OfiTE 4020-SG User manual

Model 4020-SG Automated UCA/SGSM
Patent No. 9,612,232 - OFI Testing Equipment, Inc.
Part No #120-59
Instruction Manual
Updated 4/21/2017
Ver. 3.0
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
Introduction.....................................................................................3
Description......................................................................................3
Features...........................................................................................3
Specications .................................................................................4
Requirements .................................................................................4
Components ...................................................................................5
Safety...............................................................................................8
Quick Start ......................................................................................9
UCA.............................................................................................9
SGSM .......................................................................................10
Setup.............................................................................................. 11
Test Prole ....................................................................................14
UCA................................................................................................17
Software Setup .........................................................................17
Main Screen..............................................................................19
Software Operation ...................................................................22
Cell Assembly ...........................................................................23
Connecting the Cell...................................................................29
Starting the Test........................................................................31
Stopping the Test ......................................................................32
Disassembling and Cleaning the Test Cell................................33
SGSM ............................................................................................35
Software Setup .........................................................................35
Main Screen..............................................................................38
Software Operation ...................................................................42
Cell Cap Assembly....................................................................44
Drag Check ...............................................................................52
Preparing the Test Cell..............................................................53
Connecting the Cell...................................................................54
Starting the Test........................................................................55
Stopping the Test ......................................................................56
Evaluating Test Data.................................................................57
Disassembling and Cleaning the Test Cell................................58
Table of
Contents

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Maintenance .................................................................................64
Maintenance Schedule .............................................................64
Fuses ........................................................................................65
Rupture Disk and Filters ...........................................................66
Troubleshooting.........................................................................68
Calibration.....................................................................................72
Pressure Transducer.................................................................72
Thermocouple ...........................................................................74
Ultrasonic Transducer ...............................................................77
SGSM Transducer.....................................................................78
UCA Transducer Archives .........................................................80
SGSM Calibration Archives.......................................................81
Appendix ......................................................................................83
Multiple Instruments..................................................................83
Electrical System Grounding.....................................................84
UCA Cell Assembly Diagram ....................................................85
SGSM Cell Assembly Diagram .................................................86
Drive Assembly Diagram...........................................................87
Warranty and Return Policy ........................................................88

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UCA
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.
SGSM
The Static Gel Strength Measurement (SGSM) device uses a vaned bob to
condition a cement slurry inside a pressurized test cell and measure static gel
strength at down-hole conditions. By directly measuring the forces required
to initiate movement in the sample, the SGSM provides an accurate way of
determining the static gel strength.
UCA
The cement slurry to be tested is placed in an autoclave unit with temperature
and pressure adjusted to simulate down hole 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.
SGSM
In an SGSM test, a vaned bob is submerged in the cement. During the test,
the bob turns periodically and measures the static gel strength of the sample.
Main Features
- Programmable temperature and pressure control
- Data transmission via USB for UCA software and RS-232 for SGSM
software
- Instant data availability on-screen and automatically converted to CSV
format
- Nondestructive comprehensive strength cement test
- Mechanical measurement of static gel strength
- Cement conditioned in the test cell before the gel strength test.
- Rapid cooling system
Safety Features
- High temperature light indicator
- Automated cool down routine
- Over pressure/temperature alarm
- Over pressure/temperature shutdown
- Rupture disc to prevent over pressure situations
- Anti-boil algorithm to prevent slurry from boiling at high temperatures.
Introduction
Description
Features

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Software Features
- Two separate executable software applications for the UCA and SGSM
- Calibration stamp and archive
Max Test Conditions
- Maximum Temperature: 400°F (204.4°C)
- Maximum Pressure: 20,000 PSI (137.9 MPa)
Size:
- 29" × 20" × 14" (73.6 × 50.8 × 35.6 cm)
- 85 lb (39 kg)
- Air Supply: 100 PSI (690 kPa) Recommended, 150 PSI (1,035 kPa)
Maximum, ¼" NPT Connector
- Water Supply: 40 – 100 PSI, 40° – 100°F, ¼" NPT Connector
- Water Drain: ¼" NPT Connector
- Coolant Supply: ¼" NPT Connector
- Coolant Drain: ¼" NPT Connector
- Heater: 230 – 240 VAC, 10 Amp, 50 – 60 Hz
Electronics Power: 230 – 240 VAC, 2 Amp, 50 – 60 Hz
Specications
Requirements

