OfiTE HTHP 100 User manual

HTHP Consistometer
Model 100 (25,000 PSI, 400°F):
120-00 (Single Cell) / 120-05 (Dual Cell)
Model 120 (40,000 PSI, 600°F):
120-10 (Single Cell) / 120-15 (Dual Cell)
Instruction Manual
Updated 11/15/2011
Ver. 2.3
OFI Testing Equipment, Inc.
11302 Steeplecrest Dr. · Houston, Texas · 77065 · U.S.A.
Tele: 832.320.7300 · Fax: [phone] · www.ofite.com
©Copyright OFITE 2011

Table of
Contents
Intro....................................................................................................2
Description........................................................................................2
Features ............................................................................................2
Requirements ...................................................................................2
Specifications ...................................................................................3
Components......................................................................................4
Setup..................................................................................................8
Consistometer...............................................................................8
Chart Recorder ...........................................................................10
Pressure Indicator.......................................................................14
Temperature Controller...............................................................15
Potentiometer Indicator...............................................................17
Operation ........................................................................................18
Filling the Slurry Cup ..................................................................18
Loading the Test Cell..................................................................20
Completing the Test....................................................................23
Maintenance....................................................................................24
Cleaning......................................................................................24
Potentiometer Calibration ...........................................................26
Potentiometer ............................................................................28
Troubleshooting ..........................................................................30
Appendix .........................................................................................33
Cell Diagram ...............................................................................33
Slurry Cup Diagram ....................................................................34
Plumbing Diagram ......................................................................36
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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 place-
ment, begins to develop compressive strength. However, if insufficient 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 con-
siderable time to cure, consume valuable rig time, which is also quite cost-
ly. Laboratory tests should be conducted under simulated reservoir condi-
tions to examine the actual thickening time of the slurry. The OFITE HTHP
Consistometer was specifically 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 profile, while a magnetic drive
mechanism rotates the slurry cup assembly at 150 RPM. A potentiometer
controls an output voltage, which is directly proportional to the amount of
torque the cement exerts upon an API-approved paddle. A chart recorder
registers cement consistency and temperature as a function of time.
Temperature and consistency are digitally displayed via LED indicators.
- Pressure generated via an air-driven hydraulic pump
- Drive table is rotated with a magnetic drive
- External cooling jacket aids cooling of test cell
- Electronic timer with alarm, elapsed 0.1 minute resolution
- Deadweight calibration unit included
- Temperature, pressure, and consistency alarms provide automatic shut-
down
- Safety head with rupture disk are provided
- Unit is fully capable of testing cements in strict accordance to the guide-
lines as stated in API Specification 10
- Air/Nitrogen Supply (100 - 150 PSI / 690 - 1,035 kPa)
- Water Supply for Cooling (40 PSI / 276 kPa)
- Water Drain
- 220 Volt, 50/60 Hz, 25 Amp electrical power supply
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Requirements
Features
Description
Intro

Model 100:
Maximum Temperature: 400°F (204.4°C)
Maximum Pressure: 25,000 PSI (172,375 kPa)
Model 120:
Maximum Temperature: 600°F (315.5°C)
Maximum Pressure: 40,000 PSI (275,800 kPa)
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Size 66 × 36 × 32 inches (168 × 92 × 82 cm)
Weight 1,400 lbs (635.6 kg)
Crated Size 74 × 44 × 40 inches (188 × 112 × 102 cm)
Crated Weight 1,600 lbs (726.4 kg)
Temperature Controller Digital PID, 1° Resolution
Pressure Indicator 100 PSI (690 kPa) Resolution; High and Low
Pressure Alarms
Slurry Cup 150 RPM Rotational Speed; 316 Stainless
Steel; Expansion Chamber
Specifications

