODUCTION 5 Instrument Body The Instrument Body is normally a 17 4 PH ferritic stainless steel tube designed to contain and protect the main components of the DHT from the hostile environment of the well Instrument Tube Assembly The Instrument Tube Assembly is a stainless steel tube approximately 1 25 dia x 15 1 It has a large probe connector at one end and a small battery connector at the other end The Instrument Tube Assembly contains electronic circuitry which accurately measures the Probe Element and internal temperature sensor Probe Assembly The Probe Assembly is a specially modified CORROSOMETER probe The Probe Assembly contains an element made from the same or similar material as the well bore A reference element of the same material is contained within the Probe Assembly to compensate for resistance changes due to temperature Since the Probe Assembly is very delicate care must be taken to avoid damage WARNING The tip of the Probe Assembly is extremely sharp Handle with care to avoid injury or damage Probe Shield The Probe Shield is used to protect the Probe Assembly from damage and debris in the well and provide as smooth a flow as possible over the Probe Element surface The Probe Shield slides over the Probe Assembly a
4. 13 Assembly 13 DisassemblySegquence RN P 26 Chapter 4 DHT Assembly nnn 29 g os9uirgoleWnr S 29 Assembly Sequencoe ppp 30 Disassembly Sequegeeeee eee 40 ii DCMS Appendix A Lithium Thionyl Chloride Batteries Handling Storage MSDS 45 Emergency ProcedureS pp 45 Emergency 45 Causes of Hazardous Conditions Electrical tercia redi iue ox uen 45 Sate Storage me P 46 Safe ER D dde ias 46 umet E 46 Safe 47 Bits eet 48 Figure 4 1 4 2 4 3 4 4 TABLE OF CONTENTS Figures and Drawings Page Cross Sectional View of Fully Assembled DHT 3 DHT Carrying Case Layout 4 DEMS TOOK E 10 DHT Assembly Drawing pp 30 Mounting Head Adapter O Ring and Back Up Ring Placement 31 Probe Adapter O Ring and Back Up Ring Placement ppp 32 Probe Assembly Attached to Probe Adapter 34 iv DCMS M IMPORTANT INSTRUCTIONS Rohrback Cosasco Systems is committed to providing the safest and highest quality products services and training for the industries it serves We are committed to ensuring that all users of our equipment work safely and efficiently Fully ant
5. 1 Lay the Instrument Tube Assembly and the Probe Assembly on a table or other flat horizontal surface 2 Connect the Probe Assembly to the Instrument Tube Assembly by mating the connector end of the Probe Assembly to the large connector on the Instrument Tube Assembly 3 Carefully rotate the Probe Assembly until the connector keys are aligned and then push in the connectors together as far as possible Step 5 Test DHT Operation with Probe Monitor Use the DHT Probe Monitor P N 724024 as described below to determine if the DHT is operational NOTE Regardless of the preprogrammed time setting the DHT will take the first Probe Element reading about 12 minutes 30 seconds after the Battery Assembly is connected to the Instrument Tube Assembly This allows sufficient time for final assembly of the DHT and attachment of the Probe Monitor to catch the first reading made by the Instrument Tube Assembly Connect the RED lead to the exposed metal surface of the Probe Element near the Probe Wrench Flats 2 Connect the BLACK lead to the exposed metal surface of the Probe Element near the probe tip The best sensitivity is achieved when the BLACK and RED leads are spaced as far apart as possible while making positive electrical contact to the Probe Element 3 Press the ON key Wait for the display prompt Ready to Test DHT 4 Press the CONFIG key If the cycle time which is expressed in minutes is correct proceed to ste
6. SEES PROTECTION REQUIREHENTS Chemical worker safety glasses and full face shield SKIN PROTECTION REQUIREMENTS Neoprene Polyethylene or Viton gleves boots and aprons appropriate fer exposure conditions RESPIRATOR REQUIREMENTS NIOSH approved for acid gases Do met exceed tha use limits of the respirator VENTILATION RBQUIREMENTS Use local exhaust gatnaral room Ventilation aufficient to prevent overexposure ADOITIONAL PROTECTIVE HEASURES Pull body acid resistant suite amd prezaurs self contained breathing apparatus should zvailable im of large spills or other similar emergencies Emergency showers amd eyewash should be located im areas where thionyl chloride Educate and train eeployees in the safe and handling of this product et ee ee VIII REACTIVITY DATA om 9 ee ee e ae e e e e e m e a e e ae ae me e a ae ae e a e e lt This im stable material HAZARDOUS POLYMERIZATION Will nat occur INCOMPATIBILITIES violently with water Avoid contact with redocisg agents and organic matter Hay react vigorously with Antimony Sodium Aluminum Magnesium and Titanium fren and Zinc ca
7. P N 724046 2 PLACES LOADING WASHER P N 202027 PROBE SLEEVE PRIMARY SEAL E P N 724050 03005 P N 724045 2 PLACES PROBE ASSEMBLY P N 724050 3005 Seal 77777777 IIIZ LLII Do Not Discard ZZE 22 LA SET SCREW 46 32 PROBE SEAL PROBE P N 003767 1 8 LOADING NUT ADAPTER 2 P N 724044 724038 Figure 4 4 Probe Assembly Attached to Probe Adapter CAUTION Primary Seal Do not discard 7 Coat the Probe Assembly threads with High Purity Goop P N 006308 This is an anti galling agent 8 Install the Seal Loading Nut on the threaded end of the Probe Assembly 9 Hold the flat portion of the Probe Assembly with a 5 8 open end wrench and then torque the Seal Loading Nut to 30 foot pounds with a 13 16 open end torque wrench 30 lbs on a 12 wrench Step 4 Temporarily Install Probe Shield 1 Check that the protective paper is over the Probe Element 2 Verify that the Probe Shield Set Screws are backed out enough to clear the threads 3 Carefully install the Probe Shield over the Probe Assembly and screw onto the Probe Adapter It is not necessary to install the Probe Tip Insulator at this time 4 Install the Probe Shield hand tight to protect the Probe Element during the following operations DO NOT tighten either the Probe Shield or the Set Screws at this time Step 5 Program Instrument T
8. The DCMS is a specific adaptation of the CORRDATA system for the severe Downhole environment and provides an accurate means of determining corrosion rates at various depths within a well bore The corrosion data provided by the DCMS permits quantitative evaluation of inhibitors and treatment regimes for the most cost effective results The DCMS consists of the following major components Downhole Tool DHT CORRDATA II Software DHT Communications Adapter Battery Depassivation Instrument Probe Monitor Instrument Cross Flow Adapter Customer Supplied Downhole Tool DHT The Downhole Tool DHT is a tubular electronic instrument as shown in Figure 1 1 that is designed to be run and retrieved by wire line operation into the production tubing of a well for an extended period of time The DHT uses CORROSOMETER Probe Element to determine the rate of metal loss within the well bore The Probe Element is electrically isolated from the rest of the tool and the well bore to prevent galvanic corrosion from influencing measurement data The Probe Element is made from the same or similar type material as the well bore being monitored The DHT itself with 1 25 diameter provides a very small percentage restriction in the pipe The Cross Flow adapter and tubing lock from which the DHT is suspended provides the main flow restriction of approximately 50 area on the pipe An RTD temperature sensor internal to the DHT provides temperature data Th
9. rcchlaric Acid and Sulfur Dioxide Moisture amd beat greater than 122 50 C will result in bteild up of internal pressure containers Each storage should be equipped with pressure relief devices which are cometrected with materials compatible with thionyl chleride at SHIPPING INP RMATIUM TECHNICAL SHIPPING HAM Chlorida FREIGHT CLASS BULK 3 Thisayl Chlorida FREIGHT CLASS PACKACE 7 Thiomyl Chloride PRODUCT LABBL ven ssi Chler de Produet Cede 405 505 Page 5 Approval date 11 02 95 Continued om next page 56 DCMS C E SS Samy XI SHIPPING IMFORMATIUM Cont m m DOT SURFACE PROPER SHIPPING Thieayl Chloride HAZARD CLASS OK DIVISION 6 1 UN MINEBER scccccsccuscasucaald UN12314 PACKAGING GROUP PG 1 DOT PRODUCT KO ibe kga Mone HAZARD LABEL Coppedive Poison HAZARD Poison IHD CODE OCEAN PROPER SHIPPING Chloride HAZARD CLASS DIVISION NEZMBER B UN1E14 PACKAGING I HAZARD LABEL Corrsaive HAZARD PLACARD S 3 Toxic TUKICITY DATA
10. the potential for hazardous situations does exist Most hazards are due to internal or external heating of a hermetically sealed battery Overheating causes liquid electrolyte to expand increasing hydrostatic pressure inside the can which might cause the battery to burst Further heating can cause the lithium anode to melt which in turn will react spontaneously with the electrolyte and bring about explosive behavior Causes of Hazardous Conditions Electrical and Physical Hazardous electrical conditions include recharging short circuiting and forced discharging voltage reversal Battery Engineering Inc s bobbin and moderate rate anode batteries are generally not capable of hazardous behavior unless external power is applied or they are short circuited at elevated temperatures 46 DCMS Hazardous physical conditions include external heating due to uncontrolled storage incineration and physical destruction of the battery case via crushing puncturing and disassembly Excessive heating can cause explosive behavior with any type of battery Physical destruction can result in leakage of toxic and highly corrosive electrolyte For further information about the safe handling and storage of lithium thionyl chloride batteries contact a Battery Engineering Inc Applications Engineer at 1 800 685 4844 Safe Storage Shelf Batteries should be stored in their original shipping containers if possible to keep them isolated fr
