OfiTE 2040 User manual

Model 2040 Automated HTHP Consistometer
#120-40 - Consistometer
#120-40-DAS - With Computer
Instruction Manual
Updated 3/22/2021
Ver. 1
OFI Testing Equipment, Inc.
11302 Steeplecrest Dr. · Houston, Texas · 77065 · U.S.A.
Tele: 832.320.7300 · Fax: [phone] · www.ote.com
©Copyright OFITE 2021

OFITE, 11302 Steeplecrest Dr., Houston, TX 77065 USA / Tel: [phone] / Fax: [phone] / www.ote.com 1
Requirements .................................................................................3
Intro..................................................................................................3
Description......................................................................................3
Features...........................................................................................3
Specications .................................................................................4
Components ...................................................................................4
Safety...............................................................................................7
Quick Start ......................................................................................9
Starting a Test.............................................................................9
Completing a Test .....................................................................10
Setup.............................................................................................. 11
Software ........................................................................................16
General Setup...........................................................................16
Setup.........................................................................................17
Prole Builder............................................................................19
Main Screen..............................................................................21
Events .......................................................................................24
Calculated Values .....................................................................25
Onboard Display...........................................................................26
Real-Time Data.........................................................................27
Test Setup - Test Cong............................................................28
Test Setup - Prole....................................................................29
Calibrate....................................................................................30
Utilities.......................................................................................31
Archive ......................................................................................32
Manual Control..........................................................................33
Start Test...................................................................................34
Operation ......................................................................................35
Filling the Slurry Cup.................................................................35
Starting a Test ...........................................................................37
Completing the Test ..................................................................39
Table of
Contents

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Maintenance .................................................................................40
Cleaning....................................................................................40
Potentiometer ...........................................................................42
Rupture Disk .............................................................................44
Oil Filter.....................................................................................45
Pressure Relief Valve Regulator...............................................46
Troubleshooting.........................................................................47
Calibration.....................................................................................51
Potentiometer ...........................................................................51
Value Chart ...............................................................................53
Pressure....................................................................................54
Temperature..............................................................................55
Appendix .......................................................................................56
Metal Seal Ring Installation ......................................................56
Cell Diagram .............................................................................59
Slurry Cup Diagram ..................................................................60
Potentiometer Diagram .............................................................62
Potentiometer Adjustment.........................................................63
Fuses and Breakers..................................................................64
Multiple Instruments..................................................................65
Warranty and Return Policy ........................................................66

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During cementing operations, the time required for a cement slurry to set is
of primary concern. Under an ideal situation, minimal time would be required
to successfully pump the slurry, which immediately upon placement, begins
to develop compressive strength. However, if insu󰀩cient time is allowed to
fully pump the cement, it will be necessary to drill the cement remaining in the
casing string. Remedial operations such as this are very costly. Conversely,
cements that are successfully placed, but require considerable time to
cure, consume valuable rig time, which is also quite costly. Laboratory tests
should be conducted under simulated reservoir conditions to examine the
actual thickening time of the slurry. The OFITE HTHP Consistometer was
specically engineered to determine the thickening time of well cements
under simulated downhole pressures and temperatures.
A cement is mixed and poured into the slurry cup assembly. The slurry cup
is placed into the test vessel and pressure is increased via an air-driven
hydraulic pump. A PID temperature controller governs an internal heater,
which maintains the necessary temperature prole, while a magnetic drive
mechanism rotates the slurry cup assembly. A potentiometer controls an
output voltage, which is directly proportional to the amount of torque the
cement exerts upon an API-approved paddle. The included software controls
the instrument and records temperature, pressure, and cement consistency
as a function of time.
- Touch screen display for standalone operation
- Computerized Data Acquisition and Control system provides detailed test
information in convenient formats and can control multiple units from one
computer. RS-232, Ethernet, and USB connections available.
- Automatic temperature and pressure control
- External cooling jacket aids cooling of test cell
- Automatic, programmable speed motor (0 – 300 RPM) powered by a
magnetic drive
- Easy-to-use two-piece lift-o󰀨 cap for pressure cell
- Drip tray next to cap provides a place to set the cap between tests without
dripping oil on the unit casing
- Convenient oil reservoir features a cap with built-in funnel to help prevent
spills, a removable top and bottom that make cleaning easy, and a sloping
bottom that collects sediment for easy removal
- Visual indicator provides an at-a-glance status update during testing
- Small footprint saves valuable lab space
- Temperature, pressure, and consistency alarms provide automatic
shutdown for safety
- Conforms to API Specication 10 guidelines
- Air/Nitrogen Supply (100 – 120 PSI / 689.5 – 827.4 kPa)
- Water Supply for Cooling (40 PSI / 276 kPa)
- Water Drain
- 220 Volt, 50/60 Hz, 25 Amp electrical power supply
Intro
Description
Features
Requirements

