EP Lubricity Tester
Contents
1. SCAR WIDTH 100th inch W Figure 6 Nomograph for Extreme Pressure 20 7 Troubleshooting and Maintenance 7 4 Cleanup The area in contact with the sample must be thoroughly cleaned after completion of tests This includes the lower end of main shaft test ring retainer nut block holder block adjustable offset bushing threads and adjusting nut If the machine is to be stored for a long period coat the above areas with oil to prevent rusting Avoid fluid spillage on control panel since this can seep around electrical components and cause electrical damage to the components Disconnect the machine and remove panel if required for cleaning 7 2 Belt Adjustment After extensive use check belt tension Ensure sufficient tightness to that when the motor stalls the belt does not slip To adjust belt tension use the following procedure 7 2 1 Remove belt guard top half by removing 4 screws 7 2 2 Loosen motor mount bolts and slide motor toward torque adjust handle then re tighten mounting bolts Make sure motor remains square with frame thereby maintaining pulley alignment 7 2 3 Replace belt guard Tighten screws 7 3 Lubrication The roller bearing lower bearing of the main shaft is greased with high temperature grease such as Lubriplate 12601 via the zerk fitting This bearing should be greased each 6 months under normal use Do not over grease The top bearing and torque shaft DO NOT require grease 7 4 Be2. Model 212 EP Lubricity Tester User Manual Part No 206905 RevE Copyright 2009 Fann Instrument Company Houston Texas U S A All rights reserved No part of this work covered by the copyright hereon may be repro duced or copied in any form or by any means graphic electronic or mechanical without first receiving the written permission of Fann Instrument Company Houston Texas U S A Printed in U S A NOTE Fann reserves the right to make improvements in design construction and appearance of our products without prior notice FANN is registered trademark of Fann Instrument Company Fann Instrument Company P O Box 4350 Houston Texas U S A 77210 Telephone 281 871 4482 Toll Free 800 347 0450 Fax 281 871 4358 Contact FANN a a Phone TELEPHONE 281 871 4482 TOLL FREE 800 347 0450 FAX 281 871 4358 Mail Fann Instrument Company P O Box 4350 Houston Texas 77210 USA Location Fann Instrument Company 15112 Morales Rd Gate 7 Houston Texas 77032 USA Online www fann com fannmail fann com Document Conventions The following icons are used in this manual to distinguish elements of text Contains additional information for the reader that is not safety NOTE related Describes a situation or practice that if ignored will result in equipment damage or loss of data Describes an unsafe condition or practice that if not WARNING Eu corrected will result i
3. to respond to magnet movement If switch is switching and signal is entering circuit board measure base of If the emitter of Q is not sending signal to then replace Qo The ON breaker may be opening because of a short hot to neutral 5 Fig 7 Unplug power cord and using an ohmmeter see if breaker is closed with the ON switch in the ON position Follow the heavy wires from 5 to find the short hot to neutral or ground The unit may be operating on a noisy AC Power The unit can pick up signals from other SCR control devices if MOV is damaged or burned out by excessive noise A new line 120VAC MOV METAL OXIDE VARISTOR will quiet the unit down Check the small white and yellow wires on the 0 1 ohm rib wound resistor 6 Fig 7 Repair if loose or broken Check 14 pin DIP plug 7 Fig 7 Check speed torque panel switch functions Check the 5K pot leads 3 Fig 7 to motor control board Check SCR s 4 Fig 7 on motor control board NAJEL NMSI S Qavsb S 94 53100 9998 d A AQOWNAS YOL JWOD 0832 SOHOL OLAV L4VHS H3NNI 0832 3NI4 HOS OHOL 64 LON JWOD B I il G ep 9 ta 84 ea 033 Y lv OH3Z 0801 gt 5 L m piz 8
4. 2 JE 2 iL v E NI CE Y 2i 0 W1 80 amp 14 vol L 10 ason aas OLN HOLIMS IT uaxvaug X X 31 8 Accessories PART NO ITEM NO DESCRIPTION 206896 E me oo u 206900 Test Ring EP Test Test Block EP Test 206902 A5 Test Ring Lubricity Test 206904 __ Calibrated Lubriity Ring Block Pair wiData Sheet 206947 A3 A4 Torque Adjust Wrenches Set 206949 iu 3 Reticulated Magnifier 205641 20573 230 Vac Step Down Transformer for 230 Volt Operation 206945 Torque Arm Adjusting Nut 32 19503 276902 HON34M LAVHS 9519443593 9 986902 MAWVS 7334 SSANNIVLS 276905 HON34M Lsnray 3NDHOL 106905 15018 1S31 da YO 006902 7 15049 SONIA 1531 06905 42018 206902 29 1531 ALDIHAMI HO 1 1531 189505 O LAN Woy a3nbuyol 9 5 Figure 11 33 9 Parts List 20098 6 _____ Torque Am Shat S 200929 Block Holder Assembl 20984 lo Test Ring Retaining Nut Torque Wrench Clam Torque Adjust Nut Torque Adjust Handle Torque Adjust Shaft Cup Stand Rod 205765 Harness Cable 14 Conductor wth Pug Torque Arm AdjustNut ooo O Torque Arm Adjust Nut 1 4 20 Thu
5. 32 Torque Arm Adjust Nut Block Holder 7 A Example 8 Example C b m Knife Edge High Knife Edge Low Adjust Down Adjust Up Figure 5 Adjustment to Correct Trapezoidal Pattern Problems of EP Test Block 5 3 3 EP Test Procedure on Sample The EP Test is used to determine the load or pressure the lubricant will hold without a complete breakdown of film strength This is termed a PASS Breakdown of lubrication film allows metal to metal contact which causes galling and is termed a SEIZURE A PASS may be identified in one of two different ways One type of pass is a 5 minute run at a constant load during which the torque meter reading remains essentially constant and the wear surface is small and polished The other type is 5 minute run in which there is a moderate amount of torque meter deflection and the wear surface is moderate and either may be polished or dulled depending on the abrasiveness of the sample A SEIZURE is defined as tearing and galling Scarring of the metal in contact between the test ring and test block surfaces representing a complete breakdown of the lubricating ability possessed by the drilling fluid under test A seizure is identified by a rapid as opposed to slow rise in torque reading A seizure also may appear as a sharp substantial increase in torque which drops back to normal This second type of seizure usually occurs at a relatively low torque readi
