Model 2000 and 2000-5 UCA Manual.igr
Contents
1. alt 75 0 CONTROL CONNECTOR Far 1 WHITE WHITE 2 RED RED 3 GREEN L 4 BLACK 3 D BEATER 1 COOLING H20 3 PUMP C 1190 C 1189 5 H20 FILL 4 SB MEASUREMENT COMPUTING C 1181 popo pipi E 1186 CABLE 1183 PANEL P4 0203 PULSA BOARD 4 8 4 9 4749 4589 0089 18 STRAIN RELIEF BLACK elg E 8 3 1 WHITE RESS SDUCER WHT RED 5 emm 0481 WHT BLUE 1183 1186 PINOUTS C0352 1070843 OWER SUPPLY h WHT RED Tod D 3 WHT ORANG WHT BLUE WHT PURP WaT O SE HH RELAY BOARD 11260 JORPLE 1 2 3 RELAYS 1261 WHT BLK WHT BLK BULKHEADS C 0770 3 7 l1 5 Gens 8 FOP TRANSDUCER c 115 79 OP TRANSDUCER HH 0264 THERMOSTAT BULKHEAD 0770 C 0080 o4 IO 5 IATER FILL C 0024 Power Switch C 002. CEMENT TEST EQUIPMENT INC Tulsa Oklahoma USA Model 2000 UCA Instruction Manual CEMENT TEST EQUIPMENT INC Model 2000 Users Manual Cement Test Equipment Inc 5704 Admiral Blvd Tulsa OK 74115 Phone 918 835 4454 Fax 918 835 4475 Rev F 12 20 10 Table of Contents INTRODUCTION 1 What is Used fOr se uns 1 Description of Instrument 1 Instrument Specifications 2 Iristallatiofia n he t teret meets 3 Connecting an Uninterruptible Power Supply UPS 5 USING THE TOUCH SCREEN SOFTWARE nn has 6 What is touch screen and how does it work 6 Using the Touch Screen 6 What can you do with the touch screen software 7 Navigating the software nccrne 7 ect bete sedens 8 Test Setup Menu 0 The Mairi Menu eU ERI eed 1 MEME ae 3 Temperature Control a een er 3 Instrument Setup Menu 5 Ro ES ee 8 en een 21 Use of the USB Memory 22 Networking the Instrument 22 Transit Time Calibration sess 23 A TOUR OF THE FRONT PANEL CONTROLS nee 25 The Hydraulic Pressure Controls 25 The Pneumatic Controls 26 he Electrical and Electronic Controls and Displays27 OPERATION 52 22 22 22 22 25 22 53 29 Preparing the Test Cell 29 Setting Up a Te
3. 4 the waveform appears acceptable enter the Calibration screen and follow the directions This will store a new calibration file for water in the instrument memory Again this will force the waveform stored in memory to 17 104 micro seconds by definition 5 Exit the calibration screen 6 Start a test keep water in the cell with more than 1000 psi and check the transit time The transit time should display 17 104 or be very close to this value If the transit time is outside the range of 17 0 17 2 then repeat steps 3 6 7 If the transit time is in agreement the instrument is calibrated properly If not repeat steps 3 6 Incorrect or improper calibration values are the most likely reason for the UCA to report incorrect strength values The calibration should be checked whenever the transducers are removed or if the compressive strength values become suspect 8 7 6 5 4 3 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CEMENT TEST EQUIPMENT INC ANY REPRODUCTION IN PART OR WHOLE WITHOUT THE WRITTEN PERMISSION OF CEMENT TEST EQUIPMENT INC IS PROHIBITED D 0 2 2 9 Z 222 REVISIONS REV DESCRIPTION DATE APPROVED al Be 7 224 Rennie Per h99 NNSS gt TEM NO QTY PART NO DESCRIPTION oy
4. TI I Scaled Value NOTE NEVER CALIBRATE TRANSIT TIME WITH A CEMENT SLURRY OR STEEL BAR FROM OTHER DEVICES A TOUR OF THE FRONT PANEL CONTROLS DIAGNOSTICS The Diagnostics button displays a diagnostic screen where the user may pulse the transducer and display the waveform on the screen This tool allows the user to quickly verify transducer operation The peak of the transducer should be well above 200 with water in the vessel If the pulse amplitude is less than 200 with water in the cell the UCA will not function properly and an error message will be displayed 000 900 000 700 600 500 400 300 200 Calibrated Transit Time p T JUNTO Sep MT AUS EC NIE 0 25 50 75 100 125 1 175 200 225 250 275 300 325 380 375 400 425 450 475 500 SINGLE PULSE CONTINUOUS PULSE 17 A TOUR OF THE FRONT PANEL CONTROLS Running a Test RUN TIME MENU VIEW LIVE CHART VIEW TEST SETUP VIEW WAVEFORM MESSAGE INSTRUMENT Once a test has begun a RUN TIME MENU of current values will be shown The user may control all available parameters of the instrument from this menu Under the Pressure column the user can turn the water supply to the pressure vessel on or off and can turn the pump on when the cylinder is filled Under the Temperature column the user can select between AUTO and MANUAL temperature control When in MANUAL mode the user can adjust the temperature set point as well a
5. 1 11452014 CYLINDER 2 1 40081 BOTTOM PLUG 3 1140082 TOP PLUG 4 4 2 C 0371 ULTRASONIC TRANSDUCER i 4 S 5 1 4 0036 TABLE UY RRR NUE B 6 40089 BANANA JACK N 7 140085 JACK SUPPORT fie X 92 8 1 40086 JACKINSULATOR a2 2 9 2 4 0017 SEAL RING EZ Tol 2 C 0074 O RING EI D I xem 11 1 40088d CONNECTOR BASE 12 2 4 0026 HANDLE le ud 13 1140083 PLUG HOLDER 141 1 4 00878 BANANA JACK 15 14 00846 PLUG INSULATOR 7 17 1 C 0753 O RING NOT SHOWN 18 1 0127 O RING NOT SHOWN 4 12 19 2 C 0069 RING NS wW 20 1 0395 SPRING NOT SHOWN UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING DIMENSIONS ARE IN INCHES DO NOT MANUALLY UPDATE CEMENT TEST EQUIPMENT INC TOLERANCES ARE FRACTIONS DECIMALS ANGLES UU amies eos ET UCA CYLINDER ASSEMBLY MATERIAL CCD 6 1 1 99 T CCD 6 11 99 NEXT ASSY USED ON MES ENG CCD 6 11 99 DWG NO 4 0080 REV APPLICATION DO NOT SCALE DRAWING QUALENG 8 7 6 5 4 3 CCD 6 11 99 scar 2 CAD FILE SHEET 1 OF 1
6. Eme Ps nc a8 pm Eme eme de pum C 0075 1 3388 Switch ON OFF Circuit Breaker 10A C 0264 C08572 80 31035 Thermostat 420 Open 380 Close 39 MAINTENANCE AND TROUBLESHOOTING Number Part Number Part Number 0003 0003 P1075 High Pressure Filter Assembly Pressure Filter Assembly C 0096 Pressure Transducer 1 22 2 _____ 7 pu Power Supply Power Cord Cylinder Wrench C 0336 Touch Screen Power Supply C 0145 Monitor Touch Screen 40 Transit Time Calibration Checking the transit time calibration is very easy Follow the steps below 1 Fill the cell with water making certain there is no air trapped in the cell 2 Apply pressure of 1000 psi or more to the cell This will collapse any tiny air bubbles that may be present It is not absolutely necessary to apply pressure but experience has shown that this is the best way to ensure no air bubbles are present 3 Check the transducer waveform as described on p 14 and make certain that the amplitude of the peaks is greater than 600 and less than 600 with water it may be less with cement 4 If the waveform appears acceptable greater than 600 and less than 600 keep water in the cell with more than 1000 psi and check the transit time by starting a test The transit time value should be between 17 0 and 17 2 micro seco
7. VIEW WAVEFORM gt p E R 1 u R E gt 100 150 200 250 300 350 400 MESSAGE INSTRUMENT If there is some question as to whether the instrument is producing the desired ultrasonic waveform the user may press the VIEW WAVEFORM button 20 A TOUR OF THE FRONT PANEL CONTROLS RUN TIME MENU VIEW LIVE CHART VIEW TEST SETUP VIEW WAVEFORM 10 7 6 s 4 3 3 4 4 Er 104 MESSAGE INSTRUMENT This will display a waveform similar to the one shown below IT may take up to a minute for the waveform to be displayed since the software waits for the next pulse to occur Note that the amplitude of the first waveform peak must be greater than 20 or an error will occur If the waveform amplitude is less than 20 the instrument may have a faulty cable or ultrasonic transducer or the ultrasonic transducers may not have enough ultrasonic couplant grease Stopping a Test To stop the current test the user must press the STOP TEST button on the RUN TIME MENU screen Once the test has been stopped no further data will be logged and no further temperature control will be provided You may view the last test or any test stored on the UCA by pressing the VIEW TEST button and selecting the appropriate file name 21 A TOUR OF THE FRONT PANEL CONTROLS Use of the USB Memory Module The UCA operates under a version of the Windows operating system This allo
