fann MACS II User manual

P00000
Multiple Analysis Cement System
(MACS II)
User Manual
(P/N 101677665)
101796668 Rev. E

MACS II User Manual
101796668 Revision E ii
Multiple Analysis Cement System (MACS II) User 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
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Company, Houston, Texas, USA.
Printed in USA
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methods, and apparatus which may be covered by U.S. Patents
FANN®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.

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Document Conventions
The following icons are used in this manual to distinguish elements of text.
Contains additional information for the reader that is not safety
related.
Describes a situation or practice that if ignored, will result in
equipment damage or loss of data.
Describes an unsafe condition or practice that, if not
corrected, will result in personal injury, possibly death.

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Contact FANN®
Phone
TELEPHONE: [phone]
TOLL FREE: 800-347-0450
FAX: [phone]
Mail
Fann Instrument Company
P.O. Box 4350
Houston, Texas, 77210 USA
Location
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
OVERVIEW..........................................................................................................................................................1
1.1. MULTIPLE ANALYSIS CEMENT SYSTEM II....................................................................................................... 2
1.1.1. Thickening Time ....................................................................................................................................5
1.1.2. Transition Time......................................................................................................................................5
1.2. SPECIAL CONSIDERATIONS.............................................................................................................................. 5
SAFETY.................................................................................................................................................................7
2.1. MACHINE HAZARD ..........................................................................................................................................9
2.1.1. Pressure.................................................................................................................................................9
2.1.2. Temperature...........................................................................................................................................9
2.1.3. Electrical ...............................................................................................................................................9
2.1.4. Pinch Points.........................................................................................................................................10
2.2. ERGONOMIC CONSIDERATIONS ..................................................................................................................... 10
2.3. ENVIRONMENTAL CONSIDERATIONS.............................................................................................................10
FEATURES AND SPECIFICATIONS.............................................................................................................11
3.1. MACS II INSTALLATION PREPARATION........................................................................................................ 13
3.2. PHYSICAL REQUIREMENTS............................................................................................................................13
3.3. OPERATIONAL CONSIDERATIONS .................................................................................................................. 13
3.4. COMPUTER SPECIFICATIONS ......................................................................................................................... 14
INSTALLATION................................................................................................................................................ 15
4.1. PRE-INSTALLATION CONSIDERATIONS..........................................................................................................17
4.2. HARDWARE (MECHANICAL)INSTALLATION ................................................................................................. 17
4.2.1. Water, Air, and Coolant Connections.................................................................................................. 17
4.2.2. Electric Power Connection.................................................................................................................. 19
4.2.3. Power Up MACS II Unit...................................................................................................................... 19
4.2.4. Initial Verification of Alignment..........................................................................................................19
4.2.5. Water Test............................................................................................................................................22
4.3. SOFTWARE INSTALLATION ............................................................................................................................22
4.3.1. Software Quick Install ......................................................................................................................... 23
4.3.2. MACS II SGS Software Installation..................................................................................................... 23
4.3.3. USB Connection Configuration........................................................................................................... 24
4.3.4. Software Updates................................................................................................................................. 28
4.4. POST-INSTALLATION VERIFICATIONS............................................................................................................ 28
MACS II SOFTWARE....................................................................................................................................... 31
5.1. SOFTWARE BASICS........................................................................................................................................33
5.2. INTERFACE ELEMENTS .................................................................................................................................. 33
5.2.1. Menu Bar............................................................................................................................................. 34
5.2.2. Variable Indicators.............................................................................................................................. 34
5.2.3. Status Indicator....................................................................................................................................35
5.2.4. Start/Stop Test Button..........................................................................................................................35
5.2.5. Results Graph ...................................................................................................................................... 36
5.3. FILE MENU.................................................................................................................................................... 37
5.3.1. Connect Command...............................................................................................................................37
5.3.2. Disconnect Command.......................................................................................................................... 37
5.3.3. Save Data Command ........................................................................................................................... 37
5.3.4. Exit....................................................................................................................................................... 38
5.4. EDIT MENU ...................................................................................................................................................38
5.4.1. Machine Settings..................................................................................................................................38
5.4.2. Profile Editor....................................................................................................................................... 45
5.5. CALIBRATION MENU..................................................................................................................................... 46