6. OR OFFSET BUSHING UNLESS THEY ARE TO BE REPLACED IF THIS OCCURS ALL CALIBRATIONS WILL BE LOST AND WILL REQUIRE READJUSTMENT The torque shaft is treated with a dry film lubricant and should never be sanded or filed Clean using a soft cloth 7 5 1 Remove torque wrench 22 7 5 2 Loosen the socket head cap screw in the test block holder then using a screwdriver to slightly widen the slot slide the block holder off the shaft Remove key from shaft 7 5 3 Remove shaft upward out of the bushing then remove o ring from bottom of offset bushing 7 5 4 Loosen bushing lock screw in lower bearing housing then remove offset bushing toward bottom A suitable bolt and puller may be necessary 7 5 5 Install new offset bushing with thick side to right of machine and install upward in housing with lower end approximately 3 8 inch above center of taper on main shaft The exact position will be adjusted later 7 5 6 Install adjusting nut do not tighten 7 5 7 o ring in groove at lower end of bushing Use grease to hold o ring in place 7 5 8 Install torque shaft from top and install key 7 5 9 Slide block holder upward onto torque shaft making sure o ring is properly seated and key is in place DO NOT leave any vertical play in the assembly However when rotated with the torque wrench no reading should be observed Tighten lock bolt in block holder 7 5 10 Adjust cam rotation to obtain a centered pattern on th
7. be inserted on this sheet at any time to ensure user confidence in the data produced by the pair 34 AV READING Correction Factor CF Meter Reading X CF 100 Lubricity Coefficient CALIBRATION CHECK RUN 1 RUN 2 STARTING 30 MIN 40 MIN 50 MIN 60 MIN 70 MIN Figure 3 LUBRICITY RING BLOCK PAIRS 5 2 Lubricitv Test 5 2 1 Block and Ring Standardizing Test The coefficient of friction value for water would be 34 at 60 RPM and 150 in Ib 16 95 N m torque if all ring block metallurgical structures were the same However since they are not a correction factor of 34 divided by the water reading is used A convenient form for this purpose is shown in Fig 3 5 2 1 1 Clean test ring and test block with a cleaner such as Ajax or Comet with chlorinal and rinse thoroughly with water Before starting the test all parts of machine in sample area must be clean This includes the stainless steel cup exposed portion of bushing cup retainer nut block holder and lower part of shaft RESULTS AVOID TOUCHING THE OUTSIDE OF CONTAMINATION CAN CAUSE INCORRECT TEST 7 TEST RING 5 2 1 2 Place lubricity test ring on main shaft and using wrench secure with test ring retainer nut Engage shaft lock plunger in hole in shaft to prevent shaft rotation while retainer nut is tightened Make sure the ring seats squarely on the taper of the shaft 5 2 1 3 Place lubricity test block in block holder
8. 0 in lb 16 95 N m Operate for 4 to 5 minutes or until a seizure occurs If seizure occurs remove load quickly 5 3 1 10 Remove load by rotating torque adjust handle counterclockwise until torque is completely released from main shaft When torque registers zero turn power off Lower cup stand Turn torque arm clamp up and away Swing torque arm back to allow removal of test block Remove and clean test block 5 3 1 11 Observe scar left on block by ring Refer to Fig 5 Proper alignment of the test block in the holder will be indicated by the appearance of a rectangular scar on the test block Fig 5 Ex C An improper alignment will be indicated by the appearance of a triangular or trapezoidal shape Fig 5 Ex amp B If alignment is proper proceed to Section C 5 3 2 Block Alignment If improperly aligned block and block holder must be repositioned 5 3 2 1 Check to be sure there is no play between the block holder and the shoulder at the bottom of the threads on the torque shaft bushing Any looseness up and down motion must be corrected Remove block holder clean and reinstall against the shoulder of bushing onto keyed shaft and tighten socket cap screw Make sure o ring if used is in place 5 3 2 2 Depending on the shape of the triangle or trapezoid adjust block holder either upward or downward If trapezoid appears larger on top than on bottom Fig 5 Ex A holder must be adjusted downward 5 3 2 3 Loosen bushi
9. ES OF SECTION 7 INVOLVE OPERATING THE MACHINE WITH THE BELT GUARD AND CONTROL PANEL REMOVED THIS EXPOSES UNPROTECTED HIGH VOLTAGE TERMINALS TOUCHING OR ALLOWING THESE TERMINALS TO TOUCH THE MACHINE OR WORK SURFACE CAN CAUSE DAMAGE AAN WARNING AND INJURY ALSO THE PRONY BRAKE IS DYNAMIC BRAKING TOOL WHICH IF NOT HANDLED CAREFULLY CAN GRAB ONTO SHAFT AND SWING UPWARDS TOWARDS OPERATOR WHILE DROPPING A 1000 GRAM WEIGHT This procedure should be carefully studied and DRY RUN made with the machine unplugged to become familiar with where moving parts will be where exposed electrical connections are and where the adjustment potentiometer are located so that neither the technician nor the machine is injured by these potential hazards Make sure to unplug the machine before re assembly 3 Features and Specifications 31 Mechanical Motor and Belt Drive The motor runs at 90 VDC maximum speed is directly variable by voltage with a maximum of 1800 RPM The speed is reduced at the V belt sheaves by a factor of 1 1 6 Lubricity Test Blocks and Rings The lubricity test blocks and rings are hardened steel components between which the fluid lubricity is tested These components must be matched and calibrated together before performing a test The ring will wear a uniform wear pattern in the block during calibration There are different types of test blocks and rings for EP tests and for lubricity tests The rectangular blocks are use