11. Assembly NOTE The Battery Depassivation Instrument is used in this step It automatically monitors the Battery Assembly output voltage while applying a nominal load BACK UP RING 2 PLACES P N 202028 O RING 2 PLACES P N 202027 TN NI m m PROBE ADAPTER P N 724038 Figure 4 3 Probe Adapter O Ring and Back Up Ring Placement The Battery Depassivation Instrument will remove the load when the output voltage of the Battery Assembly reaches a value which indicates that the passivation has been adequately removed WARNING Use only the RCS supplied Depassivation Instrument P N 724023 to depassivate the battery and verify voltage WARNING new Battery Assembly must be depassivated less than four hours prior to connecting it with the Instrument Tube Assembly Refer to Chapter 1 and Appendix A for Battery Assembly warnings and cautions DHT ASSEMBLY 33 Verify that the ambient temperature and the Battery Assembly Temperature is greater than or equal to 21 70 2 If desired monitor the voltage between the red and black terminals on the Battery Depassivation Instrument with a high impedance voltmeter 3 Connect the Battery Assembly to the Battery Depassivation Instrument The yellow lamp will illuminate immediately Depending on the degree of battery passivation the battery voltage may initially drop below 5 0V CAU
12. FOR Thiengl Chiarids ACUTE TOXICITY ORAL LD 0 Data established for product DERMAL 1080 33322552 nat selablishad for product INHALATION 1250 1 274 ppm Kat hour 558 ppm amp hour 1 756 pps Rat 1 heer 2 5 Corrosive SKIN EFFECTB 5 Corrosive SENSITIZATIOM Data established for product TOXICITT Data not established for product CHRONIC Data nat uztzbiizhad nr product OTHER TOXICITY Mutagenic Teratagsnic Reprodective Tests Data not established for product AQUATIC T KTCITY r Do not allow te entar waters wastewater or soil 1 Teste conducted at the Institute for Toxicology of Bayer AG 2 Bushy Kun Research Center October 1993 Product Code VAS HDS 6 Approval date 11 08 95 Continued page APPENDIX 57 8 5 This preduet is hazardous under the criteria of the Federal Hazard Communication Standard 29 CFA 1910 1200 3 TSCA Inventory CERCLA REPORTABLE QUANTITT Meme TITLE III SECTION 302 EXTREXMEL HAZARDOUS SUESTANCES Mome SECTION 311 317 HAZARD CATECORIES Immediate Health Hazard Delayed Health Hazard Reactive Hazard SECTION 313 TOXIC CHEHICALS None BORA 1 4 eee disc
13. Measurements 15 min 30 min 1 hr 2 hr 4 hr 5 8 Sucker Rod Connection Spec 11B 12 DOMS TM Battery Assembly Specification e RCS Part No 724089 Type Lithium Thionyl Chloride Li Weight 9 4 grams Voltage 7 34 Voc open circuit Operating Temp 20 C to 150 Shock 250 G s Max at 150 Random Vibration 30 to 300 Hz at 2 22 G Hz 25 Grms DHT Operating Duration DHT Programmed Approximate Operating Measurement Interval Time with a new Battery Assembly DHT OPERATIONAL PRETEST 13 DHT Operational Pretest CHAPTER 3 The user may wish to determine that the Instrument Tube Assembly Probe Assembly and Battery Assembly are operational before complete assembly of the DHT A Pretest may be performed by following the steps below WARNING Always perform a Pretest at room temperature Do not perform Pretest at temperatures above 125 It is highly recommended that new batteries are used on the DHT Communications Adaptor and the Probe Monitoring Tool before a new session Assembly Sequence Step 1 Depassivate New Battery Assembly WARNING Use only the RCS supplied Depassivation Instrument P N 724023 to depassivate the battery and verify voltage NOTE The Battery Depassivation Instrument is used in this step It automatically monitors the Battery Assembly output voltage while applying a nominal load The Battery Depassivation Instrument will remove t
14. VOLUME 2 100 VAPOR PRESSURE Apprex 97 HE 8 64 F 20 C FIRE AND EXPLOSDOM DATA FLASH POINT vol Net Applicable AUTO IGNITIOM TEMPERATURE 1 Mot Established EXTINGUISHING 1 Dioxide Dry Chemical SPECIAL FIRE FIGHTING PROCEDUKES Thienyl Chloride not combustible However if thionyl chloride is inwolved in Cire use carbon dioxide or dry chemicals Firefighters sheald wear full protective clothing incloding awlf rontzined breathing apparatus Toxic amd irritating gases may be present including hydrochloric acid sulfur dioxide chlorine sulfur ehloride or ofhere Druse exposed to excessive temperatures rupbure due Lo the daccmpozition of thiomyl chloride Mater will react with Freduct Code 403 HSDS Page 2 Approval date 11 04 93 Continued on next page APPENDIX A 53 11 FIRE AMD ERPL SION DATA Continued thionyl chloride generating irritating gases However water spray should be used to keep lire exposed containers cool and to help ecrub acid Crem the aire 5 OF Eye Contact Skin Contact Inhalation HUMAN EFFECTS AND SYMPTOMS OF DVEREKTOSUNE ACUTE EFFECTS OF Direct contact with thionyl chloride cause burns It is corresive to the skin ayez and
15. kept above 21 70 F 40 DCMS O SES Disassembly Sequence Step 1 Detach DHT from Cross Flow Adapter CAUTION Clean the DHT thoroughly with an appropriate solvent prior to disassembly 1 Detach the 5 8 API sucker rod connection on the DHT s Mounting Head Adapter from the Cross Flow Adapter of the running tool immediately after removal from the well Step 2 Remove Mounting Head Adapter and Spring Assembly WARNING Wear safety glasses cover the joint and carefully unscrew the Mounting Head Adapter during this step of disassembly in case any high pressure gas and or liquid have been trapped in the Instrument Body while the DHT was Downhole 1 Use a girth grip wrench to hold the Instrument Body 2 With a 1 open end wrench carefully remove the Mounting Head Adapter 3 Remove the Spring Assembly if possible The Spring Assembly need not be removed at this time Step 3 Remove Instrument Tube Assembly Battery Assembly from Instrument Body 1 Lay the Instrument Body on a flat horizontal surface 2 Use a girth grip wrench to hold the Instrument Body 3 With a 1 open end wrench remove the Probe Head Adapter from the Instrument Body 4 Carefully slide the Instrument Tube Assembly Battery Assembly completely out of the Instrument Body 5 Disconnect the Battery Assembly from the Instrument Tube Assembly 6 Mark the Battery Assembly with tape or a label to identify it as being used and handl
16. of the DHT and battery covered in the next step Set DHT Time Configure Down Hole Tool with the time from the PC recommended Twelve 12 minutes will be added to the PC time Status Monitor Waiting for Down Hole Tool to respond uJ Device Status Device Type Property Device ID Tag Alloy Reading Interval Probe Span Date Installed Date of Last Reading Number of readings Value 2 DHT K03005 15 Minutes 10 4 13 2012 3 46 24 PM 4 13 2012 3 31 24 PM 0 DHT OPERATIONAL PRETEST 23 24 DCMS Step 3 Attach Battery Assembly to Instrument Tube Assembly WARNING Always use a new Battery Assembly and depassivate immediately before use Maintain the Probe Assembly Instrument Tube Assembly and the Battery Assembly on a table or other flat horizontal surface 2 Attach the DHT Communications Adapter to the DHT Set Toggle Switch on the communications adapter to middle off position before connecting to DHT Once both sides are connected Battery and communication adapter in off position Toggle the communications SWITCH UP FOR ENABLING DHT BATTERY POWER Disconnect DHT Communications adapter after 30 seconds The 12 minute window for connecting the probe begins immediately after enabling the battery DHT COMMUNICATIONS ADAPTER SWITCH UP FOR NABLING DHT BATTERY POWER TCH DOWN MMUNICATIONS CAUTION F COMMUNICATING WITH PC DO
17. to Pore Castors rec Coroser Fate Heg rte Hee m Hide Metst Lowe Rate Tere Comp Temperature Data should display close to zero Metal Loss and Corrosion Rate DHT ASSEMBLY 29 Assembly 4 Recommended Tools The DCMS Tool Kit P N 724005 is required for the proper assembly set up disassembly and data retrieval of the DHT WARNING Use of tools other than those listed may result in damage to DHT components which may impact seal integrity pressure rating and accuracy DO NOT hold any portion of the DHT with a vice or common pipe wrench The following tools are contained in the DCMS Tool Kit ITEM UNIT PART NUMBER DESCRIPTION 724101 Girth grip Pipe wrench Assembly 1 25 000490 Torque Wrench 5 to 75 ft lbs Drive 000491 Torque Wrench 100 600 ft lbs Drive 000492 Crowfoot Wrench 1 12 Drive 000493 Crowfoot Wrench 1 Drive 000494 Crowfoot Wrench 13 16 Drive 000466 Adapter 24 Female X 72 Male 000495 Open End Wrench 1 000496 Open End Wrench 13 16 000497 Open End Wrench 028050 8021 36 00 Cheater Bar 36 Long for open end wrench 660045 S31600 36 00 Cheater Bar 36 Long for girth grip wrench 000498 Hex Key Handle 1 16 000499 Hex Key Blade 1 16 129341 O ring Pick Set 724100 DHT Tool Kit Case 724020 DHT to MATE Communications Adapter 724023 Battery Depassivation Instrument 724024 Pro