#120-00-5 Graphic Recorder
#120-147 Autoclave Mag Drive
#120-201 Test Cell Thermocouple
#120-202 4000-Watt Heater
#120-628 Potentiometer Assembly:
#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
#174-13 Motor
#120-00 Model 100 HTHP Consistometer; 25,000 PSI; 400°F;
Single Cell; 115V:
#120-001 Mineral Oil; 1 Gallon; Qty: 9
#120-102 Rupture Disk; 28,000 PSI
#120-208 Slurry Cup Thermocouple
#120-401 Metal O-rings; Qty: 2
#120-519 Slurry Cup Assembly
#171-11 O-ring for 100-mL Back Pressure Receiver; 100ML; Qty: 4
#120-10 Model 120 HTHP Consistometer; 40,000 PSI; 600°F;
Single Cell: 220V:
#120-001 Mineral Oil; 1 Gallon; Qty: 3
#120-101 Release Valve; 60,000 PSI; Qty: 2
#120-103 ¼" Autoclave-Type Rupture Disk; 45,000 - 50,000 PSI;
Prebulged
#120-104 Rupture Disk; 17,500 PSI
#120-204 Heater Gasket
#120-206 2500-Watt Heater
#120-521 Slurry Cup with Extension
#122-076 1-Amp Fuse; ¼" × 1¼"; Qty: 3
#122-094 30-Amp Solid State Relay; Qty: 2
#120-01 Spare Parts for #120-00:
#120-001 Mineral Oil, 2 Gallons
#120-102 Rupture Disk (28,000 PSI), Qty: 2
#120-202 4000-Watt Heater
#120-204 Heater Gasket, Qty: 2
#120-208 Slurry Cup Thermocouple, Qty: 2
#120-401 Metal O-ring, Qty: 6
#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
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Components

#120-506 Paddle for Slurry Cup Assembly, 4.25" Long × 2.81" Wide,
Qty: 4
#120-507 Paddle Shaft for Slurry Cup Assembly, 7.75" Long × 0.25"
Wide, Qty: 10
#120-508 Diaphragm Retaining Ring, Qty: 2
#120-509 Drive Disc for Slurry Cup Assembly, 0.75" OD, 0.25" ID,
0.25" Thick, 303 Stainless Steel
#120-510 Drive Bar for Slurry Cup Assembly, 1.25" × 0.50", 303
Stainless Steel
#120-511 Slurry Cup Shear Pin, Qty: 24
#120-512 Slurry Cup Drive Pin, Qty: 12
#120-513 Slurry Cup Gasket, Qty: 6
#120-514 Drive Disk Set Screw, 6-32 × 3, Stainless Steel, Qty: 10
#120-519 Slurry Cup Assembly, No Expansion Cap
#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 Retaining Screw, 10-32 × 1/2 SHCSSS
#120-684 Large Bronze Bearing, Qty: 2
#122-072 1-Amp Fuse, 5 mm × 20 mm, Qty: 5
#122-073 2-AMP Fuse, 5 mm × 20 mm, Qty: 5
#130-75-28 1/16" Allen Key, 1.75" Long, Qty: 2
#120-11 Spare Parts for #120-10:
#120-001 Mineral Oil, 2 Gallons
#120-103 Autoclave-Type Rupture Disk, 45000 - 50000 PSI,
Prebulged, 1/4", Qty: 2
#120-202 4000-Watt Heater
#120-203 Slurry Cup Thermocouple, Qty: 2
#120-204 Heater Gaskets, Qty: 2
#120-401 Metal O-rings, 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 Assembly, 4.25" Long × 2.81" Wide,
Qty: 4
#120-508 Diaphragm Retaining Ring for Slurry Cup Assembly, Qty: 2
#120-509 Drive Disc for Slurry Cup Assembly, 0.75" OD, 0.25" ID,
0.25" Thick, 303 Stainless Steel
#120-510 Drive Bar for Slurry Cup Assembly, 1.25" × 0.50", 303
Stainless Steel
#120-511 Slurry Cup Shear Pin, Qty: 24
#120-512 Slurry Cup Drive Pin, Qty: 12
#120-513 Slurry Cup Gasket, Qty: 6
#120-514 Drive Disk Set Screw, 6-32 × 3, Stainless Steel, Qty: 10
#120-520 Paddle Shaft, 91⁄8", Qty: 10
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#120-521 Slurry Cup with Extension
#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 Retaining Screw, 10-32 × 1⁄2SHCSSS
#120-684 Large Bronze Bearing, Qty: 2
#122-072 1-Amp Fuse, 5 mm × 20 mm, Qty: 5
#122-073 2-Amp Fuse, 5 mm × 20 mm, Qty: 5
#130-75-28 1/16" Allen Key, 1.75" Long, Qty: 2
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Timer
Pressure
Regulator
Air To
Cylinder
Pressure
Release
Switches
Potentiometer
Indicator
Chart Recorder
Pressure
Indicator
Temperature
Controller
Water SupplyAir Supply
Fill Cell
Thread Gland
Cell Cap
Thermocouple Receptacle
Thermocouple
Port
Slurry/Test
Cell Switch

