BenchMark Wireline AM5K Series User manual

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AM5K COMBINED DEPTH/TENSION
MEASUREMENT DEVICE
ATEX ZONE 2 CE
HALLIBURTON ENERGY SERVICES CONFIGURATIONS
AM5KA512 one encoder, no MMD (CH) SAP # 101321352
AM5KA507 dual encoders, MMD (OH) Zone 2 SAP # 101281049
AM5KA529 dual encoders, no MMD (CH) Zone 2 SAP # 101286954
CONTENTS
1.0 GENERAL
2.0 SYSTEM DESCRIPTION
3.0 OPERATION
4.0 MAINTENANCE AND REPAIR
5.0 RECOMMENDED SPARE PARTS
6.0 DRAWINGS AND PARTS LISTS
6.1 Measure Head Assembly
6.2 Magnetic Mark Detector
6.3 Load Pin
6.4 Encoder
6.5 Backup Odometer
7.0 CERTIFICATION DOCUMENTS

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Manual Revision Log
Revision Q Oct 2007
Page 1, 38 Added reference and certificates for AM5KA529 (CH Zone 2)
Revision P Sep 2007
Page 13: Added information for checking tension wheels
Revision O Jun 2007
Page 4: Added tension measurement description
Page 11: Updated load cell factors
Page 16: Added encoder coupling installation drawing
Pages 20, 22: Added photos to clarify installation of tension wheel
Revision N Sep 2006
Changed references of flat tension wheel to shallow groove tension wheel
Revision M Aug 2006
Pages 10 – 11: Added information on the shallow and deep grooved tension wheels
Pages 19 – 21: Added information on installing tension wheel
Revision L
Pages 6-7: Updated spooling arm mounting information
Page 9: Added ratchet strap for removing cable while under
load
Page 17: Added removal procedure for encoder mount and front wheel
Page 22: Swapped SAP numbers between items 33 and 36
Page 29: Updated encoder drawing

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1.0 GENERAL
The AM5K Wireline Measuring Device is a compact and lightweight device for
measuring both wireline depth and tension. The device is designed to be mounted to
the spooling arm of a wireline unit. It is unique to other measuring devices in that it
measures both depth and tension on wireline cables from .190” to .494”. This device
will work on both open and cased hole wireline units which allows standardization on a
measuring head for all types of operations.
FEATURES AND BENEFITS:
¾Straight-line measurement (cable sizes can be changed without affecting
measurement)
¾Dual Tangential Measuring Wheels made from specially hardened steel
¾Accepts cable sizes from .190” to .494” diameter (4.8 mm to 12.55 mm)
¾Lightweight design with integral tension makes the device ideal for high angle
rigups
¾Device opens up to provide easy cable installation and removal, by removing a
single pin
¾Includes both horizontal and vertical guide rollers to minimize measuring
wheel loading
¾Rollers are oversized to increase reliability and reduce maintenance
¾Guide rollers are made from composite material to reduce weight and cable
wear
¾Rear or Center spooling arm mount to minimize head “jerking”
¾Tension Load Axle and amplifier can be configured for different outputs.
¾Digital Magnetic Mark Detector
¾Accepts single or dual encoders
¾Supports fully independent backup depth measuring system using a magnetic
pickup
¾Backup depth system reduces drag on measuring wheel by eliminating
mechanical drive cable
¾Encoder, Mark Detector, and Tension amplifier certified for Zone II area use
¾Anodized aluminum frame. All steel parts are plated or SST

