dcms™ downhole corrosion monitoring system user manual
Contents
1. M d R v HUHAM HEALTH DATA po ae ROUTE E DF Eye Contact Skin Contact HUHAH EFFECTS AND 5 DF DEREKFOSUME ACUTE EFFECTS EKPOSUHE r Direct contact with thionyl chloride gausa burns is to the skin yaa and mucous zmughzanes The vapore of thionyl chloride are strong irritants ta tha ayaa and respiratory tract Symptoms of exposure include barning in the and violent coughing In contact with humid alr hy regen chloride and aul fur dioxide C502 are predated which are thameelvec irritating Significant overexporure bo thienyl chloride wapora and ilg related decompoaitian products which could otcer if a person is trapped aprayad may delayed pulmonary amp ema CHRUHIC EFFECTS OF EKPUBURE Chronic cwerezpezurs thienyl chloride can cause symptoms of non ibretic lung imjery similar ta othar irritating v pors CARETHDGENECITT 2131111112212218 Mis protect is nat listed by WTF IARC ar regulated as carcinogen by OSHA MEDICAL CDNDITIUMS AGGRAVATED BY EXPDSURE 3 Asthma other respirat2. NIT A A A A A A A A A A 1 E 1 E 1 E 1 E 1 E 1 E 1 E 1 E 1 E 1 E 660045 531600 36 00 000498 000499 129341 724100 724020 72402 Battery Depassivation Instrumen 724024 723101 5 011422 MATE to RDC Adapter Cable EA EA SET SET EA EA EA 028050 80 6 00 heater 36 Lona for open end wrench E A EA Assembly Sequence Chapter 4 DHT Assembly 26 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 Figure 4 1 DHT Assembly Drawing Chapter 4 DHT Assembly 27 CAUTION Leave on the protective paper that covers the Probe Element until instructed to remove This prevents grease from contaminating the Probe Element Step 1 Inspect Installation of O Rings and Back up Rings 1 WARNING To avoid damage to O rings and O ring grooves only use an O ring Pick Set to install or replace O rings and Back up Rings 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 Figure 4 2 Mounting Head Adapter O Ring and Back Up Ring Placement Chapter 4 DHT Assembly 28 WARNING Never use O Rings or Back up Rings for mor
3. a mE ah STORAGE TEMPERATURE BIN HAX Ambient flit 150 C SHELF Unlimited closed containers end the absence of misture drums one year SEXUS SPECIAL SENSITIVITT 1 Molsture or heat greater than 122 50 C HANDLING ETOBRAGE PRECAUTIONS This product ig exbrsmaly carznzivm nat breathe wapare er gists Do not get nn eyes or cu skin Hash thoroughly after hamdling Store containers conl dry and wall ventilated aram oF and way Tram Firs hazsedz asseriated should JAL 3l6L zLtaimlezz taal nickel cr Lined with FIFE Polytetrafiuwsraethylaena lesd porcelain anmmml sr galvanized To pet allow enter z zrage containers thie will crure ingreaked cerresian and rslamgs of By rechloric Acid amd Sulfur Dioxide Moisture and beat greater than 122 F 50 C will result in baibld up of internal gontalnarg shpald ba equipped with pressure relief amp evices which are consirecled wikh materiala compstibie with thionyl c amp ler de at SHIPPING INP RHATIUM TECHHICAL S3HIPPIHG HAH E a ileride FREICHT CLASS Thisepl Chlorida FRETGHT CLASS PACEAEE re Thigmyl
4. 1 25 DIA Figure 1 1 Cross Sectional View of Fully Assembled DHT Chapter 1 Introduction 3 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 Plus Software for analysis The DHT consists of the following major components Instrument Body Instrument Tube Assembly Probe Assembly Probe Shield Probe Adapter Mounting Head 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 4 Chapter 1 Introduction 534 e 93534 Figure 1 2 DHT Carrying Case Layout Chapter 1 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 18 L It has a large probe connector at one end and a small battery connector
5. AppendixA 52 FIRST AID PEUCETMIRES Continued FIRST AID FUE IMHALATIUH Remove to Frerh sir parecon cole and avoid any GNGELlon ar movement Trainad perzanz should administer breathing is difficult IT not breathing give artificial respiratism contact physician FIRST AID FOR In of ingestion drink capinum gmounta of eater if available give several glasses of milk not induce 9mmibing GIVE ANYTHING BY HOUTH TO AN UNCONSCIOUS PERSUM If vomiling agentameously keep airway clear and give more water Immediately call a ghyareran VII EMFLOTEE RECOMMEHDATIDHS EFE REQUIREHEHTS Chemical wcrher safety glasses ond Full Fate akimld ZEIN REQUIREHEHTS Hmupzanse Polyethylene or Viton BR gloved and agpropriatea fcr axpasuzs canditions RESPIRATOR RHEQUIREHEHTS HIUSH approved for acid gases met eaten tha use limita af tha WENTILATION REQUIREHENTS Une local axhzmust ganaral wenmtilatian sufficimnt ta pravant overexposure ADOITIONAL PROTECTIVE HEASURES t Pull body acid zaziztmant guile amp nd pressure zalf coniszinad breathing apparatus should be available im fie of larga spilla othar similar seergenciaz
6. CORPORAT TOM PRODUKT SAFETY b BEGULATORY APFAIARZ 100 Bayer Road Pitbabu rgh 15305 9741 TEAMEPOETATION EMERGEMCY NOW TRAMEPCRTAT ION CALL amp I amp 3100 BAYER EMERGENCY 412 914 1800 DISTRICT OF COLUMBIA 4202 61 7616 INFORMATION PHONE LBMD 642 2927 1 FRODUCT IDENTIFICATION ee Meee eee Thi ony FREODUCT CODE ss VEDY CHEHICAL Thiemyl Chloride Sul bore Sal fur CAS 7719 0 FURHULA 222222222442 Il HAZARDOUS INGREDIENTZ ns SmE E D IMGEEDIENT NAME NUMBER EKFOSUBE LIMITE CORCEMTBATION I Thicey Chloride QUHA 1 000 ppm Catling minimum 9 65 1 5 000 gfe 1 000 ppm Carling 3 000 apal Coiling Bydrochloric Acid Seller Diewide Chlerime and Selfer Chloride be relesged by hydrolysis er thermal decomposition of Chloridm and be mnrmumbarad whee Chlerrdg comes contact with im the sir Hydrochloric acid T amp ET 01 0 DSNA 3 000 pee Ceiling i i 7 000 apat Cari 3 000 ppm Coiling 7 500 Ceiling Soller Di
7. Chapter 4 DHT Assembly 36 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 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 Carefully screw the Probe Adapter into the Instrument until shouldered being careful not to lift the end so high that the Battery Assembly might become disconnected inside the Instrument Tube Assembly Maintain the whole assembly as horizontal as possible Step 9 Install Spring Assembly and Mounting Head Adapter 1 Insert the Spring Assembly into the open end of the Instrument Body 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 Coat the Mounting Head Adapter threads near the O rings with High Purity Goop and the O rings themselves with High Temperature Silicone Grease Insert the Mounting Head Adapter behind the Spring Assembly Gently push the Mounting Head Adapter against the Spring Assembly and maintain pressure while sta