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Specications Size 22.5" × 27.5" × 70"
Weight Approximately 450 lb
Crated Size 26" × 34" × 76"
Crated Weight Approximately 750 lb
Temperature Controller Digital with 0.1° Resolution
Pressure Indicator Digital transducer with 1 PSI (0.1 MPa)
resolution. Analog gauge.
Slurry Cup Variable Speed: 0 – 300 RPM
Max Temperature 600°F (315.5°C)
(For tests above 400°F, refer to page 12)
Max Pressure 40,000 psi (276 MPa)
#120-001 Mineral Oil, 1 Gallon (For tests at or below 400°F)
#120-004 Phenylmethylsiloxane Silicone Fluid, PM-125, 1 gallon (For
tests over 400°F)
#120-00-1 Tool Kit (Includes slurry cup stand, slurry cup tool, lifting
tongs for heater shield, and lifting tongs for potentiometer)
#120-103 Rupture Disk, 45,000 PSI (310 MPa)
#120-201 Thermocouple, Bath
#120-203 Thermocouple, Slurry Cup
#120-35-015 Drip Tray, Stainless Steel
#120-35-033 Air Filter
#120-35-132 Oil Filter
#120-40-753 Backup Ring
#120-40-755 Filter Element for High Pressure Filter
#120-401 O-ring for Cell Cap, Metal
#120-401-V O-ring for Cell Cap, Viton (For tests below 10,000 PSI and
below 300°F only.)
#120-35-031 O-ring for Oil Reservoir, Viton
#120-50-037 Air Regular
#120-521 Slurry Cup with Expansion Chamber
#120-628 Potentiometer Assembly
#120-75-10 Slotted Weight Set
#120-75-9 Weight Hanger
#130-75-28 Allen Key,   ", 1¼" Long
#130-77-027-1 Pump
#141-28 Hose Kit
#141-15 Air Hose, 6', Qty: 2
#141-19 Air Hose Adapter, Qty: 6
#141-27 Drain Hose, Stainless Steel
#143-01 Gauge, 0 – 200 PSI
Components

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Potentiometer Components:
#120-602 Calibration Spring
#120-603 Potentiometer Body
#120-604 Potentiometer Resistor
#120-605 Contact Spring
#120-606 Potentiometer Contact Arm
#120-607 Contact Strip
#120-608 Grounding Cable Retaining Screw
#120-609 Grounding Contact Spring
Slurry Cup Components:
#120-501 Slurry Cup Sleeve
#120-502 Molded Diaphragm (For tests at or below 400°F)
#120-40-502 Diaphragm (For tests above 400°F)
#120-502-1 Flat Diaphragm, Buna (For tests below 200°F)
#120-503 Paddle Pin
#120-504 Pivot Bearing
#120-505 Pivot Bearing Gasket
#120-506 Paddle
#120-508 Diaphragm Retaining Ring
#120-509 Drive Disk
#120-510 Drive Bar
#120-512 Drive Pin
#120-513 Gasket for Bottom Cap
#120-514 Drive Disk Set Screw, 6-32 × 3, Stainless Steel
Optional:
#120-40-SP Spare Parts Kit
#120-001 Mineral Oil, 1 Gallon, Qty: 2
#120-10-1 Consistometer Tool Kit
#120-103 Rupture Disk, 45-50 KSI, Qty: 2
#120-202 Heater, 4000 Watt
#120-203 Thermocouple, Qty: 2
#120-204 Heaters Gaskets, Qty: 2
#120-401 O-ring for Cell Cap, Metal, Qty: 10
#120-501 Slurry Cup Sleeve
#120-502 Molded Diaphragm, Qty: 25
#120-503 Paddle Pin, Qty: 12
#120-504 Pivot Bearing, Qty: 6
#120-505 Pivot Bearing Gasket, Qty: 5
#120-506 Paddle for Slurry Cup, Qty: 4
#120-508 Diaphragm Retaining Ring, Qty: 2
#120-509 Drive Disk for Slurry Cup
#120-510 Drive Bar for Slurry Cup
#120-511 Shear Pin for Slurry Cup, Qty: 24
#120-512 Drive Pin for Slurry Cup, Qty: 12
#120-513 Gasket for Slurry Cup, Qty: 6
#120-514 Drive Disk Set Screw, Qty: 10
#120-520 Paddle Shaft, 9 ⅛", Qty: 10
#120-521 Slurry Cup with Extension