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5.5.1. Zero Drive............................................................................................................................................ 46
5.5.2. Calibrate Pressure............................................................................................................................... 47
5.5.3. Calibrate SGS...................................................................................................................................... 53
5.5.4. Test Repeatability ................................................................................................................................ 54
5.6. OPERATE MENU ............................................................................................................................................ 58
5.6.1. Cell Operations.................................................................................................................................... 58
5.6.2. Valve Operations................................................................................................................................. 60
5.6.3. Manual Operation ............................................................................................................................... 61
5.6.4. Release Pressure.................................................................................................................................. 62
5.7. HELP MENU .................................................................................................................................................. 62
5.7.1. Online Help.......................................................................................................................................... 62
5.7.2. Check for Updates ...............................................................................................................................62
5.7.3. About....................................................................................................................................................62
5.8. START TEST WIZARD .................................................................................................................................... 62
5.8.1. Step One...............................................................................................................................................63
5.8.2. Step Two ..............................................................................................................................................65
5.8.3. Step Three............................................................................................................................................ 66
5.8.4. Step Four............................................................................................................................................. 66
5.8.5. Step Five.............................................................................................................................................. 67
5.9. TEST RUN...................................................................................................................................................... 69
5.10. STOP TEST..................................................................................................................................................... 69
INSTRUMENT OPERATIONS ........................................................................................................................71
6.1. START TEST WIZARD MODULE ..................................................................................................................... 73
6.2. PHYSICAL EQUIPMENT ACTIVITY.................................................................................................................. 73
6.3. CEMENT TEST ...............................................................................................................................................76
RESULTS ANALYSIS .......................................................................................................................................77
7.1. MACS II SOFTWARE..................................................................................................................................... 79
7.1.1. Show Cursor ........................................................................................................................................79
7.1.2. Show Torque........................................................................................................................................79
7.1.3. Autoscale X.......................................................................................................................................... 79
7.1.4. Autoscale Y..........................................................................................................................................79
7.2. DATA MANAGER SOFTWARE ...................................................................................................................... 795
7.3. DATA INTERPRETATION ................................................................................................................................ 80
MAINTENANCE AND TROUBLESHOOTING ............................................................................................81
8.1. PREVENTIVE MAINTENANCE.........................................................................................................................83
8.1.1. Pneumatic Maintenance ...................................................................................................................... 83
8.1.2. Hydraulic Maintenance.......................................................................................................................83
8.1.3. Mechanical Maintenance.....................................................................................................................94
8.2. TROUBLESHOOTING ...................................................................................................................................... 94
ACCESSORIES AND SCHEMATICS .............................................................................................................98
9.1. MACS II TOOL KIT..................................................................................................................................... 100
9.2. MACS II ACCESSORY PARTS KIT ............................................................................................................... 100
9.3. MACS II CALIBRATION KIT........................................................................................................................102
9.4. MACS II SCHEMATICS................................................................................................................................ 102
PARTS LIST.................................................................................................................................................111
10.1. MASTER ASSEMBLY 101677665.................................................................................................................113
10.2. ELECTRICAL BOX ASSEMBLY 101676548................................................................................................... 115
10.3. MECHANICAL ASSEMBLY 101595348......................................................................................................... 121
10.4. TOP PLATE AND PRESSURE CELL BODY 101723011 ...................................................................................128
10.5. TURN TABLE ASSEMBLY 101723010.......................................................................................................... 135

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10.6. FRAME DRAWER,MECHANICAL ASSEMBLY 101723012.............................................................................138
10.7. SGS TEST CUP ASSEMBLY 101636768....................................................................................................... 147
10.8. SLURRY CUP ASSEMBLY 100072017 .......................................................................................................... 149
10.9. PADDLE ASSEMBLY,SGS 101636441......................................................................................................... 151
WARRANTY AND RETURN..................................................................................................................................155