8. pe Er TOUCHSCREEN PRINTER POWER USB KEYBOARD us COAX TO CONTROL BOX USB MAIN POWER BOTTOM TRANSDUCER POWER TO CONTROL BOX DATA TRANSFER CABLE THERMOCOUPLE ORIENTATION SPECIFIC CONNECTOR UPS UNIVERSAL POWER SUPPLY OPTIONAL FOR THE INSTALLATION OF UPS FOR POWER OUTAGE OR SURGES IF NO UPS USE SUPPLIED CABLE FOR JUMPER INSTRUMENT BACK PANEL 4 PORT USB HUB SUPPLIED COM VGA ETHERNET 6 PIN MINI DIN BOTTOM 4 400 NEN USB CONNECTORS MEMORY STICK NOT USED TOUGH SCREEN NETWORK NOT USED TRANSDUCER TRANSDUCER FOR DATA STORAGE TRANSFER CABLE CABLE SUPPLIED COMPACT FLASH CARD COMPUTER MEMORY DO NOT REMOVE POWER FROM UCA INSTRUMENT COMPUTER CONTROL BOX BACK PANEL THERMOCOUPLE TRANSDUCER UCA VERSION 5 OR 230 VOLT 50 60 2 POWER SOURCE PRESSURE VESSEL 230 VOLT 50 60H7 POWER SOURCE REVISIONS APPROV
9. 01 237 1 Base ring 189 3610 0438 VP 10 06 06 MAXIMATOR GmbH 37449 Zorge Walkenrieder Sir 15 Tel 49 0 5586 803 0 Fax 49 0 5586 803 40 e mail info maximator de website www maximator de MAXIMATOR MAXIMATOR GmbH 23 09 2004 Anz Benennung Artikel Nr VP 10 00 127 05 Seite 3 3 Bemerkung Zeichnungs Nr 38 1 Lock nut 3610 0444 VP 10 06 12 139 1 nut 3610 0443 VP 10 06 11 40 2 Ball bracket 3610 0397 VP 10 05 50 41 2 Spring 3610 0399 VP 10 05 52 42 2 Ball 3610 0358 VP 10 05 16 43 Inlet gland 3 8NPT 3610 0420 VP 10 05 69 44 Outlet gland 9 16 18UNF 3610 0424 VP 10 05 71 45 Mounting bracket bottom 3610 0182 VP 10 03 19 46 4 Hex head screw 3610 1069 VP 10 15 02 47 2 U Washer 3610 0185 10 03 21 48 4 Spring washer 3610 0184 VP 10 03 20 50 Pumphead side inlet Optional type 189S HL 3610 0405 VP 10 05 58 51 plate drop at 189 HL 3610 0128 VP 10 02 05 52 Hex head screw drop at PP 189 HL 3610 0129 VP 10 02 06 58 Adapter 1 4 3620 0160 VP 15 02 32 254 0 ring 3660 1112 OR 70 04 46 01 MAXIMATOR GmbH 37449 Zorge Walkenrieder Sir 15 Tel 49 0 5586 803 0 Fax 49 0 5586 803 40 e mail info maximator de website www maximator de MAXIMATOR
10. Start button on bottom left of screen and Shut down computer properly 5 Turn POWER switch to its OFF position 6 Close the PRESSURE RELEASE valve clockwise Failure to do so will result in water leakage if cooling water is circulating when the U tube or thermocouple are loosened 7 Remove the U shaped high pressure tubing connecting the test cylinder to the bulkhead fitting on the top of the instrument 8 Disconnect the transducer cable 32 OPERATION 9 Disconnect the thermocouple cable 10 Lift the test cell from the instrument The test cylinder is now ready to be cleaned Cleanup should be done as soon after completion of a test as possible when the sample is easiest to remove Cleaning the Test Cell When the test cylinder has been cooled and removed from the instrument it should be cleaned according the following guidelines 1 Place the test cylinder in a vice topside up The top of the cylinder is marked on the cylinder wrench flats Use the wrench flats to clamp the plugs and cylinder and do not scratch or nick the cylinder or plugs The spiral 2 Remove the cylinder from the vice and replace in the vice top side down retaining ring found on the 3 Unscrew and remove the bottom plug from the test cylinder bottom plug is used to retain the 4 Turn the cylinder over and tap the cement sample out of the test cell with a seal ring and o ring hammer The cylinder is tapered outward from top to bottom so the c
11. amp 1040146 SAFETY HEAD 21 PRESSURE a l ELTER HP RELEASE 1 8 3120048 COLLAR 1 4 HP T T l 4 310 0050 IGLAND 1 4 HP 10 112 1096 PRESSURE TRANSDUCER 11 60839 1 4 HP 90 299 1 210021 VALVE HP 1 1 100 PUMP 10 000 PSI 14 21 000 ADAPTER 1 4 HP x 1 8 FNPT 4 1 15 110250 ELBOW 187 x 1 4 1 16 11c 0078 RELIEF VALVE PUMP 1 TEE BRANCH 1 48 1 6022 a conss 20 20054 ELBOW 1T x 1 8 MNPT l 1 110 018 ICON 1 47 x 3 8 MNPT 1 4100778 ELBOW UNION 1 4 Tx 14T 1 100051 TEE UNION 1 4 116 0081 RUPTURE DISC 22000 PSI 5 110 0283 BUSHING 1 28 110 0284 ELBOW 187 x 1 8 MNPT OO 1 Conn ia ner x tT 28 0184 TEE 1 4 T x 1 8 1 l 29 020 ADAPTER 1 8 FNPT x 1 8 FNPT l 30 210018 PRESSURE GAUGE 31 2100180 ELBOW 14T x 1 8 MNPT i 1160021 REGULATOR T Tl x 3 0181 ELBOW 14T 1 4 MNPT Wessr 1160004 SOLENOID l 1 4 SST 5 1 60 8 PLUG HP l COPPER 1100630 PLUG BRS Wo HE ES ri 14 3 ADAPTER 1 4 PLASTIC BLUE 38 1 00888 PRESSURE 9 eee 1 4 PLASTIC BLACK ET E CEMENT TEST m o LOWER REAR mia xp we 1 PANEL E P a ms UCA PIPING SCHEMATIC WATER WATER COOLING COOLING AIR INLET INLET OUTLET INLET OUTLET m Ee ar Chan 11296 mr
12. and relatively free from dirt and oil The air should be supplied at a pressure of 20 100 psig 1 4 6 8 bar Compressed nitrogen may also be used in place of the compressed air if necessary If high pressure bottles of nitrogen or air are used to operate the instrument make certain that the pressure supplied to the instrument does not exceed 100 psig 6 8 bar Applying high pressure gas to the instrument can cause tube rupture and possible injury Electrical connections are made using the receptacle on the rear of the instrument A power cord part number C 0156 is supplied with the instrument Please observe the following precautions when making the wiring connections e Wiring should be done by a qualified installer in accordance with local electrical codes e The instrument should be securely connected to a separate earth ground The ground wire must be larger in diameter than the supply conductors e An 8BC or larger fire extinguisher to fight electrical and oil fires should be placed within 50 feet of the consistometer Some components such as touch screen LCD monitors may be removed from the instrument prior to shipment and shipped in a separate container to prevent damage This device must be reinstalled before operating the instrument The monitor cables include one USB and one VGA cable which must be connected to the control box and one AC power cable which must be connected to 110 230 VAC If a UPS is not used the C 02
13. assembly has good contact make certain the test cell is pushed down firmly inside the heating 29 OPERATION 10 11 12 jacket Do not turn the test cell assembly counterclockwise or the plugs may come unthreaded Connect the one end of the coaxial cable to the BNC connector on the top plug and the other end to the connector on the rear panel labeled TRANSDUCER Align pressure port in top plug with high pressure fitting on top of autoclave assembly Rotate test cell in a clockwise direction only The top or bottom plugs may come unscrewed if the test cell is rotated counterclockwise Attach the high pressure tube from the cabinet to the test cylinder Place the U shaped tube in place Tighten fittings on both ends of U tube finger tight only When the U shaped tube is in place complete tightening using a 5 8 inch open end wrench Connect the thermocouple cable to the connector on the rear of the autoclave labeled J THERMOCOUPLE Install the thermocouple into the remaining high pressure port in the top plug of the test cell until the fitting is finger tight Slowly open the water supply valve until water begins to come out the thermocouple connection vent hole Tighten the thermocouple with a 5 8 inch open end wrench It is recommended rag or paper towel be placed near the thermocouple vent hole to collect the spilled water and prevent it from running down inside the instrument or into the sensor cavity The instrument