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#120-602 Calibration Spring, Qty: 3
#120-604 Potentiometer Resistor, Qty: 4
#120-606 Potentiometer Contact Arm, Qty: 6
#120-607 Contact Strip, Qty: 6
#120-608 Grounding Cable
#120-684 Bearing, Bronze, Large, Qty: 2
#122-072 Fuse, 1 Amp, 5 mm × 20 mm, Qty: 5
#122-073 Fuse, 2 Amp, 5 mm × 20 mm, Qty: 5
#130-75-28 Allen Key,   ", Qty: 2

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Safety
Explanation of Symbols
Caution: Risk of Danger - This symbol directs the operator to consult the
instruction manual for safety related warnings. (ISO-7000-0434)
Whenever this symbol is used on the equipment, the user must
consult the manual to determine the nature of the hazard and any
actions which have to be taken.
Hot: This symbol indicates that a surface may be hot to the touch.
Shock Hazard: This symbol indicates a risk of electrical shock.
Note: This symbol will indicate important notes and helpful hints for the
operation of the equipment.
Tip: This symbol is used to identify operational information and best
practices to obtain the most reliable data.
Caution: Note - This symbol is used to indicate statements in the manual
which warn against actions which may cause damage to the equipment
during routine service or maintenance.

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• The Consistometer conforms to the relevant safety regulations; however
the user is solely responsible for the correct handling and proper usage of
the instrument.
• The equipment should be operated in such a way that will not endanger
people.
• The equipment must not be operated if there is any evidence of external
damage, leading to any doubt regarding safe operation.
• The user must comply with the instructions in this instruction manual,
otherwise safe operation cannot be guaranteed.
• This instruction manual must be readily available for all operators.
• Do not bend or stress connection cables and mains cable.
• Do not subject connection or mains cables to high temperatures (higher
than 70°C).
• Check integrity of cables at regular intervals.
• The unit must be powered down before any cables are connected or
disconnected. This reduces the risk of electrostatic charging and resultant
damage to electronic circuit boards.
• The operator must have a good familiarity with the installation of the unit
and its surroundings.
• Suitable protective gear should be worn in the factory environment in
which the unit has been installed.
• The unit should be serviced at regular intervals as detailed on page 40.
• The user is responsible for the safe handling of any materials tested. If in
doubt the material safety data sheet should be read, relevant safe han-
dling regulations should be read and observed and good operating and
manufacturing practices should be followed.

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Quick Start
Starting a Test
1. Before turning on the Consistometer, make sure the MOTOR, HEAT,
COOLING, PUMP, and FILL/DRAIN CELL switches are all o󰀨.
2. Turn the MAIN POWER switch on.
3. Turn the MOTOR switch to ON.
4. Slowly lower the slurry cup into the test cell until the drive table engages
with the drive pins on the bottom.
5. Lower the potentiometer into the test cell so that it sits on top of the slurry
cup.
6. Turn the MOTOR switch to AUTO.
7. Carefully lower the cell cap into the test cell and tighten it.
If you are using a metal o-ring and you tighten the cell cap past the
marked position, you must use a new o-ring for the next test.
8. Plug the thermocouple into the port near the test cell. Insert the
thermocouple into the hole in the top of the cell cap and tighten the thread
gland nger tight and loosen it ¼ of a turn.
9. Close the pressure release valve by turning it clockwise.
10. Turn the FILL/DRAIN CELL switch to FILL. When the cell is full, oil will
leak out of the thermocouple tting on the cell cap. Tighten the tting to
seal the cell.
Leave the FILL/DRAIN CELL switch in the FILL position during
testing.
11. Turn the HEAT, COOLING, PUMP, and POT VOLTS switches to AUTO.
12. Turn the DAQ PAUSE switch to OPERATE and the ALARM swtich to ON.
13. Load the test:
a. If you will be using the software to run the test, select a Test Prole
and click the Start Test button on the Main Screen (see page 21).
b. If you will be using the onboard controls to run the test, rst select a
test to run (see page 29), then touch the Start Test button.