8. 13 Battery Assembly 14 DHT Operating Duration 14 Chapter 3 DHT Operational 15 Assembly Sequence mei rct EFE EFE 15 Disassembly 22 Chapter 4 DHT Assembly nacura nau no stu a aua nara xo suu ora ae pai nara so nodu uiua ak ig uaa da 25 Recommended OOS EE 25 Assembly Sequence e Dee Den eerte perte rM pt eere karate iE 26 Disassembly 39 Appendix A Lithium Thionyl Chloride Batteries Handling Storage MSDS 43 Emergency Procedures doo nda donent a LL LRL LED 43 Emergency Conditions eA EM AA CA AM LM LL A E 43 Causes of Hazardous CondgitionS pp 43 Electrical and PAYS de RE MIU 43 DAIS Storage aeaa E 44 Safe Incoming Inspection s css race ter e Mae 44 HR ee 44 Safe Transportat Ne eee Det tO eiae ettet NE 45 Safe Disposal I 46 Figures and Drawings Figure Figure 1 1 Figure 1 2 Figure 1 3 Figure 4 1 Figure 4 2
9. PRODUCT 1 Thigmyl Product Cade 9905 FSGS Page 5 approval date LL COR w5 on AppendixA 54 KL SHIPPING IMFORMATIUM Cont imped BBE BB de oom eee DOT SURFACE PROPER SHIPPING Thieagl Chloride HAEARD CLASS OR DIVISIOH 3 8 amp l UM sewed 812156 FACKAGING I E DOT PRODUCT EO 168 Ck 3 Mens HAZARD LABEL US 44 222 252542 Poison HAZARD 2 Poison PROPER SHIPPING Chloride HAZARD CLASS DIVISION NEHBEE B UM HUHBER UH1E14 PACKAGING 4 2 2 4 1 HAZARD LABELS3 45 5 22 55525 2 Cnrrzaiva Taxie HAEAED 1 Cnrremiwva ICA HAZARD CLASS DIVISION N HBEK Forbidden TUKTCITT DATA POR Thismgl Chieride ACUTE TOXICITY TRAL Datm nnt oeteabliehed for produci DERMAL LD50 Bate nnt srbzblizhad for product TNHALATTUM LC 0 s 1 274 ppa kat 1 houri 65 ppm iat amp bour 41 736 ppm Ret 1 2 T ETE EFFECTS 1324341588 1 SKIN EFFECTS SEMSITIZATIOM 5 Gate n
10. Emergency showers amd eyewash fountains sheuld ba located im whara Chionyl chloride Educata and train ampglaysaz in the sale use and hmndling of this priit p VIII HBEARCTIVITT SRB SSS ee ee ee ee eee eee ee ee ee ee ee ee eee ee ee ee ee eee ee ee ee m Thin im matsrial HAZABDCORIE POLTHERIZATIOM Bill nat occur Reactia violently with water Avoid contact with agenta and organic matter Hay react vigarausiy with nk Aluminum Hagnasium and Titmnium and Zinc violent r amp ctia ns af Thiseyl Chlarida wilh organic chemicals Thionyl Chloride mixturaa with organic chemicals must gEunrad containers Tree of iran amd zinc and be equipped with relief device Refer te Zaectian X Capecial precautiung storage data IMSTABILITY COHDITIOHS 2 Excaamiva tamparazlurer hECOMPFOEITION TEHPERATUBE Daccsmpsasitian bsgimnas af 284 140 D
11. operations DO NOT tighten either the Probe Shield or the Set Screws at this time Step 5 Program Instrument Tube Assembly 1 WARNING The Instrument Tube Assembly must NOT be programmed while connected to the Battery Assembly Program the Mate from the PC with the probe configuration required or set up the configuration on the Mate manually Refer to the CORRDATA Plus Corrosion Management Solutions Manual for details on setting up the Mate via PC It is the recommended to CLEAR the Mate memory prior to programming this WILL erase all previously saved data on the Mate Follow the steps below to set up the Mate manually l Turn the Mate ON and wait for the main display is shown below ROHRBACK COSASCO SYSTEMS Read Disp Dump SetUp Click SetUp F4 to advance to the Configuration Options display depicted below Configuration Options Phone Mate RDC Timer EXIT Choose Mate F1 to enter the following Mate Configuration screen Mate Configuration AUTO MAN NEW CONF CONF PROBE EXIT Chapter 4 DHT Assembly 32 IV Choose MAN CONF F2 and enter the Manual Configuration screen below MANUAL CONFIGURATION CONF SET CLR ID TIME MEM EXIT V Choose CLR MEM F3 and select CLEAR F1 to clear the memory WARNING This is the recommended method to successfully configure the DHT Performing the CLEAR WILL erase all previously saved data on the Mate Transfer needed data to CORRDATA Plus prior to erasing
12. 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 f 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 the EDIT Chapter 4 DHT Assembly 38 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 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
13. Timer EXIT VI VII Chapter 3 DHT Operational Pretest 17 Choose Mate F1 to enter the following Mate Configuration screen Mate Configuration AUTO MAN NEW CONF CONF PROBE EXIT Choose MAN CONF F2 and enter the Manual Configuration screen below MANUAL CONFIGURATION CONF SET CLR ID TIME MEM EXIT Choose CLR MEM F3 and select CLEAR F1 to clear the memory WARNING This is the recommended method to successfully configure the DHT Performing the CLEAR WILL erase all previously saved data on the Mate Transfer needed data to CORRDATA Plus prior to erasing memory Once the previously stored settings are cleared the Mate will return back to the MANUAL CONFIGURATION screen Follow the instructions below to configure the Mate i Choose CONF ID F1 to proceed Enter the ID number for the DHT and press Enter F1 iii Enter the rest of the information such as the Probe Tag the appropriate Time Interval for the DHT to perform readings Probe Alloy and finish the setup process NOTE A one 1 hour reading interval is most commonly used The Probe Assembly type is D cylindrical with a 5 mil span for T10 model or a 10 mil span for 20 model and the probe is 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
14. and a flashing green lamp will illuminate The Battery 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 Chapter 1 Introduction 9 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 seconds 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
