OfiTE 4005 User manual

Model 4005 Automated UCA-SGSM
Patent No. 9,612,232 - OFI Testing Equipment, Inc.
#120-56 - UCA Only
#120-56-C - UCA with SGSM
Instruction Manual
Updated 12/3/2020
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 2018

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Introduction.....................................................................................3
Description......................................................................................3
Features...........................................................................................3
Specications .................................................................................4
Requirements .................................................................................4
Components ...................................................................................4
Safety...............................................................................................5
Quick Start ......................................................................................6
UCA.............................................................................................6
SGSM .........................................................................................7
Setup................................................................................................8
Software ........................................................................................ 11
General Setup........................................................................... 11
UCA Setup ................................................................................12
SGSM Setup .............................................................................14
Prole Builder............................................................................18
Main Screen..............................................................................20
Events .......................................................................................22
Calculated Values .....................................................................23
Onboard Display...........................................................................24
Real-Time Data.........................................................................25
Test Setup - Test Cong............................................................26
Test Setup - Prole....................................................................27
Calibrate....................................................................................28
Utilities.......................................................................................29
Archive ......................................................................................30
Manual Control..........................................................................31
Start Test...................................................................................32
UCA................................................................................................33
Cell Assembly ...........................................................................33
Connecting the Cell...................................................................36
Starting the Test ........................................................................37
Table of
Contents

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Stopping the Test ......................................................................38
Disassembling and Cleaning the Test Cell................................39
SGSM ............................................................................................40
Cell Assembly ...........................................................................40
Drag Check ...............................................................................46
Preparing the Test Cell..............................................................47
Connecting the Test Cell ...........................................................48
Starting the Test ........................................................................49
Stopping the Test ......................................................................50
Evaluating Test Data .................................................................51
Disassembling and Cleaning the Test Cell................................52
Maintenance .................................................................................58
Maintenance Schedule .............................................................58
Fuses ........................................................................................59
Rupture Disk .............................................................................60
Filters ........................................................................................61
Troubleshooting.........................................................................63
Calibration.....................................................................................67
Pressure Transducer.................................................................67
Thermocouple ...........................................................................68
UCA Ultrasonic Transducer.......................................................69
SGSM Load Cell .......................................................................71
Appendix .......................................................................................73
Electrical System Grounding.....................................................73
UCA Cell Assembly Diagram ....................................................74
SGSM Cell Assembly Diagram .................................................75
SGSM Drive Assembly Diagram ...............................................76
Warranty and Return Policy ........................................................77

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By measuring the change in velocity of an acoustic signal, the Ultrasonic
Cement Analyzer provides a continuous non-destructive method of
determining compressive strength as a function of time.
The cement slurry to be tested is placed in heating jacket with temperature
and pressure adjusted to simulate downhole conditions. An acoustic signal is
then transmitted through the cement sample. As the strength of the cement
increases over time, the acoustic signal travels faster through the sample.
A computer running customized Windows®software measures the transit
times of the signal over time and interpolates the compressive strength
values. This data is available in real time on-screen and is also stored in an
Excel®spreadsheet for easy graphical viewing and printing.
The Twin Cell UCA features two test cells in a single enclosure. Both
units share electrical power; air, water, and drain plumbing; and PC to
UCA connectivity. All other systems (heating, pressurization, etc.) are
completely separate.
- Cement samples are not destroyed
- Programmable temperature control (up to 400°F or 204.4°C)
- Self-venting regulators provide extensive pressure control (up to 5,000 psi
or 34.5 MPa)
- Data is available instantly on screen and is automatically converted to
Excel®spreadsheet format
Introduction
Description
Features