10. Example C With block holder rotated to wear ring note the eccentricity of shaft in hole This figure shows the shaft left in hole Loosen bushing adjuster lock screw 32 with a 3 16 allen wrench and rotate bushing 29 in hole counterclockwise to move block forward to correct for too much wear at tip Example A or clockwise to correct for too much wear at of block Example B Retighten bushing adjuster lock screw Repeat until wear is near center of curvature Example C Figure 4 Adjustment for Curvature of Lubricity Test Block 5 3 Extreme Pressure EP Test A test made with the EP Lubricity Tester using the EP ring and block is a measure of the relative extreme pressure lubricating ability of a drilling fluid 5 3 1 Block and Ring Alignment Test Before a test can be run accurately the machine must be in proper adjustment as indicated by the rectangular shape in Fig 5 Ex C To test for proper adjustment or to do a standard test proceed through the following steps If alignment is a problem go to BLOCK ALIGNMENT 5 3 1 1 Clean EP test ring A5 ring Part No 206902 with narrow raised surface and EP test block block Part No 206903 with 6 flat surfaces with a cleaner such as Ajax or Comet with chlorinal and rinse thoroughly with water Before starting test all parts of the machine in the sample area must be clean These include the stainless steel sample cup exposed portion of bushing test ring ret
11. HIGH SPEED TACH TACH READING 2000 SPINDLE SPEED 1000 RPM REFLECTOR TAPE STRIPS Qaaas ouaz alan ansvyon e mou damod 212 AAVA da Figure 8 Speed Calibration 27 7 6 3 3 Turn unit its side and install prony brake the shaft between the upper and lower bearing housing as shown in Fig 9 Make sure panel is temporarily supported and no electrical connections can short or may be touched 7 6 3 4 Turn Panel meter switch to torque position and turn speed control to far counterclockwise and torque zero knob to mid range Turn the machine on Adjust torque zero pot R7 Refer to Fig 7 to zero on meter 7 6 3 5 Adjust speed to 60 RPM then adjust the tightness of the screws in the prony brake until it balances horizontally with the 1000 gram weight hanging in the notch Make sure that the speed in maintained at 60 RPM Carefully support arm of prony brake until screws are sufficiently tight The arm of prony brake must be maintained as nearly horizontal as possible Refer to Fig 9 7 6 3 6 Adjust PC meter board potentiometer R11 to 41 0 41 5 units of torque on meter Refer to Fig 7 7 6 3 7 Release prony brake by removing weight and or loosing bolts and adjust zero potentiometer on meter board so that meter in torque mode reads zero Refer to Fig 7 7 6 3 8 If necessary repeat steps 4 and 5 above until the 41 0 41 5 and zero are maintained with no furthe
12. NG BLOCK AND RING A blank form as illustrated in Fig 3 should be used 5 2 2 Standardizing Block and Ring If the coefficient of friction value for water is not in the proper range is drifting excessively or has scoured surfaces the ring and block surfaces must be reconditioned or standardized If a block is standardized it will have a substantial portion at least 1 3 of its curved surface worn to a shined condition with a minimum of groove lines through this polished area as seen in Fig 4 Ex C Also a ring block calibration data sheet should be filled out and maintained for the pair When the ring and block are engaged in the following procedures no new wear surfaces should appear and no unexpected results occur using the pair 5 2 2 1 Check to ensure all surfaces are clean and that the wear surface is in the middle or just forward of the curvature on the block Refer to Fig 4 Ex C If an adjustment is required follow the procedure given in Fig 4 5 2 2 2 Operate the machine at 100 to 200 RPM If there is scouring recondition the surfaces in water by applying fine valve grinding compound with finger to ring and applying 150 in lb 16 95 N m of torque Remove torque after 5 minutes to reapply grinding compound on ring Then reapply constant 150 in Ib 16 95 N m of torque for 5 minutes This procedure is repeated 3 to 4 times 5 2 2 3 Use Ajax or Comet with chlorinal to remove grinding compound and grease then rinse
13. ace 4 13 16 4 812 inches or 122 3 mm from bearing seat in top bearing housing of casting or if top bearing was not removed the bottom surface of top ball bearing 7 4 10 Install top seal lip down and flush with top of casting Use washers and puller bolt 7 4 11 Install double lip lower seal Install seal flat side down and flush with bottom side of casting 7 4 12 If the top ball bearing was removed install a new sealed bearing then replace the bearing cap and 3 screws 7 4 13 If the lower bearing inner race was removed a new inner must be pressed onto shaft Thoroughly clean shaft remove any rough spots or burrs then lubricate the area where inner race is to be located Press DO NOT HAMMER inner race sleeve onto shaft 7 4 14 Lubricate lower bearing and seals and with a good grease such as Lubriplate 12601 then carefully slide shaft through from bottom being careful not to damage lips of seals Install shaft tang washer tangs upward and shaft nut with bevel downward onto shaft Tighten to 35 to 40 foot pounds 47 to 54 N m then bend one tang into a slot of nut as a lock 7 4 15 Reassemble pulley hub and pulley then belt 7 4 16 Tension belt and tighten motor mount bolts 25 to 30 foot pounds 34 to 41 N m Make sure motor remains square with frame thereby maintaining pulley alignment 7 4 17 Replace belt guard 4 screws 75 Torque Shaft and Cam Bushing Removal and Replacement DO NOT REMOVE THE CAM BUSHING