14. is now ready to begin a compressive strength test Setting Up a Temperature Ramp See Chapter 2 Setting Up Automatic Pressure Control This section describes the steps used to control pressure in the Model 2000 UCA Use of the internal pump and pressure regulator will also be discussed Follow the steps below the to configure the pump and pressure regulator for automatic pressure control 30 OPERATION 1 Make certain the test cylinder is installed properly the HIGH PRESSURE INLET port on the rear of the instrument if equipped is plugged the PUMP and COOLING WATER is in the ON position in the software and the COOLING WATER is in the OFF position in the software and the instrument is supplied with compressed air 2 Turn the AIR TO PUMP regulator clockwise until air pressure is sufficient to raise pressure to the desired pressure set point The air pressure should not exceed 100 psig 690 kPa 3 Turn the blue PRESSURE REGULATOR knob clockwise until the regulator pressure is sufficient to prevent the regulator from opening at the required pressure set point 4 Turn the AIR TO PUMP knob clockwise and increase pressure until the pressure exceeds the desired set point Turn the PUMP switch OFF in the software Make certain the system is holding pressure before proceeding The pump contains metal to metal inlet and outlet check valves that may not be bubble tight so a small amount of pressure leakage is to be expected This shou
15. recalibrate Transit time calibration is different from older UCA s The steel calibration bar is no longer required The unit is now calibrated with water It is imperative that there be no air in the water during calibration or while a test is in progress Incorrect or improper calibration values are the most likely reason for the UCA to report incorrect strength values The calibration should be checked whenever the transducers are removed or if the compressive strength values become suspect 24 It may be convenient to refer to the piping drawings in Chapter 6 when studying this section A TOUR OF THE FRONT PANEL CONTROLS Chapter A Tour of the Front Panel Controls Chapter 3 will discuss in detail each front panel control found on the UCA component found on the front panel The controls can be divided into three categories hydraulic controls that control the pressure inside the reservoir pneumatic controls that control the air pressure to the pump and the switches that control the electrical components of the instrument T he sections below will describe the function of each The Hydraulic Pressure Controls This section consists of the following controls the PRESSURE RELEASE valve the PRESSURE REGULATOR the REGULATOR BYPASS valve and the WATER SUPPLY switch Components that make up this section are used to control the flow of water used to pressurize the cylinder The PRESSURE RELEASE valve is used to relea
16. the Test Cell The steps that should be used to set up the test cell are listed below 1 Apply a light coating of grease to the inside of the test cylinder including the top and bottom plug surfaces that are in contact with the cement slurry Coating the threads will grease or anti seize lubricant is also recommended Screw the bottom plug into the bottom of the pressure cylinder The top of the cylinder is stamped TOP on the wrench flats Add cement to the test cell until the proper fill level is obtained using the Slurry Level Gauge P N 4 0058 The slurry should touch the lower tab marked WET but not the upper tab marked DRY Be careful not to get cement into the threads If cement sets up in the threads it may make plug removal and installation difficult or impossible Gently pour a small amount of water into cylinder on top of the cement just enough to reach the water fill line on the Slurry Level Gauge Try not to mix the water and cement Screw the top plug in place Do not tighten with a wrench Hand tight or hand tight less 1 8 turn is optimal A small amount of water should come out the pressure or thermocouple port when the top plug is in place Wipe the cylinder assembly clean and gently place in autoclave chamber Make certain the electrical contacts in the bottom of the cabinet and plug are free from corrosion and debris Rotate cylinder clockwise if necessary insure the banana connection on the bottom the cylinder
17. 0 82 01 14 4 O ring 3660 0106 OR 70 01 12 01 15 3 Head socket screw 3610 0107 VP 10 01 07 16 1 Muffler 3610 0108 VP 10 01 09 17 1 Pilot screw 3610 0127 VP 10 02 04 18 1 Gasket 3610 1264 VP 10 18 49 MAXIMATOR GmbH 37449 Zorge Walkenrieder Sir 15 Tel 49 0 5586 803 0 Fax 49 0 5586 803 40 e mail info maximator de website www maximator de MAXIMATOR MAXIMATOR GmbH 23 09 2004 10 00 127 05 Seite 2 Anz Benennung Bemerkung Artikel Nr Zeichnungs Nr 19 1 Spring 3610 0130 VP 10 02 07 20 1 Pilot tappet 3610 3180 VP 10 02 47 22 1 Seal 3610 3181 VP 10 02 48 23 1 O ring 3660 0843 70 01 24 01 224 tf 1 2O ring 3660 0221 OR 70 115 1501 25 1 Air cylinder 3610 0178 VP 10 03 15 26 1 Plunger PP 189 3610 0147 VP 10 03 02 S2 1 Air piston PP 3610 0157 VP 10 03 07 28 sod sOerung 3660 0207 OR 70 23 22 01 29 1 Plunger bracket 3610 0191 VP 10 03 27 30 1 Spring 3610 0181 VP 10 03 18 31 1 O ring 3660 0108 OR 70 01 32 01 32 1 Bottom SPP ss HE 3610 0203 VP 10 04 01 133 1 Vent 3610 0205 VP 10 04 03 234 1 Pumphead 189 HL 3610 0403 10 05 56 235 1 Seal 189 3610 0492 VP 10 06 40 236 1 Back up 189 3610 0432 VP 10 06
18. 75 20 D RED ON Power Inlet C 0271 0472 Load POWER BOTTOM TRANSDUCER ERMINAL BLOC gt 230 VOLTS YELLOW 20 AMPS o o 50 60 HZ o 2 o C 0080 o o o4 IO o 4 Pume 0024 ere 272 ol 20 Lt ee o o c 0275 ELLOW O 0472 0271 ERMINAL BLOCK WATER C 0024 Ultrasonic Cement Analyzer QP with External Control Box mE ES Cement Test Equipment Inc DRAWN BY GRH 10 07 09 Version 5 0 Control Box APPROVED BY REV DATE BY CHK DESCRIPTION APPROVED BY pua 4 0008 V5 REVISIONS APPROVED BY T T T T 1 T T T T T T T T T T T T T T PUMP AIR PRESSURE AIR SUPPLY 9 COOLING WATER 1 que EH 9 D 1 WATER SUPPLY LI 4 i 1 H l l ITEM NO amv IPART NO DESCRIPTION 1 21 009 BULKHEAD CONNECTOR i 2 s caa BULKHEAD CONNECTOR PRESSURE 1044056 BRACKET 1 VESSEL 4 slcasse BULKHEAD FASTENER 5 1160838 8055 1 4 HP
19. 75 cord must be installed between the two rear panel receptacles or the instrument will not operate INTRODUCTION If a printer is included with the instrument it may be connected to the control box Connect the USB connector on the printer cable to the control box The printer must also be connected to a suitable power source Refer to the printer documentation for power requirements Connecting an Uninterruptible Power Supply UPS There are two receptacles on the rear of the unit labeled UPS that may be used to connect an uninterruptible power supply UPS In the event of a power failure the UPS will operate all functions of the UCA except the heater for up to one hour to prevent loss of test To connect the UPS select the power cord supplied with the UPS and connect one end to the UPS input and the other end to the UCA The cord will fit only one receptacle Locate the other power cord supplied with the instrument part number C 0275 and connect one end to the output of the UPS and the other end to the other UPS receptacle on the rear of the UCA Press the ON button on the UPS A green light will appear on the UPS when it is operating properly If the unit beeps and a red light comes on a power failure has occurred and the unit is being powered by the UPS Note that if the POWER switch is turned OFF and the UPS is not turned OFF the instrument will not power down Before attempting to operate the instrument it is recommended
20. ED BY 03 27 2010 PERIPHERALS INSTALL GUIDE ES Cement Test Equipment Inc DRAWN BY 03 27 2010 APPROVEDBY 03 27 2010 REV DATE DESCRIPTION APPROVEDBY 03 27 2010 Pen UCA PERIPHERALS INSTALL GUIDE C9 Co 5 9720 9 G2 C2 DI gt 5 2 9 5 3 69 8 0 9 09 2 3 09 9 AER 225 d 6960696309 6369623 CI CD Gd 4I 6209 A A A 6 2 Valid at serial No 659 699 pw A N o 5 2 2 2 4 2 2 5 2 29 69 0909 60202 ADAI 69 AMA ALLEN NS Le 20000000 0000 0 MAXIMATOR Pocket Pump Optional side inlet PP 1 lt 3810 0216 9 nee TYPE 10 04 00 3610 0202 LE ERA 8 Air drive section 10 13 128 05 NOS 2 ENS 3610 0807 555 NO 5 S Hydraulic section VP 10 13 129 05 3610 0812 in case of order please indicate serial No MAXIMATOR GmbH D 99734 Nordhausen D 37449 Zorge Gericht Denke 189 PP 1895 1 14 rt ser Erste s ca Pe 1898 en 03 oaf sen fiep Pest wer wini s 05 08 02 sen peor Pocket Pump rm FRE US representative MAXPRO TECHNOLOGIES INC imr 7728 Klier Driv
