fann 415C User manual

©2019 Fann Instrument Company
Model 415C & 415 SGS
HPHT Pressurized Consistometer and
Cement Consistometer with Gel Strength Analyzer
Instruction Manual
Manual No. D01669102, Revision A
Instrument No. 102547776, 102538946

D01669102 April 2019, Revision A 2
Model 415C & 415 SGS Instruction Manual
©2019 Fann Instrument Company
Houston, Texas, USA
All rights reserved. No part of this work covered by the copyright hereon may be reproduced or
copied in any form or by any means (graphic, electronic, or mechanical) without first receiving the
written permission of Fann Instrument Company, Houston, Texas, USA.
Printed in USA.
The information contained in this document includes concepts, methods, and apparatus which may be
covered by U.S. Patents. Fann Instrument Company reserves the right to make improvements in
design, construction, and appearance of our products without prior notice.
FANN® and the FANN logo are registered trademarks of Fann Instrument Company in the United
States and/or other countries. All other trademarks mentioned in the operating instructions are the
exclusive property of the respective manufacturers.
Contact Fann Instrument Company
Phone [phone]
1-800-347-0450
Fax [phone]
Postal Address Fann Instrument Company
P.O. Box 4350
Houston, Texas, 77210 USA
Shipping Address Fann Instrument Company
14851 Milner Road, Gate 5
Houston, Texas, 77032, USA
Online www.fann.com
[email protected]

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Table of Contents
1 Introduction ................................................................................................................ 5
1.1 Model 415C ....................................................................................................... 5
1.2 Model 415SGS .................................................................................................. 6
1.3 Document Conventions ..................................................................................... 7
2 Safety ......................................................................................................................... 8
2.1 Safe Pressurization ............................................................................................ 8
2.2 Safe Heating ...................................................................................................... 8
2.3 Safe Electrical Operation ................................................................................... 8
3 Specifications ............................................................................................................. 9
4 Installation ................................................................................................................ 10
4.1 Air and Water Cooling Connections ................................................................. 10
4.2 Electrical Connections and Control Box .......................................................... 10
4.3 Pressure Vessel Installation ............................................................................ 12
5 Hydraulic, Pneumatic, Cooling and Electronic Controls ........................................... 13
5.1 Hydraulic Pressure Controls ............................................................................ 13
5.2 Pneumatic Controls ......................................................................................... 13
5.3 Electronic Controls and Displays ..................................................................... 14
6 Using the Touchscreen Software ............................................................................. 15
6.1 What is a touch screen and how does it work? ............................................... 15
6.2 Using the Touch Screen .................................................................................. 15
6.3 What can you do with the touch screen software? .......................................... 15
6.4 One Key Recovery for the Computer ............................................................... 15
6.5 Software Upgrades .......................................................................................... 16
6.6 Using the USB Port and the Printer ................................................................. 16
6.7 The Main Menu ................................................................................................ 17
6.8 Instrument Setup ............................................................................................. 18
6.9 Test Setup ....................................................................................................... 27
6.10 Start Test ......................................................................................................... 32
6.11 Live Testing Screen ......................................................................................... 33
6.12 View Test ......................................................................................................... 33
7 Operation ................................................................................................................. 35
7.1 Running a Thickening Time Test ..................................................................... 35
7.2 Stopping a Thickening Time Test .................................................................... 36
7.3 Thermocouple Retainer ................................................................................... 37

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7.4 Removing Slurry Cup Plug from Pressure Vessel ........................................... 38
7.5 Slurry Removal ................................................................................................ 39
8 Maintenance and Troubleshooting ........................................................................... 41
8.1 Slurry Cup Bottom Removal and Reinstallation ............................................... 41
8.2 Paddle Shaft and Paddle ................................................................................. 42
8.3 Slurry Cup Plug Disassembly and Reassembly .............................................. 43
9 Warranty and Returns .............................................................................................. 48
9.1 Warranty .......................................................................................................... 48
9.2 Returns ............................................................................................................ 48

