OfiTE 120-05 User manual

Dual Cell HTHP Consistometer
#120-05: 25,000 PSI, 400°F
#120-15: 40,000 PSI, 600°F
Instruction Manual
Updated 12/21/2016
Ver. 5.0
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 2015

OFITE, 11302 Steeplecrest Dr., Houston, TX 77065 USA / Tel: [phone] / Fax: [phone] / www.ote.com 1
Intro..................................................................................................2
Description......................................................................................2
Features...........................................................................................2
Requirements .................................................................................2
Specications .................................................................................3
Components ...................................................................................4
Setup................................................................................................8
Consistometer.............................................................................8
Pressure Indicator.....................................................................10
Temperature and Pressure Controller....................................... 11
Potentiometer Indicator.............................................................13
Software ........................................................................................14
Setup.........................................................................................14
Operation ..................................................................................17
Test Builder ...............................................................................18
Calibration.................................................................................19
Test Data...................................................................................20
Operation.......................................................................................21
Filling the Slurry Cup.................................................................21
Loading the Test Cell ................................................................23
Completing the Test ..................................................................26
Cleaning....................................................................................27
Potentiometer Calibration .........................................................29
Potentiometer ...........................................................................31
Troubleshooting.........................................................................33
Pressure Relief Valve Regulator ...............................................36
Appendix .......................................................................................37
Cell Diagram .............................................................................37
Slurry Cup Diagram ..................................................................38
Warranty and Return Policy ........................................................40
Table of
Contents

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Intro 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 insuf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 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
shutdown
- Safety head with rupture disk are provided
- Unit is fully capable of testing cements in strict accordance to the
guidelines as stated in API Specication 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
Description
Features
Requirements

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Specications Size 66 × 36 × 32 inches (168 × 92 × 82 cm)
Weight 1,400 lbs (635.6 kg)
Crated Size 51" × 45" × 76" (130 × 114 × 193 cm)
Crated Weight 2250 lbs (1020.6 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
Model 100: (120-05)
Maximum Temperature: 400°F (204.4°C)
Maximum Pressure: 25,000 PSI (172,375 kPa)
Model 120: (120-15)
Maximum Temperature: 600°F (315.5°C)
Maximum Pressure: 40,000 PSI (275,800 kPa)

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Components #120-00-5 Graphic Recorder
#120-147 Autoclave Mag Drive
#120-201 Test Cell Thermocouple
#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
#120-05 Model 100, 25,000 PSI; 400°F
#120-001 Mineral Oil; 1 Gallon; Qty: 6
#120-102 Rupture Disk; 28,000 PSI; Qty: 2
#120-203 Slurry Cup Thermocouple; Qty: 2
#120-401 Metal O-rings; Qty: 2
#120-519 Slurry Cup Assembly
#120-15 Model 120, 40,000 PSI; 600°F
#120-001 Mineral Oil; 1 Gallon; Qty: 6
#120-103 Rupture Disk; 45,000 - 50,000 PSI; Prebulged; Qty: 2
#120-208 Slurry Cup Thermocouple; Qty: 2
#120-401 Metal O-ring; Qty: 2
#120-521 Slurry Cup with Extension
#122-072 1-Amp Fuse, 5 mm × 20 mm, Qty: 10
#122-073 2-AMP Fuse, 5 mm × 20 mm, Qty: 9

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#120-01 Spare Parts for Model 100:
#120-00-1 Consistometer Tool Kit
#120-001 Mineral Oil, 2 Gallons
#120-102 Rupture Disk (28,000 PSI), Qty: 2
#120-202 4,000-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
#120-506 Paddle for Slurry Cup Assembly, Qty: 4
#120-507 Paddle Shaft for Slurry Cup Assembly, 7.75" Long, Qty: 10
#120-508 Diaphragm Retaining Ring, Qty: 2
#120-509 Drive Disk for Slurry Cup Assembly
#120-510 Drive Bar for Slurry Cup Assembly
#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 × ½SHCS SS
#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   " Allen Key, 1.75" Long, Qty: 2
#120-11 Spare Parts for Model 120:
#120-001 Mineral Oil, 2 Gallons
#120-10-1 Consistometer Tool Kit
#120-103 Rupture Disk, 45,000 – 50,000 PSI, Prebulged, Qty: 2
#120-202 4,000 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, Qty: 4
#120-508 Diaphragm Retaining Ring for Slurry Cup Assembly, Qty: 2
#120-509 Drive Disc for Slurry Cup Assembly

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#120-510 Drive Bar for Slurry Cup Assembly
#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, 9⅛", Qty: 10
#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 × ½ SHCS SS
#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   " Allen Key, 1.75" Long, Qty: 2