21. MAXPRO Anderungsprotokoll MAXPRO Record of changes Typ Type Zeichnungs Nr Drawing No Artikel Nr Ident No nderungsdatum Date of change nderungshinweise Change directions MAXIMATOR GmbH PP 189 5 01 10 00 127 05 3810 0192 3810 0170 23 09 2004 HD Dichtsatz war VP 10 13 129 01 3610 0808 ersetzt durch HD Dichtsatz VP 10 13 129 05 3610 0812 HP seal kit VP 10 13 129 01 3610 0808 removed through HP seal kit VP 10 13 129 05 3610 0812 37449 Zorge Walkenrieder Str 15 Tel 49 0 5586 803 0 Fax 49 0 5586 803 40 e mail info maximator de website www maximator de
22. TARE TUR 41 427777 43 FAIRVIEW PA 16415 at n So MAXIMATOR Pocket Pump H 22222 5 PHONE 814 474 9191 vor wn a2 s 05 17 03 5eh Bear w hand lever FAX 814 474 9391 estar 3810 0197 1 7 3 5 5 7 8 Zast Anderung Dotun Urspr VP 10 00 127 Ersatz f rgl Zchng v 08 09 97Ersetzt durch MAXIMATOR GmbH 37449 Zorge Walkenrieder Sir 15 Tel 49 0 5586 803 0 Fax 49 0 5586 803 40 Technische Anderungen vorbehalten e mail info maximator de website www maximator de MAXIMATOR MAXIMATOR GmbH 23 09 2004 10 00 127 05 Seite 1 Anz Benennung Bemerkung Artikel Nr Zeichnungs Nr 21 1 PP ea 014 AL 3610 4094 VP 10 02 107 2 L sO ring 3660 0151 OR 70 11 42 01 3 1 Bushing PP ss 01 HL 3610 4095 VP 10 02 108 4 1 Spool housing G3 8 3610 0106 VP 10 01 06 So 1 Spool sleeve 3610 0105 VP 10 01 05 6 2 3 O0 rang 3660 0111 60 01 62 01 57 24 Spool 3610 0110 VP 10 01 02 8 4 O ring 3660 0505 80 08 39 01 29 3 0 ring 3660 0109 70 01 42 01 10 5 2 PO ring 3660 0112 70 01 72 01 211 1 Spool plug 3610 0104 VP 10 01 04 512 1 ring 3610 0109 VP 10 01 10 213 2 0 ring 3660 0103 OR 70 0
23. TE logo This should consist of a number and perhaps a letter for example 5 1b This version number is important when calling CTE for support or questions As noted in the instructions on the screen all the user needs do is touch a button to begin START TEST Pressing this button begins a test The instrument takes the current test parameters and begins a new test If a temperature profile has been programmed a screen will prompt the user to turn on A TOUR OF THE FRONT PANEL CONTROLS the heater Once a test has started the main testing screen will be displayed TEST SETUP This button takes the user to the Test Setup Screen Here the user may enter test parameters for the instrument Test name cement parameters UCA algorithm and Temperature Control are all accessed through this screen INSTRUMENT SETUP This button takes the user to the Instrument Setup Screen From this screen the user may verify transducer signal calibrate the instrument or archive the data to a USB memory module or network drive VIEW TEST This button allows the user to view any previously stored test The software looks for the tests in the c CTE directory and you will be prompted to select a file Use care when choosing a file name so you will be able to retrieve it if desired A TOUR OF THE FRONT PANEL CONTROLS Test Setup Menu From this menu the user can setup the parameters for the next test STORED TEST PROMILES CUSTOMER Retriev
24. UP This button takes the user to the Test Setup Screen Here the user may enter test parameters for the instrument Test name cement parameters UCA algorithm and Temperature Control are all accessed through this screen INSTRUMENT SETUP This button takes the user to the Instrument Setup Screen From this screen the user may verify transducer signal calibrate the instrument or archive the data to a USB memory module or network drive VIEW TEST This button allows the user to view any previously stored test The software looks for the tests in the c CTE directory and you will be prompted to select a file Use care when choosing a file name so you will be able to retrieve it if desired 12 A TOUR OF THE FRONT PANEL CONTROLS Test Setup Menu From this menu the user can setup the parameters for the next test STORED TEST PROMILES CUSTOMER Retrieve Test Setup NEW TEMPERATURE PROFILE SAMPLE PROPT RIS ALARMS Add Edit Test Sample Add Delete Alarms Temperature Control No longer is entering a temperature ramp a confusing process On the temperature setup screen is a standard numeric keypad On the left side are three values that define a ramp Once a ramp is entered the user may advance to the NEXT STEP or press DONE to finish Set Point EN c Ramp Time 13 A TOUR OF THE FRONT PANEL CONTROLS When finished a graph of the desired temperature ramp is displayed The user may accept the cur
25. e FAIRVIEM PA 16415 PHONE 814 474 9191 FAX C814 474 9391 indt gat tke 3810 0135 MAXIMATOR 1 7 3 F 5 6 8 10 11 7 10 2 2 00 A 626009 G9 69 0905 Q9 DO OOOE Lii EI as B 2 B ZEI 5 B O cor gt 5 ONE _ 2 v 36 TOA LN ENSIS E 99 4 00000 E 40 A N 46 O 0 0 E 22 gt 49 FE i 41 AC lt lt a Spare parts kits 9 GA ses VP 10 01 00 3610 1366 p Air drive section VP 10 03 00 3610 0144 60 gt Hy rautie set Hydraulic section VP 10 13 129 05 3610 0812 42 9 case of order please indicate serial No For optional type PP 189 HL w handlever 5 MAX IMATOR 50 connect drawing VP 10 08 00 05 3610 0509 6 42 2 HL 40 Valid at ser No 752 219 MAXIMATOR 2810 0170 40 4 iind H US representative Mo stob 1 1 Gewicht 44 42 MAXPRO TECHNOLOGIES INC 189 S HL PP 189 5 01 1728 Klier Drive Fer
26. e Test Setup NEW TEMPERATURE PROFILE SAMPLE PROPT RIS ALARMS Add Edit Test Sample Add Delete Alarms PROGRAM TEMPERATURE Program Temperature button displays the setup screen to enter a temperature profile This will be discussed further in a later section Set Point Bas Ramp Time MORE STEPS 10 A TOUR OF THE FRONT PANEL CONTROLS The Main Menu CYLINDER FILL COOLING OFF PUMP OFF The main menu is the starting point for the instrument From here users may start new tests setup test parameters setup instrument parameters or view an old test Located at top left is the current temperature reading for the thermocouple Current pressure is also displayed The Exit button is used to stop the UCA software and go into the Windows operating system Please note the software version number underneath the CTE logo This should consist of a number and perhaps a letter for example 5 1b This version number is important when calling CTE for support or questions As noted in the instructions on the screen all the user needs do is touch a button to begin START TEST Pressing this button begins a test The instrument takes the current test parameters and begins a new test If a temperature profile has been programmed a screen will prompt the user to turn on 11 A TOUR OF THE FRONT PANEL CONTROLS the heater Once a test has started the main testing screen will be displayed TEST SET
27. ement during sample must always be removed through the bottom of the cylinder disassembly In some cases it 5 Clean the cement and grease from the top and bottom plugs and cylinder may make removal of the bottom plug 6 When all traces of cement have been removed grease the inner surfaces of more difficult Its the test cell including the seals and o rings use is strictly optional and may 7 be omitted if desired Replace the o tings if they were damaged during the test The test cylinder is now ready to be used for the next test 33 MAINTENANCE AND TROUBLESHOOTING Chapter Maintenance and Troubleshooting This chapter contains information about the necessary periodic maintenance of the instrument as well as common service and troubleshooting guidelines Maintenance serviced and maintained properly Instruments that are neglected and receive infrequent service or are subject to abuse are certain to cause trouble The maintenance requirements for UCA are very simple and should consume little time U CA s can be relatively reliable and trouble free provided they are The first maintenance item is to check and replace the 2 micron filter element inside the high pressure filter housing periodically The filter housing is located on top of the instrument cabinet and is connected to the high pressure tubing leading to the test cylinder The filter housing should be thoroughly cleaned at this time The high pre