18. Assembly is now ready for immediate use The depassivation procedure should not last more than 60 minutes The Battery Depassivation Instrument provides test terminals to monitor the battery voltage with an external voltmeter Probe Monitor To confirm that the Downhole Tool DHT is functioning correctly after complete assembly a non intrusive Probe Monitor P N 724024 has been designed The Probe Monitor continuously monitors the voltage across the Probe Element and detects when the probe is energized Counting these events provides high confidence that the DHT is functioning properly Since the DHT performs periodic measurements based on a programmed cycle time a countdown timer has been provided in the Probe Monitor to indicate when the next probe measurement will be made When the DHT performs a measurement of the Probe Assembly the probe is actually energized for two consecutive intervals each lasting about 3 seconds There is about 5 second s duration between these intervals where the probe is not energized The two intervals have been named CYCLE ONE and CYCLE TWO The Probe Monitor indicates which cycle is presently occurring during the measurement Both cycles must be measured before the Instrument will decrement the countdown timer The countdown timer should be accurate to within a few seconds of actual DHT measurements as long as the cycle time for the Probe Monitor is the same as the DHT configured cycle time The Probe Monitor
19. Download Data from Device 7 Clicking this icon will allow you to download from an attached device to the Corrdata software database 18 DCMS Configure Device Clicking this icon will allow you to configure an attached device from the Corrdata Il database Data Entry Manual E Clicking this icon will allow you to enter data to a selected probe on the Equipment Layout screen This can be used for correcting data or entering data into a manual entry device such as the CK 4 Expand All 2 Clicking this icon will expand the Tree view F5 key is also a short cut Collapse All 25 Clicking this icon will collapse the Tree view The F6 key is also a short cut Expand Node 2 Clicking this icon will expand the selected Node F7 key is also short cut Collapse Node Clicking this icon will collapse the selected Node The F8 key is also a short cut DHT OPERATIONAL PRETEST 19 Palette Screen Corrdata File gt m 54 AF Cy 5 ewan Show Devices System You Drag the System onto the Equipment Layout screen At least System is required to be dropped on the Equipment Layout screen The System can be dropped on the main screen on any other Sub System You Drag and Drop the Sub System onto a System or another Sub System Sub Systems a
20. ER VITCH UP FOR ENABLING DHT BATTERY POWER WITCH DOWN COMMUNICATION CAUTION IF COMMUNICATING WITH PC DO NOT CONNECT DHT BATTERY 2 Coat the Probe Adapter threads near the O rings with High Purity Goop and the O rings themselves with High Temperature Silicone Grease 3 When the present time is equal to the preset time value entered in Step 5 above immediately slide the small connector on the Instrument Tube Assembly into the Battery Assembly connector as far as possible 4 Once the Battery Assembly is connected the Instrument Tube Assembly is powered and will take its first Probe Element reading after about 12 minutes 30 seconds WARNING If the battery is removed at any time after this step steps 3 5 of chapter 3 must be repeated The DHT will not work without the battery enabled Step 8 Place Instrument Tube Assembly Battery Assembly into Instrument Body 1 Lay the Instrument Body on the same flat horizontal surface as the Instrument Tube Battery Assembly If not already done coat the Probe Adapter threads near the O rings with High Purity Goop and the O rings themselves with High Temperature Silicone Grease 3 Support the Battery Assembly to keep it in line with the Instrument Tube Assembly to avoid connector damage then carefully slide these two items into the Instrument Bogy 4 Carefully screw the Probe Adapter into the Instrument until shouldered being careful not to li
21. GINEERING 1 DCMS SUB SYSTEM m DCMS Off Line moo Down Hole Tool DHT 1 T Down Hole Probe ID 1 2 Metal Loss Temperature Corrosometer Probe Configuration 1 Building 1 Device Down Hole Tool Device Name Down Hole Tool Probe Configuration Down Hole Probe 108 2 Metal Loss 10 1 1 50 Temperature Tag Add Remove Probe Element T10 Cylindrical D z 4 8 Select 05 Carbon Steel a Span 5 Corrotemp RDC Time Interval Hours Minutes 4 NOTE 1 hour reading interval is most commonly used The Probe Assembly type is D cylindrical with a 5 mil span for 10 model or a 10 mil span for 20 model and the probe is a Corrotemp type CAUTION The minimum read time interval for the DHT is 15 minutes User may set up the read time to 15 or 30 minutes or 1 2 or 4 hour increments If an increment other than the above is chosen the DHT will default the read time interval to the nearest valid time increment 22 DCMS Select Configure Device icon to program DHT WARNING This is the recommended method to successfully configure the DHT to the time and date of the PC Performing the configuration will erase all previously saved data on the DHT The DHT will have 12 minutes added ahead to allow for complete assembly time
22. NOT CONNECT BATTERY Once the Battery has been enabled with the communications adapter the assembly is energized and will take the first Probe Element reading after about 12 minutes This will be the first stored reading in the non volatile memory Next reading will commence at the specified interval from this reading It is possible and highly recommended for the user to validate the performance of the DHT by using the Probe Monitoring Tool see step 5 below NOTE The instrument will NOT work until the DHT Communications Adapter has enabled the battery for 30 seconds Step 3 Also the Instrument Tube Assembly does NOT contain a real time clock Therefore the date time setting does NOT change with time Instead the date time setting is purely a reference time to denote when the Instrument Tube Assembly actually begins recording data Whenever the Battery Assembly is connected the Instrument Tube Assembly collects readings at the programmed interval and time stamp the readings starting from the user programmed time This is the reason for setting DHT OPERATIONAL PRETEST 25 the time 12 minutes than the present time to let the user finish the rest of the steps and have enough time to begin the readings at the current time CAUTION DHT can store a maximum of 1024 readings on its non volatile memory Once this limit is met the DHT will not store anymore readings Step 4 Attach Probe Assembly to Instrument Tube Adapter
23. TION If no status lamps on the Battery Depassivation Instrument are illuminated while the Battery Assembly is connected then the Battery Assembly is either excessively passivated or depleted and should not be used 4 Monitor the Battery Depassivation Instrument status lamps until the yellow lamp extinguishes and the green lamp begins to flash Depassivation may take from several minutes to one hour CAUTION If the green lamp doesn t flash within one hour of connecting the Battery Assembly then the Battery Assembly is either excessively passivated or depleted and should not be used Disconnect the Battery Assembly from the Battery Depassivation Instrument The Battery Assembly is now ready for immediate use Step 3 Attach Probe Assembly to Probe Adapter See Figure 4 4 CAUTION careful not to get any lubricant the Probe Element 1 Check that the protective paper is over the Probe Element 2 Lubricate the entire Probe Sleeve with a thin coat of High Temperature Silicone Grease P N128371 3 Slide the threaded end of the Probe Assembly through the Probe Adapter opposite the O ring end 4 Lubricate one Insulating Washer P N 724046 and one Load Washer P N 724045 with High Temperature Silicone Grease 5 Place the Insulating Washer over the threaded end of the Probe Assembly 6 Place the Load Washer over the threaded end of the Probe Assembly 34 DCMS NSULATING WASHER BACK UP RING P N 202028
24. User Manual 2012 Rohrback Cosasco Systems Inc All rights reserved Corrosometer Corrdata Corrdata and DCMS are trademarks Rohrback Cosasco Systems Inc No part of this manual may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording for any purpose without the express written permission of Rohrback Cosasco Systems Inc TABLE OF CONTENTS Table of Contents Chapter 1 Introduction ne 1 Downhole Corrosion Monitoring System 1 Downhole 1 Instrument OGY RE Ea 5 Instrument Tube Assembly pp 5 Probe A ssembly E 5 Prohs 5 5 Probe 5 Mounting Head 5 Battery Assembly ERNEUT 6 GORRDATA eII Software 6 Battery Depassivation Instrument pp 6 miscet eeeeseee 7 Cross Flow Agapter M n 7 NET ETT 8 Chapter 2 Specification c 11 Downhole Tool Specificatiom deere 11 Battery Assembly Specificatiom s ied adit eie EE ER EL te ri 12 DHT Operating Duration re x 12 Chapter 3 DHT Operational Pretest
25. WITCH UP FOR ENABLING DHT BATTERY POWER Disconnect DHT Communications adapter after 30 seconds The 12 minute window for connecting the probe begins immediately after enabling the battery 3 Once the Battery has been enabled with the communications adapter the assembly is energized and will take the first Probe Element reading after about 12 minutes This will be the first stored reading in the non volatile memory Next reading will commence at the specified interval from this reading NOTE The instrument will NOT work until the DHT Communications Adapter has enabled the battery for 30 seconds Step 3 Also the Instrument Tube Assembly does NOT contain a real time clock Therefore the date time setting does NOT change with time Instead the date time setting is purely a reference time to denote when the Instrument Tube Assembly actually begins recording data Whenever the Battery Assembly is connected the Instrument Tube Assembly collects readings at the programmed interval and time stamp the readings starting from the user programmed time This is the reason for setting the time 12 minutes later than the present time to let the user finish the rest of the steps and have enough time to begin the readings at the current time CAUTION DHT can store a maximum of 1024 readings on its non volatile memory Once this limit is met the DHT will not store anymore readings 36 DCMS DHT COMMUNICATIONS ADAPT
