fann 422 User manual

©2015 Fann Instrument Company
Model 422 (Single Cell) & Model 422CC (Dual Cell)
Auto Consistometer
Instruction Manual
Manual No. D01187869, Revision A
Instrument No. 102538934, 102546632

D01187869 Revision A, December 2015 2
Model 422 & Model 422CC Automatic Consistometer Instruction Manual
©2015 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
1-281-871-4482
1-800-347-0450
Fax
1-281-871-4358
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 ..............................................................................................................6
1.1 Document Conventions....................................................................................8
2 Safety.......................................................................................................................9
2.1 Safe Pressurization..........................................................................................9
2.2 Safe Heating ....................................................................................................9
2.3 Safe Electrical Operation..................................................................................9
3 Specifications.........................................................................................................10
4 Installation..............................................................................................................11
5 Using the Touchscreen Software............................................................................15
5.1 One Key Recovery for the Computer..............................................................16
5.2 Software Upgrades ........................................................................................16
5.3 Using the USB Port and Printer......................................................................16
5.4 Software Main Menu ......................................................................................17
5.5 Instrument Setup............................................................................................18
6 Test Setup..............................................................................................................27
6.1 Temperature Control......................................................................................27
6.2 Pressure Control ............................................................................................28
6.3 Hesitation Squeeze (Squeeze Schedule).......................................................28
6.4 Sample Properties..........................................................................................29
6.5 Alarms............................................................................................................29
6.6 Customer Data...............................................................................................30
6.7 Save Test.......................................................................................................30
7 Start Test ...............................................................................................................31
7.1 Live Testing Screen........................................................................................31
7.2 Stopping a Test..............................................................................................32
8 View Test...............................................................................................................33
8.1 Graph Tab......................................................................................................33
8.2 Scale Tab.......................................................................................................34
8.3 Data Tab........................................................................................................35
8.4 Printing Tab....................................................................................................35
9 Pneumatic, Cooling, and Electronic Controls..........................................................36
9.1 Pneumatic Controls........................................................................................36
9.2 Cooling Controls.............................................................................................37
9.3 Electronic Controls.........................................................................................37

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10 Operation ...............................................................................................................39
10.1 Example of Running a Thickening Time Test .................................................39
10.2 Example of Stopping a Thickening Time Test.................................................40
11 Maintenance and Basic Servicing...........................................................................42
11.1 Pressure Vessel and Hydraulic System Maintenance.....................................42
11.2 Potentiometer Mechanism Maintenance.........................................................43
11.3 Slurry Cup Maintenance.................................................................................44
11.4 Replacing the Low Pressure Filter..................................................................45
11.5 Potentiometer Mechanism Resistor Replacement..........................................45
11.6 Potentiometer Mechanism Spring Replacement.............................................46
12 Warranty and Returns............................................................................................47
12.1 Warranty ........................................................................................................47
12.2 Returns ..........................................................................................................47

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List of Tables and Figures
Table 3-1 Model 422 and Model 422CC Specifications.................................................10
Figure 4-1 Installing the monitor mount.........................................................................14
Figure 5-1 Alligator clips attached to potentiometer mechanism springs.......................21
Table 5-1 Consistency as a Function of Weight vs. Torque*.........................................23