Setup
Consistometer
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. Connect an air or nitrogen (100 - 150 PSI / 690 - 1,035 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. Make sure all electrical switches are turned off and the unit is ground-
ed. Make the necessary electrical connections in accordance with local
codes.
6. To fill the oil reservoir, open the front cabinet door and remove the oil
reservoir cap. Using a funnel, pour approximately four liters (or until
full) of mineral oil into the reservoir. Replace the cap. Make sure the
seal is air tight. Use the sight glass on the side of the reservoir to
check the oil level.
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Note
Reservoir Cap
Sight Glass

7. Periodically inspect the oil level within the air line lubricator. This unit is
located just upstream of the air inlet on the hydraulic pump inside the
Consistometer cabinet. You can access it by opening the cabinet doors
on the back of the unit. If the oil level is low, refill it with mineral oil.
The lubricator has been adjusted at the factory. Under normal opera-
tion, one drop of oil should be discharged into the air stream every 12
to 20 pump strokes. This discharge can be observed through the clear
control needle on top of the lubricator. If adjustment is necessary, turn
the hex screw on top of the control needle until you observe normal dis-
charge. Rotate the screw clockwise to decrease the oil flow rate and
counter clockwise to increase it.
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Air Line
Lubricator
Control
Needle

Setup
Chart Recorder
The OFITE HTHP Consistometer includes a Eurotherm Chessell 6100V
chart recorder for displaying and recording test data. It features a remov-
able drive for easily transferring test data to a PC for processing. The unit
is setup to automatically record data onto the disk during the test.
However, for this feature to work, you must have the disk inserted into the
drive when the unit is powered on. Otherwise, the data must be manually
archived at the end of the test.
It is strongly recommended that you carefully study the Eurotherm
Chessell 6100V instruction manual before using this equipment.
To manually archive test data:
1. Press the “Menu” button.
2. Press “Operator” from the menu.
3. At the top of the screen, press “Security”
and then choose “Log In”.
4. You will then be prompted for a UserID.
Touch the UserID field and choose
“Engineer” from the list.
5. Now touch the “Password” field. At the
bottom of the screen, choose “Numeric”
as the input method and then type “100”
and press “OK”.
6. At the top of the screen, choose “Archive”
and then choose “Local”.
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Important
!
Menu Button
Recorder Disk
Eject Button

7. Now choose the data you wish to archive
and press the appropriate button.
When the archive process starts, you will
see a green light at the top, right-hand
side of the screen. When the archive is
complete, you will see a message saying
“Demand Archive Finished”.
The chart recorder is shipped to you with a
pre-programmed configuration file. It is
highly recommended that you do not
change any of these settings. However, in
case of emergency, it is possible to restore
your configuration from the disk that is
shipped with the unit.
1. Log in as “Engineer” as described in
steps 1 through 5 above.
2. At the top of the screen, press
“Save/Restore” and choose “Restore”.
3. Make sure all four options are selected,
then touch the “File Name” field.
4. Press the up arrow to access the root
directory.
5. Select “mediacard” and press the down
arrow to access the disk.
6. Choose the file titled “config” and press
“Open”.
7. When the progress bar at the top of the
screen stops, the restore process is com-
plete.
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To transfer the test data to a PC:
1. If the Eurotherm software has not already been installed on the comput-
er, install it from the disk provided with the Consistometer.
2. Remove the disk from the chart recorder and insert it into the appropri-
ate drive on the PC.
3. From the Start Menu, select “Programs” then “Eurotherm” and then click
“Review”. This will open the Eurotherm Review software application.
4. From the “File” menu, select “Transfer” and then click “Files”.
5. Click the “Browse” button, then choose the appropriate drive for your
removable media. Open the “History” folder and select the files you
wish to transfer.
6. Type a name in the “Name” field and click “OK”.
At this point you will receive a warning message. Click “OK” again.
7. When the file transfer is complete, go to the “File” menu and click “New
Chart”.
8. Click “Add Point”.
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9. From the “Instrument” drop-down menu, choose the name you selected
in step 6.
10. Choose “Group 1” from the “Log Group” menu.
11. Now, select the Point IDs you wish to display on the chart. Hold down
the “CTRL” button to select more than one. Click “OK”.
12. The software will now create the chart based on the data collected from
the test.
13. To jump directly to a specific data point,
click the “Go To” button at the top of the
screen. Choose the data point you wish
to view and click “OK”.
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Go To

Setup
Pressure Indicator
The pressure indicator not only shows you the current pressure, but it also
alerts you when the pressure rises above the value you set. During an
alarm condition, the heater, pump, and motor will automatically shut down.
The display shows the current pressure in KPSI. This means a reading of
12.501 indicates a pressure of 12,501 PSI.
To set the high-pressure alarm:
1. Press the “Page” button until the display reads “AL”.
2. Press the “Enter” button until the display reads “1FSH”.
3. Press the up and down arrows to set the high-pressure setpoint.
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Pressure Indicator
Page Key
Enter Key