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1 Introduction
1.1 Model 415C
Model 415C pressurized consistometer is able to test cement slurries at
temperatures up to 400ºF/204ºC and pressures to 15,000 psig / 103 MPa. The
instrument is designed to perform thickening time tests in accordance with API
specifications and recommended practices. If the instrument is also fitted with gel
strength testing software it also is designed to perform static gel strength tests in
accordance with API specifications. The consistometer slurry cup assembly uses a
rotating paddle and a stationary cylindrical slurry cup assembly / pressure vessel.
Pressure is applied to the vessel using mineral oil and an air driven hydraulic pump.
A 1500-watt heater surrounding the slurry cup outside the pressure vessel supplies
heat to the pressure chamber. A sidewall thermocouple is provided for determining
the temperature of the cement slurry.
The slurry cup paddle is rotated through the use of an electric motor and a magnetic
drive unit. The rotational speed of the slurry cup is set to the API prescribed speed
of 150 rpm. Variable speed option is available for testing at RPM’s from .0005 to
250.
The consistency of the cement slurry is measured through a servo motor which
monitors the torque applied to the paddle in maintaining a constant rpm. The
rotational force is proportional to the consistency of the cement slurry and is
measured through the servo drive and customized software. The consistency is
indicated and displayed on a plot generated by the data acquisition system (DAQ).
The consistency values are recorded in Bearden Units of consistency (Bc).
Fann pressurized consistometers are equipped with a state-of-the-art temperature
controller and data acquisition system that provides unparalleled ease of use for the
operator. The parameters of interest may be displayed in either English or SI units.
Temperature control and data acquisition are programmed through the use of a
touch screen monitor. A separate PC and keyboard/mouse are not required but can
be attached for added functionality. The plots may also be downloaded to a USB
flash drive or network folder for transfer to a separate computer.
The equation for consistency as a function of torque (g-cm) is Bc = .05 x T - 3.91.
So at a torque value of zero it's at least theoretically possible for the Bc be negative.
In reality, the torque can never be zero. Even if there is air in the slurry cup there
will be some drag on the paddle from friction, etc. When instruments only had
voltmeters in the past, there was no way to ever make the Bc negative since the
voltage was never negative. Now that computers have data scaling, they can be
calibrated to indicate almost anything. The API consistency equation clearly states
that consistency could start negative on ultra-thin slurries.

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1.2 Model 415SGS
Model 415SGS combines thickening time and static gel strength testing into one
compact, easy to use, simple to maintain unit. Model 415SGS represents the easiest
to operate and most reliable static gel strength tester in the industry. This additional
gel static gel strength determination software package is designed to perform static
gel strength tests in accordance with API specifications.
The static gel strength of cement slurry is measured using a standard paddle and
with the same configuration as a thickening time test. This makes transitioning
from thickening time to static gel strength testing instantaneous, simulating real-
world downhole conditions. The paddle is held in a virtually stationary position
allowing for extremely precise direct measurement of static gel strength
development in real time.
Model 415SGS represents the new standard for static gel strength measurement and
is backed by over 20 years of proven research and results. The portable
combination of API thickening time tester and static gel strength determination
make his an economical and powerful tool for any laboratory.
Critical static gel strength (CSGS) is the specific static gel strength of a cement in
which hydrostatic-pressure equilibrium is reached between the decayed hydrostatic
pressure transmission of the cement column (and other fluids in the annulus) and
the pore pressure of the formation. CSGS is measured in pascals or newtons per
square meter (pounds force per 100 square feet).
Critical static gel strength period is the time interval required for the cement to
progress from the CSGS to a static gel strength of 250 Pa (500 lbf/100 ft2). Static
gel strength (SGS) is the shear strength (stress) measurement derived from force
required to initiate flow of a fluid. Also measured in pascals or newtons per square
meter (pounds force per 100 square feet).
The apparatus contains a pressure chamber that can be heated and pressurized
according to a simulated cement job schedule. The SGS is calculated from the
torque required to rotate a paddle of known geometry at very low speed. The
rotation speed of the paddle during the SGS measurement portion of the test is
normally a continuous
0.0000092 r/s (0.2°/min). The initial stirring to simulate placement in the well is
typically conducted at 2.5 r/s ± 0.25 r/s (150 r/min ± 15 r/min). The permissible
range of rotational speed for the apparatus is 0.0000069 r/s to 0.0000231 r/s.