15. memory Vl Once the previously stored settings are cleared the Mate will return back to the MANUAL CONFIGURATION screen Follow the instructions below to configure the Mate i Choose CONF ID F1 to proceed Enter the ID number for the DHT and press Enter F1 iii Enter the rest of the information such as the Probe Tag the appropriate Time Interval for the DHT to perform readings Probe Alloy and finish the setup process NOTE A one 1 hour reading interval is most commonly used The Probe Assembly type is D cylindrical with a 5 mil span for T10 model 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 VII Check the setup configuration l From the main display of the Mate press Disp F2 followed by ID F2 Type in the ID number and press Enter F1 Check the configuration values to make the desired values are set IV Press the More F 1 check other values 2 Setthe Mate for a data rate of 300 BAUD by pressing Read F1 MODE F2 Baud F2 and 300 F1 See Chapter 1 CORRDATA Mate section for more details Chapter 4 DHT Assembly 33 NOTE Communication between the Mate and the Instrument Tube Assembly occurs
16. 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 Hazardous physical conditions include external heating due to uncontrolled storage Appendix A 44 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 from each other preventing connector damage and potential short circuits Do not store batteries loosely and
17. read time interval to the nearest valid time increment Check the setup configuration l From the main display of the Mate press Disp F2 followed by ID F2 Chapter 3 DHT Operational Pretest 18 Il Type in the ID number and press Enter F1 Check the configuration values to make the desired values are set IV Press the More F 1 check other values Set the Mate for a data rate of 300 BAUD by pressing Read F1 MODE F2 Baud F2 and 300 F1 See Chapter 1 CORRDATA Mate section for more details NOTE Communication between the Mate and the Instrument Tube Assembly occurs at 300 BAUD This causes data transfer to be fairly slow Configuration may take up to 30 seconds Connect the Mate to the DHT Communications Adapter Connect the Instrument Tube Assembly to the DHT Communications Adapter Program the Instrument Tube Assembly with the desired configuration by following the steps below Turn the Mate ON and wait for the main display is shown below ROHRBACK COSASCO SYSTEMS Read Disp Dump SetUp Click SetUp F4 to advance to the Configuration Options display depicted below Configuration Options Phone RDC Timer EXIT Choose RDC F2 to enter the following screen Enter ID gt lt 1 50 ENTER BkSp EXIT Chapter 3 DHT Operational Pretest 19 IV Enter the ID number from the above step 1 and press Enter F1 The following display will appear RDC C
18. 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 reading Immediately following each Probe Element reading the Probe Monitor will display the current tally of Probe Element readings ie 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 1 Remove the protective paper from the Probe Element 2 Install the Probe Tip Insulator on the tip of the Probe Element 3 Coat the exposed threads of the Probe Adapter with High Purity Goop 4 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 girthgrip wrench on the Probe Shield 6 Torque the Probe Shield to 30 ft Ibs Chapter 4 DHT Assembly 39 7 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 no
19. the Probe Monitor is the same as the DHT configured cycle time The Probe Monitor 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 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 Chapter 1 Introduction 10 RCS offers a custom DCMS Tool Kit P N 724005 to provide for the complete assembl
20. the two energization cycles of one DHT Probe Element reading Immediately following each Probe Element reading the Probe Monitor will display the current tally of Probe Element readings ie DHT 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 4 minutes 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 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 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 1 Turn on the Mate 2 Clear the memory of the Mate See Chapter 3 Assembly Sequence S
21. CURR PROBE F1 for reading values and MORE F1 for number of readings 8 To transfer data from the Mate to a personal computer a Mate to PC interface cable P N 748063 and CORRDATA Plus software are required Set the Mate to 9600 Baud for data transfer to the PC by pressing Read F1 MODE F2 Baud F2 and 9600 F3 see Chapter 1 CORRDATA Mate section for more details Follow the standard procedure for data transfer from the Mate to the PC NOTE The data may now be downloaded to the CORRDATA Plus software to be viewed graphically to check its validity 9 Turn off the Mate 25 Chapter 4 DHT Assembly 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 UNT PARTNUMBER DESCRIPION o EA 724101 Githarip Pinewrench Assemblv 1 25 O D EA ooo Toraue Wrench 100 600 ft lbs 92 Drive EA oos QmoworWenc EA 000466 Adagens FemdeXYzMae EA 00495 openenawrencn ooo EA oos openenawrencn ign EA EA sr EA EA EA EA
22. Communications Adapter Chapter 4 DHT Assembly 41 5 Connect the Instrument Tube Assembly to the DHT Communications Adapter 6 Read data from the Instrument Tube Assembly by following the steps below Turn the Mate ON and wait for the main display is shown below ROHRBACK COSASCO SYSTEMS Read Disp Dump SetUp Press Read F1 to advance to the What to Read display shown below What to Read PROBE MODE RDC EXIT Choose F3 to enter the following screen Connect Mate to RDC START EXIT IV Press START F1 to collect the data When the data collection is completed EXIT F4 to return to the main display NOTE Due to the low data communication rate the Mate requires about 4 minutes to read data from the Instrument Tube Assembly 7 Disconnect the Instrument Tube Assembly and the Mate from the DHT Communications Adapter The number of readings taken and the value of the last reading may be read back directly from the Mate by using the Display Mode Disp F2 CURR PROBE F1 for reading values and MORE F1 for number of readings 8 To transfer data from the Mate to a personal computer a Mate to PC interface cable P N 748063 and CORRDATA Plus software are required Set the Mate to 9600 Baud for data transfer to the PC by pressing Read F1 MODE F2 Baud F2 and 9600 F3 see Chapter 1 CORRDATA Mate section for more details Follow the standard procedure for data transfer from th
