Instruction Manual Pressurized Curing Chamber Model 1910 Revision C.5 March 2010 P/N:

Transcription

1 Instruction Manual Pressurized Curing Chamber Model 1910 Revision C.5 March 2010 P/N: S/N: 2001 N. Indianwood Ave. Broken Arrow, OK Telephone: Fax: Website:

2 Copyright 2010, by Chandler Engineering Company, LLC 2001 N. Indianwood Ave. Broken Arrow, OK All rights reserved. Reproduction or use of contents in any manner is prohibited without express permission from Chandler Engineering Company, LLC. While every precaution has been taken in the preparation of this manual, the publisher assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. This publication contains the following trademarks and/or registered trademarks: AMETEK, CHANDLER ENGINEERING. These trademarks or registered trademarks and stylized logos are all owned by AMETEK, Inc. All other company, product and service names and logos are trademarks or service marks of their respective owners.

3 TABLE OF CONTENTS T-1 Table of Contents General Information... P-1 Introduction... P-1 Features and Benefits... P-1 References... P-1 Specifications... P-2 Safety Requirements... P-2 Where to Find Help... P-3 Section 1 - Installation Unpacking The Instrument Utilities Required Tools and Equipment Required Setting up the Instrument Controller Set-Up Section 2 - Operation Operating the Curing Chamber Protection of Relief Valve Seat To Apply Heat To Cylinder To Cool Cylinder at End of Test Empty the Chamber of Oil Section 3 Maintenance Schedule Tools Required Cleaning and Service Tips Maintenance Schedule Section 4 Troubleshooting Guide Section 5 - Parts List Section 6 - Drawings and Schematics

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5 PREFACE P-1 General Information Introduction This manual contains installation, operation, and maintenance instructions for the Chandler Engineering Model 1910 Pressurized Curing Chamber. Purpose and Use The Pressure Curing Chamber is used for curing tensile or compression specimens of oil well cements at elevated temperatures and at pressures above atmospheric, simulating conditions in the well. Briefly, the procedure is to prepare the test specimens according to API Spec. 10 (1). The specimen slurries are poured into molds, and the molds are lowered into the pressure curing cylinder. The cylinder plug is installed, the thermocouple is inserted into the cylinder head, and the cylinder is filled with water to expel air. Heat, regulated by an Automatic Temperature Program System, and pressure is then applied to the cylinder in accordance with applicable schedules of API Spec. Maximum pressure and temperature are maintained until shortly before the end of the curing time specified. The temperature is then reduced, pressure is regulated to atmospheric, and the test specimens are removed for testing. Description Safety features are incorporated into the curing chamber. Adjustable switches are installed in the pressure gauge to shut off operational power if, pressure falls below, or goes above, a selected point. Over-pressure protection is furnished by a relief valve, through which water exhausts if pressure exceeds the 3500 psi/21 MPa indicating pressure-gauge limit. A rupture disc rated at 5000 psi/34 MPa is also incorporated as an additional safety feature. Features and Benefits Microprocessor-based temperature controller Digital temperature indicator Programmable multi-slope temperature controller High wattage heater Metal-to-metal sealing ring Operating temperatures to 700 F/371 C Operating pressures to 25,000 psi/172 MPa Stainless steel enclosure Cooling jacket on pressure vessel Single or dual cells available References (1) American Petroleum Institute; API Specification 10 for Materials and Testing for Well cements, Latest Edition; Dallas, Texas

6 P-2 PREFACE Specifications Model No. No. of Cubes Maximum Temperature Maximum Pressure Shipping Weight Shipping Dimensions F C psi Mpa kva lb kg W x D x H , x 38 x 79 The pressure rating varies with temperature. See the Temperature Rating chart below. Rated Pressure, psig: 25,000 Rated Temperature, Deg. F: 700 Rated Pressure, Deg. F De-rating Factor psig Safety Requirements READ BEFORE ATTEMPTING OPERATION OF INSTRUMENT! Any instrument that is capable of extremely high temperatures and pressures, as a curing chamber, should always be operated with CAUTION. The instrument is designed for operator safety; however, to ensure that safety: Locate the instrument in a low traffic area. Post signs where the instrument is being operated, to warn non-operating personnel. Read and understand instructions before attempting operation; observe warning and caution notes throughout this manual. Observe and follow the Warning Labels on the instrument. Never exceed the instrument maximum pressure and temperature ratings secured on the machine. Always disconnect main power to the instrument before attempting any repair or when opening the instrument cabinet; HIGH VOLTAGE CAN KILL! Keep front access doors closed when operating instrument. A fire extinguisher, Type 8 BC should be located within 50 feet of instrument. Note: All Chandler Engineering equipment are calibrated and tested prior to shipment.