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2.0 SYSTEM DESCRIPTION
DEPTH MEASUREMENT:
The AM5K Measuring Head uses dual spring-loaded measuring wheels to measure the
amount of wireline moving to and from the borehole. The measuring wheels are
coupled to one or two optical encoders that transmit electrical signals via a cable to the
hoistman’s panel and/or logging computer. An independently powered magnetic
encoder is used for back up depth indication.
The hardened measuring wheels are 2.0000 ft. (.609600 m) in circumference. Springs
are used to hold the measuring wheels in contact with the wireline. The springs are
sized to provide the appropriate friction between the wheels and wireline. The frame
members are anodized 6061-T6 aluminum.
Under ideal conditions, without magnetic marks, the measuring heads have an accuracy
of +/- 3 m in 3000 m (10 ft in 10,000 ft.). With magnetic marks and accurate line stretch
calculations, an accuracy of .3 m in 3000 m (1 ft in 10,000 ft) can be achieved. The
Hoistman's panel is required to fully utilize the mark detection and stretch correction
algorithms.
TENSION MEASUREMENT:
The AM5K uses an electronic load axle to measure line tension. Three wheels are used
to create a force on the load axle. To generate this force the wheel mounted on the
load axle is offset from the other two slightly. This offset creates a slight bend in the
cable.
As wireline tension increases the small offset creates a corresponding bending force on
the strain-gauged load axle. An electronic signal is transmitted via cable to the
hoistman’s panel and/or logging computer representing wireline tension. A calibrate
resistor is included in the load pin to send out a signal to calibrate the computer system.
GENERAL SPECIFICATIONS:
WEIGHT: 58 lbs 26.3 kg
LENGTH: 26.5” 673 mm
HEIGHT: 10.8” 274 mm
WIDTH: 15.3” 389 mm
MAXIMUM TENSION: 20,000 lbs 9072 kg
MEASURING WHEEL SIZE: 24.000” 609.60 mm
CABLE SIZES: .190” to .494” 4.8 mm to 12.55mm
CABLE BEND OVER TENSION WHEEL: 2.5 – 7.5 degrees (depends on cable)
Minimal or no affects on magnetic marks

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3.0 OPERATION
3.1 SPOOLING ARM INSTALLATION – OVERHEAD SPOOLING ARM
Install the measuring head on to the spooling arm by using the top adapter mount
assembly to mount to an overhead spooling arm. The mount is designed to
mount with a standard U-joint yoke.
MOUNTING YOKE

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Make sure that the head can freely sit on the wireline. If the mounting
arrangement will not let the head travel up and down freely and if the cable puts
a upward or downward force on the measuring head, this force will cause an
offset to the tension measurement which will result in an incorrect tension
reading.

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3.2 CABLE INSTALLATION
To install cable, first open the wheels by shifting the red release handles.
Next, remove the push pin, and hinge the head open.
Lifting up on the wireline cable makes it easier to remove the push pin.
The cable can now be inserted or removed.
Close the red release handles to tighten the wheels against the wireline.
Swing the head closed and reinsert the pin.

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3.3 CABLE REMOVAL UNDER LOAD
3.4.1 If under load, the load will need to be removed from the device prior to
removing the retaining pin. A “C-clamp" or a nylon "ratchet strap" can be
used to remove the load.
3.4.2 Install a C-Clamp across the top and bottom frames as shown in the
drawing below. The ratchet strap can be installed in a similar way.
3.3.3 Tighten the C Clamp until the load is removed from the retaining pin.
Remove the retaining pin then loosen and remove the C Clamp.

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3.4 CHANGING CONFIGURATION BETWEEN OPEN HOLE AND CASED
HOLE
A measuring head configured for open hole will typically contain a magnetic mark
detector and a 2nd encoder. Cased hole operations rarely require a magnetic
mark detector and typically use only one encoder.
If the head is configured for open hole, no changes are required to run it on a
cased hole unit. You may elect to remove the magnetic mark detector if you
have no plans to use the head on an open hole unit any time in the near future.
The cased hole head can be configured with a different wear plate. The cased
hole wear plate is thicker and stepped on one end to the keep the line from riding
near the top of the wheels. This can occur when going in the hole with a small
cable (7/32") with a very light load. The open hole wear plate is flat. Both plates
are made from hardened tool steel. The wear plate is mounted on the upper
frame above the measure wheels.
Part number for the open hole wear plate is: AM5KM034
Part number for the cased hole wear plate is: AM5KM074
3.4.1 To remove the magnetic mark detector, refer to item 12 of drawing 6.2.
Remove the four screws holding the detector in place then remove the
detector. To install a magnetic mark detector, reverse this procedure.
3.4.2 To remove an encoder, remove the four screws securing the encoder
adapter to the head. Remove the encoder and adapter. Remove the
coupling from the measuring wheel shaft.
3.5 INSTALLING THE DEEP GROOVED TENSION WHEEL
3.5.1 A Deep Groove High Load tension wheel is available for use when line
tension greater than 12,000 lbs is commonly encountered. This wheel has
a deeper groove to better support the wireline at high tensions. The deep
groove also reduces the radius of the wheel which lowers the bend angle
of the wireline.
This wheel is only for use with .472 Slammer or .494 Super Slammer
cables and cannot be used with smaller cable sizes. For cables larger
than .472, the severe load tension wheel should be used.
The normal wheel can be used at high loads for short pull durations but
should not be used when loads exceed 12,000 lbs for an extended period
of time.