28. es To adjust the pressure of the air supplied to the pump 26 If the PUMP AIR PRESSURE drops off significantly when the pump is operating an air line may be blocked or the compressor may be insufficient to deliver the volume of air required A TOUR OF THE FRONT PANEL CONTROLS pull the knob on the regulator out to unlock it Turn the regulator knob clockwise to increase the pressure and counterclockwise to decrease the pressure When the adjustment is finished push the knob in to lock it in place The part number of this regulator is C 0021 This regulator is used to control the pressure of the air supplied to the pump part number C 0077 The hydraulic pressure output of the pump is directly proportional to the air pressure supplied to the pump As the air pressure increases the hydraulic pressures increases and vice versa Air pressure to the pump may be decreased by turning the AIR TO PUMP regulator knob counterclockwise or increased by turning the knob clockwise If the regulator is set to a value and the pump switch is turned to the ON position the pump will increase pressure until the pneumatic force of the air air pressure multiplied by pneumatic piston area equals the hydraulic force of the pressurizing water water pressure multiplied by pump piston area At this point the hydraulic and pneumatic pressures will be in equilibrium and the pump will cease to stroke If the water pressure falls for some reason a force i
29. ffler Cause psi Dirt or debris on transducer faces Not enough ultrasonic couplant on transducers Dirt or debris on transducer faces Bad coaxial cable Loose coaxial connector inside control box Pressure was below 1000 psi during test Faulty high pressure seal Remedy Increase pressure above 1000 psi Clean transducers and apply new couplant Clean transducers and apply new couplant Pea size amount is sufficient Clean transducers and apply new couplant Replace cable Check connections and tighten if necessary Check data file and make certain pressure remains above 1000 psi during a test Replace the high pressure seal and remove all water from air side of pump Pump may also be sent back for repair 37 MAINTENANCE AND TROUBLESHOOTING Parts List and Cross Reference The following table contains a list of spare parts for the CTE Model 2000 UCA A list of equivalent Halliburton and Chandler part numbers is also listed Number Part Number Part Number 4 0080 Pressure Vessel Assembly mel ne Gn d Pressure Vessel i Ca me ____ me jee 0775 m 3 uu mw wu em I Qe 7 C 0079 C08582 Bulkhead Fitting 1 4 HPT 1 4 HPT 38 MAINTENANCE AND TROUBLESHOOTING Number Part Number Part Number i Emu rm eto ct km rss tee 40087 Spacer Compression Spring Top
30. hat can you do with the touch screen software The purpose of the touch screen is to provide the user with a single interface to the instrument Temperature control instrument setup and current test data are accessed through the touch screen This eliminates the need to individually program separate temperature controllers or other off site PC software to begin running a test Additionally the touch screen allows the user to access current information from the instrument during a test Each instrument is complete and requires no additional software or hardware to function Navigating the software The software is designed to be intuitive to the user In addition to the options the different screens include directions and helpful hints to allow the user to quickly setup and run the instrument The first timer will find an easy to follow path to set up a test Most users will become highly proficient within a very short time A TOUR OF THE FRONT PANEL CONTROLS The Main Menu CYLINDER FILL COOLING OFF PUMP OFF The main menu is the starting point for the instrument From here users may start new tests setup test parameters setup instrument parameters or view an old test Located at top left is the current temperature reading for the thermocouple Current pressure is also displayed The Exit button is used to stop the UCA software and go into the Windows operating system Please note the software version number underneath the C
31. larm values for compressive strength and test time The PC will notify the user when these values have been reached and at what time they were reached The highest value entered here will become the default AUTO SHUTDOWN value during a test Instrument Setup Menu ADMINISTRATION AUTO COOL TIME CALIBRATE DIAGNOSTICS From this menu the user can run diagnostics on the ultrasonic transducer circuitry to determine if everything is functioning properly This menu is also used move the data files from the UCA computer to another PC in order to free space in the UCA memory ARCHIVE DATA FILES Select this command to move tests from the UCA to the USB memory module or external ZIP Drive If the instrument reports a Disk Full message it will be necessary to do this before additional tests may be run After this step is completed the stored tests on the UCA are moved then deleted After this button is pressed a message box similar to the one below will appear indicating which files were copied from the UCA to the storage device 15 A TOUR OF THE FRONT PANEL CONTROLS CALIBRATE The Calibrate button gives the operator the option of calibrating temperature pressure or transit time To calibrate the transit time the cylinder must be COMPLETELY full of water with no air bubbles inside the cell Calibration of transit time is discussed in more detail at the end of this chapter 0 000 Raw Value Scaled Value 000
32. ld not be a problem under normal operation 5 Turn the blue PRESSURE REGULATOR knob counterclockwise slowly until the test cylinder pressure begins to drop Continue turning the regulator knob slowly until the pressure in the test cell is at the upper limit of the desired test pressure 6 Release pressure in the test cell using the PRESSURE RELEASE valve 7 Turn the AIR TO PUMP regulator counterclockwise until the AIR TO PUMP is approximately zero 8 Turn the PUMP switch ON in the software 9 Slowly turn the PUMP AIR PRESSURE ADJUST regulator knob clockwise until the pump actuates Continue to slowly turn the regulator knob clockwise until the lower limit for the control pressure is reached As the test cylinder gets hot pressure in the test cylinder will increase When the pressure in the test cylinder exceeds the control pressure upper set point the pressure regulator will open and pressure will be reduced the heating rate is reduced as during the transition from a temperature ramp to a temperature soak the pressure in the test cylinder may decrease If the pressure falls below the control pressure lower limit the pump will actuate and bring the pressure back within the established limits 31 OPERATION The pump and pressure regulator will have hysteresis or a deadband in their operation For example if the pressure regulator is set to open at 3000 psig it may open at 3000 psig but may not close until the pressu