23. DCMS DOWNHOLE CORROSION MONT HARING SYSTEM USER MANUA rm D 1991 2006 Rohrback Cosasco Systems Inc All rights reserved Corrosometer Corrdata Corrdata Plus and DCMS are trademarks of 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 Chapter 1 Introduction m 1 Downhole Corrosion Monitoring System 1 Downhole Tool DHT TEM 1 Instr ment Eiaeai na 5 Instrument Tube Assembly pp 5 Probe Assembly TIT 5 PPO UGC E E A E 5 Probe Adapter e A Mu LU AE 5 Mounting Head 5 Battery ASSambly uineis ta ita iae dna ioca ia ata ata 6 CORDA TAS Cu 6 Mate Reprogramming it de tue et du cad 7 CORRDATA EIS SOWA 8 Battery Depassivation Instrument pp 8 Probe MONNOF fte 8 Siue Prom P 9 FOO Sts ue DA D IUD TUS 9 Chapter 2 Specification rad AER s dE rk cei aed x cx cU cpi dd se Fur 13 Downhole Tool
24. ECOMPOSITION PRDDECTS 5 tharmal daccmpzmitian Chiarina Sulfur Deride Sulfur Chlarida contact with water Wydrashlorls Acid Zulfur Dioxide Predurt Coda s 4 Approval date 11 08 95 Continued on next page Appendix A 53 SPILL 08 LEAK PROCEDURES vmcuat amp arma afd stay upeind 18 it is safe ta de sp trained personnel should attempt to stop er reduce lask Large Spills should be contained and pumped inte salvage dryms other appropriate containere Fall acid sesistant suits ame sel f conteined breathing apparatus ehoeld be worn during emergency operations Vapor elouds formed by reaction of the apilled thionyl chloride with atmospheric moisture can be controlled by water fog water spray After bulk of material is removed large quantities of ash lime sr s combination of these can be posi gp and nautralize the remaining 1 1 chloride Beall spills be handled by zxbzarpliaon and reacted with large amounts of dey alkali soda esh ander lime Shovel inte apprepriate container For disposal HASTE DISPOSAL Boeke diapoaal must be in ccordangs with federal stake and locml environment comtrel regulations wee eS ee ee ee eee PREEAUTICNS amp STORAGE DATA RR GR UR RE
25. F RDC F2 Following display will appear Chapter 3 DHT Operational Pretest 20 Connect Mate to RDC CO SET NEW START MUX PROBE EXIT VII Press START F1 to begin configuring the DHT Press EXIT F4 when the configuration is complete Disconnect the Instrument Tube Assembly and the Mate from the DHT Communications Adapter Turn off the Mate Step 3 Attach Probe Assembly to Instrument Tube Adapter 1 Lay the Instrument Tube Assembly and the Probe Assembly on a table or other flat horizontal surface 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 Carefully rotate the Probe Assembly until the connector keys are aligned and then push in the connectors together as far as possible Step 4 Attach Battery Assembly to Instrument Tube Assembly 1 2 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 When the present time is equal to the time value entered in Step 5 sub step V above slide the small connector on the Instrument Tube Assembly into the Battery Assembly connector as far as possible Once the Battery Assembly is connected to the Instrument Tube Assembly it is energized and will take the first Probe Element reading aft
26. Figure 4 3 Figure 4 4 Page Cross Sectional View of Fully Assembled 2 DHT deed a 4 DOMS No EXPE kel amete eiua ora astu Dare ROREM 11 DHT Assetbly DRAWING s ioo re ERO ie tria eade idR eM pti lice 26 Mounting Head Adapter O Ring and Back Up Ring Placement 27 Probe Adapter O Ring and Back Up Ring 28 Probe Assembly Attached to Probe Adapter 30 Chapter 1 Introduction Downhole Corrosion Monitoring System DCMS The RCS Downhole Corrosion Monitoring System DCMS is the only system which provides continuous corrosion history of downhole tubing 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 Mate CORRDATA Plus 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 electron
27. LOADING NUT P N 724044 6 32 SET SCREW PROBE ADAPTER 2 REQ D P N 003767 1 8 P N 724038 Figure 4 4 Probe Assembly Attached to Probe Adapter Lubricate the entire Probe Sleeve with a thin coat of High Temperature Silicone Grease P N128371 Slide the threaded end of the Probe Assembly through the Probe Adapter opposite the O ring end Lubricate one Insulating Washer P N 724046 and one Load Washer P N 724045 with High Temperature Silicone Grease Place the Insulating Washer over the threaded end of the Probe Assembly Place the Load Washer over the threaded end of the Probe Assembly Coat the Probe Assembly threads with High Purity Goop P N 006308 This is an anti galling agent Install the Seal Loading Nut on the threaded end of the Probe Assembly Hold the flat portion of the Probe Assembly with a 5 8 open end wrench then torque the Seal Loading Nut to 30 foot pounds with a 13 16 open end torque wrench 30 Ibs on a 12 wrench Step 4 Temporarily Install Probe Shield Check that the protective paper is over the Probe Element Chapter 4 DHT Assembly 31 Verify that the Probe Shield Set Screws are backed out enough to clear the threads 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 Install the Probe Shield hand tight to protect the Probe Element during the following
28. MS to allow data transfer between the DHT and the Mate To change the Mate baud rate switch ON the Mate After the self test screen clears and the main menu appears ROHRBACK COSASCO SYSTEMS Read Disp Dump SetUp A Press Read F1 MODE F2 to display the screen Special Testing Code Run PMATE from PC to update MATE REV BAUD TEST EXIT A A Press Baud F2 to display Baud Rate is 9600 Select 300 for DHT 9600 for RDC or PC 300 9600 EXIT EM EE Chapter 1 Introduction 7 Press 300 F1 for the DHT The Mate will automatically shut off and restart with the Baud rate changed CAUTION Remember to repeat the procedure and set the Baud rate to 9600 to communicate with the PC Mate Reprogramming Utility This reprogramming utility is only required if for any reason the Mate software program has become corrupted This program utility in the CORRDATA Plus installation disk operates Chapter 1 Introduction 8 through the normal connection cables to the Mate to reload the Mate software program To run this utility plug the Mate into the PC with the serial adapter cable P N 748063 Run the CORRDATA Plus Installation CD by inserting it into the CD ROM Click the Mate Programming Utility link and choose Install Follow the PC prompts to install the utility Once the utility is successfully installed run the application from Start gt Programs gt Rohrb