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1.3 Document Conventions
The following icons are used as necessary in this instruction manual.
NOTE. Notes emphasize additional information that may be
useful to the reader.
CAUTION. Describes a situation or practice that requires operator
awareness or action in order to avoid undesirable consequences.
MANDATORY ACTION. Gives directions that, if not observed,
could result in loss of data or in damage to equipment.
WARNING! Describes an unsafe condition or practice that if not
corrected, could result in personal injury or threat to health.
ELECTRICITY WARNING! Alerts the operator that there is risk of
electric shock.
HOT SURFACE! Alerts the operator that there is a hot surface and
that there is risk of getting burned if the surface is touched.
EXPLOSION RISK! Alerts the operator that there is risk of
explosion.

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2 Safety
Safe laboratory practices and procedures should be observed while operating and
maintaining the Model 422 & 422CC. Follow the instructions provided to avoid
personal injuries or damage to the equipment.
Always wear appropriate personal protective equipment (PPE) when operating or
maintaining the Consistometer.
2.1 Safe Pressurization
This Consistometer has pressurized air, water, and hydraulic lines that present a
hazard if not depressurized before maintenance or disassembly.
The hydraulic diaphragm pump and the pressure relief valve require compressed
air. Before working on any of these devices or connected air lines, shut off the
compressed air supply to the machine, and carefully relieve air pressure from the
machine.
2.2 Safe Heating
Before opening the pressure chamber, use the cooling system to lower the
temperature to at least 120°F (49°C). The machine uses domestic water as coolant.
Shut off the domestic water supply before servicing.
NEVER operate the heater on an empty chamber. The heater element will quickly
overheat and fail. To prevent smoke and possible fire, always fill the chamber and
pressurize before heating.
2.3 Safe Electrical Operation
Disconnect the power cable before attempting any electrical or mechanical
maintenance. Be aware that after the power switch is turned off, the electrical
terminals inside the panel will remain electrically energized.
Refer to the electrical schematic before performing any maintenance or
troubleshooting.
Always disconnect the power cable before attempting any repair.

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3 Specifications
Table 3-1 415C & 415SGS Specifications
Category Specification
Electrical
Input Voltage 230 VAC (+10%)
Current 10A
Input Frequency 50-60Hz
Mechanical
Height 15 in. (38 cm)
Width (single) 26 in. (67 cm)
Depth 15 in. (38 cm)
Weight (single) 150 lb. (68 kg)
Environmental
Operating Temperature (32º to 105º F) 0-40º C
Operating Humidity 0-95% noncondensing
Heater
Heater Power 1500W
Utilities – Water and Air
Compressed Air 80 - 150 psig (5.4 – 10.2 bar); Must be water
separated and filtered.
Cooling Water Pressure 100 psig (6.8 bar) maximum; Must be filtered and
sediment free.
Utility Inlets ¼ inch MNPT (1): max 120psi, dry