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Only use replacement parts that have been supplied by OFITE.
Included:
#120-50-TR Acoustic Transducer, set of 2
#120-50-021 Test Cell Assembly
#120-50-021A Cell Body
#120-50-021B Cell Cap, Bottom
#120-50-021C Cell Cap, Top
#120-50-027-1 Seal Ring, Qty. 2
#120-50-026 Retaining Ring
#120-59-081 Handle for Cell Cap, Qty. 2
#123-011 O-ring, Qty. 30
#120-50-023 Upper Transducer Spring Holder
#120-50-039 Open-End Wrench, ½"× "
#120-50-040 CombinationWrench,⅝"
#120-50-041 Wrench, Strap, 18"
#120-50-090 Wrench, Cell Cap
#120-51-047 Transducer Spring, Qty. 2
#120-52-021 Fill Gauge
#120-53-25 LPT Cable
#120-53-81 Wrench, Combination,  "
#120-58-005 Drive Assembly (See diagram on page 87 for parts list)
#120-58-006 SGSM Cell Assembly (See diagram on page 86 for
parts list)
#120-58-07 Wrench, Allen,   "
#120-58-08 Calibration Stand
#120-58-16 Wrench, Strap, 5"
#120-59 Automated UCA/SGSM
#120-59-355 Fill Tube
#120-59-520 USB Cable
#120-75-9 Weight Hanger
#120-75-10 Weight Set
#120-209 Thermocouple Assembly
#123-024 Couplant, High Temperature
#130-75-27 Wrench, Allen, T-handle, "
#130-75-71 Monitor
#130-75-74 Desktop Computer
#130-79-15 Serial Cable, DB9, M/F
#141-15 Hose, Qty. 5
#141-19 Hose Adapter, Qty. 5
#220-10A-EURO Power Cords, European plugs, Qty. 2
#220-15A-USA Power Cords, USA plugs, Qty. 2
Instruction Manual
CalibrationCerticate
Software
Components

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Replacement Parts:
#120-50-027-1 Seal Ring
#120-50-026 Retaining Ring
#120-50-TR Acoustic Transducer, set of 2
#120-50-047 Spring for Transducer
#120-50-053 Heater
# 120-53-82 Retaining Ring, SGSM Adaptor, Upper
#120-53-01 SGSM Vane Assembly
#120-53-02 SGSM Drive Magnet
#120-53-041 Bearing, SGSM Drive Head
#120-53-33 Tension Spring
#120-53-34 Load Cell
#120-53-58 Back-Up Ring, SGSM Adaptor, Upper
#120-53-59 Back-Up Ring, SGSM Adaptor, Lower
#120-58-010 SGSM Magnet Shaft Assembly
#120-58-05 Retaining Ring, SGSM Adaptor, Lower
#120-58-23 SGSM Diaphragm
#120-59-355 Fill Tube
#120-59-520 USB Cable
#120-90-033 Air Filter
#120-106-001 High Pressure Filter Elements, Qty. 3
#120-209 Thermocouple Assembly
#120-53-25 LPT Cable
#122-053 Rupture Disk, 22,500 PSI
#130-79-15 Serial Cable
#172-24 Solid State Relay, 240V–25A
Consumables:
#120-106-001 High Pressure Filter Elements
#120-53-31 O-Ring, SGSM Adaptor, Lower
#120-53-32 O-Ring, SGSM Adapter, Upper
#120-53-42 Graphite Bushing
#122-073 Fuse, 2 Amp, 5 mm × 20 mm, Qty. 2,
Fan, Pump/Cooling Solenoid
#122-075-2 Fuse, 6 Amp, 5 mm × 20 mm, Heater
#122-077 Fuse, 10 Amp, 5 mm × 20 mm, Qty. 2, Main Power
#123-011 O-ring
#123-024 Acoustic Couplant