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3.5.2 To install the deep grooved tension wheel, replace the standard shallow
grooved tension wheel with the deep grooved tension wheel. The load pin
does not need to be changed. To account for the decreased bend angle
of the cable, the Load Cell Angle value will need to be changed when
using this wheel (refer to page 11). The SDDP calibrate value should
remain at 3250.
Ensure that the slot in the bushing of the tension wheel is aligned with the
roll pin on the side of the frame. The roll pin is only installed on one side
of the frame and it needs to be inserted in the slot.
Also ensure that the grease hole in the tension wheel is installed on the
opposite side as the load pin amplifier.
DEEP GROOVED HIGH TENSION WHEEL
STANDARD SHALLOW GROOVED TENSION WHEEL

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3.6 SYSTEM OPERATION
3.6.1 Determine cable size to be used – .490" to .190”. Since the wireline cable
actually bends over the tension wheel, the bend radius of the wireline
cable will affect the tension measurement.
3.6.2 Enter tension calibrate factor. These corrections are automatically made
in the WSDP Hoistman's panel by selecting the proper cable size from the
menu. If a different panel is used, enter the tension factor at this time.
SDDP Calibrate Values: VALUES CABLE SIZE
3250 15/32" through .472"
3480 7/16"
4171 3/8"
4656 5/16"
4808 9/32"
6187 7/32"
"Comprobe" Calibrate Values: VALUES CABLE SIZE
10000 15/32" through .472"
10700 7/16"
12800 3/8"
14300 5/16"
14800 9/32"
19000 7/32"
SDDP-A or SDDP-B Load Cell Angle
Standard Shallow Groove Tension Wheel = 0
.472 cable with Severe Load (Deep Groove) Tension Wheel = 131
.484 cable with Severe Load (Deep Groove) Tension Wheel = 128
.490 cable with Severe Load (Deep Groove) Tension Wheel = 125
Note: As the groove in the tension wheels wears deeper, the angle will
decrease causing the output signal to decrease. To compensate for this
the Load Cell Angle will need to be increased.
3.6.3 Install line in measuring head (refer to section 3.2).
3.6.4 Make sure line is lying slack and head is free to move. Press the Ten
Zero Cal button and tension value should read 0.
3.6.5 Press the Ten Cal button and tension should read the value indicated in
paragraph 3.6.2.
3.6.7 At this point, the system is ready to log. Watch for visual indications of
problems such as excessive vibration, wheel or roller slippage or lockups
that signify bearing or shaft failures, or cable tracking problems.

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4.0 MAINTENANCE AND REPAIR
4.1 PRE-JOB CHECK
Each time the system is used perform the following steps:
Verify that the AM5K is properly and securely attached to the spooling arm.
Several different mounting kits are available for different types of spooling arms.
Verify that the depth measuring wheels are clean and that no groove has been
worn into the measuring wheel surface. Check the measuring and guide wheels
for looseness, play, out-of-roundness, worn or rough sounding bearings, or other
mechanical conditions that could affect measurement accuracy. Ensure that the
wheel bearings inner race is not spinning on the shaft and that the shaft is not
spinning in the bushings.
Verify that all fasteners are tight and that the ball lock pushpin is secure. Verify
that the encoder, electronic load pin, and backup counter cable are installed and
properly routed. Verify that the depth system is working by turning the wheel
and observing the hoistman’s panel and backup display unit to indicate cable
movement. The hoistman's panel and backup display should measure 2' for
each rotation of the wheel. If more than one encoder is installed check both
encoders by turning each wheel and verifying that the hoistman's panel will read
2' for each rotation of either wheel.
4.2 POST-JOB MAINTENANCE
At the completion of each job, thoroughly clean and dry the device as soon as
possible. This avoids problems caused from borehole residues transferred from
the wireline onto the measuring device. Borehole residues should be washed
from the device with a cleaning solvent such as Varsol or an equivalent type.
Rinse the device with water, dry, and wipe down with an oily rag.
Do not pressure wash