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Quick Start
Completing a Test
When the test is complete, the red light on the Status Indicator will turn on
and an alarm will sound. To acknowledge the alarm, touch the alarm icon.
1. Stop the test:
a. If you are using the software to run the test, click the Stop Test button.
b. If you are using the onboard controls to run the test, touch the Stop
Test button.
3. Turn the HEAT and MOTOR switches o󰀨.
4. When the cell temperature has reached 150°F, turn the PUMP switch o󰀨
and slowly open the Pressure Release valve.
Never release pressure while the temperature is above 200°F
(93.3°C).
5. Turn the FILL/DRAIN CELL switch OFF for 5 seconds. Then set it to
DRAIN. This will allow air into the test cell and force the oil back into the
reservoir.
6. When you hear air venting from the Consistometer, turn the FILL/DRAIN
CELL switch o󰀨.
7. Remove the thermocouple from the cell cap.
8. Unscrew the cell cap and remove it from the test cell.
9. Remove the potentiometer and the slurry cup from the test cell.
10. Turn the COOLING switch o󰀨.
11. Return the cell cap to the test cell to prevent dust and other material from
entering the cell.
12. Turn the MAIN POWER switch o󰀨.

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Setup 1. Carefully remove the instrument from the wooden crate.
2. Once the unit is in place, lock the casters by depressing the lever on the
side. This will prevent the unit from moving.
3. Make sure all valves are closed and all switches are o󰀨. Connect an air
or nitrogen (100 – 120 PSI / 690 – 827 kPa) supply to the air supply on the
back of the instrument.
This unit uses ¼" NPT female connectors for all supply lines.
4. Connect the drain and coolant supply lines, also on the back of the unit.
5. The consistometer has two power inlets on the back of the cabinet. The
MAIN POWER inlet provides power to the entire unit. The BACK-UP
POWER inlet is optional. It powers the electronics only.
To protect the electronics from a power outage, plug the BACK-UP
POWER into an uninterruptible power supply (UPS). In the event of a
power outage, the heaters will shut o󰀨, but the rest of the electronics will
continue to work and the test will keep running.

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6. To ll the oil reservoir, remove the right-hand side panel and remove the
oil reservoir cap. Pour approximately four liters (or until full) of oil into the
reservoir. Replace the cap. Make sure the seal is air tight. Use the sight
glass on the front to check the oil level.
Mineral Oil (#120-001) is recommended for tests up to 400°F. For
tests above 400°F, use only Phenylmethlsiloxane Silicone Fluid
(#120-004).
7. Turn the “Main Power” switch On.
8. Calibrate the potentiometer before connecting the Consistometer to a
computer. See page 51.
Reservoir
Cap

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Onboard
Display
USB Port
Switches
Cell
Pressure
Scroll Wheel
Thermocouple
Port
Cell Cap
Thermocouple
Storage
Pressure Release Valve

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Status Indicator:
The lights on the Status Indicator correspond to the consistency of the
sample. The threshold values can be set in either the onboard controls or
in the software. There are three setpoints, specied in Bearden units of
consistency (Bc).
- Max Bc for Green Light: When the consistency is below this value, the
green light will be on.
- Max Bc for Green and Yellow: When the consistency is below this
value, the green and yellow lights will both be on.
- Max Bc for Red Light: When the consistency is below this value, the
yellow light only will be on. When the consistency is above this value,
the red light will be on and the test will stop.
Refer to page 18 for instructions on setting these values.
The Status Indicator also indicates an alarm condition. If an alarm is
triggered, all three lights on the status indicator will blink until the alarm is
acknowledged.
Switches:
- FILL/DRAIN CELL: Controls the ow of oil into the cell.
- DRAIN: Oil ows out of the cell and into the reservoir.
- OFF: The oil is not moved in either direction.
- FILL: Oil ows out of the reservoir and into the cell for testing.
- POT VOLTS: Controls power to the potentiometer
- ON: Power is supplied to the potentiometer.
- AUTO: Power is only supplied to the potentiometer only during a
test or calibration.
- DAQ PAUSE:
- PAUSE: No test data is collected
- OPERATE: Test data is collected
- MOTOR: Sets control of the motor
- AUTO: The motor will turn according to the parameters of the test
that is currently running. If no test is running, the motor will be
stopped.
- OFF: The motor will not turn at all.
- ON: The motor will turn at 150 RPM until stopped.
- ALARM: Turns the audible alarm on or o󰀨.