14. ainer nut block holder and lower part of shaft 5 3 1 2 Install test ring squarely onto tapered portion of shaft Then using wrench secure with test ring retainer nut Engage shaft lock plunger in hole in shaft to prevent shaft rotation while retainer nut is tightened Refer to Fig 1 Take care not to contaminate outside of test ring Contamination by skin oil can cause inaccurate test results 5 3 1 3 Place EP test block in block holder 5 3 1 4 With meter switch in RPM position turn power switch to ON Rotate speed control knob clockwise or counterclockwise until torque RPM meter registers 1000 100 RPM 5 3 1 5 Turn meter switch to TORQUE Rotate torque zero adjustment knob clockwise or counterclockwise until torque registers zero 5 3 1 6 Do not apply load yet Operate machine at 1000 50 RPM for approximately 3 minutes or until the torque zero reading stabilizes ceases to drift appreciably Reset torque knob to zero if necessary 5 3 1 7 Position torque arm so that it fits inside concave portion of torque arm clamp making sure not to apply load yet 5 3 1 8 Fill stainless steel sample cup with distilled water Place on cup stand and raise cup stand so that test ring test block and block holder are immersed in fluid Tighten thumb screw Refer to Fig 1 5 3 1 9 Rotate torque adjust handle clockwise so that torque is increased at the rate of 5 in lb 565 N m per second until torque meter attains torque reading of 15
15. aring and Seal Replacement Bearing and or seal replacement requires the removal of the main shaft 7 4 4 Remove top section of belt guard 4 screws 7 4 2 Loosen motor mount bolts and release belt tension then remove belt 7 4 3 Remove 3 hub to pulley bolts in driven pulley Screw these bolts into the tapped holes in the pulley to separate pulley from hub and remove pulley Remove hub from shaft 7 4 4 Bend tang of tang washer out of the slot in nut Holding shaft with shaft lock button remove shaft nut and tang washer 7 4 5 Tap the top of shaft with soft hammer to drive shaft downward out of top bearing Shaft is removed downward through the bottom bearing 7 4 6 To remove top bearing remove the 3 screws holding bearing cap then remove the cap Tap bearing upward and remove 7 4 7 To replace lower bearing and seals remove lower seal with a suitable seal 21 puller Slide lower needle bearing out the bottom of casting The top seal now can be removed upward from the casting 7 4 8 The inner lower bearing race is pressed onto the shaft It should not be removed unless it is to be replaced Extreme care must be used when removing this race to avoid bending the shaft Heating the race will assist in releasing the press fit Using a suitable punch drive sleeve toward top of shaft 7 4 9 Install new lower bearing outer race in casting bore using a suitable washer and puller bolt DO NOT hammer on this race Position bottom edge of r
16. as stopped is found by dividing this force by the scar area This pressure is referred to as the film strength of the sample An equation for the calculation is written as follows Force T 15 P Unit Area Wx 01x 125 T P 533 W Where P Film Strength psi T Torque meter reading in lb W Scar width hundredths of an inch W contains square inch units The Nomograph ANN Note shown in Fig 6 may be used to derive the film strength without calculation 6 2 3 Reporting Test Results 6 2 3 1 The lowest load torque meter reading in inch pounds and the average torque in inch pounds at which the seizure occurred are recorded 6 2 3 2 Record the following at the conclusion of a Pass or if a 5 minute test does not produce a seizure 6 2 3 2 1 Load torque meter reading in inch pounds 6 2 3 2 2 Scar width in hundredths of an inch 6 2 3 2 3 Film strength in psi 6 2 3 2 4 Average torque meter reading in inch pounds 600 550 500 450 400 350 300 250 150 100 50 LOAD CARRYING CAPACITY in Ibs T NOMOGRAPH FOR EXTREME PRESSURE LUBRICATING PROPERTIES OF DRILLING FLUIDS This nomograph was developed for the Fann EP Lubricitv Tester using 1 8 inch test cup contact length 8 1 5 inches moment arm TORQUE ARM READING 100 000 80 000 70 000 60 000 50 000 40 000 30 000 25 000 20 000 15 000 10 000 5 000 1 000 FILM STRENGTH psi P 533
17. d for EP tests The blocks used for lubricity tests have a rounded inset surface See Figures 1 4 and 5 Prony Brake The prony brake shown in Figure 9 is a device for checking torque and horsepower from a motor A torque wrench serves as the torque arm and provides a means for measuring torque values The torque wrench is held in place by the retainer arm 3 2 Electrical Analog Meter The analog meter displays RPM or torque as selected by the toggle switch This meter is a specialized unit for the Model 212 EP Lubricity Tester and must be serviced by Fann Instrument Company Magnetic Speed Pickup Sensor This meter reads the RPM of the test ring by magnetic change on the main shaft sends a micro amp signal to the calibrated analog meter for accurate measurements Motor Control Board The motor control board shown in Figure 7 converts AC power to DC for the motor There are adjustments to the board that are outlined in the maintenance section Preparation for Soeed and Torque Calibration FUNCTIONAL DIAGRAM EP LUBRICITY TESTER CONTROL CURRENT FEEDBACK U VOLTAGE is MOTOR p 1 SPEED amp TORQUE CIRCUITS LAS INPUT 1 DC VARIBLE SPEED COMMUTATOR MOTOR 2 MAGNETIC SPEED PICKUP SENSOR 3 TEST RING READOUT METER SPEED TORQUE 4 TEST BLOCK 5 TEST BLOCK HOLDER 6 APPLIED TORQUE GAUGE Figure 2 Functional Diagram EP Lubricity Tester 4 Installation The Model 212 EP Lubricity Tester is
18. e EP tests Fig 1 are performed by applying a measured torque with a torque arm to a torque sensitive rotating bearing cup This provides a means of testing lubrication under extreme pressure conditions and produces an indication of the film strength of the fluid being tested The problem of reduction of friction between the drill string and the borehole requires a different simulation The more common lubricity test Fig 1 measures fluid resistance lubricating character between two hardened steel moving surfaces at 100 pounds force which translates into a 5 000 to 10 000 psi 34 470 to 68 940 kPa pressure on the intermediate fluid film During the lubricity test a steel block is pressed against a rotating steel ring Load in inch pounds in lb is read directly from the dial on the torque arm Measure of friction is a requirement for the determination of the film strength of a lubricant for bit bearing wear as is obtained in EP test and for the determination of torque or drag of the drill pipe as determined in the lubricity test Friction is measured as the coefficient of friction u The coefficient of friction u between two solids is defined as F W where F denotes the frictional force and W is the load or force perpendicular to the surfaces Thus the coefficient of friction is independent of the apparent area of contact as long as this area is not so small as to break through the film that is with the same load W the force to ov