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Specications
Requirements
• Maximum Pressure: 5,000 psi (34.5 MPa)
• Maximum Temperature: 400°F (204.4°C)
• Size: 26" × 21" × 13" (66 × 53 × 33 cm)
• Weight: Approximately 70 lb (31.8 kg)
• Air Supply: 100 psi (690 kPa) Recommended, 150 psi (1,035 kPa) Maxi-
mum, ¼" NPT Connector
• Water Supply: 40– 100 psi, 40° – 100°F, ¼" NPT Connector
• Water Drain: ¼" NPT Connector (suitable for high temperatures)
• Coolant Supply: ¼" NPT Connector
• Coolant Drain: ¼" NPT Connector (suitable for high temperatures)
• Power Supply:
• Electronics: 230– 240 Volt, 50– 60 Hz, 5 Amp, Fuse: T5A, 250 Volt
• Heaters: 230– 240 Volt, 50 – 60 Hz, 8 Amp, Fuse: T8A, 250 Volt
• Computer:
• Windows XP or higher
• Minimum Screen Resolution: 1,280 × 680
• Environmental Conditions:
• For indoor use only
• Maximum Altitude: 2,000 m (6,562 ft)
• Temperature: 5° – 40°C (41° – 104°F)
• Maximum Relative Humidity: 80% for temperatures up to 88°F (31°C)
decreasing linearly to 50% at 104°F (40°C)
Only use replacement parts that have been supplied by OFITE.
#120-50-TR Ultrasonic Transducer, Set of 2
#120-50-063 Set of Transducer Cables
#120-50-1 Cell Body
#120-51-2 Cell Cap, Bottom
#120-51-3 Cell Cap, Top, For UCA Tests
#120-51-021 Fill Gauge
#123-011 O-ring for Test Cell, Viton
#123-024 Acoustic Couplant
Optional:
#120-56-SP Spare Parts Kit
#120-56-505 Heater, 1200 Watt, Qty: 2
#120-51-020-2 Thermocouple, Type J, Qty: 2
#122-073-1 Fuse, 3 Amp, 5 m × 20 m, Qty: 12
#123-011 O-ring for Cell, Viton 90D, Qty: 120
#123-024 High-Temperature Ultrasonic Couplant, 4 oz, Qty: 4
Components

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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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Quick Start
UCA
1. Set up the test in the software (page 12) or in the onboard display (page
24).
2. Create a Test Prole in the software (page 18) or in the onboard display
(page 25).
3. Mix the cement slurry.
4. Assemble the test cell (page 30), ll the cell with cement, load it into the
heating jacket, and make all the necessary connections (page 33).
5. Turn the Water Supply valve to “FILL” and wait for water to come out of
the thermocouple port.
6. When the cell is full, turn the tighten the thermocouple and turn the Water
Supply valve to “OPERATE”.
7. Set the “HEAT”, “COOL”, and “PRESSURE” switches to “AUTO”.
8. Click or touch the “Start Test” button.
9. After the test, allow test cell to cool down and remove it from the heating
jacket (page 38).
10. Disassemble the test cell and remove the hardened cement (page 39).
11. Clean and inspect all of the test cell components.

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1. Set up the test in the software (page 14) or in the onboard display
(page 26).
2. Create a Test Prole in the software (page 18) or in the onboard display
(page 27).
3. Assemble the test cell (page 40) and run a Drag Check (page 46).
4. Mix the cement slurry.
5. Fill the cell with cement and load it into the heating jacket.
6. Connect the Water Fill Tube to the inlet port on the top of the cell.
Connect the thermocouple to the thermocouple port on the cabinet (page
48).
7. Turn the Water Supply valve to “FILL” and wait for water to come out of
the weep hole on the SGSM magnet cover.
8. When the cell is full, tighten the weep hole and turn the Water Supply
valve to “OPERATE”.
9. Set the “HEAT”, “COOL”, and “PRESSURE” switches to “AUTO”.
10. Click the “Start Test” button in the software or touch the “Start Test” button
on the display.
11. After the test, allow test cell to cool down before removing it (page 50).
12. Disassemble the test cell and clean the cement from the test cell and all
other components (page 52).
13. Clean and inspect all of the test cell components for damage or wear.
Quick Start
SGSM