33. mbalance will be created between the pneumatic and hydraulic sides of the pump and the pump will begin to stroke and increase the hydraulic pressure until it is balanced with the pneumatic pressure then it will stop pumping In this way the pump may be used as a pressure control device combined with the relief valve to establish the lower pressure limit for a test This will be discussed further in Chapter 4 The Electrical and Electronic Controls and Displays The only front panel electrical controls are the POWER and WATER SUPPLY switches These controls are discussed in detail below The switch labeled POWER controls electrical power to the entire instrument Nothing else is operable if this switch is not on The part number for the POWER switch is C 0075 1 27 A TOUR OF THE FRONT PANEL CONTROLS The WATER SUPPLY switch is used to supply water to the UCA test cell pump and cooling water This switch should be in the ON position when the instrument is running 28 Do not overfill the test cell or cement will be forced into the pressure and or thermocouple ports and plug them small gap between the top and bottom plugs and the cylinder is advisable Overtightening does not cause better sealing it only causes plug removal difficulty OPERATION Chapter Operation Chapter 4 will discuss in detail the steps required to run a compressive strength fest Examples will be provided when necessary Preparing
34. mperature Ramp 30 Setting Up Automatic Pressure Control 30 Stoppitiqid Testa etat ete es nettes 32 Cleaning the Test Cell 33 MAINTENANCE AND TROUBLESHOOTING 34 MIGIMTERGINCES og 34 t eie tt ets 35 Parts List and Cross 38 INTRODUCTION Chapter Introduction This chapter contains general information about the UCA and its uses as well as detailed specifications for the instrument and installation instructions What is a UCA used for DEN KEY ements are a critical element in the drilling completion workover Speer Te and abandonment of wells For each application a cement slurry is designed with specific properties and is given additives that provide 2 Potential Danger Safety Hazard Operational Warning Our temperature controller and data acquisition system are so easy to operate you won t even need a manual We ve thrown one in anyway just in case predictable slurry density volume viscosity compressive strength fluid loss gas migration and thickening time The Model 2000 Ultrasonic Cement Analyzer UCA is used to provide a history of the strength development of a cement slurry as it cures under elevated temperature and pressure Description of Instrument The Model 2000 Ultrasonic Cement Analyzer UCA transmits an ultra
35. nds msec If it is within these values the transit time calibration is correct 5 If the transit time falls outside these limits recalibration will be necessary Follow the instructions below Transit time calibration is different from older UCA s The steel calibration bar is no longer required The unit is now calibrated with water It is imperative that there be no air in the water during calibration or while a test is in progress The easiest way to insure this is to apply 1000 psi or more to the cell during calibration The calibration screen will also not tell whether the calibration is valid This can only be determined using the method described above Rather the calibration screen forces whatever waveform it records to be by definition that of water with a transit time of 17 104 micro seconds For example if a calibration is done with the coax cable disconnected the instrument will store the flat line signal as that of water and it will report the transit time to be 17 104 micro seconds This is not the correct waveform for water and when the calibration is checked according to the above procedure the instrument will not report the correct transit time Follow the steps below when calibration is required 1 Fill the cell with water making certain there is no air trapped in the cell 2 Apply pressure of 1000 psi or more to the cell 3 Check the pulse as described earlier and make certain the waveform has sufficient amplitude
36. nnections can be made The air inlet water inlet and water drain connections are each 1 4 inch female NPT connections and are located on the lower right rear of the instrument A number of 1 4 inch male NPT to 8mm tube fittings are included for international locations Connect the coolant and pressurizing water to the connectors labeled COOLING WATER and WATER INLET respectively on the rear panel of the instrument Each fitting has a inch female N P T connection The water must be clean and free of debris that could cause failure of the pump or relief valve If in doubt a water filter is recommended Connect drain lines to the connectors labeled WATER DRAIN and COOLING DRAIN on the rear panel of the instrument The fittings have inch female N P T connections The drain system must be capable Before plugging the monitor into the rear of the UCA make certain power to the instrument is off INTRODUCTION of handling hot water up to 212 F 100 C or brief surges of up to 400 F 204 C steam for short periods of time during initial cooling of the instrument If two or more UCA s are connected to a common drain line it is recommended that the drain be 3 8 inch 10mm inside diameter minimum It is also recommended that the drain system be all metal Connect the air supply to the connector labeled AIR INLET on the rear panel of the instrument The fitting has inch female connection The air should be dry
37. ollowing section consists of a table listing possible remedies for the most common UCA problems Cause Remedy Leak Check fittings for leaks and tighten fittings TESCOM Regulator Leaking PRESSURE RELEASE valve is not closed tightly PRESSURE RELEASE valve is worn out Short circuit is system wiring Rebuild regulator or replace Close valve tightly Replace valve stem or entire valve Disconnect power to instrument and check for short circuits with an ohm meter Faulty POWER switch PRESSURE RELEASE valve open severe leak blown rupture disc Replace switch Locate problem and correct obtained Open thermocouple connector slightly and release trapped air Open WATER SUPPLY valve and check flow of water to the instrument Test cylinder has trapped air WATER SUPPLY valve is not open or water is 35 MAINTENANCE AND TROUBLESHOOTING Symptom Instrument not receiving power Heater will not get hot Temperature display is erratic Software will not start Pump will not operate Waveform amplitude is too low Cause not being supplied to the instrument PRESSURE REGULATOR is not holding pressure Faulty pump check valve UPS Jumper not connected or seated properly Instrument not plugged in Blown fuse or thrown breaker on circuit Supplying power Blown fuse HEATER switch not in the ON position Faulty heater Faulty solid state relay Faulty thermocouple L
38. oose connection in thermocouple wiring USB Cable unplugged Touchscreen unplugged or power off Insufficient air pressure to pump Solenoid valve controlling flow of air to pump is not functioning Not enough ultrasonic couplant on transducers Pressure is below 1000 Remedy Turn PRESSURE REGULATOR knob clockwise Overhaul replace regulator Clean and or overhaul pump check valves Install UPS Jumper cable to back of instrument making sure it snaps into place and is fully seated Connect instrument to the correct power source Check fuses and breakers on electrical supply circuit Check fuses on rear panel Replace any that are blown Turn HEATER switch to ON position Replace Replace Replace thermocouple Check for loose wiring and correct if necessary Ensure that USB from computer to back of instrument is connected Check power plug make sure power button on right side of screen is on Check air supply and make certain instrument is supplied with air between 30 and 100 psig Check air lines for blockage Adjust PUMP AIR PRESSURE ADJUST regulator to a higher pressure If no solenoid click is heard when the PUMP switch is turned to the ON position a faulty solenoid valve is likely Clean transducers and apply new couplant Pea size amount is sufficient 36 MAINTENANCE AND TROUBLESHOOTING Symptom Transit time and compressive strength values are erratic Water comes out of pump mu