19. e test block as described in Fig 4 and STANDARDIZING BLOCK AND RING 7 5 11 Adjust cam elevation as described in Fig 5 and BLOCK ALIGNMENT 7 5 12 After completion of all adjustments make sure bushing lock screw is tight to 20 25 foot pounds 27 34 N m 7 6 Calibration Check and Electrical Adjustment The EP Lubricity Tester is carefully calibrated when manufactured and no additional adjustments should be necessary However with use and age it may become desirable to check and possibly readjust the instrument A functional diagram is shown in Fig 2 The procedure as described in Section A below is provided for this purpose 7 6 1 Calibration Check This procedure requires a calibrated ring block pair Part No 206904 and the accompanying data sheet The data represents the data this particular pair produced on a prony brake calibrated instrument 7 6 1 1 The block holder and main shaft must be cleaned 7 6 1 2 Use distilled water not deionized as the test medium 7 6 1 3 Check for the correct distance from torque shaft to main shaft eccentric adjustment The wear pattern should match as closely as possible the shiny zone on the block of the ring block pair being used Refer to Section 5 and Fig 4 Example C 23 7 6 1 4 Also check to determine whether the block holder requires adjustment up or down to match shiny zone on the block If adjustment is required refer to BLOCK ALIGNMENT and Fig 5 7 6 1 5 The difference i
20. easily mounted on a laboratory countertop 115 VAC power source is the sole service required for this unit The Model 212 requires 5 A current at 115 VAC A separately available 230 VAC step down transformer is needed to reduce the power from 230 to 115 VAC See Section 8 for the part number 5 Operation 5 1 Calibration 5 1 1 and Ring Pair Calibration Verify the alignment of the eccentric bushing up or down and in or out with ring block submerged in water so that wear pattern being generated is in the center of the shiny portion of the block Operate pair in distilled water for at least 15 minutes before taking any data at standard conditions 60 rpm and 150 in lbs 16 95 n m This must be done as new pattern will develop over the old one when a pair is moved to another tester as no two machines will have exactly the same geometry If adjustments are required refer to Section 5 After using pairs for testing slurries periodically return to water to be certain of trend of pair or to be confident that a migration of 3 4 units has not occurred Life of a pair is determined by wear depth Measure the OD of ring when new and note that when 0 025 in 635 mm has been worn from case hardened surface 0 050 on the OD then the ring is devoid of consistent case hardening and will not produce reasonable readings Block life should never extend beyond a 0 1 inch 2 54 mm wear depth As the pair ages new calibration data can
21. ectrical This instrument is powered by 115 VAC power The motor is 90 VDC The control panel enclosure contains electronic control components Only a qualified electrician or Fann service representative should try to perform maintenance on these components Make sure the machine is unplugged when cleaning or moving it Be sure it is unplugged when wiping the bench around or under it Do not allow the panel containing the meter to get wet If test fluid or water is spilled on it wipe clean with a damp cloth Excessive water could cause damage to the electrical components on the under side of the panel and could also be an electrical shock hazard Temperature The test blocks become hot due to the friction generated by the tests Use caution immediately after stopping a test as these parts may get hot enough to cause burns Mechanical This machine is driven by a motor connected by a V belt drive to the main shaft assembly A belt guard offers protection from the V belt itself The output shaft can still be a hazard so precaution should be exercised to keep hands clothes and other objects clear of all rotating parts Do not put hands or fingers in or near the sample cup test block or test ring while the machine is running Safety Precautions during Calibration Calibration procedures are described in Section 7 These procedures will determine if it is necessary to partially disassemble the machine for a complete calibration PROCEDUR
22. ercome friction will be the same for a small area as for a larger area Applied to the Lubricity Tester the load is the force with which the test block is pressed against the test ring through the torque arm The force F required to slide the block and ring surfaces across each other at a given rate is measured by the power required to turn the test ring at a prescribed number of revolutions per minute The coefficient of friction F W Refer to Figure 1 EP Extreme Pressure Lubricity Film Strength Test F Force Fluid Level w 10 to 500 pounds to produce seizure Usually higher shear rate 1000 RPM for EP test Here fluid pressures run from 5 000 to 100 000 psi between surfaces The pressure force at various speeds at which film breaks and galling occurs can be measured and improved additives tested W Load Lubricity Surface to Surface Drag Test F force or drag with Fiuid Level w 10 to 500 pounds 100 pounds typical 100 psi 60 RPM for standard lubricity coefficient test Lubricity additives to lessen drag losses can be easily tested The wear on a part can be predicted by making block or both ring and block of material used in part and running in fluid expected in application The procedure for this test is described in API procedure RP138 as well as in this instruction Figure 1 Comparison of EP and Lubricity Test 2 Safety 2 1 Machine Hazard 2 1 1 El