26. al fuse but may explode if either recharged or short circuited especially at high temperatures Failure to follow these warnings could result in serious injury or death Be sure to read the paragraph titled Battery Depassivation Instrument in Chapter 3 before installing the battery pack Also refer to Appendix A at the end of this manual for safe handling and storage of lithium thionyl chloride batteries CORRDATA Software CORRDATA II Software is supplied with the DCMS Tool Kit Please refer to the CORRDATA II Corrosion Management Solutions Manual on the USB stick for details Battery Depassivation Instrument A new Battery Assembly must be depassivated just prior to use in order to remove a passivation layer that naturally inhibits energy transfer from the Battery Assembly to the DHT electronics The depassivation procedure requires that a Battery Depassivation Instrument P N 724023 be connected to the Battery Assembly for a period of time INTRODUCTION 7 The Battery Depassivation Instrument initially loads the Battery Assembly to begin depassivation It then monitors the output voltage of the Battery Assembly under load until it rises to an acceptable level While the Battery Assembly is being depassivated a yellow lamp on top of the Battery Depassivation Instrument will remain illuminated When the depassivation process is complete the yellow lamp will extinguish and a flashing green lamp will illuminate The Battery
27. alysis NOTE The Probe Assembly is preweighed so that it may also be used as a coupon See the data supplied with the Probe Assembly for weight details A serial number is marked on one of the Probe Assembly wrench flats as well as on the protective cardboard tube packaging DHT ASSEMBLY 43 44 DCMS APPENDIX 45 APPENDIX A Lithium Thionyl Chloride Batteries Handling Storage MSDS Emergency Procedures IN THE UNLIKELY EVENT OF VIOLENT BATTERY BEHAVIOR the area should be evacuated immediately Personnel should stay away from the area for 15 minutes rather than trying to correct the situation Burning or fuming batteries should be left isolated until expert handling can correct the condition Lithium fires should only be extinguished using Lith X or a Class D fire extinguisher The Material Safety Data Sheets for each cell of the DHT battery pack 2 cells per pack as well as the main ingredient Thionyl Chloride are included in this section IN CASE OF LEAKAGE leaking batteries should be isolated from all personnel and equipment Since the electrolyte can be neutralized with common baking soda leaking batteries should be placed in sealed plastic bags containing baking soda The bags should be placed in a sealed drum with vermiculite Personal protection devices should always be used around leaking batteries Emergency Conditions Because of the high energy density inherent in lithium thionyl chloride batteries
28. and Temperature data to the Selection Tool window and click on Graph Data ks Step 6 Remove Probe Shield 1 Back out the Probe Shield Set Screws with a 1 16 Allen wrench so that they clear the threads of the Probe Adapter 42 DCMS OSSES 2 Place a 1 open end wrench on the Probe Adapter and a girthgrip wrench on the Probe Shield 3 Carefully remove the Probe Shield from the Probe Adapter 4 Remove the Probe Tip Insulator from the tip of the Probe Element DHT COMMUNICATIONS ADAPTER SWITCH UP FOR ENABLING DHT BATTERY POWER CAUTION F COMMUNICATING WITH NOT CONNECT HT BATTERY CAUTION Anew Probe Tip Insulator should be fitted each time the Probe Shield is attached A new Probe Tip Insulator is included as part of the Probe Assembly Step 7 Detach Probe Assembly from Probe Adapter 1 Hold the flat portion of the Probe Assembly with a 5 8 open end wrench then detach the Seal Loading Nut with a 13 16 open end wrench 2 Remove and keep the Load Washer from the threaded end of the Probe Assembly CAUTION To establish a reliable seal a new Insulating Washer and Probe Sleeve must be used each time the Probe Assembly is attached to the Seal Loading Nut Both Insulating Washer and Probe Sleeve are included as part of the Probe Assembly 3 Remove and discard the Insulating Washer from the threaded end of the Probe Assembly 4 Slide the Probe Assembly out of the Probe Adapter and keep for further an
29. arded in ifs purchased form this meet the criteria of corrosivity Harar suz Waste Humber 0002 and reactivity Hazardous Waste Number 0003 under 40 1261 20 241 The following chemicals are gpecifically listed individual states other praduct specific health and gafely data in ofher sectione nf he MEUS may also be applicable for state requirements For detaile on your regulatory fequiresents you rhald contact the in your etate COMPONENT JCAS COMCENTILAT ION STATE Thionyl Chloride 7119 09 7 minimum 99 6 1 PAL HA MIS H Mass chusetta Eaxardaus Substance Liet WJJ Special Hazith Hazardous Substance List PAL Pennsylvania Bazardous Sebatance List CALTPORMTA PROPOSITION 65 the best of cur hnowledge thie product contains levels of Listed substances Which the state cf California hae found to csere cancer birth defects or other reproductive effects Product Code 405 505 Page 7 Approval date 11 08 94 Comtimeed on next page 58 DCMS SSS SS S S APPROVALS REASON POR ISSUE 2 Revise Sections XII IMO amd KIV PREPARED BY ss D Nelly APPROVED BY 2 J M APPROVAL DATE 11 08 95 SUPEKSEDES DATE 09 28 93 MSDS MUMBER 01987
30. be Monitor Instrument 30 DCMSm Assembly Sequence Prior to assembly be sure to thoroughly clean all threads inner and outer and O ring grooves The following Steps refer to the DHT Assembly Drawing of Figure 4 1 Primary Seal Do not discard N d 2 9 135 JN3WM313 380Nd GIHS 380Nd 9 135 MOLVINSNI 3A331S E E ORUM 1 30 l d 1 9 N d egoyZL 8 6yOyZL TS 0 2 M3ldvOV 380dd 2 8 1 494 00 4 26 9 w3NOS 135 820202 dn v8 22222227772 1 ssowmd 2 9yOyZL SyoyZL N d rrOvZL N d otorzL N d 1 220202 N d M3HSYM 9NUVInSNI e M3HSVM 0 01 9NIQYO W3S 380dd AnBW3SSV IJANU IN3WMISNI ssovia 2 N0123NNO2 orovz N d M3idv v CY3H Figure 4 1 DHT Assembly Drawing N a ze ac ovOvZ N d N d 2 811 0345 ASN3SSY ACOB nyGSSY 8ZOZOZ N d ONIN NOUO3NNOO P 4 M34OnS idv 8 5 5320718 2 020202 N d DHT ASSEMBLY 31 CAUTION Leave on the protective paper that covers the Probe Element unti
31. ct Follow all instructions during the installation operation and maintenance of this product To prevent personal injury ensure that all components are in place prior to and during operation of the product 5 If you do not understand an instruction do feel comfortable following the instructions contact an RCS service technician for clarification or assistance 6 Ifthis user manual is not the correct user manual for your RCS product contact RCS at 1 562 949 0123 and RCS will provide you with the requested manual 7 Use only replacement parts specified by RCS Unauthorized parts and procedures can affect this product s performance safety and invalidate the warranty Look a like substitutions may result in improper operation and may result in serious injury or death 8 Save this user manual for future reference TM TABLE OF CONTENTS V NOTICE It is imperative that the safety warnings throughout this user manual are taken into important consideration during assembly disassembly installation and removal of the Downhole Tool Safety warnings are noted throughout this document to ensure precautions are taken for all procedures where there are risks involved Failure to follow these warnings could result in serious injury or death Information provided in this User Manual should not be considered as all encompassing or suitable for all situations conditions or environments Each individual and the organizat
32. ct press the EDIT key again to store the reading the old value will be lost or press the CONFIG key to abort no changes will occur NOTE It is suggest setting the cycle time with few extra minutes compared to the actual reading interval to avoid and erroneous timeouts 6 Press the DISPLAY key to determine how many measurements were made This will be zero for initial use TM Press the MEAS key to initiate monitoring the Probe Element It may be necessary to let the Probe Monitor warm up for a couple of minutes before performing measurements The countdown timer will be activated counting from the cycle time down toward zero If zero is reached before a Probe Element measurement is detected a time out message is displayed Press any key to stop the measurement process If the MEAS key is pressed again the number of measurements will be initialized to zero and the measurement process will start over If the OFF key is selected the number of measurements will be saved to be viewed the next time the Probe Monitor is turned on DHT ASSEMBLY 39 uu 9 When the DHT Probe Element is read the display of the Probe Monitor will first show CYCLE ONE and shortly thereafter change to CYCLE TWO to account for the two energization cycles of one DHT Probe Element reading Immediately following each Probe Element reading the Probe Monitor will display the