39. power supply UPS that will keep all functions except heater of the UCA operating for up to one hour during power outages A cross reference list of Chandler and Halliburton part numbers and equivalent CTE part numbers is provided in Chapter 5 Maintenance and Servicing Instrument Specifications The specifications below apply to the CTE Inc Model 2000 UCA ELECTRICAL Input Voltage 230 VAC 15 Input Power 2500W Input Current 11A Input Frequency 50 60 Hz It is a good idea to leave room behind the instrument so that qualified personnel may have service access If this is not possible try to make the unit easy to disconnect and move for service INTRODUCTION MECHANICAL Height 14 5 in 36 8 cm Width 26 in 66 cm Depth 15 3 in 38 9 cm Weight 110 Ib 50 kg ENVIRONMENTAL Operating Temperature 32 to 120 F 0 50 C Operating Humidity 0 95 non condensing HEATER Heater Power 2 000 W Heater Type Cast heater with cooling coils Heater Control Solid state relay UTILITIES WATER AND AIR Compressed Air 100 psig 6 8 bar Cooling Water Pressure 100 psig 6 8 bar maximum Utility Inlets Ya inch female Installation Upon uncrating the instrument verify that the instrument and any spare parts on the packing have been received and are undamaged Notify CTE if anything is missing or damaged Once the instrument has been moved to its desired location air water and electrical co
40. re falls to some lower value perhaps 2900 psig This 100 psig differential between opening and closing is referred to as the deadband or hysteresis As another example the pump may be set to actuate if the pressure falls to 3000 psig but the pressure may reach perhaps 3100 psig before the pump stops This 100 psig differential between the initial pressure and the final pressure is also known as deadband or hysteresis If the upper and lower set points are too close together this deadband may overlap and cause system instability The system will then go into a continuous oscillation where the pump increases pressure and the pressure regulator releases all the pressure the pump is able to build The solution to this problem is to decrease the lower set point raise the upper set point or both Stopping a Test When the test has been completed follow the steps below to end the test 1 Press the STOP TEST button to manually stop a test 2 Press the COOLING WATER button to cool the test cell Use the pump to maintain pressure on the test cell until the cell is cool When the temperature is below 200 F 93 C the PUMP switch may be turned to the OFF position and the PRESSURE RELEASE valve opened Failure to maintain pressure at temperatures above 212 F 100 C may cause water in the test cell to vaporize into steam 3 Turn WATER SUPPLY switch to its OFF position 4 To shut down instrument press EXIT and confirm Next press Windows
41. rent profile and continue or cancel to make further modifications Once the first ramp has been entered press the NEXT STEP button to proceed to the next ramp or DONE to end the profile programming you end the programming at this point and start the test the temperature will reach set point and then fall because there was no second ramp or soak entered From this screen a second ramp may be entered or the user can enter a soak To initiate a soak the user must use the Soak keypad button in the Ramp Time box This will tell the computer to hold continuously at the programmed temperature If you enter Soak as the time the Start Value temperature and the End Value temperature must be the same After entering all of your ramps and soak you may press Done to complete the programming process If you press Done a graph will be displayed showing exactly what you have entered for your temperature profile as shown below 1 180 240 Time minutes From this screen the user may press Accept if the graph is correct or Change to go back to the programming screens to correct any programming errors If Accept is pressed the TEST SETUP screen will be displayed again From here press DONE and the main menu will appear Press START TEST to begin the test or any of the other buttons to change alarm values slurry type etc 14 A TOUR OF THE FRONT PANEL CONTROLS ALARM VALUES The Alarm Values Button allows the user to enter unlimited a
42. rsonnel to view a test in progress from home or on location provided they have access to the network to which the UCA is connected 22 A TOUR OF THE FRONT PANEL CONTROLS Since the UCA operates under Windows 98 or later the instrument can be easily connected to a network It may be necessary to assign an IP address to the instrument in some instances and this can be done in the usual way through the system setup The UCA should always be kept behind a secure network firewall to prevent unauthorized access via the internet or other portal Allowing UCA access via the internet is not recommended Transit Time Calibration Checking the transit time calibration is very easy Follow the steps below 1 Fill the cell with water making certain there is no air trapped in the cell 2 Apply compressed air pressure of 60 180 psi to the cell 3 Connect all cables as at the start of a test Calibrated Transit Time 0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 475 450 475 500 SINGLE PULSE CONTINUOUS PULSE cum 23 A TOUR OF THE FRONT PANEL CONTROLS 4 Select CALIBRATE TRANSIT TIME from the touch screen menu When the calibration screen appears press the CALIBRATE button If the waveform appears acceptable press DONE to save the new calibration values In general the peak amplitude should be 600 or greater with water If an acceptable waveform is not displayed check the transducers and cables and
43. s turn cooling on off Under the Time column the user can STOP TEST or select SHUTDOWN parameters for the Auto Shutdown feature The user can select between Time hr or Compressive Strength and adjust the target value using the Shutdown Value control When the test reaches 18 A TOUR OF THE FRONT PANEL CONTROLS the Shutdown Value the test will be stopped and cooling automatically turned on By selecting the VIEW LIVE CHART tab at the top of the screen the user view real time data in chart form From this screen the user may print the chart at any time by pressing the PRINT button located at the bottom of the screen Please note that a printer must be connected to the instrument before trying to print Pressing the PRINT button displays the full TEST VIEWER screen where the user may select specific printing options such as header footer information before printing to any installed printer LIT I fr CH TER 1 19 A TOUR OF THE FRONT PANEL CONTROLS A complete table of numerical data can also be viewed here by selecting the DATA tab located on the left side of the screen in the Test Viewer Return to the test controls by selecting CLOSE This will not have any effect on the actual testing process and can be opened closed at any time The VIEW TEST SETUP tab is simply a review of parameters entered during the TEST SETUP and cannot be changed RUN TIME MENU VIEW LIVE CHART VIEW TEST SETUP
44. se pressure from the pressurized cylinder This valve must be closed during testing except when it is necessary to manually release pressure This valve must also be closed when removing the pressure vessel with cooling water circulating or cooling water may back up and leak out the pressure port in the top of the instrument The part number for the PRESSURE RELEASE valve is C 0002 1 The PRESSURE REGULATOR may be used to set the upper limit on the system pressure up to 10 000 psig 680 bar When the hydraulic force on the regulator exceeds the spring force of the regulator the regulator valve will open and release pressure until the hydraulic and spring forces balance again The regulator will then close preventing 25 gauge displays pressure in both English and SI units A TOUR OF THE FRONT PANEL CONTROLS any additional pressure release until the hydraulic force again exceeds the spring force Turn the PRESSURE REGULATOR knob clockwise to increase pressure and counterclockwise to reduce pressure The use of the pump and PRESSURE REGULATOR to control pressure automatically will be discussed in Chapter 4 The PRESSURE REGULATOR part number is C 0078 The pressure regulator is only usable at pressures up to 10 000 psig 680 bar If it is necessary to operate the UCA at pressures above 10 000 psig 680 bar the REGULATOR BYPASS must be turned clockwise to the closed position For automatic operation at pressures belo