23. eviated holes Desirable characteristics of a lubricant for this purpose aside from the obvious requirement of performing well as a lubricant are that it is non toxic and bio degradable and does not form an oily slick on water Since evaluation of the various lubricating materials in the various types and quality of drilling fluid cannot realistically be done on the drilling rig a functional drilling fluid lubricity test was designed to simulate the torque and drag produced by a given drilling fluid downhole The tester models or approximates the speed of rotation of the drill pipe and the pressure with which the pipe bears against the wall of the hole where the friction is generated Extreme pressure lubricants have been developed to increase the life of bit bearings Extreme pressure lubrication deals with metal surfaces in rubbing contact with each other at very high pressures 30 000 to 100 000 psi 206 820 to 689 400 kPa Lubrication for the metal surfaces is provided by a pressure resistant film that is produced as a result of the chemical reaction initiated by a high temperature generated from friction at the area of contact The combination EP Extreme Pressure and Lubricity Tester is a high quality instrument designed to measure the lubricating quality of drilling fluids provide data to evaluate the type and quantity of lubricating additives that may be required and predict wear rates of mechanical parts in known fluid systems Th
24. mb Screw Lock Screw F bushing 204370 Strain Relief 205626 la Grease Fitting 2 5 l2 Torque Arm Torque Wrench 205655 14 16 x 1 2 x 3 32 Quad Ring 205670 34 205674 p Motor Sheave with Bushing 2 8 diameter 34 PART NO DESCRIPTION 205675 Main Shaft Sheave with Bushing 4 7 diameter Bearing Nut 205678 Lock Washer Roller Bearing 205688 Ball Bearing Grease Seal Upper Grease Seal Lower 205747 Circuit Breaker 205748 Meter Switch Bat Handle 205763 Torque RPM Meter 50 Microamp 205768 7 AC Power Cord w plug 205775 Knob Large Speed Control 205776 Knob Small Torque Zero Adjust 205779 36 Rubber Foot 205781 RPM Torque PC Board 205785 Permanent Magnet Motor 56C Frame 1750 RPM 1 2 HP 4 8A Frame Assembly 204494 NM Name Tag with Part amp Serial Numbers 205786 E Motor Speed Controller 35 A m atenn LI wi SS iu DC AS EESE A GERD wee noe fe Figure 12 Parts Locations 36 10 Warranty and Returns WARRANTY Fann Instrument Company warrants its products to be free from defects in material and workmanship for a period of 12 months from the time of shipment If repair or adjustment is necessary and has not been the result of abuse or misuse within the 12 month period please return freight prepaid and correction of the defect will be made without charge Out of
25. n personal injury possibly death TABLE OF CONTENTS SECTION 1 Introduction to the Model 212 EP Lubricity Tester 2 Safety 2 1 Machine Hazard 3 Features and Specifications 3 1 Mechanical 3 2 Electrical 4 Installation 5 Operation 5 Calibration 5 2 Lubricitv Test 5 3 Extreme Pressure EP Test 6 Analyzing Results 6 1 Sample Lubricitv Calculations 6 2 EP Calculations and Measurements 7 Troubleshooting and Maintenance 7 1 Cleanup 7 2 Belt Adjustment 7 3 Lubrication 7 4 Bearing and Seal Replacement 7 5 Torque Shaft and Cam Bushing Removal and Replacement PAGE 13 18 18 18 21 21 21 21 21 22 7 6 Calibration Check and Electrical Adjustment 7 7 Electrical Maintenance and Diagnosis 8 Accessories 9 Parts List 10 Warranty and Returns vi 23 30 32 34 37 1 Introduction to the Model 212 EP Lubricity Tester Frictional resistance to rotation of the drill string is called torque and frictional resistance to hoisting and lowering the drill string is called drag Many different materials have been used as drilling fluid additives to improve lubricity thereby reducing friction The lubricity or drill string to bore hole wall drag of drilling fluid is a property of special importance in drilling directional wells An increase in friction between drill string and borehole is expected when drilling a hole off vertical Most of the wells drilled from fixed platforms offshore are completed in d
26. n these readings at 150 in lb 16 95 N m and 60 RPM from this instrument and the original RUN readings is the percent calibration error in this unit If the percentage is not over 10 and readings do not fluctuate more than 5 units in 5 minutes a new calibration factor can be used Refer to CORRECTION FACTOR 7 6 1 6 If the error is over 10 the machine probably has 7 6 1 6 1 Worn main bearing 7 6 1 6 2 Worn motor bearings 7 6 1 6 3 Belt slippage 7 6 1 6 4 Brush contact corrosion or other problem requiring repair 7 6 2 Preparation for Speed and Torque Calibration If the calibration check procedure outlined above in Part A is insufficient the complete procedure for speed adjustment and calibration is as follows Speed Adjustment 1000 RPM 60 RPM Use an RPM measuring device such as a non contacting tachometer that is accurate or a strobe light A contact type tachometer may be used but the accuracy will not be as precise Fig 8 shows using a non contacting tachometer 7 6 2 1 Remove belt guard top section 4 screws Place two reflector tape strips for tachometer on driven sheave no contact tachometer These are placed 180 apart Turn outer panel speed control knob all the way clockwise Then turn back until sheave reflectors stand still with the strobe light set at 2000 or until tachometer reads 2000 This is actually 1000 RPM 7 6 2 2 Locate PC board potentiometer R5 Fig 7 and adjust meter to 1000 RPM If speed will
