fann 640 User manual

©2016 Fann Instrument Company
HTHP Consistometer Model 640 & 640CC
Instruction Manual
Manual No. D01206676 Revision A
Instrument No. 102538936 (Model 640)
102546634 (Model 640CC)

Model 640 & 640CC Instruction Manual
D01206676 Revision A February 2016 2
HTHP Consistometer, Single & Dual Cell Instruction Manual
©2016 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]

Model 640 & 640CC Instruction Manual
D01206676 Revision A February 2016 3
Table of Contents
1 Introduction ..............................................................................................................6
1.1 Document Conventions....................................................................................7
2 Safety.......................................................................................................................8
2.1 Safe Pressurization ............................................................................................8
2.2 Safe Heating ......................................................................................................8
2.3 Safe Electrical Operation....................................................................................8
3 Instrument Overview ................................................................................................9
4 Specifications.........................................................................................................10
5 Installation..............................................................................................................11
6 Touchscreen Software ...........................................................................................14
6.1 Using the Touchscreen ..................................................................................14
6.2 View Test.......................................................................................................14
6.3 Instrument Setup............................................................................................15
6.4 Calibrate Temperature/Calibrate Pressure.....................................................15
6.5 Sample Rate ..................................................................................................15
6.6 Units...............................................................................................................16
6.7 Archive Data ..................................................................................................16
6.8 Edit Instrument...............................................................................................16
7 Test Setup..............................................................................................................17
7.1 Temperature Control (Pressure When Available) ...........................................17
7.2 Hesitation Squeeze........................................................................................18
7.3 Optional Parameters and Profile Saving.........................................................19
8 Start Test ...............................................................................................................20
8.1 Live Testing Screen........................................................................................20
9 Stopping a Test......................................................................................................21
9.1 Software Upgrades ........................................................................................21
9.2 Using the USB Memory and Printer................................................................21
10 Front Panel Controls ..............................................................................................22
10.1 Hydraulic Pressure Controls...........................................................................22
10.2 Pneumatic Controls........................................................................................23
10.3 Cooling Water Controls..................................................................................24
10.4 Other Electrical and Electronic Controls.........................................................24
11 Operation and Calibration.......................................................................................26
11.1 Running a Thickening Time Test....................................................................26

Model 640 & 640CC Instruction Manual
D01206676 Revision A February 2016 4
11.2 Stopping a Thickening Time Test...................................................................27
11.3 Calibration......................................................................................................27
11.4 Pressure Calibration Procedure .....................................................................28
11.5 Consistency Calibration Procedure ................................................................29
12 Maintenance and Servicing....................................................................................31
12.1 Pressure Valve and Hydraulic System Maintenance ......................................31
12.2 Potentiometer Mechanism (Pot Mech) Maintenance ......................................32
12.3 Slurry Cup Maintenance.................................................................................32
12.4 Changing the Metal O-ring on the Cylinder Assembly ....................................33
12.5 Changing/Cleaning the High Pressure Filter Element.....................................33
12.6 Replacing the Low Pressure Filter Element....................................................34
12.7 Potentiometer Mechanism Resistor Replacement..........................................34
12.8 Potentiometer Mechanism Spring Replacement.............................................35
12.9 Servicing the Inner Magnetic Drive Shaft........................................................36
12.10 Servicing the Outer Magnetic Drive Rotator...............................................36
12.11 Removal of the Magnetic Drive Housing....................................................37
12.12 Heater Replacement..................................................................................38
13 Troubleshooting .....................................................................................................40
14 Warranty and Returns............................................................................................44
14.1 Warranty ........................................................................................................44
14.2 Returns ..........................................................................................................44

Model 640 & 640CC Instruction Manual
D01206676 Revision A February 2016 5
List of Tables
Table 4-1 Model 640 & 640 CC Specifications..............................................................10
Table 11-1 Consistency as a Function of Weight vs Torque*........................................30
Table 13-1 Troubleshooting Model 640 & 640 CC ........................................................40

Model 640 & 640CC Instruction Manual
D01206676 Revision A February 2016 6
1 Introduction
Cements are a critical element in the drilling, completion, workover, 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
typical test schedules are listed in API Specification 10 on oilwell cements.
The Model 640 & 640CC Pressurized Consistometers are able to test cement
slurries at temperatures up to 600 F/316 C and pressures as high as 40,000 psig/276
MPa.

Model 640 & 640CC Instruction Manual
D01206676 Revision A February 2016 7
Document Conventions1.1
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.

Model 640 & 640CC Instruction Manual
D01206676 Revision A February 2016 8
2 Safety
Safe laboratory practices and procedures should be observed while operating and
maintaining the Model 640 & 640 CC. 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.
Safe Pressurization2.1
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.
Safe Heating2.2
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.
Safe Electrical Operation2.3
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.

Model 640 & 640CC Instruction Manual
D01206676 Revision A February 2016 9
3 Instrument Overview
The consistometer Slurry Cup Assembly 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 Bearden Units of consistency (Bc). Bearden units are defined
in API Specification 10. The consistometer is equipped with one or 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 optionally equipped
with an oil reservoir cooling coil as well.
These 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 is programmed through the use of a touch
screen monitor. A separate PC and keyboard/mouse are not required but may be
connected through a network cable. A plot showing temperature and consistency
(pressure is optional) may be plotted on any compatible ink jet printer. The plots
may also be transferred automatically to a network or USB drive for use on a user
supplied computer.

Model 640 & 640CC Instruction Manual
D01206676 Revision A February 2016 10
4 Specifications
Table 4-1 Model 640 & 640 CC Specifications
Category Specification
Electrical
Input Voltage 230 VAC (±10%)
Input Power 5500W (single), 11000W (dual)
Current 24A (single), 48A (dual)
Input Frequency 50-60Hz
Mechanical
Height 70in (175cm)
Width (single) 33in (83cm)
Width (dual) 51in (129 cm)
Depth 29in (72cm)
Weight (single) 1100lb (500 kg)
Weight (dual) 2050lb (930 kg)
Environmental
Operating Temperature (32º to 105º F) 0-40º C
Operating Humidity 0-95% noncondensing
Heater
Heater Power 5000W
Heater Type Internal tubular with MgO insulation
Heater Control Solid state relay
Drive Unit
Drive Motor 1/8 Hp (93W), 180 VDC
Drive Speed 25-250 rpm (variable)
Utilities – Water and Air
Compressed Air
maximum: 150 psig (10.2 bar)
minimum: 80 psig (5.4 bar)
Cooling Water Pressure 100 psig (6.8 bar)
Utility Inlets ¼ inch female NPT