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#120-58-SP Spare Parts Kit for SGSM:
#120-50-026 Retaining Ring, External, Qty: 2
#120-50-027-1 Seal Ring, Qty: 2
#120-53-01 Vane Assembly
#120-53-041 Bearing
#120-53-31 O-ring, Qty: 5
#120-53-32 O-ring, Qty: 5
#120-53-33 Tension Spring, Qty: 2
#120-53-42 Graphite Bushing, Qty: 20
#120-53-58 Backup Ring, Upper, Qty: 2
#120-53-59 Backup Ring, Lower, Qty: 2
#120-53-82 Retaining Ring, External, Qty: 2
#120-58-05 Retainer Ring, External, Qty: 2
#120-58-23 Diaphragm
#120-58-38 Retainer Ring, Internal, Qty: 2
#123-011 O-ring for Test Cell, Qty: 5

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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 software with the desired parameters. See page 17.
2. Prepare the cell caps and cell body.
3. Assemble the bottom cell cap. See page 23.
4. Install the bottom cell cap to the bottom of the cell body. See page 25.
5. Assemble the top cell cap. See page 26.
6. Mixtheslurryandllthecell.Seepage28.
7. Install the top cell cap to the cell assembly.
8. Install the test cell to the cabinet. See page 29.
9. Connect water supply line, thermocouple, and transducer to the test cell.
10. Run the test. See page 31
11. Allow test cell to cool down. See page 32.
12. Remove test cell. See page 33.
13. Disassemble the test cell.
14. Remove the cement from the test cell. See page 34.
15. Clean and inspect all of the test cell components.

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Quick Start
SGSM
1. Set up the software with the desired parameters (see page 35).
2. Prepare the cell caps and cell body.
3. Assemble the bottom cell cap. See page 44.
4. Install the bottom cell cap to the bottom of the cell body. See page 46.
5. Assemble the top cell cap. See page 47.
6. Assemble the SGSM shaft assembly and install it to the top cell cap.
See page 49.
7. Install the top cell cap to the cell assembly.
8. Install the test cell to the cabinet.
9. Connect the SGSM head to the shaft assembly and run a drag check.
See page 52.
10. Mixtheslurryandllthecell.Seepage53.
11. Connect water supply line, thermocouple, and transducer to the test cell.
See page 54.
12. Run the test. See page 55.
13. Allow test cell to cool down. See page 56.
14. Evaluate the test data. See page 57.
15. Remove test cell.
16. Disassemble and clean the cement from the test cell. See page 58.
17. Clean and inspect all of the test cell components.

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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.
To ensure personal safety, always use proper lifting techniques.
Position the unit so that the user can quickly disconnect plugs in case of
an emergency.
2. Make sure all switches are off and the pressure relief knob is turned
completely counterclockwise.
3. Connect the “Air Supply”, “Water Supply”, “Drain”, “Coolant Supply”, and
“Coolant Drain” connectors on the back of the unit to their appropriate
source and plug in the power cords.
Make sure the “Coolant Drain” is suitable for high temperature discharge.
4. Connect the UCA/SGSM -to a PC with the supplied cables (USB for the
UCA and RS-232 for the SGSM).
5. Connect the SGSM head to the UCA with the supplied LPT cable.
6. Turn the “Main Power” switch on.
7. Put the “UCA/SGSM” switch to the correlating position of the desired test.
PC
S
G
S
M
UCA/SGSM
Cell
RS-232 (For SGSM)
LPT
USB
(For UCA)

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Cell Pressure
Gauge
Water Supply
Tube (Not
Shown)
LPT Cable
SGSM
Head
Eurotherm
Display
Control
Panel
Cell Pressure
Release Valve High
Temperature
Indicator
Thermocouple
Front View
Rear Panel
Hoses
Electronic Connections
LPT Port
USB Port
RS232 Port
Heater
Power Cable
Receptacle
Electronics
Power Cable
Receptacle