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4 Installation
Upon uncrating the instrument, verify that the instrument and any spare parts on the
packing list have been received and are undamaged.
4.1 Air and Water Cooling Connections
Once the instrument has been moved to its desired location, air, water, and
electrical connections can be made. The air inlet, coolant inlet and drain
connections are each ¼ inch female NPT connections and are located at the rear of
the instrument. ¼ inch compression tube fittings and 5/8” hose barb fittings and
associated tubing are included for your convenience. You may select either
depending on your preference.
Connect the coolant to the connector labeled Coolant Supply on the rear panel of
the instrument. The water or coolant must be clean and free of debris, sediment,
minerals, etc. that could cause major scaling, blockage, premature wear, or
malfunction. Use of a heavy-duty water filter is required. Do not use a corrosive
coolant mixture or any liquid that could damage copper, stainless steel, plastic or
Teflon.
4.1.1 Connecting the Drain Line
Connect the drain line to the connector labeled Coolant Drain on the rear panel of
the instrument. The drain system must be capable of handling hot water up to 212
ºF (100 ºC) or brief surges of up to 400 º F (204 º C) steam for short periods of time
during initial cooling of the instrument. If two or more RP Consistometers 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 on the rear panel of the
instrument. The air is required to be dry and free from dirt and oil. The air should
be supplied at a pressure of 80-150 psig (5.4 – 10.2 bar). The compressed air
supply is required to be free from moisture and contamination of any kind. A
heavy-duty filter is required to prevent premature wear, scaling, blockage or
malfunction.
4.2 Electrical Connections and Control Box
Electrical connections are made using the receptacle on the rear of the instrument.
A power cord is supplied with the instrument. Please observe the following
precautions when making the wiring connections.

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Wiring should be done by a qualified installer in accordance with
local electrical codes.
The instrument should be securely connected to a separate earth
ground. The ground wire must be larger in diameter than the
supply conductors.
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 cables on the
touch screen monitor must be plugged into the correct location on the supplied
control box. These connections include a 15-pin SVGA cable, USB, and AC (120-
240VAC) power. The touchscreen power should be powered by the instrument and
not into a separate power source prevent electrical ground loops.
If a printer is included with the instrument, it may be connected to the rear of the
control box. Connect the USB connector on the printer cable to an available USB
port on the control box. The printer must also be connected to a suitable power
source. A USB flash drive may also be connected to the instrument in lieu of a
printer. Test data may be downloaded to the USB drive and then transferred to a PC
for archival storage.
The control box must be properly wired to the instrument for
operation.
Connect the 5-pin round power plug into the outlet labeled COMPUTER on the
back of the instrument. In addition, a USB type-A to Type-B cord must be
connected from the back of the control box to the back of the instrument, also
labeled COMPUTER.

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An uninterruptable power supply (UPS) is recommended for any
areas experiencing poor power conditions. If you are installing a
UPS, connect the output of the UPS to the outlet labeled UPS on
your instrument. If not, you MUST CONNECT A POWER JUMPER
(included). This jumper cable will connect the two outlets on the
back of the machine labeled UPS. Make sure to fully seat the
jumper cable.
4.3 Pressure Vessel Installation
The pressure vessel is shipped separately from the instrument; locate the pressure
vessel assembly and the motor/drive assembly. The pressure vessel is installed into
the heater block by carefully sliding it in from the top. A thermocouple is contained
inside the instrument.
The thermocouple must be inserted into the bottom sidewall of
the pressure vessel anytime the vessel is inserted into the
instrument.
Installation of the thermocouple may be easiest if the thermocouple is pulled
through the heater block and inserted before the pressure vessel is dropped into the
instrument.

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5 Hydraulic, Pneumatic, Cooling and Electronic Controls
5.1 Hydraulic Pressure Controls
This section consists of the pressure gauge and the pressure release valve.
Components that make up this section are used to control the flow of oil used to
pressurize the cylinder and to display the cylinder pressure. The pressure gauge is
used to display the pressure inside the pressure vessel.
The pressure release valve is used to release pressure from the pressurized cylinder
and discharges waste oil into a small plastic reservoir cup. The pressure release
valve must also be fully opened to release pressure from the cylinder but should
always be opened as slowly as possible the prevent cement spillage into oil lines.
The part number for the pressure release valve is C-1302. This valve should remain
closed while testing and should be opened following the test procedure to vent
pressure from the slurry vessel.
Use caution when opening this valve when the slurry is still very
hot (>150ºF).
Opening the valve will cause oil and possibly cement to vent from the pressure
vessel into a supplied plastic container on the back of the instrument. If the test
pressure is exceedingly high, then slowly open the valve to release pressure to a
more suitable level taking caution not to remove all pressure especially at high
temperatures.
5.2 Pneumatic Controls
The pneumatic section consists of the air pressure REGULATOR and the PUMP
switch. The components in this section are used to power the air driven hydraulic
pump that applies pressure to the sample.
The air pressure REGULATOR is used to control the air pressure to the air driven
hydraulic pump. To adjust the pressure of the air supplied to the pump, 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 if desired.