29. SOLUBILITT WATER 1 MONIS 1 64 77 F 1 c MELE 177 2 Mad Eatablilahad 1 WOLATILE BT 1 TODE TAPOR PRESSURE 1 97 68 F 20 ORE Rd m FILE 4WD LKFLORION E DONE ER neca n AUNTO IONITION Mat Eatabliaihed EXTINGOIEBING MEDIA 52225552 Diaal s Dry Chemical SPECIAL FILE FICHTING PROCEDURES Thienyl hloride net combustible Hewavar if thionyl chloride ia invelved im a lire use carbon digniss or dry chemicals Firefighters amp hbuld wear full protective clothing self contained breathing apparatus aad irritating be praesent imtluding hydrachlarit etid aulfur ehlerine wulfur thleride ethers Drums axcepirve Daeperaturas ruptere ds the decomposition of thiceyl Sater sill with Freie Cade 2 Approval date 11 08 93 Cai isod on neat page Appendix A 51 FIRE AND ERPLOSDOWN DATA Continued thicny r amp leride generating irritating gases However weber zpray whould be bo keep lire exposed 6001 amp nd Eo help scrub acid paces Crom Ehe air XER 7EETSRIGDEGC
30. able over temperature protection DO NOT SHORT CIRCUIT batteries that are heated above 25 Batteries that have been heated above 100 C 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 hazard class is CLASS 9 Miscellaneous and the packing group is PACKING GROUP II The regulations state that the batteries ha
31. ack Cosasco Systems gt Mate Programming Utility The PC will display the instructions of keys to press on the Mate In most cases the user will be able to successfully re program the Mate using the Quick Mode This re programs the Mate without losing any of the stored data NOTE If the Mate program has been severely corrupted Complete Mode must be run In this case repeat above steps and select Complete Mode and follow the wizard instructions to complete the programming Plus Software The CORRDATA Plus Software is supplied with the Mate Please refer to the CORRDATA Plus Corrosion Management Solutions Manual on the CD ROM 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 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
32. at 300 BAUD This causes data transfer to be fairly slow Configuration may take up to 30 seconds Connect the Mate to the DHT Communications Adapter Connect the Instrument Tube Assembly to the DHT Communications Adapter Program the Instrument Tube Assembly with the desired configuration by following the steps below l Turn the Mate ON and wait for the main display is shown below ROHRBACK COSASCO SYSTEMS Read Disp Dump SetUp Click SetUp F4 to advance to the Configuration Options display depicted below Configuration Options Phone Mate RDC Timer EXIT Choose RDC F2 to enter the following screen Enter ID gt lt 1 50 ENTER CLR BkSp EXIT IV Enter the ID number from the above step 1 and press Enter F1 The following display will appear Chapter 4 DHT Assembly 34 RDC Configuration Connect Mate to RDC DATE CONF TEST TIME RDC MODE EXIT V Choose DATE TIME F1 and choose SET F2 The hour is set on the military 24 hour clock where 00 00 hours depict midnight at the start of the day and 12 00 is mid day See below for the display Set RDC Date amp Time YYMMDDHHMMSS gt lt ENTER CLR BkSp EXIT WARNING This will reset the DHT Date and Time and erase all the previously stored data on the DHT This MUST be done to accurately date and time stamp the readings Set the time to be about ten minutes later than the present time for reasons explained below and pr
33. at 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 43 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 the potential for hazardous situations does exist Most hazards are due to internal or external heating
34. 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 and 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 Chapter 1 Introduction 6 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 hand
35. 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 engineering Appendix A 45 If testing batteries at elevated temperatures the temperature chamber MUST HAVE reli
36. e Mate to the PC Chapter 4 DHT Assembly 42 NOTE The data may now be downloaded to the CORRDATA Plus software to be viewed graphically to check its validity 9 Turn off the Mate 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 Place a 1 open end wrench on the Probe Adapter and a girthgrip wrench on the Probe Shield Carefully remove the Probe Shield from the Probe Adapter Remove the Probe Tip Insulator from the tip of the Probe Element 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 5 8 open end wrench then detach the Seal Loading Nut with a 13 16 open end wrench 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 Remove and discard the Insulating Washer from the threaded end of the Probe Assembly Slide the Probe Assembly out of the Probe Adapter and keep for further analysis NOTE The Probe Assembly is preweighed so th
37. e 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 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 Figure 4 3 Probe Adapter O Ring and Back Up Ring Placement Step 2 Depassivate New Battery Assembly 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 the load when the output voltage of the Battery Assembly reaches a value which indicates that the passivation has been adequately removed Chapter 4 DHT Assembly 29 WARNING Use only the RCS supplied Depassivation Instrument P N 724023 to depassivate the battery and verify voltage 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 Verify that the ambient temperature and the Battery Assembly Temperature is greater than or equal to 21 70 F If desired monit