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4.3 MONTHLY MAINTENANCE
Visually inspect the interiors of the electrical connectors for the encoders and
electronic load axle for dirt and evidence of insulation breakdown. Clean or
replace as necessary. Install dust caps on the connectors if the cables are
removed.
Manually rotate each wheel by hand to verify its condition. Inspect the depth
measuring wheels for signs of abnormal wear, diameter changes, or
shaft/bearing play that can affect measurement accuracy. The wheel should be
replaced if it is grooved more than .005". The wheel should be 7.639 / 7.640"
(194 mm) in diameter with a 24" circumference (609.6 mm).
Inspect the tension wheel for signs of abnormal wear, diameter changes, or shaft
and bearing play that could affect tension measurement accuracy. The shallow
groove tension wheel (item 33 in section 6.1 of this manual) should be 5" in
diameter at the bottom of the groove. It should be replaced if it is worn more
than .010".
The deep grooved tension wheel (item 33 in section 6.1 of this manual) should
be 4.375" in diameter at the bottom of groove. It should be replaced if it is worn
more than .010".
Inspect the two grooved guide wheels on either side of the tension wheel (items
34 in section 6.1 of this manual). They should be 4" (101.6 mm) in diameter
(bottom of groove). They should be replaced if they are worn more than .010".
NOTE: If the tension wheels or guide wheels mentioned above are worn
more than .010” then the tension reading will be less than the actual line
tension. The amount of error is relative to the amount of wear.
Grease all the wheels and bearings that are fitted with a flush mount grease
fitting (see following diagram). Use a water-proof, marine grade grease. An
inverted grease nozzle (p/n AM5KP130) is supplied with each head. This nozzle
will fit any standard grease gun.

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4.4 ASSEMBLY / DISASSEMBLY PROCEDURES
4.4.1 MEASURING WHEEL, SHAFT, AND BEARING REMOVAL
Either measuring wheel can be removed from the measuring head. First shift the
red release handle to move the wheel away from the frame. Next remove the
encoder with its adapter.
On the later model heads, the wheels are keyed onto the shaft and can be
removed simply by removing the screw holding the wheel to the shaft.
On earlier model heads, the wheels are pressed on to the shaft. The lower snap
ring between the wheel and the bearing must first be removed. Pull the wheel
and shaft from the mount. Reassemble in the opposite order. The bearing
should also be replaced at this time.
4.4.2 ELECTRONIC LOAD PIN REMOVAL
The electronic load pin is held in place by one retaining ring on the outer end of
its shaft. Remove the retaining ring by using a small screw driver to lift one end
of the ring out of the groove then “walk” the ring off of the pin. The load pin can
then be removed from the mounting frame.
4.4.3 BACKUP DEPTH MAGNETIC PICKUP REMOVAL AND INSTALLATION
The backup depth magnetic pickup is mounted to the encoder adapter. It is held
in place by four screws. Remove the screws and the pickup can then be
removed. The pickup must be properly oriented to work correctly. The slot
should be oriented to the top. The top side is the encoder side. Ensure that an
o-ring is inserted between the plastic housing and the mount. An additional o-
ring is used between the connector and the housing to keep moisture out.
If the backup display is counting backward (i.e. counting negative when going
down hole), simply rotate the pickup 180 degrees to change the direction.

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4.4.4 ENCODER COUPLING INSTALLATION
To install the encoder coupling, first remove the plug in the encoder adapter.
Install one of the metal parts of the three piece coupling (item 36) to the wheel
shaft and tighten it using a hex wrench. Next, install the center plastic piece of
the coupling onto the wheel shaft coupling. Place the other metal coupling on the
encoder shaft and set the encoder on the mount. Snug up the encoder coupling
then remove the encoder and tighten the coupling.
Reinstall the encoder with o-rings (item 98) and tighten it to the encoder mount
(item 6). Next tighten the plug.

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4.4.5 ENCODER MOUNT REMOVAL
Follow these steps to remove the encoder mounts.
1. Using a pair of vice grips, grab the end of the pin and pull on it (see
photo).
2. Use a screw driver to capture the end of the spring (see photo).
3. The end cap and the pin can now be removed (see Photo)

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4 Use a hook to pull the spring out far enough to remove the screwdriver
(Careful not to bend the spring).
5. Remove the floating encoder assembly.
6. Repeat for the other side.
7. Remove anti-rotation screw (if equipped).
8. Remove snap ring and pull out sliding shaft.
9. Remove the wheel assembly.
10. Re-assemble in reverse order.

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4.4.6 INSTALLING THE LOAD AXLE WHEEL
1. Insert the tension wheel into the frame. Make sure the slotted hole in
the tension wheel bushing is on the same side as the roll pin hole in
the frame and the grease hole is on the opposite side.
2. Use a bolt in place of the load pin to hold it in place. Install an allen
wrench or other long tool to align the hole in the bearing with the
slotted hole in the frame.

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3. Insert a 3/16” x 1/2” long roll pin into the hole. Do not use a longer
roll pin as it will put the wheel into a bind.