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The REGULATOR pressure should not exceed 100psi and may
not power the pump below 25psi.
The PUMP switch is used to turn the pump on and off. The user must take care not
to over-pressure the vessel or apply pressure without properly bleeding air from the
slurry.
5.3 Electronic Controls and Displays
The switch labeled POWER controls electrical power to the entire instrument.
Nothing else is operable if this switch is not on including the touchscreen software.
The touch screen is used to control temperature and motor speed, display a plot of
consistency and temperature as a function of elapsed time, and perform various
operations.
A thermocouple is plugged into the THERMOCOUPLE connector located on the
middle wall inside the instrument. This connector may be used for calibration or
thermocouple replacement.
Always ensure the thermocouple is properly seated into the
pressure vessel before beginning a test.

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6 Using the Touchscreen Software
6.1 What is a touch screen and how does it work?
Touch screens were created to provide users with an easy to use interface. This
allows 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.
6.2 Using the Touch Screen
A finger or stylus is most often used on the touch-screen. 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
pen-like touch stylus has been included in your accessories to use if desired.
6.3 What 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. All instrument operations are accessed and controlled through the
touch screen. This consistometer is a leap forward in design because it is the first
time that mechanical control has been eliminated from the point of view of the
operating technician. Filling and draining the pressure vessel with oil, heating and
cooling, pressurizing and depressurizing, and rotational speed are all fully
automated. Our unique testing and test data screens offer detailed control over test
parameters and the way your plot looks including color designations and job
properties. Alternately, test data can be exported raw and utilized however one
wishes. Each instrument is complete and requires no additional software or
hardware to function.
6.4 One Key Recovery for the Computer
Instruments manufactured after March 2014 have computer systems which have
One Key Recovery factory restoration points. What this means is that if the
computer has a severe virus attack, operating system crash, hard disk failure or
corrupted programs and software then the user may take simple steps to restore the
system to its original factory condition. Simply pressing F3 during the 10 second
boot sequence brings up access to the recovery menu. Select option 1 for a factory
restore. Original application programs and configurations will be restored.
Alternately, a newer backup point can be created. For example if you have updated
the CementLab software to a newer version, performed new calibrations, and have

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installed any new programs then a new backup point would restore these. Option 2
creates a new backup.
6.5 Software Upgrades
From time to time, Fann makes software upgrades available that provide increased
functionality or problem fixes. Generally, the only file that needs to be upgraded is
CementLab.exe. It is located in the C:\Program Files\Fann folder. If it is necessary
to install an updated CementLab.exe file, it may be copied from the USB memory
stick. It may also be copied over a network if the instrument is connected to one.
To copy the file from a memory stick, put the new file on the memory stick,
rename the old CementLab.exe file to “Old.exe” and copy the new file into the
proper folder using Windows Explorer, which is accessible from the start menu or
My Computer icon. The memory stick will generally be the D: drive. Should the
new CementLab.exe program not work properly, simply delete it and restore
Old.exe to the original. However, we recommend you only upgrade your system
with the expressed permission of a Fann engineer.
6.6 Using the USB Port and the Printer
The instrument is equipped with a Universal Serial Bus (USB) port on the front
panel that allows the use of a USB memory stick for mobile storage. The memory
stick is a flash disk that can be connected to the USB port on the instrument control
box and used as an external hard drive. Simply insert the memory stick into the
USB port and the memory stick will become the D: drive. Software upgrades may
be installed using the memory stick and tests may be archived to the memory stick
and transferred to a PC for permanent storage. A color inkjet printer is pre-installed
at the factory and is shipped with a new instrument. The printer is a useful tool for
providing immediate printed results directly from the instrument. A 115/230V
power adapter and a USB data cable are provided to connect the printer. The printer
power adapter must be connected to the back of the instrument to prevent
instrument malfunction. See Installation section in section 4. The printers use
8.5x11” paper.