Setup
Temperature Controller
The Eurotherm Model 2404 Temperature Controller is the most important
component of the temperature control system and it is strongly recom-
mended that operators carefully study the Model 2404 instruction manual
included with the Consistometer.
If a test requires a custom program, it is important to build and save the
program prior to creating the slurry and loading the slurry cup.
Below is an example that illustrates how to program the controller. In this
example, the target temperature is 150°C, which is obtained at a rate of 2.5
degrees per minute. The target temperature of 150°C is maintained for the
duration of 180 minutes (3 hours), after which you want to stop the heat.
Press the “Page” button until the display reads “ProG List.” Use the scroll
button to decide which setting to change. Use the arrow buttons to change
the values for that setting.
For the test described above, you will want the following settings:
ProG List Setting Explanation
Seg 1 (segment 1)
Type rmp.r (ramp rate - other choices include ramp time
and dwell)
Tgt 150 (final temperature)
Rate 2.5 (rate per minute)
Segm 2 (segment 2)
Type Dwell (holds the temperature for the amount of time
chosen for Dur below)
Dur 180 (duration time)
Segm 3 (segment 3)
Type end
End.t sop
To run the test, push and hold the “Run/Hold” button until the light for Run
turns on. To stop the test, push and hold the “Run/Hold” button until the
light for Run and Hold both turn off. Be sure and turn the “HEATER” switch
off as well.
The temperature controller utilizes a high alarm setpoint which will bring the
unit to an alarm condition if the temperature ever exceeds the set value.
This value is defaulted to 200°C or 400°F, but can be programmed to differ-
ent values.
An alarm condition will also occur if the slurry thermocouple is unplugged.
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When an alarm condition occurs, the unit will automatically stop the heater,
motor, and pressure pump, the “ALARM” switch will light up red, and the
“TEMPERATURE CONTROLLER” will display “1FSH”. If the “SONALERT”
switch is turned on, the unit will start to beep. If the alarm condition is
resolved, the heater and pressure pump will automatically be turned back
on.
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Temperature Controller
RUN/HOLD
Page Scroll

Setup
Potentiometer Indicator
The HTHP Consistometer includes a built-in Eurotherm 2408i 15V
Potentiometer Indicator. As the slurry cup rotates within the unit, the poten-
tiometer creates a small voltage charge, which is displayed on the indicator.
This charge increases as the strength of the slurry increases.
The potentiometer indicator features a high-voltage alarm. When the
charge reaches the specified level, an alarm condition is triggered and the
heater, pump, and motor are automatically shut off.
To change the alarm setting, perform the following steps:
1. Push the “Page” key twice. The display will read “AL”.
2. Push the “Enter” key. The display will read “IFSH”.
3. Push the up arrow key once to read the current setting.
4. Push the up or down arrow keys to change the setting.
5. After choosing the appropriate setting, press the “Page” key three times
to return to the original display.
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Page Key
Enter Key

Operation
Filling the Slurry Cup
1. With the slurry cup disassembled, examine the threads on the inside of
the cylinder. The end with the larger set of threads is the top.
2. Coat the surface of the paddle and the inside of the slurry cup with a
high-temperature grease to facilitate cement removal.
3. Insert the paddle assembly all the way into the
top of the cylinder.
4. Slide the slurry cup lock ring on top of the paddle assembly with the two
notches facing upward. Tighten the locking ring completely using the
provided slurry cup tool.
5. Prepare the cement slurry as stated in API Specification 10.
6. Pour the cement into the slurry cup through the open bottom of the
cylinder.
7. Place the metal o-ring around the threads of the bottom cap. Apply
high-temperature grease to the o-ring and cap surface. Screw the cap
onto the cup and tighten with the slurry cup tool.
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Cylinder
Locking Ring
Bottom Cell Cap
Metal O-ring
Paddle

The slurry cup should contain enough cement slurry that it leaks out of
the hole in the center of the cap. If it is not, remove the cap and refill
the slurry cup. Do not add cement through the hole in the cap.
8. Screw the pivot bearing into the hole in the center of the cap and tighten.
9. Wipe the entire slurry cup clean to ensure that no cement remains on
the outside.
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Slurry Cup Tool
Slurry Cup Stand
Slurry Cup
Pivot Bearing
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Note