38. er about 12 minutes 30 seconds 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 for the user to validate the performance of the DHT by using the Probe Monitoring Tool see step below Chapter 3 DHT Operational Pretest 21 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 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 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
39. ess ENTER F1 The date and time display that follows is an actual read back of the values presently stored in the DHT Instrument NOTE 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 10 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 Press Exit F4 to return to the Configuration screen Choose CONF F2 Following display will appear Connect Mate to RDC CO SET NEW START MUX PROBE EXIT VII Press START F1 to begin configuring the DHT Press EXIT F4 when the Chapter 4 DHT Assembly 35 configuration is complete 6 Disconnect the Instrument Tube Assembly and the Mate from the DHT Communications Adapter 7 Turn off the Mate 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 Connect the Probe Assembly to the Instrument Tube Assembly by sliding the Seal Loadin
40. 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 correct 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 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 Chapter 3 DHT Operational Pretest 22 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
41. g Nut end of the Probe Assembly over the large connector on the Instrument Tube Assembly Carefully rotate the Probe Assembly until the connector keys are aligned and then push the connectors together as far as possible 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 WARNING Always use a new Battery Assembly and depassivate 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 NOTE Once the Battery Assembly is connected to the Instrument Tube Assembly the Instrument Tube Assembly is energized and will take the first Probe Element reading after about 12 minutes 30 seconds Lay the Instrument Tube Assembly and the Battery Assembly on a table or other flat horizontal surface Coat the Probe Adapter threads near the O rings with High Purity Goop and the O rings themselves with High Temperature Silicone Grease 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 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
42. g Point Thionyl Chloride 77 C Vapor Pressure Thionyl Chloride 92mm 20 C Vapor Density Thionyl Chloride 4 1 Melting Point Thionyl Chloride 105 C Evaporation Rate N A Water Reactive Thionyl Chlonde hydrolyzes to form SO and HCL Appearance and Odor Thionyl 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 Extinguisber 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 Hazards Do not short circuit recharge overdischarge puncture crush expose to above 180 C SECTION 4 REACTIVITY HAZARD DATA Stability Stahle Conditions te Avoid Temperatures in excess of 180 C High humidity for extended periods Incompatibility N A Hazardous Decomposition Products Sulfur Dioxide Hydrogen Chloride Hazardous Polymerization Will not occur Other N A Appendix A 48 SECTION 5 HEALTH HAZARD DATA Primary Routes of Entry inhalation Carcinogen Listed in Not listed Health Hazards Acute Vapors very irritating to skin eyes and mucous membranes Chronic Overexposure can cause symptoms of nonfibrotic lung injury Si
43. gns and Symptoms of Exposure Eye and mucous membrane irritation Mri Caen Grm A perd en ee ee E Emerguny Firet AM Procedures Bod medial fv 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 SECTION 7 PRECAUTIONS FOR SAFE HANDLING AND USE Steps to be Taken if Material is Spilled 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 C Do not recharge overdischarge puncture or crush Other Precautions and or Special Hazards Do not store batteries in high humidity environments for long periods SECTION 8 TRANSPORTATION INFORMATION US DOT per 49 CFR 172 101 and IATA ICAO Proper Shipping Name Lithium Batteries Liquid Cathode UN Number UN 3090 Hazard Classification Class 9 Miscellaneous Packing Group 11 Page 2 of 25 102 180MR Appendix A 49 Bayer gt
44. ic 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 a 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 5096 area on the pipe An RTD temperature sensor internal to the DHT provides temperature data The DHT electronically measures the Probe Assembly and temperature sensor at user programmable intervals and stores each reading in nonvolatile memory Upon retrieval of Chapter 1 Introduction 2 5 8 SUCKER ROD CONNECTION MOUNTING HEAD ADAPTER SPRING ASSY BATTERY ASSY INSTRUMENT BODY F INSTRUMENT TUBE ASSY SS PROBE SEAL LOADING NUT LOADING WASHER NSULATING WASHER N PROBE ADAPTER _H PROBE ASSY PROBE SHIELD uM PROBE INSULATOR
45. ighly 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 the 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 Chapter 3 DHT Operational Pretest 16 CAUTION no status lamps on the Battery Depassivation Instrument are
46. illuminated while the Battery Assembly is connected then the Battery Assembly is either excessively passivated or depleated 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 green lamp doesn t flash within one hour of connecting the Battery Assembly then the Battery Assembly is either excessively passivated or depleated and should not be used 5 Disconnect 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 Mate from the PC with the probe configuration required or set up the configuration on the Mate manually Refer to the CORRDATA Plus Corrosion Management Solutions Manual for details on setting up the Mate via PC It is the recommended to CLEAR the Mate memory prior to programming this WILL erase all previously saved data on the Mate Follow the steps below to set up the Mate manually l Turn the Mate ON and wait for the main display is shown below ROHRBACK COSASCO SYSTEMS Read Disp Dump SetUp Click SetUp F4 to advance to the Configuration Options display depicted below Configuration Options Phone RDC