33. current tally of Probe Element readings i e where the total number of Probe Element readings countdown timer will be reset to its programmed value Step 13 Install Probe Shield CAUTION Do NOT handle or get any lubricant on the Probe Element the from the Probe Element 2 Install the Probe Insulator the tip of the Element CD Coat the exposed threads of the Probe Adapter with High Purity Goop m Carefully install the Probe Shield over the Probe Assembly and screw onto the Probe Adapter 5 Place a 1 open end torque wrench on the Probe Adapter and a girth grip wrench on the Probe Shield O Torque the Probe Shield to 30 ft lbs N Torque the Probe Shield Set Screws to 10 inch pounds with a 1 16 Allen torque wrench or as tight as a standard 1 16 Allen key will allow 8 The DHT is now ready to be attached to Cross Flow adapter and tubing lock and run into the well Step 14 Attach DHT to Cross Flow Adapter CAUTION The DHT should only be attached to the running tools immediately prior to running into the well by wireline 1 Attach the 5 8 API sucker rod connection on the DHT s Mounting Head Adapter to the Cross Flow Adapter on the running tools immediately prior to running into the well 2 Torque the connection to 175 ft lbs minimum WARNING During this time the temperature of the tool should be
34. e encountered whem Chloride comes im contact with eoialure im the air Hydrochloric Acid 7647 01 0 OSEA 3 000 ppa Ceiling i Noted 7 000 mg m Ceiling Sulfer Diexide 7445 09 5 OSHA ACGIH Freduct Code 1409 Approval date 11 08 95 1 Net Noted KSDS Paga 1 Continued next pags 52 DCMS 11 HAZARDOUS INCREDIENTS Cont imed CAS NUMBER EXPOSURE LIMITS COMCENTRATION X Chlorine 7782 5075 OSHA 1 500 ppm 1 Nat Noted 1 500 mg mi 1 000 ppa STEL 3 000 mm STEL ACGIH 800 ppm TWA 1 500 mg m3 Tea 1 000 pps STEL 2 900 mg m3 STEL Chloride 10025 67 98 OSHA 1 000 pps Ceiling 1 Noted ACGIH 1 000 Ceiling 111 PHYSICAL PROPERTIES assum MR amp d Re c nce kk PHYSICAL Liquid 0 Celerless to slightly yellow Sharp irritating MOLECULAR WEIGHT esses 119 pH Bet Apo licable BOTLIRG Apprex 159 MELTING FREEZING POINT 2 Approx 156 104 3 C VISCOSITY se oo o22222292237 Apprex 0 6 Pas 77 F 25 e SULUBTLITT IN MATER 3 SPECIFIC GRAVITY 1 66 77 25 BULK 5 Established 1 VOLATILE MY
35. e DHT electronically measures the Probe Assembly and temperature sensor at user programmable intervals and stores each reading in nonvolatile memory Upon retrieval of the DHT corrosion and temperature data may be downloaded to the CORRDATA Mate The data may then be transferred from the Mate to a personal computer containing the CORRDATA II Software for analysis 2 DCMS The DHT consists of the following major components Instrument Body Instrument Tube Assembly Probe Assembly Probe Shield Probe Adapter Mounting Adapter Battery Assembly When not in use the DHT and other DCMS components may be stored in a protective carrying case The arrangement of the carrying case is shown in Figure 1 2 INTRODUCTION 3 5 8 SUCKER ROD CONNECTION MOUNTING HEAD ADAPTER SPRING ASSY BATTERY ASSY INSTRUMENT BODY INSTRUMENT TUBE ASSY 48 51 4 PROBE SEAL LOADING NUT LOADING WASHER INSULATING WASHER gt 5 PROBE ADAPTER PROBE ASSY PROBE SHIELD PROBE INSULATOR 1 25 DIA B Figure 1 1 Cross Sectional View Fully Assembled Z 6S0y60 SON AN3IIVB AG 3AM353H WALSAS NOILOJTIOO 310W3 7080 03 Q3AN3S3H yzZ0yZL 1 30049 NOUYAISSYd30 504 3 pd XOOBL3N 503 383539
36. e Password that was set in last step Database Select the database created during an earlier running of this software or select Create New Database to create a new database If this is the first time being run you must select Create New Database Then hit the OK button Enter name of database to create Select a name for your new Database and then hit the OK button DHT OPERATIONAL PRETEST 17 I Configure DHT with Corrdata Main Screen Equipment Layout Clicking this icon will bring up the Equipment Layout screen This is where you will configure your System Sub Systems Devices and Probes The Equipment Layout screen is shown as a Tree View and works like the Explorer tool in Windows Selection Tool 5 Clicking this icon will bring up the Selection Tool screen You will drag items from the Equipment Layout for selecting graph points The Selection Tool screen is shown in a list view Equipment Layout Selection Tool Clicking this icon will bring up both the Equipment Layout and the Selection Tool screens Equipment Layout Screen E corden E 7 File Help Remove Item Clicking this icon will remove a node and all children of that node that you have selected on the Equipment Layout screen Item Palette Clicking this icon will bring up the Palette screen where you will select Devices and Probes for placing on the Equipment Layout screen
37. e in accordance with Appendix A of this manual 7 Remove the Spring Assembly if not already done Step 4 Detach Probe Assembly from Instrument Tube Assembly DHT ASSEMBLY 41 1 Use 1 16 Allen wrench to back out the Seal Loading Nut Set Screws enough to clear the connector opening 2 Disconnect the Probe Assembly from the Instrument Tube Assembly by sliding the Seal Loading Nut end of the Probe Assembly away from the Instrument Tube Assembly Step 5 Read Data from Instrument Tube Assembly WARNING Disconnect Battery Assembly prior to downloading Data from the Instrument Tube Assembly 3 Download DHT data from the PC with the Communications Adapter Set Toggle Switch on communications adapter to middle off position before connecting to DHT Connect Serial connection from DHT to PC and verify COM port being used Follow the steps below to set up the DHT manually Note For further details on Corrdata 11 refer to the CORRDATA II User Manual for instructions on configuring a DHT 4 Read data from the Instrument Tube Assembly by following the steps below VII Toggle the communications SWITCH DOWN FOR PC COMMUNICATIONS to enable power and configuration to the DHT from the communications adapter VII Corrdata IX Click Equipment Layout Selection Tool EE X Expand down to your configured DHT Xl Click to Download Data from Device and wait for download to complete XII Drag the Metal Loss
38. e wrench on the Mounting Head adapter 3 Tighten to 175 ft lbs minimum Step 11 Remove Probe Shield 1 Carefully remove the Probe Shield from the Probe Adapter 2 Carefully remove the protective paper from the Probe Element 38 DCMS Step 12 Test DHT Operation with Probe Monitor Use the DHT Probe Monitor P N 724024 as described below to determine if the DHT is operational NOTE Regardless of the preprogrammed time setting the DHT will take the first Probe Element reading about 12 minutes 30 seconds after the Battery Assembly is connected to the Instrument Tube Assembly This allows sufficient time for final assembly of the DHT and attachment of the Probe Monitor to catch the first reading made by the Instrument Tube Assembly 1 Connect the RED lead to the exposed metal surface of the Probe Element near the Probe Wrench Flats 2 Connect the BLACK lead to the exposed metal surface of the Probe Element near the probe tip The best sensitivity is achieved when the BLACK and RED leads are spaced as far apart as possible while making positive electrical contact to the Probe Element 3 Press the ON key Wait for the display prompt Ready to Test DHT 4 Press the CONFIG key If the cycle time which is expressed in minutes is correct proceed to step 6 5 If the cycle time is not correct press the EDIT key followed by the UP and DOWN arrow keys to correctly program the cycle time When the cycle time is corre
39. eatment FIRST AID FOR SKIN Rinse immediately with large amcamte of cool reaming water Avoid hot water and hard rubbing When splashed with thionyl chloride immediately proceed te an emergency shower and begin resoving all contaminated clothing while rinsing Fluehing the body with large amounts water should continua until all of the thiomy chloride removed If the eyes are mol contaminated do not remove safely to avoid washing thiomyl chloride into the eyes If contact is extensive or burns develop physician should be contacted immediately Product Code VADS MSDS Page 3 Approval date 11 08 95 Continued an naxt page 54 DCMS r VI FIRST AID PROCEDURES Continued FIRST AID FOR INHALATION Remove to fresh air Keep parzon and avoid amy unnecessary exertion or movement Trained persons should administer if breathing is difficult IT not breathing give artificiml respiration Immediately contact physician FIRST AID FOR In case of ingestion drink amounts of water EF available give several glasses of milk Do nof induce Vomiting GIVE ANYTHING BY MOUTH AN UNCONSCIOUS PERSON If vomiting occurs spontaneously keep airway clear and give more water Immediately call a physician a lt lt lt WII EMPLOYEE PROTECTION RECOMMENDATIONS
40. ft the end so high that the Battery Assembly might become disconnected inside the Instrument Tube Assembly 37 5 Maintain the whole assembly as horizontal as possible Step 9 Install Spring Assembly and Mounting Head Adapter Insert the Spring Assembly into the open end the Instrument such that the outward end extends beyond the Instrument Body threads by no more than 14 If the spring assembly extends further than this check that the battery is still correctly engaged 2 Coat the Mounting Head Adapter threads near the O rings with High Purity Goop and the O rings themselves with High Temperature Silicone Grease 3 Insert the Mounting Head Adapter behind the Spring Assembly 4 Gently push the Mounting Head Adapter against the Spring Assembly and maintain pressure while starting to screw the Mounting Head Adapter into the Instrument Body Once the threads have engaged use a 1 open end wrench to tighten the Mounting Head Adapter until shouldered Step 10 Tighten Adapter Seals 1 Use a girth grip wrench to hold the Instrument 2 With a 1 open end torque wrench tighten the Probe Adapter into the Instrument Body to 175 ft lbs torque minimum 3 Use a 1 open end torque wrench to tighten the Mounting Head Adapter into the Instrument Body to 175 ft lbs torque minimum Alternate Method 1 Place a 1 open end wrench on the Probe Adapter 2 Place a 1 open end torqu