27. ng adjuster lock screw Tighten torque arm adjusting nut until finger tight against shoulder at bottom of shaft 5 3 2 4 Place 3 4 eccentric shaft wrench A4 on threaded shaft flat and place 1 1 4 torque adjust wrench A3 on torque bushing adjusting nut Tighten nut pulling eccentric shaft downward in increments of 005 inch 13 mm to 010 inch 25 mm 1 12 to 1 6 turn until a rectangular pattern is obtained If the pattern changes as shown in Fig 5 Ex B Refer to Step 5 3 2 7 below DO NOT ALLOW ECCENTRIC NA BUSHING TO ROTATE AS THIS WILL DESTROY THE LUBRICITY ADJUSTMENTS 5 3 2 5 Tighten socket head screw 5 3 2 6 Position block on block holder so that a new side will come in contact with the ring Eight tests can be run on one block Repeat the test outlined in Block and Ring Alignment Test to obtain a rectangular scar If required continue to repeat until a rectangular scar is obtained 5 3 2 7 If the trapezoid appears smaller on top than on the bottom Fig 5 Ex B loosen bushing adjuster lock screw and loosen the adjusting nut one revolution 1 16 inch 1 5 mm 5 3 2 8 Tap end of shaft upwards about 1 16 inch 1 5 mm or until nut is against shoulder 5 3 2 9 Adjust block holder downward in increments of 005 inches 13 mm or 010 inches 25 mm as described in Block and Ring Alignment Test until a rectangular pattern is obtained Adjustable Offset Bushing 3 Bushing Adjuster Lock Screw
28. ng or during tests of highly abrasive drilling fluids or drilling fluids with high solids content A seizure is accompanied by an obvious change in the pitch sound of the machine usually a sudden rasping sound or in the case of the second type an intermittent rasping sound After a seizure the wear surface on the test block will be very large and will appear very rough and scarred The surface of the test ring also will be rough and scarred 5 3 3 1 Install new test ring squarely onto tapered portion of shaft Then using wrench A2 secure with test ring retainer nut Engage shaft lock plunger in hole in shaft to prevent shaft rotation while retainer nut is tightened Take care not to contaminate outside of test ring Contamination by skin oil can cause inaccurate test results 5 3 3 2 Place EP test block in block holder making sure a new side will contact ring 5 3 3 3 With meter switch in RPM position turn power switch to ON Rotate speed control knob clockwise or counterclockwise until torque RPM meter registers 1000 100 RPM 5 3 3 4 Turn meter switch to TORQUE Rotate torque zero adjustment knob clockwise or counterclockwise until torque registers zero 5 3 3 5 DO NOT apply load yet Operate machine at 1000 50 RPM for approximately 3 minutes or until the torque zero reading stabilizes ceases to drift appreciably Reset knob to zero if necessary Turn machine OFF 5 3 3 6 Position torque arm so that it fits inside concave p
29. not reach 1000 RPM turn Fig 7 potentiometer on motor control until 1050 RPM is attained with speed control full clockwise then adjust control to 1000 RPM 7 6 2 3 Turn outer panel speed control knob all the wav counterclockwise Adjust motor controller potentiometer labeled MIN Fig 7 until panel meter reads 40 50 RPM Turn panel speed control knob all the way clockwise and read 1025 1050 RPM Repeat adjustments if necessary 24 FRAME pp REED SWITCH BUTT SPLICES CABLE PC METER BOARD FRONT PANEL VIEWED FROM BACK SIDE Figure 7 Electric Controls 25 7 6 3 Motor Torque Adjustment on Motor Control Board 7 6 3 1 Set RPM to 60 Install a worn in lubricity wear block into the test block holder and distilled water in the sample cup Operate the machine at 150 in lb 16 95 N m on the torque wrench Refer to STANDARDIZING BLOCK AND RING for details Watch RPM meter for speed up or slowdown while loading from 0 to 150 in Ib 16 95 N m and back to 0 in Ib 7 6 3 2 Adjust IR compensating potentiometer on motor controller until speed with no load and speed with 150 16 95 N m is the same at 60 RPM If motor slows with 150 in Ib 16 95 N m load increase IR if motor speeds up with the 150 in lb 16 95 N m load decrease IR If motor stalls increase CL current limit pot setting on motor control board 26 SET LOW SPEED a TACH READING 120 DJ SPINDLE SPEED 60 RPM SET
30. ortion of torque arm clamp making sure not to apply load yet 5 3 3 7 Fill stainless steel sample cup with sample to be tested Place on cup stand and raise cup stand so that test ring test block and block holder are immersed in fluid Tighten thumb screw Turn machine ON 5 3 3 8 Rotate torque adjust handle clockwise so that torque is increased at the rate of 5 in Ib 565 N m per second until an acceptable loading for the sample is reached then operate for 4 to 5 minutes If the maximum film strength is to be determined continue the loading until a seizure is encountered Note the maximum load torque wrench reading When seizure occurs remove load quickly 5 3 3 9 Repeat the test using a new block surface and limiting the load to 50 in lb 5 65 N m under where a seizure occurred and try for a Pass 5 3 3 10 Repeat previous step if necessary to obtain a pass 6 Analyzing Results 6 1 Sample Lubricity Calculations 6 1 1 Coefficient of Friction Torque Reading 100 Coefficient of friction with the instrument set at 60 RPM and a pressure of 100 165 150 in lbs h readi in lbs Torque wrench reading That is 1 2 ches Torque shaft lever arm 6 1 2 Correction Factor Correction Factor F Meter Reading for Water Standard 34 Meter Reading obtained in water calibration _ Meter Reading obtained 28 to 48 6 1 3 Lubricitv Coefficient Meter Reading x Correction Factor 100 Lubricit