47. ling and storage information CAUTION 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 new 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 internal fuse but may explode if either recharged or short circuited especially at high temperatures 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 Mate Operation of the CORRDATA Mate herein referred as simply Mate with the DHT is almost identical to that with an RDC The Mate s baud rate must be set to 300 to communicate with the DHT and then reset to 9600 baud to communicate with the PC A DHT Communications Adapter is supplied as part of the DC
48. lth and safely dala in other of Che MSDS may slep applicable for stale requirements Far on your cegulatery fequiresents you contact the appraprisie agency in your COMPONENT NAHE JCAS HUHBEK NCENTRAT EUH STATE Thionyl Chlarida 719 09 7 minimum 99 6 X HA NIJ Husk chusetts Exrardaur Lieg 23 Special Hamith Hazardous Substance List FAL Pennsylvania Eaxardourz Subatance List LALIPFUEMIA PROPOSITION 65 To Ehe best of cor knowledges this product containe mn levele of Listed eubrLanosg the atete California has found bn cancer birth defects or other reproductive affects Product Code 509 Page 7 Approval date 11 08 94 Cnt ised next pags Appendix A m mm rmm ay APPROWALS 4 REASON POR 5 Review Sections KI and KIF PREPARED D Kally APPROVED 1 M APPROVAL 11 04 95 SUPERSEDES DATE Om 22 931 KADE HUMEBER 0987 This information is Furnished withewt warranty expressed or implied except it is accurate te the beat knowledge of Bayer Corporation data this sheet relates only te tha apecific malerial designated herein Baper Corporation assumes legal ras
49. m Vibration 30 to 300 Hz at 2 22 G Hz 25 G rms Temperature 285 F 140 C maximum Pressure 10 000 psi 69 MPa maximum Flow Velocity 90 feet per second maximum gas flow 20 feet per second maximum liquid flow Body Material Standard UNS 17400 17 4 5 5 Conforming to NACE 0175 CORROSOMETER Probe Assembly Repeatability 0 596 of Span Resolution 0 196 of Span Temperature Sensor Accuracy 3 F Repeatability 3 F Resolution 0 1 F Memory Capacity 1024 Measurements via CORRDATA Mate Measurement Intervals programmable 15 min 30 min 1 hr 2 hr 4 hr Thread Attachment 5 8 Sucker Rod Connection Spec 11B 14 Battery Assembly Specification RCS Part No 724088 Lithium Thionyl Chloride Li Weight 7 4 grams Voltage 7 32 Voc open circuit Operating Temp 20 to 180 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 15 Chapter 3 DHT Operational Pretest 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 a Pretest at temperatures above 125 F It is h
50. nt Tube Assembly Battery Assembly from Instrument Body 1 2 Lay the Instrument Body on a flat horizontal surface Use a girthgrip wrench to hold the Instrument Body With a 1 open end wrench remove the Probe Head Adapter from the Instrument Body Carefully slide the Instrument Tube Assembly Battery Assembly completely out of the Instrument Disconnect the Battery Assembly from the Instrument Tube Assembly Mark the Battery Assembly with tape or a label to identify it as being used and handle in accordance with Appendix A of this manual Remove the Spring Assembly if not already done Step 4 Detach Probe Assembly from Instrument Tube Assembly 1 Use a 1 16 Allen wrench to back out the Seal Loading Nut Set Screws enough to clear the connector opening 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 Turn on the Mate Clear the memory of the Mate See Chapter 3 Assembly Sequence Step 2 Program Instrument Tube Assembly for more details on this procedure Set the Mate for a data rate of 300 BAUD by pressing Read F1 MODE F2 Baud F2 and 300 F1 See Chapter 1 CORRDATA Mate section for more details Connect the Mate to the DHT
51. nt oeteblished product SUBCHR HTC TUKTCITT Data nnt osteblished product CHREOHTC Data nat axztzablizhad product OTHER TOKICITY DATA Mutagenic Teratagenic Reproductive Tests Data not established product AQUATIC 05 De not alles te antar wxzlewaler cr scil 1 Teste conducted at the Instituts Eer Tazicnlngy cf Bayer AG i Bushy Research Center October 1993 Preduct Code VAS Approval date 11 08 95 Continued on mext page AppendixA 55 ALII PEDEKAL KECULRTORT INPORRATION STATUS 3 This preduct hazardous under the criteria of the Federal Hazard Communication Standard I CFA 1910 1200 DInvantary CERCLA REPORTABLE QLANTITT TITLE ILI SECTION 302 EXTRENMELT HAZARDOUS SUBSTANCES Noms SECTION 311 311 HAZARD CATEGORIES Immediate Health Hazard Delayed Health Hazard Hazard SECTION 313 TOXIC CHEHICALE Momm BCAA STATUS eee eee eee discarded in itz purchased Form Chis predmct meet the criteria of Hirir suz Waste Humbar 0002 and reactivity Wasta Kueber 0003 under 40 261 20 24 The following chemicals specifically listed by individual other pBr duct specific hea
52. onfiguration Connect Mate to RDC DATE CONF TEST TIME RDC EXIT V Choose DATE TIME F1 and choose SET F2 The hour is set on the military 24 hour clock where 00 00 hours depict midnight at the start of the day and 12 00 is mid day See below for the display Set RDC Date amp Time YYMMDDHHMMSS gt lt ENTER CLR BkSp EXIT WARNING This will reset the DHT Date and Time and erase all the previously stored data on the DHT This MUST be done to accurately date and time stamp the readings Set the time to be about ten minutes later than the present time for reasons explained below and press ENTER F1 The date and time display that follows is an actual read back of the values presently stored in the DHT Instrument NOTE 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 10 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 VI Press Exit F4 to return to the RDC Configuration screen Choose CON
53. or the voltage between the red and black terminals on the Battery Depassivation Instrument with a high impedance voltmeter 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 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 depleated and should not be used 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 green lamp doesn t flash within one hour of connecting the Battery Assembly then the Battery Assembly is either excessively passivated or depleated 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 Be careful not to get any lubricant on the Probe Element Check that the protective paper is over the Probe Element Chapter 4 DHT Assembly 30 BACK UP RING P N 724046 LOADING WASHER P N 724045 PROBE ASSEMBLY O RING 2 PLACES P N 202027 P N 724050 TXX K03005 PROBE SEAL