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6.7 The Main Menu
Figure 6-1 Software Screenshot
The main menu is the starting point for controlling the instrument. From here users
may start new tests, setup test parameters, setup instrument parameters, or view an
old test. Also located on the main menu is the reading for current temperature,
consistency, and pressure. On the right side of the screen you will also notice the
version software that is currently installed on your instrument.
The cooling button is located on the main screen and is operated by selecting it to
turn it on. Select again to turn off. The cooling button is connected to a solenoid
valve which is connected to the cooling input located on the back of the instrument.
Typically, water is used at house pressure and temperature. However, you may also
connect a circulating chiller. If cooling is turned on when start test is activated, the
cooling will remain on and heating will not ensue. Turn cooling off if you wish to
start a normal test.
The motor switch is located on the main screen and is operated by selecting it to
turn it on. Select again to turn off. The motor speed is set to turn at 150 rpm.

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6.8 Instrument Setup
Figure 6-2 Software Screenshot
The instrument setup button takes the user to the instrument setup screen shown.
From this screen the user may perform a variety of operations and change options.
6.8.1 Calibrating Temperature

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Figure 6-3 Software Screenshot
Temperature calibration must be performed by a qualified individual that has a
certified temperature calibration device. When the screen in above appears, connect
a J type temperature calibrator to the thermocouple connector input on the
instrument. Enter a lower-limit temperature value on the calibrator. Touch the Enter
Low Value parameter box shown above and then enter the correct temperature
value for the low data point using the touchpad at the right. The raw value is the
voltage signal read directly from the I/O hardware and it should change as the
calibration signal changes. When the low data point has been entered, press the
SAVE LOW VALUE button. The user can now enter the high data point on the
calibrator and then again on the touchscreen as before. The raw value should be
different for the low and high data points or there will be a computation error. After
the high data point has been established, press the SAVE HIGH VALUE button.
We recommend using a low value of room temperature and a high value of 400F or
near maximum operating temperature. The user can now vary the calibration signal
and see how the calibrated signal compares with that of the calibration device in the
VERIFY NEW CALIBRATION box. If the signals compare favorably, press the
SAVE button to save the calibration. The calibration values will be stored in a
configuration file and take effect upon saving and exiting the Instrument Setup
menu.

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6.8.2 Calibrating Pressure
Figure 6-4 Software Screenshot
Pressure calibration must be performed by a qualified individual that has a certified
pressure calibration device. When the screen above appears, connect the pressure
calibrator to the top of the pressure vessel using a 9/16-18 high pressure nut. Enter
a lower-limit pressure value on the calibrator. Touch the Enter Low Value
parameter box shown in and then enter the correct pressure value for the low data
point using the touchpad at the right. The raw value is the voltage signal read
directly from the I/O hardware and it should change as the calibration signal
changes. When the low data point has been entered, press the SAVE LOW VALUE
button. The user can now enter the high data point on the calibrator and then again
on the touchscreen as before. The raw value should be different for the low and
high data points or there will be a computation error. After the high data point has
been established, press the SAVE HIGH VALUE button. We recommend using a
low value of house air pressure and a high value of 20,000psi or near maximum
operating pressure. The user can now vary the calibration signal and see how the
calibrated signal compares with that of the calibration device in the VERIFY NEW
CALIBRATION box. If the signals compare favorably, press the SAVE button to
save the calibration. The calibration values will be stored in a configuration file and
take effect upon saving and exiting the Instrument Setup menu.