31. r adjustments Make certain that torque zero panel knob stays in mid range throughout this procedure 7 6 3 9 Turn panel outer speed knob all the way clockwise and note torque zero shift This should be less than 5 units of torque Be sure that center zero knob can zero meter and readjust meter board potentiometer R 7 to zero if necessary and repeat steps 4 through 6 above 7 6 3 10 Return speed to 60 RPM and note torque zero Adjust center knob to attain torque zero Readjust R 7 slightly until meter torque zero can be obtained at both 60 and 1000 RPM Return torque meter to zero using center knob 7 6 3 11 Remove prony brake and reassemble panel onto instrument making sure wires are properly routed and not pinched 28 mg Prony Brake Calibration Figure 9 29 7 7 PROBLEM LOSS OF RPM READING LOSS OF POWER SPEED CONTROL ERRATIC TORQUE READINGS LOW OR ERRATIC LOSS OF BOTH TORQUE AND SPEED READINGS LOSS OF SPEED CONTROL 30 Electrical Maintenance and Diagnosis CAUSES Make sure reed switch connector is plugged in to circuit board header Check the Reed switch function sensing bar magnets on main shaft Signal may not be reaching circuit board at connector 1 Fig 7 Place Ohm meter lead in receptacle 1 from switch and turn shaft magnets past switch and note meter go low and high on ohms reading If no switching adjust bracket by bending or move bracket
32. thoroughly Mix 2 tablespoons of aluminum oxide powder into a cup of distilled water and submerge block and ring in this slurry 5 2 2 4 Operate the instrument for 5 minutes at 700 1000 RPM with 50 in lb 5 65 N m torque between ring and block then reduce the torque to 25 in lb 2 83 N m for another 5 minutes 5 2 2 5 Rotate torque adjust handle counterclockwise until torque handle can be released from torque arm clamp Lower cup stand and discard fluid Wipe fluid from sample cup block block holder and ring 5 2 2 6 Examine ring and block for shiny condition with a minimum of scars If acceptable retest block and ring standardization Refer to BLOCK AND RING STANDARDIZING TEST 5 2 2 7 lf an acceptable torque 28 48 steady 3 units reading is still not attained check prony brake calibration of instrument Refer to PRONY BRAKE TORQUE CALIBRATION 5 2 2 8 Precalculated ring block pairs are available as Part No 206904 with the correction factor already determined Use of the precalibrated block and ring eliminates the procedures described above in BLOCK AND RING STANDARDIZING TEST and STANDARDIZING BLOCK AND RING and allows check out of an instrument just as soon as the unit s eccentric bushing is adjusted to fit the blocks wear surface If necessary refer to Fig 5 for adjustment procedure Casting 0 Torque Arm Shaft 6 Bushing 29 ka Mt Block Adjuster Lock Screw 32 AT p Example A Example
33. warranty products will be repaired for a nominal charge Please refer to the accompanying warranty statement enclosed with the product RETURN OF ITEMS For your protection items being returned must be carefully packed to prevent damage in shipment and insured against possible damage or loss Fann will not be responsible for damage resulting from careless or insufficient packing Before returning items for any reason authorization must be obtained from Fann Instrument Company When applying for authorization please include information regarding the reason the items are to be returned Our correspondence address is Fann Instrument Company P O Box 4350 Houston Texas USA 77210 Telephone 281 871 4482 Toll Free 800 347 0450 FAX 281 871 4446 Email fannmail fann com Our shipping address is Fann Instrument Company 15112 Morales Road Gate 7 Houston Texas USA 77032 37
34. with indentation towards main shaft away from torque shaft Refer to Fig 2 5 2 1 4 With meter switch in RPM position turn power switch to ON Let machine run approximately 15 minutes 5 2 1 5 Rotate speed control knob counterclockwise until the Torque RPM meter registers 60 RPM 5 2 1 6 Turn meter switch to TORQUE Turn torque zero adjustment knob until torque registers zero Turn off machine 5 2 1 7 Fill stainless steel sample cup with distilled water Place on lowered cup stand Raise cup stand until ring is submerged Secure with thumb screw 5 2 1 8 Release the torque adjust handle turning it counterclockwise as far as is necessary then position torque wrench handle so that it fits inside concave portion of torque arm clamp 5 2 1 9 Start machine and let it run approximately 5 minutes then recheck RPM and torque as in steps 5 and 6 5 2 1 10 With meter switch in TORQUE position rotate torque adjust handle clockwise to apply 150 16 95 N m of torque Let machine run 4 to 5 minutes 5 2 1 11 ring block pair calibration sheet Fig 3 with water readings is supplied with each new machine Compare torque reading to this average value in the range of between 28 to 48 within 3 If the ring block surfaces are smooth and a record is available proceed to C LUBRICITY MEASUREMENT OF TEST SAMPLE and D SAMPLE LUBRICITY CALCULATIONS Otherwise the block and ring must be calibrated using procedure B STANDARDIZI
35. y coefficient 6 1 4 Percent Torque Reduction The percent torque reduction is based upon the torque reading of sample treated with a lubricant relative to the same sample untreated A simple equation of this calculation may be written as follows BL Yo Torque Reduction at a given load 1 AL x 100 a Torque reading of treated sample under a constant force b AL Torque reading of untreated sample under same force 6 2 EP Calculations and Measurements 6 2 1 To measure scar width on the block use a magnifier calibrated to read to 0 005 inch 0 13 mm An appropriate magnified may be obtained from Fann Instrument Company Part No 206949 Before measuring the test block should be wiped clean The magnifier is placed at the center of the scar parallel to the edges so that the average width of the scar can be obtained The scar measurement is taken in hundredths of inches Thus when a scar width of 0 095 inch for example is measured it should be referred to and recorded as 9 5 hundreaths of an inch 6 2 2 calculate the pressure on the block compute the area of the scar which is found by multiplying the width of the scar by its length The length is a constant 0 125 inches 3 18 mm Area Width W X 0 125 The force acting on the scar area is found by dividing the torque meter reading at which a Pass was obtained by the lever arm which is a constant of 1 5 inches The pressure on the test block at the time the test w
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