54. ory diserders amphyrems hyperresetivity skim seve EXP SUR 5 4 2 Beater En LI Ti AND FIRST AID PROCEDURES FIRST AID Immediately flugh eyes with mening water at laxat 15 minules To akgure thorough flughimg of a1 tissue the eyelids should held spart during irrigation Fermament eye injury can accer particularly if ringimg le delayed Immedixtely refer Ln phyarrias preferably pyp spegisnligt for medical Lr amp almmenL FIBZT AID SEIN Rings immediately with large of roni running water hot water amd hard rubbing When splashed with thionyl ehleride pracesd ta an emergency shower and begin removing ali zenlaminatad clething while rimaing Flughimg the body with large Geter continua until all af the Ehdeny chloride removed tee are ccnisminaled nok remgve safely poppies svnid Wishing Lhionyhb chloride into the eyes contact ig extengive burns develop physician should be cankacted immediately Preduct Code VANS H5D5 Page 3 Approval date 11 08 95 Cantinuad an next
55. ponaibility for uae or reliance upon these dala y US UU UU Jum mem onem sumo ee eee ITITIITTTTTTTTTTIITTTTEEEI MG GG MM RR Freduct Code 9404 5 Page Approval 11 06 93 Last pags 56
56. rting to screw the Mounting Head Adapter into the Instrument 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 2 Use girthgrip wrench to hold the Instrument Body With a 1 open end torque wrench tighten the Probe Adapter into the Instrument Body to 175 ft lbs torque minimum Use a 1 open end torque wrench to tighten the Mounting Head Adapter into the Instrument to 175 ft Ibs torque minimum Chapter 4 DHT Assembly 37 Alternate Method 1 Place a 1 open end wrench on the Probe Adapter 2 Place a 1 open end torque wrench on the Mounting Head adapter 3 Tighten to 175 ft los 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 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
57. s 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 A 47 MATERIAL SAFETY DATA SHEET Battery Engineering Inc Date Prepared November 27 1995 1636 Hyde Park Ave 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 Thi Chionde 39 5 25 102 180 AumiwnClod e 65 Lithium Chloride 2 6 LITHIUM THIONYL CHLORIDE CELL Com Stainless Steel 42 5 Nickel 0 4 04 Carbon 47 Lithium Content 4 7 grams SECTION 2 PHYSICAL CHEMICAL CHARACTERISTICS Boilin
58. sxida TAA C 5 GEHA poe 1 Met Hoted Lo LA LA Lin ps ACGIH Freducl Code ESDS Paga 1 approval dater 11708799 Continued next pags Appendix A 50 11 EINCHEDIENTS Coat Om mo tag MUNDER EXPOSURE LIMITS CONCENTRATION X m EE ee ome ee CNN CUN CU m om m o Se m o GE UL GEO Gn Gs 2781 51 38 DEH 300 1 1 550 mg m 1 000 ETEL 3 000 ACCTHI 350 ppa 1 500 i ppa TEL 2 900 mg Salfer Chlaride 10028 67 1 600 ppa 1 Hat Hated 8 000 apial Ceiling AC EH t L 000 pps 31 5100 _e umm i11 PROPERTIES wee Sp ee Lu uui ee EEE Ee me um ua FHYSILAL 1816 eli yel los L Rare irritating MOLECULAR WEIGHT isss 11 pu rr ee ipplicabla 158 rU amp MELTING FALEIING FOINT 1 Appr es 196 F 104 3 C 1 Appi ud 0 0 mFua 1 c
59. tep 2 Program Instrument Tube Assembly for more details on this procedure Chapter 3 DHT Operational Pretest 23 WARNING This WILL erase all previously saved data on the Mate Transfer needed data to CORRDATA Plus prior to erasing memory Set the Mate for a data rate of 300 BAUD by pressing Read F1 MODE F2 Baud F2 and 300 F1 See Chapter 1 CORRDATA Mate section for more details Connect the Mate to the DHT Communications Adapter Connect the Instrument Tube Assembly to the DHT Communications Adapter Read data from the Instrument Tube Assembly by following the steps below l Turn the Mate ON and wait for the main display is shown below ROHRBACK COSASCO SYSTEMS Read Disp Dump SetUp Press Read F1 to advance to the What to Read display shown below What to Read PROBE MODE RDC EXIT 1 Choose RDC to enter the following screen Connect Mate to RDC START EXIT Press START F1 to collect the data When the data collection is completed EXIT F4 to return to the main display NOTE Due to the low data communication rate the Mate requires about 4 minutes to read data from the Instrument Tube Assembly Chapter 3 DHT Operational Pretest 24 7 Disconnect the Instrument Tube Assembly and the Mate from the DHT Communications Adapter The number of readings taken and the value of the last reading may be read back directly from the Mate by using the Display Mode Disp F2
60. ve 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 Appendix A 46 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 NOTE Save the shipping packaging in which the batteries are received since this packaging meets these requirements and may be re used for returning batteries to RCS or a disposal facility Safe Disposal Lithium thionyl chloride batterie
61. w 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 kept above 21 C 70 F 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 has been trapped in the Instrument Body while the DHT was downhole 1 Use a girthgrip 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 Chapter 4 DHT Assembly 40 Step 3 Remove Instrume
62. y and disassembly of the DHT In addition to mechanical tools four custom 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 11 Chapter 1 Introduction ppb Bog Lobo bono obo b 1 1 41 1 L 1 4 1 4 4 1 L1 1 4 44 4 4 P 4d d 4 au i tee ttt tt t 4 4 E N3APSISN 4 ttt t 4 ft 2 E op op dod N gt 5 t udi 090 2 pora F444 4 4 27 Oo op dod d 4 od 5 42 t t t 69000 N o s i 2 tt tet 1 ood pb dp gt depo obe db qp xp 11414 44 4 10099 4 4 TO ttt dO Od do tt OY EO EO ot tt tet ptt Od OO OO d Od oo ttt OE Figure 1 3 DCMS Tool Ki Chapter 1 Introduction 12 13 Chapter 2 Specification Downhole Tool Specification 9 9 9 Environment Oil Gas Water production Sweet or Sour Service subject to running tool specifications Shock 30 G s Max Rando
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