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Table of Figures
Figure 1-1 MACS II Front View (Shown with Customer Laptop) ............................. 2
Figure 1-2 MACS II with Door Open................................................................... 3
Figure 1-3 Turn Table Assembly And Pressure Cell............................................... 4
Figure 4-1 MACS II Hydraulic and Pneumatic Ports .............................................18
Figure 4-2 X Direction Adjustment....................................................................19
Figure 4-3 Y Direction Adjustment....................................................................20
Figure 4-4 Z Direction Adjustment....................................................................20
Figure 4-5 R Direction Adjustment....................................................................21
Figure 4-6 MACS II Limit Switches....................................................................21
Figure 4-7 Found New Hardware Wizard............................................................26
Figure 4-8 Unable to Import Configuration Settings Dialog Box ............................27
Figure 4-9 Software Updates Dialog Box............................................................28
Figure 5-1 MACS II SGS Software Main Screen ..................................................33
Figure 5-2 XY Graph .......................................................................................36
Figure 5-3 General Tab Screen.........................................................................39
Figure 5-4 Test Header Tab Screen...................................................................41
Figure 5-5 Slurry Cup Paddle Motion Tab Screen ................................................42
Figure 5-6 Constants Tab Screen......................................................................43
Figure 5-7 PID Tab Screen...............................................................................44
Figure 5-8 Profile Editor Screen........................................................................45
Figure 5-9 Zero Drive Adjusting Drive Mechanism Message..................................46
Figure 5-10 Reference Position Dialog Box.........................................................47
Figure 5-11 Calibrate Screen Old Calibration (Top) Portion ..................................47
Figure 5-12 Calibrate Screen New Calibration (Bottom) Portion............................48
Figure 5-13 Calibrate SGS Screen.....................................................................53
Figure 5-14 Test Repeatability Step One Dialog Box............................................55
Figure 5-15 Test Repeatability Step Two Dialog Box............................................55
Figure 5-16 Test Repeatability Step Three Dialog Box .........................................56
Figure 5-17 Test Repeatability Results Screen....................................................57
Figure 5-18 Cell Operations Dialog Box .............................................................58
Figure 5-19 Valve Operations Screen ................................................................60
Figure 5-20 Operate Manually Dialog Box..........................................................61
Figure 5-21 Test Information Screen.................................................................63
Figure 5-22 Mandatory Text Boxes ...................................................................64
Figure 5-23 Temperature Reference Screen.......................................................65
Figure 5-24 Cement Sample Cell Dialog Box ......................................................67
Figure 5-25 Wizard Complete Screen ................................................................68
Figure 6-1 Complete Slurry Cup and Paddle Assembly (Eng. Drawing #101636768)74
Figure 6-2 Slurry Cup and Paddle (Eng. Drawing #101636768)............................75
Figure 8-1 High Pressure Valve Location............................................................85
Figure 8-2 Items to Disconnect ........................................................................86
Figure 8-3 Wrenches on Valve..........................................................................87
Figure 8-4 Removing Air Actuator Assembly.......................................................87
Figure 8-5 Internal Sensor Assembly Location....................................................88
Figure 8-6 Internal Sensor Assembly Removal ...................................................88
Figure 8-7 Seat Retainer .................................................................................89

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Figure 8-8 - Lubrication of Threads...................................................................89
Figure 8-9 Torque Sensor Tool.........................................................................90
Figure 8-10 Vise with Soft Jaws........................................................................90
Figure 8-11 Spring Pad ...................................................................................91
Figure 8-12 Valve Parts...................................................................................91
Figure 8-13 Stem and Spring...........................................................................92
Figure 8-14 O-ring and Backup Ring .................................................................92
Figure 8-15 Loctite Application.........................................................................93
Figure 8-16 Reassembled Sensor......................................................................93