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1 Introduction
Cements are a critical element in the drilling, completion, work over, and
abandonment of wells. For each application, cement slurry is designed with specific
properties and is given additives that provide predictable slurry density, volume,
viscosity, compressive strength, fluid loss, gas migration, and thickening time.
Slurry thickening time, or the time a slurry remains pumpable in a well, is one of
the most critical properties in designing cement slurry. A predictable thickening
time is desired, while maintaining the other specific properties of the cement slurry.
The thickening time can be measured in a laboratory by testing a sample of the
cement slurry in a pressurized consistometer. The elapsed time between initial
application of pressure and temperature on the slurry sample and occurrence of a
predetermined value of consistency (usually 100 Bearden Units, Bc) is the
thickening time for the sample at the particular specification test schedule.
The Model 422 (single cell) and 422CC (dual cell) automatic pressurized
consistometers are able to test cement slurries at temperatures up to 400°F/204°C
and 22,000 psig/151 MPa. The consistometer slurry cup assembly 02-0030 uses a
rotating, cylindrical slurry cup and a stationary paddle assembly enclosed in a
pressure vessel. Pressure is applied to the vessel using mineral oil and an air driven
hydraulic pump. A tubular heater surrounding the slurry cup supplies heat to the
pressure chamber. A centerline thermocouple is provided for determining the
temperature of the cement slurry.
The slurry cup is rotated through the use of an electric motor and a magnetic drive
unit. The rotational speed of the slurry cup is variable between 25 and 250 rpm to
allow the user to study slurries at speeds other than the API prescribed speed of 150
rpm.
The consistency of the cement slurry is measured through a potentiometer
mechanism commonly referred to as a ‘pot mech’. The potentiometer is coupled
with a torsion spring to resist the rotating force of the paddle. The rotational force
is proportional to the consistency of the cement slurry and is measured through the
potentiometer resistor as the spring deflects under load. The consistency is
displayed on the plot generated by the data acquisition system. The consistency
values are recorded in Bearded Units of consistency (Bc).
The consistometer is equipped with two devices for post-test cooling of the
instrument. The first is an external-cooling coil attached to the pressure vessel.
After completion of the test, cooling water may be circulated through this coil to
cool the pressure vessel. The instrument is also equipped with an oil reservoir
cooling coil to independently cool the oil after a test.
Fann pressurized consistometers are equipped with a state-of-the- art control 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 is programmed through the use of a 22” touch screen

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monitor. A plot showing temperature, pressure and consistency may be plotted on
any compatible ink jet printer. The data and plots may also be transferred
electronically to a network or USB drive for use on a separate computer.

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1.1 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 Model 422 and Model 422CC Specifications
Category Specification
Electrical
Input Voltage 230 VAC (±10%)
Input Power 5500W (single), 10000W (dual)
Current 25A (single), 50A (dual)
Input Frequency 50-60Hz
Mechanical
Height (single) 66 in. (157 cm)
Height (dual) 61 in (155 cm)
Width (single) 24 in. (61 cm)
Width (dual) 48 in. (122 cm)
Depth (single) 24 in (61 cm)
Depth (dual) 30 in. (76 cm)
Weight (single) 850 lbs. (386 kg)
Weight (dual) 1600 lb. (726 kg)
Environmental
Operating Temperature (32º to 105º F) 0-40º C
Operating Humidity 0-95% noncondensing
Heater
Heater Power 5000W (per pressure vessel)
Heater Type Internal cast rod member
Heater Control Solid state relay
Drive Unit
Drive Motor 1/8 Hp (93W), 180 VDC
Drive Speed 25-250 rpm (variable)
Air/Water Connections
Water In/out ¼ MNPT (2)
Air Input ¼ MNPT (1) maximum 120psi

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4 Installation
The instrument’s center of gravity is located near the front of the
instrument due to the weight of the pressure vessel. Be very
careful when rolling or transporting the instrument that it does not
tip over toward the front.
It is ideal 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.
Once the instrument has been moved to its desired location, air, water, and
electrical connections can be made. The air inlet, water inlet, and water drain
connections are each ¼ inch female NPT connections and are located on the lower
right rear of the instrument. A number of ¼ inch male NPT to 8mm tube fittings are
included for international locations. The air and water inlet connections may be
made with either metal or plastic tubing. It is recommended that the water drain
lines be made from metal, since this line may carry very hot water and steam from
time to time. Electrical connections are made using the twist lock receptacle on the
rear of the instrument. A 30 amp female plug is included with each consistometer.
Please observe the following precautions when making the wiring
connections.
•A qualified installer should do the wiring 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
8-gauge minimum ground wire is recommended for a dual consistometer
and a 10-gauge minimum ground wire is recommended for a single
consistometer.