45. sonic pulse through a cement slurry and measures the travel time of the pulse through the slurry The travel time of the pulse through the slurry gives an indication of the compressive strength of the slurry The compressive strength along with temperature and pressure are monitored as a function of time for the purpose of providing a strength history of a setting cement slurry The major features of the Model 2000 UCA are listed below e Easy to install and use e Direct replacement for Halliburton or Chandler UCA systems INTRODUCTION e Completely self contained No need for pressure controllers control boxes or PC s e All software is Windows based e Data may be plotted on a standard ink jet printer stored on a USB flash memory stick or archived to an external PC via an Ethernet connection e Tests are stored as ASCII files and may be retrieved and viewed by most word processors text editors spreadsheets and database programs e Has built in easy to use touch screen control panel for control of data acquisition and temperature control No more clunky temperature controllers to program Temperature profile is displayed graphically before test starts to reduce mistakes e Available with integral pump and relief valve for soak pressure control Does not require separate pressure controller e May be used with Halliburton Pressure Controller as an option e Unit may be operated with an optional uninterruptible
46. ssure filter is designed to prevent cement particles from entering the PRESSURE REGULATOR and damaging it The second maintenance item is to thoroughly clean and lubricate the test cylinder after every test Be sure to inspect the o rings for damage and replace if damaged or severely distorted 34 Problems related to corrosion of the lower transducer connection can be minimized by not allowing water to run down the side of the cylinder and into the bottom of the instrument Symptom System builds pressure but will not hold pressure POWER circuit breaker switch trips off Pump strokes but little or no pressure is MAINTENANCE AND TROUBLESHOOTING It is recommended that the thermocouple and water line connections on the top plug be cleaned periodically to prevent buildup of cement in the bore and threads Periodically inspect the electrical connector in the bottom of the instrument where the test cylinder rests If this connector get dirty or corroded the lower transducer may not make good electrical contact Clean the connector if necessary Unlike other UCA s it is not necessary to coat the ultrasonic transducers with couplant prior to every test In fact the transducers should not be removed unless they are believed to be faulty or unless they need additional couplant The top transducer is sealed to prevent water from entering the transducer chamber during cylinder filling or cleanup Troubleshooting The f
47. that the operators read the remainder of the manual and study the drawings that appear in the Drawings Schematics section of this manual to become familiar with the UCA operation A TOUR OF THE FRONT PANEL CONTROLS Chapter Using the Touch Screen Software This chapter contains specific information on how to use the touch screen safbuare plus instructions on how to network the UCA and connect and use the USB Memory Module What is a touch screen and how does it work Touch screens were created to provide operators with an easy to use interface They allow the user to input and view data without a keyboard or mouse The touch surface is able to detect contact and send position information back to the processor Using the touch screen has the same result of using a mouse to point and click One mouse click is accomplished by one touch of the screen A double click is achieved with two quick touches With this standard method of input no special software is required to utilize the screen Using the Touch Screen Most any object may be used on the touch screens Experimentation will quickly show which objects will activate the screen and which will not It is important to note the touch surface does NOT use pressure to detect input A light touch is all that is needed In addition sharp instruments such as pencils pens screwdrivers etc should not be used as they may damage the touch surface A TOUR OF THE FRONT PANEL CONTROLS W
48. w 10 000 psig 680 bar the PRESSURE REGULATOR SHUTOFF valve must be turned counterclockwise to the fully open position The part number for this valve is C 0002 1 The WATER SUPPLY valve is used to control the flow of water to the pump and test cell This valve must be closed any time the test cell is not installed This valve must be open to fill the pressure vessel with water or to operate the pump Opening this valve when the test cell is not connected will cause a serious water leak The Pneumatic Controls The pneumatic section consists of the AIR TO PUMP gauge and the AIR TO PUMP regulator The components in this section are used to power the air driven hydraulic pump that applies pressure to the sample The AIR TO PUMP gauge indicates how much air pressure is being supplied to the instrument The part number for the AIR PRESSURE gauge is C 0138 If there is no pressure indicated on this gauge the pump will not operate The pressure should be between 20 and 100 psig 1 4 and 6 8 bar when the pump is not in use It is normal for the inlet air pressure to drop when the pump is in operation If the air pressure drops significantly and the pump seems unable to achieve the desired pressure it may be because the compressed air system is not capable of delivering enough air to operate the pump The AIR TO PUMP regulator is used to control the air pressure to the air driven hydraulic pump Higher hydraulic pressures require higher air pressur
49. ws the use of certain Universal Serial Bus USB peripherals such as USB flash memory modules These USB memory modules may be used to archive or move UCA test files to another computer The USB memory modules may be used without special drivers on any Windows XP or Windows 2000 based PC s The memory module will simply appear as another disk drive when inserted into the USB port on the PC To archive the stored tests on the UCA to the memory module follow the steps below 1 Connect the memory module to the USB port on the UCA control box No cables are required 2 Press the ARCHIVE DATA button on touch screen 3 Navigate to the USB drive and select the desired save location on the pop up window 4 The files will be copied to the USB memory module and deleted from the UCA 5 Once the files are copied to the USB memory module they may be moved to a desktop PC Note that once the UCA data files are archived they are still longer available for retrieval on the UCA Deleting files from the UCA must be done manually by selecting the files and moving them to the trash bin in Windows Networking the Instrument The UCA may be connected to any Ethernet network LAN This makes it convenient to move UCA data files from one computer to another on the network It is also possible to view a UCA test in progress or an old test from another computer networked to the UCA using the UCA Remote Viewer software This will allow pe
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