Ametek Chandler Engineering 8040D10 User manual

INSTRUCTION MANUAL
MODEL 8040D10
PRESSURIZED CONSISTOMETER
Revision P – April 2015
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Copyright 2015, by Chandler Engineering Company, LLC
All rights reserved. Reproduction or use of contents in any manner is prohibited without express permission from Chandler Engineering Company, LLC. While every
precaution has been taken in the preparation of this manual, the publisher assumes no responsibility for errors or omissions. Neither is any liability assumed for damages
resulting from the use of the information contained herein
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TABLE OF CONTENTS i
Table of Contents
General Information .......................................................................P-1
Application of the Consistometer.....................................................................................................P-1
Test Procedure................................................................................................................................P-1
Description of Apparatus.................................................................................................................P-1
Specifications..................................................................................................................................P-3
Section 1 - Installation.................................................................... 1-1
Unpacking the Instrument................................................................................................................1-1
Utility Requirements........................................................................................................................1-1
Tools and Equipment Required........................................................................................................1-1
Setting up the Instrument ................................................................................................................1-1
Connecting Air and Water ...........................................................................................................1-1
Connecting Power to the Consistometer......................................................................................1-2
Section 2 – Operating Instructions................................................. 2-1
Training...........................................................................................................................................2-1
Preparing the Instrument for a Test..................................................................................................2-1
Configuring the Consistency Display............................................................................................2-1
Programming the Temperature and Pressure Controllers..............................................................2-1
API Slurry Cup Preparation.........................................................................................................2-1
Running a Test................................................................................................................................2-3
After the Test is Complete...............................................................................................................2-5
Cooling the Cylinder....................................................................................................................2-5
Section 3 - Maintenance................................................................. 3-1
After Every Test..............................................................................................................................3-1
Pressure Cylinder.........................................................................................................................3-1
Potentiometer Mechanism............................................................................................................3-1
Slurry Cup...................................................................................................................................3-1
Thermocouple (Slurry Cup).........................................................................................................3-1
Monthly ..........................................................................................................................................3-2
Potentiometer Mechanism............................................................................................................3-2
Resistor Replacement ..................................................................................................................3-2
Calibration Spring Replacement...................................................................................................3-2
Potentiometer Calibration............................................................................................................3-2
Magnetic Drive............................................................................................................................3-3
High Pressure Filter.....................................................................................................................3-4
Thermocouple and Temperature Control System.........................................................................3-4
Three Months..................................................................................................................................3-4
Oil & Filter..................................................................................................................................3-4
Drive Motor................................................................................................................................3-4

ii TABLE OF CONTENTS
Six Months......................................................................................................................................3-5
Timer ..........................................................................................................................................3-5
Air Operated Valve......................................................................................................................3-5
Annually..........................................................................................................................................3-5
Pump...........................................................................................................................................3-5
Reservoir.....................................................................................................................................3-5
Heater.........................................................................................................................................3-5
Thermocouples (Slurry Cup and Cylinder) and Temperature Controller .......................................3-6
Section 4 - Troubleshooting........................................................... 4-1
Section 5 - Replacement Parts........................................................ 5-1
Section 6 - Drawings and Schematics............................................. 6-1

PREFACE P-1
General Information
Application of the Consistometer
Cements have numerous applications in the drilling, completion, work-over, and abandonment of
wells. For each application, the cement is designed with special properties and is given additives
that provide predictable slurry density, volume, viscosity, compressive strength, and thickening
time. Thickening time, or the time a cement slurry remains able to be pumped into the well, is the
most critical properties in designing a cement. A short thickening time is desired, while maintaining
the special properties of the cement's design. The thickening time of a cement can be measured in a
laboratory by testing a sample of the cement slurry in a Pressurized Consistometer. The elapsed
time between an initial application of pressure and temperature on the slurry sample and the
development of 100 Bearden units of consistency (Bc) is the thickening time for the sample at a
particular specification test schedule [Table 8.2, API Spec 10(1)].
Test Procedure
Briefly, the test procedure for the Model 8040D10 Pressurized Consistometer entails the
preparation of the slurry sample, placing it in the Consistometer, applying pressure and increasing
temperature according to the API Spec 10 Code Schedule(1), and recording the consistency of the
slurry as a function of time. Details of the procedure are contained in the Specification.
Description of Apparatus
The Pressurized Consistometer incorporates a rotating, cylindrical Slurry Cup equipped with a
stationary paddle assembly enclosed in a pressure chamber designed for a working pressure of 275
MPa (40,000 psi) at a maximum temperature of 315°C (600°F). (An air-operated hydraulic pump
generates pressure to the cylinder assembly.) The hydraulic system incorporates a reservoir, piping,
valves and filters. Heat is supplied to the chamber by a 5000-watt, internal, tubular heater
controlled by the automatic temperature control system program. Thermocouples are provided for
determining the temperatures of the oil bath and cement slurry.
The programmable temperature controller will automatically control the rate of temperature rise of
the slurry (i.e. temperature gradient). When the slurry reaches the desired maximum temperature,
the controller will hold the slurry temperature at that level. Pressure settings are maintained
through the control of a pressure release valve and air pressure available to the pump.
The slurry container is rotated at a constant speed of 150 +/- 15 rpm by a Magnetic Drive (Drawing
8-229). Drive torque is transmitted from a set of outside drive magnets, through a non-magnetic
housing, to permanent magnets attached to the rotating shaft within the cylinder. Permanent, rare
earth magnets are used to ensure high torque and a long magnetic-field life.
REFERENCES
American Petroleum Institute; API Specification for Materials and Testing for Well Cements, Latest Edition; Dallas,
TX.