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Setup 1. Carefully remove the instrument from the crate and place it on a at,
stable surface. Make sure to allow for adequate air ow around the unit,
especially near the vents on the sides and back.
To ensure personal safety, always use proper lifting techniques.
Position the unit such that the user can quickly disconnect all electrical
plugs in case of an emergency.
2. Make sure all switches are o󰀨 and the valves on the front are turned to
DRAIN.
3. Connect the AIR, CHILL IN, CHILL OUT, WATER SUPPLY, and DRAIN
connectors on the back of the unit to their appropriate source and plug in
the power cords.
Make sure the “Drain” and “Chill Out” are suitable for high temperature
discharge.
Make sure the compressed air supply is clean and dry.
4. Connect the UCA to the PC. The UCA can connect to the PC via serial
(RS-232), Ethernet, or USB.
Do not connect an Internet device (PC, laptop, wall-mounted Ethernet
port, etc.) to the SGSM port. This could damage your devices.
5. If you will be running an SGSM test, connect the SGSM head to the
corresponding port on the back of the UCA with the supplied Ethernet
cable. The cell on the left is SGSM 1 and the cell on the right is SGSM 2.
6. Make sure the HEAT, COOL, and PRESSURE switches are all in the OFF
position before turning on the main power.
7. Turn the “Main Power” switch on.
8. Open the software and connect using the device manager (page 11).
Ensure that the live data on the front panel displays matches the data
displayed on the software.
Ethernet
Cable

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AC Power
Heaters
AC Power
Electronics SGSM RS-232 USB
Air
Chill In
Chill
Out
Drain
Water
Supply
Ethernet
Cell 1
Pressure
Water Supply Valve
Cell 1
Main
Power
Water Supply Valve
Cell 2
Cell 2
Pressure
Pump
Pressure
Control Knob
Cell 1
Control Knob
Cell 2

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Power - Main power switch
Heat
Manual - Cell temperature is controlled through the Onboard Display
(page 31)
O󰀨 - Heaters are disengaged
Auto - Cell temperature is controlled by the Test Prole. (See page 18
for building a Test Prole in the software or page 27 for the Onboard
Display.)
Cool
Manual - Cooling uid is circulating to cool the cell
O󰀨 - Cooling uid is not circulating.
Auto - Cooling uid circulation is controlled by the test.
Pressure
Manual - Pressure is controlled through the Onboard Display (page 31)
O󰀨 - The pump is not engaged
Auto - Cell pressure is controlled by the Test Prole. (See page 18 for
building a Test Prole in the software or page 27 for the Onboard
Display.)
Onboard Display Control Knob - Controls the cursor on the Onboard Display.
Turn the knob to move the cursor around the screen. Push the knob in to select
an option or parameter.
Control Panel
Control Knob

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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
device. If you have connected the UCA 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 → Cell 1 (or Cell 2) → Test
2. On the Information tab, enter the necessary information.
The Cement Density field is used to calculate the compressive strength
during UCA tests. All other fields on this tab are optional.
The Bob Height and Bob Diameter fields are only used in SGSM tests.
For UCA tests, they can be ignored.
3. On the Configuration tab, set the following parameters:
Type: Select UCA
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.
Temp Unit: Choose either F (Fahrenheit) or C (Celsius)
CS Unit: Choose units for compressive strength (psi or MPa)
Density Unit: Choose either lb/gal or kg/cu m
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
UCA Setup

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DAQ Rate: Set the interval for data points to be recorded (hh:mm:ss).
Press Unit: Choose units for cell pressure (psi or MPa).
TT Algorithm: Choose an algorithm for calculating compressive strength
based on the density of the sample. Choosing “Auto” allows the software
to pick the best algorithm depending on the cement density entered on
the Information tab.
4. On the Profile tab, select a Test Profile from the list. To create a new Test
Profile, click the “Open Builder” button (page 18).
5. Click “Save”

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1. Select Edit → Cell 1 (or Cell 2) → Test
2. On the Information tab, enter the necessary information.
The Bob Height and Bob Diameter fields are used to calculate the gel
strength during SGSM tests. All other fields on this tab are optional.
3. On the Configuration tab, set the following parameters:
Type: Select SGSM
Stop at End: When this option is “No”, the test will run until you click
the “Stop Test” button or the gel strength reaches the value in the Final
Strength field. The final temperature and pressure setpoints will be main-
tained indefinitely. If this option is “Yes”, the test will end when all steps in
the Test Profile are complete.
Temp Unit: Choose either F (Fahrenheit) or C (Celsius)
Density Unit: Choose either lb/gal or kg/cu m
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
SGSM Setup