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•An 8BC or larger fire extinguisher to fight electrical and oil fires should be
placed within 50 feet of the consistometer.
Certain components are supported during shipment with wooden blocks, foam
padding, plastic ties, etc. to prevent damage. Open the front doors and remove all
the packing materials that would interfere with the operation of the instrument
before powering the instrument. Some components such as touch screen LCD
monitor and computer control modules are removed from the instrument prior to
shipment and may be in a separate container to prevent damage. These devices
must be reinstalled and reconnected before operating the instrument. Before
operating the instrument, it is a good idea to check the bottom of the consistometer
for loose screws or bolts that may have loosened and/or fallen out during shipment.
This is particularly true for overseas shipments.
Locate the box containing the monitor, reticulating arm and computer and remove
them from their shipping containers. Secure the arm and monitor to the
consistometer by sliding the arm mount onto the rear side of the cabinet mounting
panel as shown in Figure 4-1.
Connect the power cord from the monitor to the A/C outlet on the back of the
instrument. Failure to do so can cause the instrument to malfunction. Alternately,
the touchscreen may be powered using a DC power adapter.
Plugging the touchscreen and printer into a different outlet creates
an undesirable ground loop to occur. This creates an unstable
electrical system.
The control box should be connected to the instrument by connecting the 5-pin
power cord to the back of the instrument frame as well as the supplied USB cable.
The instrument will not operate without this USB cable connected from the
computer to the machine.
It is strongly recommended that a 230V uninterruptable power supply (UPS) be
installed on the instrument. This will condition the power signal and prevent loss of
power to the computer. There are two power connectors on the back of the
electrical box. A UPS may be connected between these power connectors to
maintain consistometer computer operation during short power outages or
interruptions. If a UPS is not used, a jumper cord must be connected between these
two connectors or the unit will not power on. An appropriate jumper cord is
included with the consistometer accessories.
A printer is included with the instrument and may be connected to the computer
control box. Connect the USB connector on the printer cable to any USB input on

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the control box. The printer must also be connected to the A/C power outlet on the
back of the instrument. Failure to connect the power adapter to the A/C power
outlet on the back of the instrument can cause the instrument to malfunction. A
USB flash drive may also be connected to the control box in lieu of a printer. Test
data may be uploaded to the USB drive and then transferred to a computer for
archival storage. It is considered a best practice to keep a keyboard connected to
the computer as it will be necessary to input programming features, save data files,
etc.
Before attempting to operate the instrument, it is recommended that operators read
the remainder of the manual to become familiar with the consistometer operation.

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Figure 4-1 Installing the monitor mount

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5 Using the Touchscreen Software
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.
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.
Sharp instruments (such as pencils, pens, screwdrivers, etc.)
should not be used as they may damage the touch surface.
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 designed 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 the 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.

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5.1 One Key Recovery for the Computer
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.
•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
CementLab software has been updated to a newer version, performed new
calibrations, and have installed any new programs then a new backup point
would restore these. Selecting option 2 creates a new backup.
5.2 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, system upgrades are only recommended with the
expressed permission of a Fann engineer.
5.3 Using the USB Port and 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

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power adapter must be connected to the back of the instrument to prevent
instrument malfunction. See section 4 for installation information.
5.4 Software Main Menu
The main menu is starting point for the instrument. From here users may start new
tests, set up 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, the version software that is currently
installed on the instrument is displayed. In the screenshot above, the version is
5.3.53.
•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, circulating chiller can also be
connected. If cooling is turned on when start test is activated, the cooling
will remain on and heating will not ensue. Turn cooling off if starting a
normal test is desired.
•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.
•The fill button is located on the main screen. This button operates several
functions in one. As shown below, the fill button shows fill off, fill on, run
test, and drain cylinder. The fill off position neither allows oil or air into the
cylinder. The fill on position allows oil to flow from the reservoir into the

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cylinder. The run test position performs the same function as fill on but
gives the user the understanding that the cylinder is ready for pump pressure
application. The drain cylinder position will open the pressure release valve
thereby releasing any high pressure and start the flow of oil back to the
reservoir.
•The pump button located on the main screen is operated by pressing and
holding it to turn on and releasing to turn off. This button operates the high
pressure pump connected to the cylinder.
•The release pressure button is operated by pressing and holding to open and
releasing to close. The button is connected to the high pressure release
valve.
5.5 Instrument Setup

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The instrument setup button takes the user to the instrument setup screen shown
above. From this screen the user may perform a variety of operations and change
options.
5.5.1 Calibrating Temperature
Temperature calibration must be performed by a qualified individual that has a
certified temperature calibration device. When the screen 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 400°F 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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5.5.2 Calibrating Pressure
Pressure calibration must be performed by a qualified individual that has a certified
pressure calibration device. When the screen as shown 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 above 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.
5.5.3 Calibrating Consistency
Consistency should be calibrated by using the consistency calibrator kit. Kit
includes calibrator base, weight set and hanger, wedge with cord, and 3 clip wiring
harness. This device applies a known torque to the potentiometer mechanism
spring, allowing the readout to be observed on the screen. Calibration of the
potentiometer mechanism is described in the example below. It is recommended
that consistency be calibrated at minimum once a month.
1. Connect the calibrator base near the front edge of the consistometer using
the two holes, nuts and bolts.