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Overview
Table of Contents
OVERVIEW..........................................................................................................................................................1
1.1. MULTIPLE ANALYSIS CEMENT SYSTEM II....................................................................................................... 2
1.1.1. Thickening Time ....................................................................................................................................5
1.1.2. Transition Time......................................................................................................................................5
1.2. SPECIAL CONSIDERATIONS..................................................................................................................................5

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1.1. Multiple Analysis Cement System II
The Multiple Analysis Cement System (MACS) II is a device that performs static gel
strength tests on cement slurry samples. Following are several pictures of the unit.
Figure 1-1 MACS II Front View (Shown with Customer Laptop)

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Figure 1-2 MACS II with Door Open

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Figure 1-3 Turn Table Assembly And Pressure Cell
The MACS II conducts these tests under simulated down-hole pressure and
temperature conditions to determine the following characteristics of cement:
Transition time.
In these tests, the MACS II accepts a sample of cement slurry and applies a
controlled set of temperature, agitation, and pressure parameters that simulate the

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down-hole conditions of a well. During testing, it monitors, controls, and records
these parameters to form a data set. This data can then be analyzed to assist in
predicting the performance of cement slurry in a well.
If a situation exists that a well presents particular problems or special conditions of
temperature and/or pressure, the MACS II can assist to minimize possible problems
by providing a safe and controlled environment in which to test different cement
slurries for the drilling process.
The maximum temperature for the MACS II analyzer is
600˚F. The maximum pressure for the MACS II analyzer is
30,000 PSI.
1.1.1. Transition Time
Transition time is determined by the measuring the static gel strength of cement
slurry. Transition time is the elapsed time from the occurrence of static gel strength
of 100 lb/100 ft2to the occurrence of static get strength of 500 lb/100ft2.
This test determines the gel strength development of cement slurry after it has been
placed in a well and allowed to remain static. Rapid static gel development (short
transition time) indicates good gas migration control.
1.2. Special Considerations
The MACS II is a unique device that performs analysis for cement slurry. In order to
perform reliable tests, the unit generates significant temperatures and pressures.
Care and caution should be exercised to minimize the potential for personal injury
and/or damage to facilities.
The mag drive, pressure inlet port, pressure control port, manual and dump
valve ports are all intricately designed so that routine connections and
disassembly are not necessary on the chamber. This helps prevent thread
wear in the chamber and cap.
The manual relief valve located in one of the three ports located in the
chamber bottom is designed for relieving pressure from the chamber when all
other means have failed. Do not use this to routinely relieve pressure. Do not
use this manual value until the slurry temperature is below 140˚F. .
When a test is to be run at a higher temperature, use an O-ring rated for
higher temperature (P/N 101710014) on the chamber lid. On tests less than
20000 PSI and 250˚F, use the standard O-ring (P/N 206712).

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Be alert to symptoms indicating the pressure does not
reduce. This may be an indication of a blocked control
outlet line or filter. The pressure control is a multi tiered
design with separate ports being used for pressure up,
absolute overpressure safety, manual release, controlled
dump and automatic release.
Do not use PVC or similar materials for drain lines. The hot water and/or
steam can cause melting or other significant damage.
Do not pour the slurry down a drain because it can easily clog pipes.
If the slurry is hazardous to the environment, use proper disposal
procedures.

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Safety
Table of Contents
SAFETY.................................................................................................................................................................7
2.1. MACHINE HAZARD ..........................................................................................................................................9
2.1.1. Pressure.................................................................................................................................................9
2.1.2. Temperature...........................................................................................................................................9
2.1.3. Electrical ...............................................................................................................................................9
2.1.4. Pinch Points.........................................................................................................................................10
2.2. ERGONOMIC CONSIDERATIONS ..................................................................................................................... 10
2.3. ENVIRONMENTAL CONSIDERATIONS.............................................................................................................10