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- HEAT: Controls power to the heating system.
- AUTO: The heater is controlled by the parameters of the test that
is currently running. If no test is running, the heater will be o󰀨.
- OFF: The heater is o󰀨.
- ON: The heater can be controlled by the software or onboard
displayed in Manual mode (see 33).
- COOLING: Controls the cooling system
- AUTO: The cooling system is controlled by the parameters of
the test that is currently running. If no test is running, the cooling
system will be o󰀨.
- OFF: The cooling system is o󰀨.
- ON: The cooling system is on.
- PUMP: Controls power to the pump
- AUTO: The pump is controlled by the parameters of the test that is
currently running. If no test is running, no pressure will be applied.
- OFF: No pressure will be applied.
- ON: The pump can be controlled by the software or onboard
display in Manual mode (see 33).
Thermocouple
The Consistometer uses two thermocouples for reading temperature. One is
inside the unit cabinet and measures the temperature of the oil bath around
the slurry cup.
The other is outside the unit cabinet. This one must be inserted into the top
of the cell cap so that it reaches down into the slurry cup and measures the
temperature of the slurry.
When the thermocouple is not in use, store it in the port on the right-hand
side of the cabinet to protect it from damage.
Pressure Release Valve
This valve releases the pressure in the test cell. To release the pressure,
slowly turn the valve counterclockwise. Always make sure the pump is turned
o󰀨 and the cell temperature is below 200°F before releasing the pressure.
Always release the pressure very slowly to avoid pulling cement into
the plumbing.

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1. Open the software.
The software must be run with Administrator privileges. There are two
ways to do this:
a. Right-click the icon and select “Run as Administrator”.
b. Right-click the icon and select “Properties”. On the Compatibility tab,
check the box next to “Run this program as an administrator” and click
OK.
2. When the Manage Devices screen appears, right-click the device from the
list and select “Set as Default”. Then click “Done”.
Make sure to enable the appropriate communication method for your de-
vice. If you have connected the Consistometer to the PC via USB, select
“Enable USB Comms”, etc.
Depending on the connection types you enable, your device might show
up multiple times or other OFITE equipment might appear on the list.
Make sure you select the correct device and connection type you wish to
use.
3. Choose “Options” from the “Edit” menu on the main software screen.
4. Select a folder to save all test data and click “OK”.
Software
General Setup

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1. Select Edit → Test
2. On the Information tab, enter the necessary information.
All fields on this tab are optional.
3. On the Configuration tab, set the following parameters:
Temperature Control: The instrument has two thermocouples. One is in
the cement sample in the cell. The other is in the heating jacket (Bath).
Use this option to determine which thermocouple will be used to control
the temperature. The “Sample” setting is recommended during testing.
The “Bath” setting is recommended during pre-heat.
Software
Setup

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Stop at End: When this option is “No”, the test will run until you click the
“Stop Test” button. The final temperature and pressure setpoints will be
maintained indefinitely. If this option is “Yes”, the test will end when all
steps in the Test Profile are complete.
DAQ Rate: Set the interval for data points to be recorded (hh:mm:ss).
Temp Unit: Choose either F (Fahrenheit) or C (Celsius)
Press Unit: Choose units for cell pressure (psi or MPa)
Status Light Settings: Enter the threshold (in Bc) for each level on the
status indicator. When the consistency of the cement reaches one of
these thresholds, the corresponding light(s) on the indicator will turn on.
4. On the Profile tab, select a Test Profile from the list. To create a new Test
Profile, click the “Open Builder” button (page 19).
5. Click “Save”

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Software
Prole Builder
The Test Prole Builder creates temperature, pressure, and motor proles for
Consistometer tests.
1. Select Edit → Test. On the Prole tab, click the “Open Builder” button.
2. Click "New Test" to build a new test prole. To edit a current test prole,
select a test from the list on the left-hand side by double clicking on the
appropriate test
3. In the "Prole Name" box, enter a test name.
4. Each test prole has three parameters: temperature, pressure, and motor
speed. For each parameter, there is a series of steps. Each step species
the setpoint and other options for that parameter.
To add a step, click the Temperature, Pressure, or Motor tab and then
click the “Add” button. As you add steps to the test prole, the graph
below will change to reect the new data.
When building a test at temperatures above 190°F (87.8°C), the unit will
calculate and apply a minimum pressure to prevent the sample from
boiling.
There are three types of steps:
• Ramp – This will increase the temperature or pressure up to the
target in a set number of minutes. You will be prompted for the
ramp time (hh:mm:ss) and target.