7 PREFACE P-3 Where to Find Help In the event of problems, your local sales representative will be able to help or you can contact the personnel at Chandler Engineering using the following: Telephone: FAX: Website:

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9 SECTION 1 INSTALLATION 1-1 Section 1 - Installation Prior to operating this instrument, the technician should study the drawings accompanying the operating and maintenance instructions to become thoroughly familiar with the curing chamber operation and its parts. Before a curing chamber leaves the factory, several tests are conducted to affirm that the assembly meets performance standards. Hose or copper tubing may be used for the water supply connection. Use 3/8 in. copper tube for the drain connection. The water inlet and drain are both located at a brass block on the lower rear of the cabinet. Connection from the air supply can be made with ¼ in. OD copper tubing. The air inlet connection will be found on the back of the control panel. Electrical connections should be made to the fuse block inside the cabinet, being sure that wire of sufficient size to handle the 40-ampere load is used. This wiring should be done in accordance with local electrical codes and the entire instrument should be securely connected to a separate ground. To fill the reservoir with white oil: Open the right-hand cabinet door and ensure that the drain valve on the bottom of the reservoir is closed. Remove the brass fill plug from the top of the reservoir and fill the reservoir with the white oil, and replace the fill plug. Unpacking the Instrument After the instrument is removed from the shipping crate, the operating equipment and spare parts on the packing list should be checked to affirm that all have been received and none are damaged. Note: File an insurance claim with your freight carrier if damage has occurred during shipment. Verify all parts received appear on the enclosed packing list. If items are missing, please notify Chandler Engineering, immediately. Utilities Required The utilities required to operate the instrument are compressed air at 100 psi/700 KPa and electric current of 240-volt, single-phase, 50 Hz/60 Hz, 30-ampere capacity. Clean water is used as the hydraulic medium and is wasted after each test. Tools and Equipment Required A standard maintenance or mechanics tool set is adequate for the installation, operation, and maintenance of the instrument. No special tools required. This unit is supplied with an installation kit, which includes the necessary hardware, fittings, and hoses needed for water, air, and electrical hook-ups.

10 1-2 SECTION 1 INSTALLATION Setting up the Instrument Controller Set-Up 1. Turn controller on. Press button until the program menu appears. 2. Press the scroll button until tgt (target set point) is reached. This is the temperature at end of ramp. Press στ (UP/DOWN) button to change value. 3. Press (scroll) button until dur (duration). This is the time to reach tgt set point. Press στ to change value. 4. Press (PAGE) button until the current process value is displayed. For complete operating instructions, see the 7050/7051 Operating Instructions in the Component section of this manual.