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2.1. Machine hazard
MACS II has multiple subsystems that if not understood and operated correctly can
be hazardous to the operator which can cause serious harm including death. Faulty
procedures or inadequate precautions can also damage the machine rendering it
inoperable.
2.1.1. Pressure
The Macs II has pressurized air and water lines that present a hazard if not
depressurized before maintenance or disassembly.
Shop air is needed at the unit to operate the hydraulic pump, the pressure control
system, the cell lid, the cell body and drawer assemblies. This air is pressured to 100
psi. Before working on any of these devices or connected air lines, shut off the shop
air to the machine. The air lines are plastic and are connected by quick-connect type
fittings.
Domestic water is used by the machine for cell cooling and as a pressurizing fluid.
Shut off the domestic water before working on either of these systems. In some labs,
a separate chilled water system is used for cooling below ambient. This system may
also be under pressure so it should be turned off or disconnected. The drain line has
no pressure on it; it does not need to be disconnected.
The high pressure lines present the greatest hazard as they can hold up to 30,000
PSI water. These lines are ¼ inch OD stainless steel. Operators must ensure that the
pressure in these lines has been bled down to zero before attempting to disassemble
any lines or access the high pressure filter. Dump any pressure using the manual
pressure down system provided in software and verify this by opening the manual
dump valve located on the right side of the turn table assembly. Confirm that all
pressure in the system has been relieved using the pressure gauge located at front-
top of the Macs II machine.
2.1.2. Temperature
The pressure chamber has an electric heating jacket that can heat the cement slurry
to 600°F (315°C). The metal jacket and lid itself will be even hotter than that. Before
opening the pressure chamber or performing any work on the heating jacket, use the
cooling system to lower the temperature below120°F (49°C). Use the temperature
display in the software to gauge the temperature.
The coolant return line can be very hot [212°F (100°C)] at the beginning of a cool
down cycle. Take precautions to not touch the coolant return line. Connect the
coolant return line to drain in a manner which will not cause a burn hazard.
2.1.3. Electrical
The power source for the Macs II is 230 Volts. Disconnect the power from the plug
before attempting any electrical or mechanical maintenance.

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There are still hot electrical terminals inside the panel when the power switch is
turned off It is always safe to physically disconnect the machine from the Power
source rather than using Power On/Off Switch to isolate power.
Refer to the electrical schematic before performing any maintenance or
troubleshooting.
2.1.4. Pinch Points
The pressure cell, lid and drawer are all controlled by air and operate slowly.
However, the operator should not interfere, place tools or body parts in paths of
these controlled motion.
The cell assembly is very heavy and can cause severe injury if an obstruction is
placed in its path. When Cell motion is initiated keep hands away and well clear of
the cell assembly.
The cell lid lifts up and facilitates easy removal of O-ring. While operating Cell Lid
make sure to stand clear and keep an unobstructed path for the cell lid.
The cell drawer can also be controlled in and out of the Macs II. Ensure that the front
doors are open and that nothing blocks the drawer when the process is initiated. Do
not stand in front of this area while Drawer motion is initiated
2.2. Ergonomic Considerations
The Macs II is a large, heavy machine that must be handled carefully when moving
during installation or maintenance. The casters allow the machine to be rolled easily
in the lab, operators should only roll the machine slowly and should watch for debris
on the floor. If the machine must go on an incline or decline, more than one person
should help guide it.
The pressure chamber has a heavy lid that that is slowly raised and lowered
automatically with air. The cell body as well as the cell drawer is also slowly
controlled with air. There are no heavy components that the operator must move
other than a sample loaded slurry cup at less than 10 lbs.
2.3. Environmental Considerations
This machine tests cement slurries with additives, using water as a pressurizing fluid.
The operator must be aware of proper handling and disposal practices for these
materials.

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Features and Specifications
Table of Contents
FEATURES AND SPECIFICATIONS.............................................................................................................11
3.1. MACS II INSTALLATION PREPARATION........................................................................................................ 13
3.2. PHYSICAL REQUIREMENTS............................................................................................................................13
3.3. OPERATIONAL CONSIDERATIONS .................................................................................................................. 13
3.4. COMPUTER SPECIFICATIONS ......................................................................................................................... 14