P-2 PREFACE
The viscosity (i.e. consistency) of the cement slurry is indicated by a meter and is recorded on a
chart as a DC voltage obtained from a potentiometer installed within the pressure cylinder. The
potentiometer contains a standardized torsion spring, which resists the rotating force of the paddle.
Rotational force is proportional to consistency of the cement slurry.
The chart recorder is configured at the factory and will be ready for use at power-up. A manual has
been enclosed for your reference.
The Bearden unit indicator is pre-configured at the factory to alarm at 100 Bc. The alarms control
four items. First, an audible alarm is triggered; second, the heater current is cut off; third, the motor
is shut off; and fourth, the timer is stopped.

PREFACE P-3
Specifications
This unit is in complete compliance with API Spec 10A
Model 8040D10
Maximum Temperature: 600°F (315°C)
Maximum Pressures: 40,000 psi (275 MPa)
Heater Power: 5,000 Watts
Slurry Cup Rotational Speed: 150 rpm
Viscosity Range: 0-100 Bc (Bearden Units)
Pressurizing Medium: White Mineral Oil
Mechanical and Electrical
Input Voltage: 240 VAC ± 15% 50/60 Hz
Input Power: 7.5 kva
Heater Wattage: 5,000 watts
Shipping Dimensions and Weight
Dimensions Weight
In. cm lbs. Kg
Model 8040D10 56 x 38 x 75 142 x 96 x 190 2400 1090
Environment and Utility
• Operating Temperature: 40° to 120°F (0 to 50°C)
• Compressed Air: 75 to 125 psi (517 to 862 kPa)
• Cooling Water: 20 to 80 psi (138 to 552 kPa)

P-4 PREFACE
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SECTION 1 – INSTALLATION 1-1
Section 1 - Installation
Unpacking the Instrument
After the consistometer is unpacked, the operating equipment and spare parts on the packing
list should be checked to affirm that all have been received and none are damaged.
File an insurance claim with your freight carrier if damage has occurred during shipment.
Utility Requirements
Your unit will require dry, oil-free compressed shop air (not instrument quality) of 75 to 125
psi, and a water supply of 20 to 80 psi. The unit is capable of operating in ambient
temperatures from 40°F to 120°F.
Tools and Equipment Required
A standard maintenance or mechanics tool set is adequate for the installation, operation, and
maintenance of the instrument. No special tools are required.
This unit is supplied with an installation kit, which includes the necessary hardware for the
water, air, and electrical hook-ups. The water and air hose may be cut to length and the
appropriate barbed fittings inserted into the hose and clamped into place.
Caution: The laboratory electrical power wiring must be capable of a 50-ampere
load and comply with local electrical codes. The instrument must be
securely connected to an appropriate earth ground. The ground wire must
have a larger diameter than that of the supply voltage conductors.
Setting up the Instrument
Connecting Air and Water
Water and air hose hook-ups are located at the lower rear of the instrument. Use the adapters
provided in the accessory kit for each of these connections. All of the fitting threads are 1/4”
NPT.
1. Connect the air supply line to the inlet labeled AIR.
2. Connect the water supply line to the inlet labeled WATER IN.
3. If the optional chiller is being used, connect the outlet port of the chiller system to the
water inlet port and the water drain port to the chiller inlet port. Configure the chiller to
operate at the minimum set-point temperature (41°F, 5°C).
4. Connect the water drain line to the outlet labeled WATER OUT.

1-2 INSTALLATION
Connecting Power to the Consistometer
1. Connect the supplied twist-on power connectors to the receptacles at the rear of the unit.
2. Connect the power plugs to an appropriately rated power source and receptacle. For user
safety a power plug and mating receptacle are required.
Note: This receptacle MUST be properly grounded.