41. he load when the output voltage of the Battery Assembly reaches a value which indicates that the passivation has been adequately removed WARNING A new Battery Assembly must be depassivated less than four hours prior to connecting it with the Instrument Tube Assembly Refer to Chapter 1 and Appendix A for Battery Assembly warnings and cautions 1 Verify that the ambient temperature and the Battery Assembly Temperature is greater than or equal to 21 70 F 2 If desired monitor the voltage between the red and black terminals on the Battery Depassivation Instrument with a high impedance voltmeter 3 Connect the Battery Assembly to the Battery Depassivation Instrument The yellow lamp will illuminate immediately Depending on the degree of battery passivation the battery voltage may initially drop below 5 0V 14 DCMS CAUTION If no status lamps on the Battery Depassivation Instrument are illuminated while the Battery Assembly is connected then the Battery Assembly is either excessively passivated or depleted and should not be used 4 Monitor the Battery Depassivation Instrument status lamps until the yellow lamp extinguishes and the green lamp begins to flash Depassivation may take from several minutes to one hour CAUTION If the green lamp doesn t flash within one hour of connecting the Battery Assembly then the Battery Assembly is either excessively passivated or depleted and should not be used 5 Disconnec
42. icipating the infinite variety of conditions that may be encountered in the field would be impossible but we have designed this user manual to emphasize safe working practices and as much as possible to convey the full benefit of our knowledge and collective experience in the use of the DCMS Downhole Tool and Accessories This user manual is not meant to be a sole source of instruction Because these tools are used in a broad range of environments and applications it is important that the owner and operation personnel have been assessed certified and deemed competent in all safety work management and additional risk assessment requirements in the application of this user manual BE SURE ALL PERSONNEL READ AND FOLLOW THE INSTRUCTIONS IN THIS USER MANUAL AND ALL PRODUCT WARNINGS Product Owners Purchasers 1 Use the correct product for the environment and pressures present If you are unsure discuss your needs with your RCS representative 2 Inform educate and train all personnel in the proper installation operation and maintenance of this product 3 To ensure proper performance only competent field experienced and trained personnel should install operate repair and maintain this product 4 Save this user manual for future reference Product Operation Personnel Read and understand all instructions and operating procedures for this product Follow all warnings cautions and notices marked on and supplied with this produ
43. ineering APPENDIX A 47 If testing batteries at elevated temperatures the temperature chamber MUST HAVE reliable over temperature protection DO NOT SHORT CIRCUIT batteries that are heated above 25 Batteries that have been heated above 100 have been known to explode when short circuited for less than one minute NOTE The batteries used in the DHT are custom built with an integral 1A safety fuse The fuse will open the circuit if the battery is short circuited Safe Transportation Because the shipping regulations are very complex shippers of lithium batteries are urged to obtain copies of the 49 CFR DOT regulations and the IATA regulations These regulations also explain how the paperwork is to be filled out All lithium thionyl chloride batteries with a lithium content of greater than 0 5 grams and less than 12 grams are restricted and they are subject to DOT 49 CFR and International Air Transport Association IATA shipping regulations Batteries that contain less than 0 5 grams lithium are unrestricted and may be shipped by any means ref IATA section 4 5A45 Batteries with a lithium content of 12 grams must be individually approved by the governing authority and cannot be shipped under these regulations NOTE The Battery Assembly used in the DHT contains 7 4 grams of lithium when new The proper shipping name for lithium thionyl chloride batteries is LITHIUM BATTERIES LIQUID CATHODE UN3090 The haza
44. ion he she represents is responsible for implementing training and its his her own safety injury illness prevention program in connection with this user manual and should consult with their respective legal medical or other advisors as to the suitability of using the information in connection with this user manual Application of information furnished by this user manual does not guarantee that the information furnished will meet applicable USA including OSHA United Kingdom or any other country s health or safety standards or requirements or by implementing any of the programs that you or your company will be compliant with such rules and regulations Rohrback Cosasco Systems Inc and its affiliates assume no liability arising from the use of or reliance on the information provided in this user manual Always seek the advice of your legal medical or other advisors before using this information in this user manual NEITHER ROHRBACK COSASCO SYSTEMS INC NOR ITS ENGINEERS TECHNICIANS ARE RESPONSIBLE FOR THE USE BY ANY ORGANIZATION OF THIS USER MANUAL OR ANY INFORMATION CONTAINED HEREIN ANY PERSON OR ORGANIZATION UTILIZING THIS USER MANUAL FOR ANY PURPOSE DOES SO AT ITS HIS HER OWN RISK vi 5 INTRODUCTION 1 Introduction 1 Downhole Corrosion Monitoring System DCMS The RCS Downhole Corrosion Monitoring System DCMS is the only system which provides continuous corrosion history of Downhole tubing
45. is powered by a 9V battery Alkaline or lithium batteries are recommended The Probe Monitor will operate for approximately 24 hours continuously with a fresh alkaline battery longer with a lithium battery The Probe Monitor may not store the total number of DHT measurements made if the battery is completely depleted Cross Flow Adapter A Cross Flow Adapter is attached to the Mounting Head Adapter end of the DHT While holding the DHT in the center of the production tubing the Cross Flow Adapter serves to transfer the well bore flow from the outside of the DHT to the inside of the lock mandrel The Cross Flow Adapter must minimize pressure drop as well as provide the strength required to support the DHT Typically a Cross Flow Adapter will drop only a few psi The DHT is capable of mounting on a variety of lock systems The lock mandrel and Cross Flow Adapter are usually customer specific items and are chosen or manufactured to be compatible with the wire line running tools to be used 8 DCMS Running Tools Running Tools and running procedures are critical to the successful operation of the DCMS system Consultations between RCS the customer and the wire line company are required to ensure correct tools are available and correct running procedures are used INTRODUCTION 9 RCS offers a custom DCMS Tool Kit P N 724121 to provide for the complete assembly and disassembly of the DHT In addition to mechanical tools four cust
46. l instructed to remove This prevents grease from contaminating the Probe Element Step 1 Inspect Installation of O Rings and Back up Rings WARNING avoid damage O rings and O ring grooves only use O ring Pick Set to install or replace O rings and Back up Rings 1 On the Mounting Head Adapter there are two grooves between the fine threaded end and the wrench flats A new O ring and a new Back up Ring must be placed in each groove before each Downhole run The Back up Ring in each groove must be positioned nearest the threads as shown in Figure 4 2 O RING 2 PLACES P N 202027 BACK UP RING 5 8 API SUCKER l 2 PLACES P N 202028 ROD PIN CONNECTION SPEC MOUNTING HEAD ADAPTER P N 724030 Figure 4 2 Mounting Head Adapter O Ring and Back Up Ring Placement WARNING Never use O Rings or Back up Rings for more than one Downhole run to prevent leakage and damage to the DHT internals Make sure that O Rings and Back up rings are positioned as shown in FIGURE 4 2 for the Mounting Head Adapter and FIGURE 4 3 for the Probe Adapter 32 DCMS l 2 In the Probe Adapter there are two grooves between one threaded end and the wrench flats A new O ring and a new Back up Ring must be placed in each groove before each Downhole run The Back up Ring in each groove must be positioned nearest the threads as shown in Figure 4 3 Step 2 Depassivate New Battery
47. nd is threaded onto the Probe Adapter Probe Adapter The Probe Adapter is a fitting used to adapt the Probe Assembly to the Instrument Body Mounting Head Adapter The Mounting Head Adapter is a fitting equipped with a 5 8 API sucker rod connection Spec 11B The Mounting Head Adapter is used to attach the Cross Flow Adapter to the Instrument Bogy 6 DCMS Battery Assembly WARNING Violent explosion fire and severe burn hazards Do not short circuit recharge disassemble overheat incinerate or expose contents to water Refer to Appendix A for handling and storage information Failure to follow these warnings could result in serious injury or death CAUTION An internal fuse in the Battery Assembly may open if the Battery Assembly terminals are short circuited or if current in excess of 1 Amp is otherwise produced externally CAUTION Anew Battery Assembly must be depassivated immediately prior to use The Battery Assembly is a custom engineered lithium thionyl chloride battery used to provide easy assembly and long life Downhole The Battery Assembly contains a coaxial connector which mates directly with the small connector on the Instrument Tube Assembly A new depassivated Battery Assembly must be used before installing the DHT in a well Battery Assemblies are not rechargeable Do not attempt to defeat the safety connector at the end of a Battery Assembly Battery Assemblies are protected with an intern