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Pressure
Indicator
Potentiometer
Indicator
Switches
To operate the “Pump” switch:
Up: Manual Mode
Middle: Off
Down: Auto Mode
Timer
Air Supply
Fill Cell
Water Supply
Air To
Cylinder
Pressure
Release
Temperature
and Pressure
Controller
Pressure
Regulator
Thermocouple Receptacle
Cell Cap
Thread
Gland

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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 grounded.
Make the necessary electrical connections in accordance with local
codes.
6. Connect the cell cap to the winch:
a. With the supplied allen key, unscrew and remove the hex screw from
the winch clasp.
b. Remove the cell cap and support it on blocks above the test cell.
c. Attach the winch clasp to the cell cap and secure it with the hex screw.
Winch Clasp
Hex Screw
Cell Cap

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7. To ll 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.
Reservoir Cap
Sight Glass
8. 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, rell it with mineral oil.
The lubricator has been adjusted at the factory. Under normal operation,
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 discharge.
Rotate the screw clockwise to decrease the oil ow rate and counter
clockwise to increase it.
Control
Needle
Air Line
Lubricator

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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.
Pressure Indicator
Enter Key
Page Key

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Setup
Temperature and
Pressure Controller
Page Scroll
The Eurotherm Model 3504 controls both temperature and pressure. When
running a test with the computer, the software automatically programs the
controller. However, when running a test without the computer, the controller
must be programmed manually. It is strongly recommended that operators
carefully study the Model 3504 instruction manual before attempting to
program the controller.
When running a test without the computer, always build the program prior to
mixing the slurry and loading the slurry cup.
The Eurotherm 3504 can store up to eight custom programs. Each program
consists of multiple segments. In a segment, the temperature or pressure
setpoint can be changed or held for a certain amount of time.
Each program also consists of two channels. Channel 1 controls the
temperature and Channel 2 controls the pressure. The two channels are
programmed separately and have their own set of segments.
Selector
Temperature
Pressure
To edit a program:
1. Press the “Page” button until the display reads “Program Edit”.
2. Use the up and down arrows to select the program you want to edit.
3. Press the “Scroll” button to move to the Channel parameter.
4. Use the up and down arrows to select the Channel you want to edit.
Channel 1 controls temperature. Channel 2 controls pressure.

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5. Set the parameters for the test:
Press the “Scroll” button to select a parameter to edit. Then use the up
and down arrows to modify the value of that parameter.
a. Set the following parameters for each test:
- Ramp Units: Seconds, Minutes, Hours
- Cycles: The number of times to repeat the test.
b. You must choose a Segment Type for each segment in the test.
The Segment Type will determine the parameters available for that
segment:
Rate: Increase the setpoint by a certain rate (Ramp Rate)
- Target SP: The end temperature or pressure for the segment
- Ramp Rate: The rate of increase for the setpoint. For example,
if Ramp Units is set to minutes, and Ramp Rate is set to 5, the
temperature setpoint will increase by 5° per minute.
Time: Increase the setpoint over a certain time (Ramp Time)
- Target SP: The end temperature or pressure for the segment
- Duration: The amount of time it will take to increase the setpoint to
the target.
Dwell: Hold the current setpoint.
- Duration: The amount of time to hold the current setpoint.
Step: Increase the setpoint immediately. No ramp is involved.
- Target SP: The end temperature or pressure for the segment.
End: The nal segment in every test must be End.
- End Type: Dwell is recommended. This will hold the current
setpoint until the test is stopped.
The display is split into two areas. The top area shows the temperature channel
while the bottom shows the pressure channel. Before starting a manual test,
both the temperature and pressure channels must be in auto mode:
1. Press the “Scroll” button to move the selector around the screen. When
the selector is above the dividing line, the temperature channel is selected.
When it is below the dividing line, the pressure channel is selected.
2. Press the “A/MAN” button to toggle the selected channel between auto
and manual mode.
In the temperature channel, the word “MAN” will appear at the top of the
display to indicate manual mode. This word will disappear in auto mode.
In the pressure channel, the word “Man” will appear on the left-hand side
of the display. This word will change to “Aut” in auto mode.