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Water On/Fill – Fills the cell with water from an external water source.
Alarm – Sounds an alarm when operating in SGSM mode to indicate when
thenalgelstrengthhasbeenreachedorgelstrength#5hasbeenreached
if not in multiple conditioning mode. See page 43.
Heater – Engages the heat jacket which heats the cell to the target
temperature.
Main – Controls the main power to the entire unit.
Pressure Up – Applies pressure from an external air source to the cell.
a. Manual –Constantly applies pressure until the system is switched to off,
auto, or until it reaches 20,000 PSI (Max Pressure).
b. Off –Stops the pressure application.
c. Auto –Applies pressure until the unit reaches the target pressure
entered in the software setup menu. See page 17.
Cool – Engages the cooling system to the cell.
a. Manual –Constantly applies water or coolant to the heat jacket.
b. Off –Stops the application of water or coolant to the heat jacket.
c. Auto –Automaticallyallowscoolanttoowtotheheatjacketoncethe
testisnishedandwhilethetemperatureisabove100°F.Tochange
the temperature threshold, contact OFITE technical support.
Mode – Switches the test operation modes between UCA and SGSM to
facilitate accurate communication between the unit and the computer software.
Control Panel

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Test Prole BoththeUCAandSGSMsoftwareapplicationsincludeaTestProleBuilder.
Hereyoucancreateacustomtemperatureandpressureproleforyourtest.
1. Select Utilities TestProleBuilder.
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 200°F (93.3°C), apply a
minimum of 1,000 PSI (6.9 MPa) 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.
a. Temperature – There are three types of temperature settings:
i. Hold – This will hold the current temperature for a set number of
minutes. Enter the time into the "Time" Box.
ii. Ramp – This will increase the temperature up to the target in a set
number of minutes. You will be prompted for the ramp time and
target temperature.
iii. Step – This will increase the temperature up to the target as fast
as possible. Enter the target temperature in the "Target" box.
The maximum temperature setpoint allowed is 400°F (204.4°C). The
units of measure will be the same as entered in the Setup menu. See
page 17.
4. 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.

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d. HoldIndenitely(ForUCAonly):
With this option turned on, the test will run until you click the “Stop
Test” button. If this option is not checked, the test will end when all the
stepsintheTemperatureProlearecomplete.
IntheSGSMProleBuilder,thereisno“HoldIndenitely”option.The
testwillcontinuetoholdtemperaturethroughthenalgelstrength
until the end of the test.
5. Click the “OK” button to exit the “Setup” screen. The new Temperature
Prolewillnowappearinthe“TemperatureProlesList”inthe“UCAInfo”
tab.
b. Pressure – There are two types of pressure settings:
i. Hold – This will hold the current pressure for a set number of
minutes.
ii. Ramp – This will increase the temperature up to the target in a set
number of minutes. Enter the time to temperature in the "Time"
box. Enter the target temperature in the "Target" box.
iii. Step – This will increase the pressure up to the target as fast as
possible. Enter the target temperature in the "Target" box.
The maximum pressure setpoint allowed is 20,000 PSI (138 MPa).

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UCA
Software Setup
Before you begin a UCA test, you must prepare the PC to record the data.
1. Turn on the PC and the UCA.
2. Put the “UCA/SGSM” switch to the UCA position. See page 35.
3. Open the software by double-clicking the Automated UCA icon on the
desktop.
4. Click Utilities Setup.
The UCA software will only communicate through USB.

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“CS Unit” – PSI or MPa
“Temp Unit” – °F or °C
“Archive Path”–Choosealocationtosavearchiveles.
“Logo Path” – Select a logo (.JPG format) to print on the graph at the
end of the test.
“CS #1”, “CS #2”, “CS #3” – Enter a compressive strength value in each
oftheseelds.Whenthecementreachesthatcompressivestrength,the
software will record the elapsed time and print it on the graph.
“Unit #” – Identiestheunitgeneratingthegraph.Thiseldishelpful
when multiple units are generating graphs.
“Strength @”, “Strength 2 @”, “Strength 3 @” – Enter a time period in
eachofthesethreeelds.Attheendofthetest,thecompressivestrength
at these three times will print on the graph.
“Ultrasonic Transducer”, “Pressure Transducer”, “Thermocouple” –
Calibration Frequency:Enteratimeperiodineachofthesethreeelds.
The default time period is set at six months but can be edited if needed.
The UCA software will prompt a reminder that these components need to
be recalibrated at each of these times. This will not affect the test.
“Print to Printer” – When this option is on, a graph of the test results
will automatically print to the computer's default printer when a test is
complete.

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Thesoftwareapplicationhasasetoftabsthatarespecictothetest
conguration.
The UCA Infotabshowsthecurrenttestcongurationandagraphofthe
temperatureandpressureproles.
UCA
Main Screen