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DAQ Rate: This field is not editable for SGSM tests.
Press Unit: Choose units for cell pressure (psi or MPa).
GS Unit: Choose units for gel strength (lb/100 ft2or Dyne/cm2)
Multiple Conditioning: When this option is unchecked, the SGSM will
condition the sample only once, at the beginning of the test. When this
option is checked, the SGSM will condition the sample every time the gel
strength exceeds the value in the Threshold Strength field but does not
exceed the Final Strength.
Disable Multizero: When this option is unchecked, the software will
perform the zero function after every conditioning cycle. When this option
is checked, the software will perform the zero function only once, after the
first conditioning. This option is off by default.
Threshold Strength: When the peak gel strength meets or exceeds this
value and Multiple Conditioning is turned on, the software will trigger a
conditioning cycle.
Final Strength: When the peak gel strength meets or exceeds this value,
the test will end.

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Conditioning Cycles: When Multiple Conditioning is on and the peak gel
strength meets or exceeds the value in the Threshold Strength field, the
software will advance to the next Conditioning Cycle and condition the
sample for the set time at the set speed. Cycle 0 is the initial conditioning,
before any measurements are taken. Click the Edit Cycles button to add
Conditioning Cycles.
Measure During Conditioning: When this option is unchecked, the
SGSM will condition the cement in the opposite direction from measure-
ment. This reduces the load on the transducer to prolong its life. When
this option is checked, the SGSM will condition in the same direction as
measurement and will record data during the conditioning cycle.
Enabling this option is not recommended. It will shorten the life of the
ultrasonic transducers.
Variable Test Time: When this option is checked, the SGSM will end the
measurement period immediately when it senses a gel strength peak.
When this option is unchecked, the SGSM will continue the measure-
ment period for the entire “Test Time”, regardless of when the gel strength
peack was detected.
Disable Zero Compensation: The Zero Compensation routine measures
and maps the mechanical resistance in the bushings in order to com-
pensate and give better readings. When this option is checked, the Zero
Compensation routine will be skipped.
Stop Time: The amount of time the bob will pause between gel strength
measurement periods.
Cond. Time: The amount of time the SGSM will condition the cement
before it begins measuring gel strength. This field is disabled if Multiple
Conditioning is turned on.
Cond. Speed: The speed (rpm) the bob will turn during conditioning. This
field is disabled if Multiple Conditioning is turned on.

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Test Time: The amount of time the bob will turn while measuring gel
strength.
Test Speed: The speed (rpm) the bob will turn to measure the gel
strength of the cement.
Variable Test Time: The bob will turn until the software detects a peak
gel strength. When the gel starts to break, the bob will stop turning.
4. On the Profile tab, select a Test Profile from the list. To create a new Test
Profile, click the “Open Builder” button (page 18).
5. Click “Save”

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Software
Prole Builder
The Test Prole Builder creates temperature and pressure proles for both
the UCA and SGSM tests.
1. Select Edit → Cell 1 (or Cell 2) → 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 two parameters: temperature and pressure. 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 or Pressure 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.

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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. A pressure of 1,000 psi (6.9 MPa) is also required to get a good
transit time signal during UCA tests.
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.
• Step – This will increase the temperature or pressure up to the
target as fast as possible. Enter the target in the "Target" box.
• Dwell – This will hold the current temperature or pressure for a set
number of minutes. Enter the time (hh:mm:ss) into the “Time” Box.
The maximum temperature setpoint allowed is 400°F (204.4°C). The
unit allows pressure setpoints between 100 psi (689.5 kPa) and 5,000
psi (34.5 MPa). The units of measure will be the same as entered in the
Setup menu. (See page 12 for setting UCA units and page 14 for
setting SGSM units.)
5. To edit an existing step, double click the step in the step list or highlight
the existing step and select the “Edit” button. Click OK when done.
6. Click the “OK” button to exit the “Setup” screen. The new Temperature
Prole will now appear in the “Available Proles” list on the “Prole” tab.