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Setup
Potentiometer Indicator
The HTHP Consistometer includes a built-in Eurotherm 2408i 15V
Potentiometer Indicator. As the slurry cup rotates within the unit, the
potentiometer 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 specied 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.
Enter Key
Page Key

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Software
Setup
1. Double-click the “Multi Consistometer” icon on the PC desktop.
2. To add a new unit, click “Add New”.
3. Select “Consistometer” from the list.
4. Enter a name. The name must be different from all other Consistometers
connected to this PC.
5. Enter a slave ID. The slave ID must be different from all other
Consistometers connected to this PC.
6. Choose the COM port the new Consistometer is connected to.
7. Chose a folder to save the test data. It is recommended that each
Consistometer have its own data archive folder.
8. Choose a logo le (.jpg) to display on the printed chart.
9. Select “With Pressure” if you want pressure data to print on your graph.
This feature is only available on units with a Eurotherm pressure indicator.
Units with an AMETEK/Dixson pressure indicator cannot print pressure on
the graph.
10. Select “With Pressure Control” if you want to control pressure from the
software.
This feature is not available on all units.

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11. Click “Finish” then “Save”.
12. The main screen shows all units added to the PC. For each one it shows
the type of equipment, name, slave ID, COM port, and data archive path.
Units with “[R]” after their name are currently running a test.
Right-click on a unit and select “Launch” from the menu.
13. Select “Setup” from the “Options” menu.
14. Select a “Temp Unit” (°F or °C), “Consistency” (V or Bc), and “Pressure”
(PSI or kPa).
15. Choose an “Archive Path”. This is the folder where all test data will be
stored.
16. Choose a “Chart Logo File”. This is the logo that will print on the report at
the end of a test. This le must be in .jpg format.

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17. Select “Print to Printer” if you want a chart to automatically print when
you stop a test. Select “Print to File” if you want a .jpg le to be create
automatically when you stop a test.
Both of these options can be enabled at the same time. It is
recommended that “Print to File” always be enabled.
18. Choose values for the “Consistency #1”, “Consistency #2” and
“Consistency #3” elds.
These values tell the software to record the test time when the
consistency reaches each point. A note will be made on the chart when
the test is nished.
Make sure that if you select “Bc” for consistency units that you also use
Bc for these two elds. Likewise, if you chose “V” for consistency units,
you must use voltage for these two elds.
19. Select “Automatic stop collecting data” if you want the Consistometer to
stop collecting data during an alarm condition.
During an alarm condition, the motor, heaters, and pump all stop. By
default, when the alarm condition is resolved, everything restarts.
However, if the “Automatic stop collecting data” box is checked data
collection is also stopped, and only the motor and pump restart. The
heaters remain off and no more data is collected.
20. When nished, click “OK”.
21. Select “Set Alarm” from the “Utilities” menu.
22. Enter a value in Bc. If the sample reaches this consistency, the unit will
enter alarm condition.

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Software
Operation
1. Click “Start Test”.
2. Enter the necessary information. The following elds do not affect your
test. The information will print on the report when the test is complete:
- Customer Info
- Additives
- Cement Mfr.
- Test Name
- Cement Density
- Cement Class
- Density Units
- Job Type
The following elds do affect your test:
- DAQ Time (mm:ss): determines how often test data is saved to le
- Alarm: sets the consistency alarm. Be sure to use the same
consistency units set in the “Setup” screen.
3. Select a “Test Prole”. Test proles are built in the Test Builder. Refer to
page 18 for instructions.
4. Click “OK” to start the test.
If the computer is disconnected from the Consistometer or loses power,
the test will not stop. Be sure to stop it manually. Refer to page 26 for
instructions on stopping a test manually.
5. When the test is complete, click “Stop”.

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Software
Test Builder
The Consistometer Software can control both the temperature and pressure
during a test. Tests are programmed in the Test Builder.
1. Select “Test Builder” from the “Utilities” menu.
2. Click the “New Test” button to start a new test. Or click the “Copy
Test”button to start with an existing test.
3. On the Temperature or Pressure tab click the “Add” button to add a step.
4. Choose a Step Type:
- Ramp: The software will increase the setpoint up to the target over a
specied time period.
- Step: The software will increase the setpoint to the target immediately.
- Hold: Maintain the current setpoint for the specied period of time.
5. Once you add a step, you can then go back and edit, delete, or move it
up or down in the step list.
6. Click “OK” to save the test. The new test will now be available in the “Start
Test” dialog box.

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Software
Calibration
A calibration should be performed periodically to make sure the unit is
still providing accurate information. Also, be sure to calibrate any time the
potentiometer is changed. Always calibrate with the same potentiometer
that will be used during the test.
1. Select “Calibration” from the “Operations” menu.
2. Prepare the potentiometer for calibration as described on page 29.
3. Place the weight hanger (with no weights) on the end of the string. The
weight hanger is 50 g.
4. Wait for the value on the screen to stabilize and then click “Accept”.
5. The software will prompt you to add weight to the hanger. After adding the
weight, wait for the value to stabilize, then click “Accept”.
The software will graph the calibration points as you enter them. At any
time you can click the “Back” button to re-enter a calibration point.
6. Click “Save” to save the calibration data.