48. om electronic instruments are included which are necessary to setup and monitor the DHT The contents and layout of the DCMS Tool Kit are shown in Figure 1 3 10 DCMSm 9 9 94 0 r r 4 tt tt ty REE ERE 4 10 ORO do Pod odo odo dodo ptg opu nnn HH 4 t 4 4 d Figure 1 3 DCMS Tool Ki e ENT T emm um OE Specification Downhole Tool Specification Environment Shock Random Vibration Temperature Pressure Flow Velocity Body Material Standard CORROSOMETER Probe Assembly Temperature Sensor Memory Capacity Measurement Intervals Thread Attachment Specification 11 CHAPTER 2 Oil Gas Water production Sweet or Sour Service subject to running tool specifications 30 G s Max 30 to 300 Hz at 2 22 G Hz 25 G rms 325 F 163 C maximum 10 000 psi 69 MPa maximum 90 feet per second maximum gas flow 20 feet per second maximum liquid flow UNS 517400 17 4 S S Conforming to NACE 0175 Repeatability 0 596 of Span Resolution 0 196 of Span Accuracy 3 Repeatability 3 F Resolution 0 1 F 1024
49. om each other preventing connector damage and potential short circuits Do not store batteries loosely and do not place batteries on metal surfaces Batteries should be stored on end with the connector end pointing upward Temperature and Environment Batteries should be stored in a cool dry well ventilated area with an optimal storage temperature range of 0 25 C If prolonged storage is anticipated batteries should be protected from excessive humidity Hazard Consideration Lithium battery storage areas should be clearly marked and provided with Lith X or a Class D fire extinguisher Batteries may burst if subjected to excessive heating In the event of fire only Lith X or a Class D fire extinguishers should be used DO NOT USE WATER since water will cause exposed lithium to ignite Signs should clearly state that water is not to be used in case of fire Safe Incoming Inspection The proposed flow of batteries throughout the facility should be thoroughly reviewed by plant safety personnel to identify and eliminate potential sources of electrical and physical damage to the batteries Conditions that can short circuit recharge over discharge puncture crush or overheat the batteries must be avoided and all personnel involved in the handling should be properly trained Safe Testing Physical dimensioning should be performed with all plastic calipers and no electrical test should be performed without first consulting RCS eng
50. oride 5mall spills can be handled by abzorption and reacted with large amounts of dry alkali soda ash and or lime Shovel into apprepriate container for disposal WASTE DISPOSAL METHOUID Marke disposal must be in accordance with federal state and local environment regulations emm Udemm X SPECIAL PRECAUTIONS amp STORAGE DATA aee md ed UT PR MM EE STORAGE TEMPERATURE MIN MAX Ambient 122 150 SHELF LIFE nnn n nnn nod Unlimited in closed containers and im the absence of meisture drums one year maximum SPECIAL SENSITIVITY 1 Moisture or heat greater than 121 50 HANDLING STORAGE PRECAUTIONS This product is extremely corrosive not breathe mists Do not get nn syes skin Wash hbseraughly after ham limg Store cantainers in a cool dry amd well ventilated area But of and from Tiro hazarde Stersge ssniminsrs associated sbauld be J AL or 316L steel nickel cf lised with FIFE Polytetraflusraethylana lead porcelain enmmal or galvanized steel allow moisture to enter storage containers this will cause increased corresion and release of Hy
51. p 6 5 the cycle time is not correct press the EDIT key followed by the UP and DOWN arrow keys to correctly program the cycle time When the cycle time is correct press 26 DCMS OEN SLS the EDIT key again to store the reading the old value will be lost or press the CONFIG key to abort no changes will occur NOTE It is suggested setting the cycle time with few extra minutes compared to the actual reading interval to avoid and erroneous timeouts 6 Press the DISPLAY key to determine how many measurements were made This will be zero for initial use 7 Press the MEAS key to initiate monitoring the Probe Element It may be necessary to let the Probe Monitor warm up for a couple of minutes before performing measurements The countdown timer will be activated counting from the cycle time down toward zero If zero is reached before a Probe Element measurement is detected a time out message is displayed 8 Press any key to stop the measurement process If the MEAS key is pressed again the number of measurements will be initialized to zero and the measurement process will start over If the OFF key is selected the number of measurements will be saved to be viewed the next time the Probe Monitor is turned on 9 When the DHT Probe Element is read the display of the Probe Monitor will first show CYCLE ONE and shortly thereafter change to CYCLE TWO to account for the two energization cycles of one DHT Probe Element
52. r long periods SECTION 8 TRANSPORTATION INFORMATION Non Harardous Batteries per If the batteries contain less than 0 5 gram of lithium see front of MSDS SECTION 9 DISPOSAL INFORMATION Page 2 of 25 102 180MR Bayer lt gt TRANSPORTATION EMERGEMCY CALL CHEMTREC mon amp 25 9100 DISTRICT OF COLUMBIA 202 582 7616 PRODUCT IDENTIFICATION APPENDIX A 51 MATERIAL SAFETY DATA SHEET BAYER CORPORATION PRODUCT SAFETY amp REGULATORY AFFAIRS 100 Bayer Koad Pittsburgh PA 15205 9741 NON TRANSFORTAT ION BAYER EMERGENCY 412 923 1800 BAYES INFORMATION PHONE 662 2927 PRODUCT Thionyl Chloride PRODUCT CODE 3 405 CHEMICAL Thiemyl Chloride 5 Sulfuteus Oryehloride Sulfur Oxryehloride CAS 7719 09 7 SOL TI HAZARDOUS INGREDIENTE CONCENTRATION 1 Coiling minimum 99 6 1 3 000 ag ad Ceiling NUMBER EXPOSURE LIMITS Thiomyl Chloride 7719 09 7 OSHA 1 000 ppa ACGIE 1 000 Coil ing 5 000 mp mi Ceiling Hydrochioric Acid Diexide Chlerime amd Sulfur te released by kydrolysis er thermal decomposition of Chloride and may b
53. rd class is CLASS 9 Miscellaneous and the packing group is PACKING GROUP II The regulations state that the batteries have to be separated to prevent external short circuits and they have to be packed in inner fiberboard container no more than 500 grams of lithium per inner container The containers can then be packed with at least one inch of non combustible packing material such as vermiculite separating each inner package in UN approved fiberboard boxes steel drums fiber drums or wooden boxes These packages have to be printed with a United Nations Marking Symbol section 6 0 of IATA shipping regulations For cargo aircraft transportation each package must have a gross weight no more than 35 kgs A 24 hour emergency response number must be provided on the shipping papers in order to provide instructions if an emergency condition arises during transport The batteries can be shipped by motor freight rail freight water or Cargo Aircraft only Lithium thionyl chloride batteries cannot be carried aboard passenger carrying aircraft Boxes must be labeled with a MISCELLANEOUS CLASS 9 label If the batteries are to be shipped by air then the package has to have a CARGO AIRCRAFT ONLY label attached Also boxes must be marked with the proper shipping name and the UN number near the shipping labels 48 Save the shipping packaging which the batteries received since this packaging meets these requi
54. re required to be used You can only drop Sub Systems on a System or another Sub System On Line The On Line is a Device group for holding On Line Devices e g Microcor amp System MT 9485 The On Line group is not required for On Line devices to be used The On Line can be dropped on Systems or Sub Systems 20 DCMS Off Line ie The Off Line is a Device group for holding Off Line Devices 9 Checkmate RDC CK 4 The Off Line group is not required for Off Line devices to be used The Off Line can be dropped on Systems or Sub Systems NIE Device Be The Device is used to drop a device e g Corrdata System E9020 Checkmate Plus Aquamate on the Equipment Layout screen A Device may be dropped on a System Sub System On line and Off Line Groups and in some cases other devices When the Device is dropped a dialog window will pop up for you to select the actual device to use Probes 0 0 Probes can only be dropped on devices and then only if the device accepts the type of probe being dropped When a probe is dropped it will show the measurement attributes for that probe e g Metal Loss Temperature DHT OPERATIONAL PRETEST 21 Sample Configuration Here is a sample configuration consisting of a System Plant Sub System Building1 Device RDC Down Hole Tool and Probe Down Hole Probe ID 2 J 222222 x E 2 Ws e EN
55. reading Immediately following each Probe Element reading the Probe Monitor will display the current tally of Probe Element readings i e where the total number of Probe Element readings and the countdown timer will be reset to its programmed value NOTE A typical DHT Probe Element reading takes a total time period of about 45 seconds including a warm up period and a post processing period Allow the Instrument Tube Assembly to operate long enough to collect the desired number of readings before proceeding with the Disassembly Sequence below Disassembly Sequence Verify Test Data Step 1 Remove Battery Assembly from Instrument Tube Assembly 1 Maintain the Probe Assembly Instrument Tube Assembly and Battery Assembly on a flat horizontal surface 2 Disconnect the Battery Assembly from the Instrument Tube Assembly NOTE Due to the short duration of the pretest the Battery Assembly can still considered new and should be saved for future use DHT OPERATIONAL PRETEST 27 Step 2 Detach Probe Assembly from Instrument Tube Adapter 1 Disconnect the Probe Assembly from the Instrument Tube Assembly by pulling the Probe Assembly connecter from the Instrument Tube Assembly Step 3 Read Data from Instrument Tube Assembly WARNING Disconnect Battery Assembly prior to downloading Data from the Instrument Tube Assembly Download DHT data from the PC with the Communications Adapter Set Toggle Swi
56. rements and may be re used for returning batteries to RCS or a disposal facility Safe Disposal Lithium thionyl chloride batteries must be disposed of properly in accordance with 49 CFR Lithium batteries for disposal are classified a WASTE LITHIUM BATTERIES FOR DISPOSAL and they are shipped with the same regulations as those for new lithium thionyl chloride batteries There is no long lasting contamination as a result of disposal of lithium thionyl chloride batteries there are only hazards associated with the neutralization and disposal process The end products of lithium thionyl chloride battery deactivation are not toxic once neutralized Lithium thionyl chloride batteries should be disposed of by professional disposal companies Contact Battery Engineering Inc for a recommendation of companies that can perform this disposal Because each state has different disposal regulations contact your local environmental agency for instructions on how to dispose of lithium batteries APPENDIX 49 MATERIAL SAFETY DATA SHEET Battery Engineering Inc Date Prepared November 27 1995 1636 Hyde Park Ave Hyde Park MA 02136 Tel 617 361 7555 Fax 617 361 1835 24 Hour Emergency Telephone Chem Tel 1 800 255 3924 Section 1 IDENTIFICATION Product Name Hazardous Components Approx 96 Lithium 4 6 Thi Chloride 39 5 25 102 180 Amin 65 Lithium Chloride 2 6 LITHIUM THIONYL CHLORIDE CELL Non Hazardo
57. ronic Overexposure can cause symptoms of nonfibrotic lung injury Signs and Symptoms of Exposure Eye and mucous membrane irritation Medical Conditions Generally Aggravated by Exposure Asthma other respiratory disorders skin allergies Emergency First Aid Procedures Seek medical assistance for further treatment Eye Contact Flush with running water for at least 15 minutes Hold eyelids apart Seek immediate medical treatment Skin Contact Rinse with large amounts of running water If bums develop seek medical treatment Inhalation Remove to fresh air If breathing is difficult administer oxygen and seek medical treatment Ingestion Seek medical treatment SECTION 6 CONTROL AND PROTECTIVE MEASURES Respiratory Protection Acid Gas Filter Mask Protective Gloves Butyl Rubber Gloves Protection Chemical Worker Safety Glasses Ventilation To Be Used Local Exhaust SECTION 7 PRECAUTIONS FOR SAFE HANDLING AND USE Steps to be Taken if Material is Spilled or Released Do not breathe vapors or touch liquid with bare hands Waste Disposal Methods Neutralize spill with soda lime seal leaking battery and soda lime in plastic bag and dispose of as hazardous waste Precautions to be Taken in Handling and Storage Do not short circuit or expose to temperatures above 180 Do not recharge overdischarge puncture or crush Other Precautions and or Special Hazards Do not store batteries in high humidity environments fo
58. t the Battery Assembly from the Battery Depassivation Instrument The Battery Assembly is now ready for immediate use Step 2 Program Instrument Tube Assembly WARNING The Instrument Tube Assembly must NOT be programmed while connected to the Battery Assembly 1 Program the DHT from the PC with the Communications Adapter Set Toggle Switch on communications adapter to middle off position before connecting to DHT Connect Serial connection from DHT to PC and verify COM port being used Follow the steps below to set up the DHT manually Note For further details on Corrdata ll refer to the CORRDATA II User Manual for details on setting a DHT Toggle the communications SWITCH DOWN FOR PC COMMUNICATIONS to enable power and configuration to the DHT from the communications adapter DHT COMMUNICATIONS ADAPTER SWITCH UP FOR ENABLINC DHT BATTERY POWEF DHT OPERATIONAL PRETEST 15 Run Corrdata Il and input Password select Database File To change the password select Password Options and the following dialog will pop up 16 DOMS TM SQL Server Login Server Select local if you have a standard Microsoft SQL Server installed Select local SQLExpress if you have an Express Server installed Depending on SQL Server installed SQLExpress may be local for login Select Manual Entry to enter the Server Name of another SQL Server Password Enter th
59. talyze violent reactions ef Thienyl Chloride mizteres with organic chemicals Thionyl Chloride mixturas with organic chemicals must be stored in containers free of iren amd tine and must be equipped with pressure relief device Refer te Section X apecial precautions storage data INSTABILITY CUNDITIONS Excaasiva temperatures DECOMPOSITION TEMPERATURE Detempoaition begins at 284 140 C DECOMPOSITION PRDODUCTS thermal decomposition Chlorine Sulfur Sulfur Chleride contact with water Mydrochloric Acid Sulfur Dioxide Product Code 9404 HSDS 4 Approval date 11 08 95 Continued on next page APPENDIX 55 13 SPILL AND LEAK PROCEDURES rr EFILL OR LEAK PROCEDURES vmcumte area and stay upwind If it is safe de trained pereoree should attempt to stop er reduce loak Large Spills 8250914 be contained and pumped into salvage drems or other appropriate containers Full acid resistant suits sm self contained breathing apparatus be worn during emergency operations clouds formed by reaction of the apilled thionyl chloride with atmospheric moisture can be controlled by water fog of water spray After bulk of material is removed large quantities of ash lime or a combination of these can be used to up and neutralize the remaining thianyl chl
60. tch on communications adapter to middle off position before connecting to DHT Connect Serial connection from DHT to PC and verify COM port being used Follow the steps below to set up the DHT manually Note For further details on Corrdata refer to the CORRDATA II User Manual for instructions on configuring a DHT 2 Read data from the Instrument Tube Assembly by following the steps below Toggle the communications SWITCH DOWN FOR PC COMMUNICATIONS to enable power and configuration to the DHT from the communications adapter DHT COMMUNICATIONS ADAPTER WITCH UP FOF ENABLING DHT BATERY POWER Run Corrdata Il Click Equipment Layout Selection Tool EE IV Expand down to your configured DHT V Click to Download Data from Device and wait for download to complete 28 DCMS the Metal 1055 Temperature data to the Selection Tool window click on Graph Data Sample DHT Data gon Graph Mode Metal Loss Temperature N BOR o o rrHrrrrHrrrr N w TTT FT T Metal Loss in mils Temperature 220 A w 1 304 N a 128 1 25 1 264 20 ot 1244 14 Sat 15 Sun 16 Mon 17 Tue Apr2012 Date Start Date 4 13 2012 7 49 21 PM Metal Loss 0 0216 mils Corr Rate 0 028 my End Date 4 16 2012 11 09 40 PM Pont
61. ube Assembly Repeat steps 1 4 of Chapter 3 Data analysis covered in step 6 of Chapter 3 is not necessary since that has already been performed Step 6 Attach Probe Assembly to Instrument Tube Assembly 1 Verify that the Seal Loading Nut Set Screws are backed out enough to clear the connector opening DHT ASSEMBLY 35 Er 2 Connect the Probe Assembly to the Instrument Tube Assembly by sliding the Seal Loading Nut end of the Probe Assembly over the large connector on the Instrument Tube Assembly 3 Carefully rotate the Probe Assembly until the connector keys are aligned and then push the connectors together as far as possible 4 Torque the Seal Loading Set Screws to 10 inch pounds with a 1 16 Allen torque wrench or as tight as a standard 1 16 Allen key will allow Step 7 Attach Battery Assembly to Instrument Tube Assembly immediately before use Refer to Step 2 above A battery that was used in a DHT Operational Pretest as described in Chapter 3 is considered a new battery WARNING Always use new Battery Assembly and depassivate Lay the Instrument Tube Assembly and the Battery Assembly on table or other flat horizontal surface 2 Attach the DHT Communications Adapter to the DHT Set Toggle Switch on the communications adapter to middle off position before connecting to DHT Once both sides are connected Battery and communication adapter in off position Toggle the communications S
62. us Components Approx Stainless Steel 42 5 Nickel 04 04 Carbon 47 Lithium Content 4 7 grams SECTION 2 PHYSICAL CHEMICAL CHARACTERISTICS Vapor Pressure Thionyl Chloride 92mm 2 20 C Vapor Density Thionyl Chloride 4 1 Solubility in Water Thionyl Chloride Decotmposes Specific Gravity Thionyl Chloride 1 63 Melting Point Thionyl Chloride 105 C Evaporation Rate N A Water Reactive Thionyl Chloride hydrolyzes to form SO and HCL Appearance and Odor Thiony Chloride Colorless to pale yellow sharp pungent odor SECTION 3 FIRE AND EXPLOSION HAZARD DATA Flash Point N A Auto Ignition Temp N A Flammable Limits N A Extinguisher Media Dry Lithium Chloride Graphite Powder Pyrene G 1 Lith X Class D Special Fire Fighting Procedures Cover with dry lithium chloride graphite powder Lith X powder or Class D fire extinguisher DO NOT USE WATER moist sand carbon dioxide or soda ash extinguisher Wear protective breathing apparatus Unusual Fire and Explosion Harards Do not short circuit recharge overdischarge puncture crush or expose to above 186 C SECTION 4 REACTIVITY HAZARD DATA Stability Stable Conditions te Avoid Temperatures in exoess of 180 C High humidity for extended periods Incompatibility N A Hazardous Decomposition Products Sulfur Dioxide Hydrogen Chloride Hazardous Polymerization Will not occur 50 DCMS SECTION 5 HEALTH HAZARD DATA Ch

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