11 SECTION 2 OPERATION 2-1 Section 2 - Operation Before attempting operation of the instrument, you should study the drawings in this manual. Operating the Curing Chamber 1. Prepare a cement slurry, fill molds and insert the molds into the mold bucket, then fill the bucket with water. 2. Place the filled mold-bucket assembly into the chamber. 3. Fill the chamber with oil to the top of the mold bucket. 4. Thoroughly lubricate plug threads and seal ring with Liqui-Moly or similar high temperature lubricant, lower plug into cylinder and screw down firmly to ensure metalto-metal seat. Use torque wrench to tighten set screw. 5. Install center thermocouple and insert the plug into the jack on the front panel. Screw the nut into the gland but do not tighten. 6. Remove all trapped air in the chamber. Close the air exhaust valve and open the air supply valve. When all the air has leaked by the thermocouple nut and oil appears, immediately tighten the nut. 7. Pump the chamber to the desired curing pressure. Divide the chamber curing pressure by 500 to obtain the air pressure required to drive the pump. Adjust the air pressure regulator to the calculated pressure. Note: The switch gauge "High" contact must be set above the desired chamber curing pressure, but not above: 20,300 psi/140 MPa for the ,000/200 MPa for the ,150 psi/70 MPa for the Warning: This pressure vessel is designed to operate at pressures that are considerably above 10,150 psi/70 MPa. Therefore, we recommend that the operators shall take all possible safety precautions to reduce the possibility of an accident. 8. Turn the pump switch on. The pump will begin to increase the chamber pressure, as indicated on the pressure gauge. When pressure is above "Low Contact" pressure, depress "Reset" and switch "Gauge By-pass" off. Protection of Relief Valve Seat Close the lower pressure relief cut-off valve. The relief valve has a soft seat, a requirement for leak-tight operation, and although the valve is separated by approximately 10 feet of tubing from the hot cylinder, constant bleeding will cause the seat of the valve to melt. Bleed pressure to the desired level through the pressure bleed valve.

12 2-2 SECTION 2 OPERATION To Apply Heat To Cylinder 1. Turn heater switch to on. (Current will not be supplied to the element until the START pad is depressed on the microprocessor controller.) 2. Program the desire schedule into the 7050 Controller. Complete program and operating instructions are included in the appendix. 3. The chamber pressures normally increase as the temperature increases. The relief valve regulates the pressure at 10,150 psi/70 MPa. Caution: The relief valve requires a soft plastic seat for leak-tight operation; therefore, at temperatures and pressures above 572º/300 C and 10,150 psi/70 MPa, the relief valve must be isolated using the cut-off valve. The pressure is then maintained using the pressure bleed valve. Heating the relief valve seat above 572 F/300 C will damage the seat permanently. 4. Water in the "U" shape of the cooling coils from the previous test will vaporize during a high temperature test and give a water hammer effect. To eliminate, connect air supply to the water inlet connection and blow all water from the coils prior to starting a test. To Cool Cylinder at End of Test 1. Turn Heater switch to OFF. 2. Open the cool water valve momentarily. Open and close the valve to allow temperature equilibrium of coils, then leave the valve open. 3. The internal cooling coils result in very rapid cooling and rapid reduction of pressure due to thermal contraction. By leaving the pump switch in the on position, the rate of pressure loss can be reduced. Caution: When water circulation has stopped, heat from cylinder will cause temperature to rise. Cool as long as schedule time permits, then close cooling water valve and turn off pump switch. Open the pressure release valve. Empty the Chamber of Oil 1. Open the pressure bleed valve. 2. Open the air-to-cylinder valve. Wait about two minutes for the chamber to empty, as indicated by air blowing into the oil reservoir. 3. Close the air-to-cylinder valve. 4. Loosen the thermocouple nut and remove the thermocouple. 5. Open the chamber. Loosen the set screws and turn the seal shaft and plug counterclockwise with the handles. Do not remove the ring.

13 SECTION 3 MAINTENANCE SCHEDULE 3-1 Section 3 Maintenance Schedule Tools Required None. Cleaning and Service Tips 1. Before each test, cement and other foreign matter should be cleaned off the plug and cylinder threads, the threads should be wiped dry, and the threads and seal ring should be lubricated with "Liqui-Moly" or similar high-temperature lubricant. The factory application of Everlube" and the technician's application of lubricant before each test enable effortless cylinder-plug removal, even after most severe high-temperature testing. 2. The top and sealing surface of the seal ring (see cylinder assembly drawings) and mating surface of the cylinder plug should also be kept clean and lubricated to prevent metal galling. 3. If loose cement falls into the bottom of the cylinder, the waste should be removed immediately to prevent it from being forced out through the pressure bleed valve. This will erode the stem and seat shortening the valve life, and plug the connecting tubing. 4. The relief valve seat is a high-temperature plastic and may require replacement if damaged by foreign particles. The high-pressure filter in the relief valve inlet may occasionally require cleaning. 5. Add SAE 10 oil to the air lubricator on the air-operated pressure pump as required (avoid running the lubricator dry). Occasionally, this lubricator should be checked to affirm that oil is being fed into the air inlet to the pump at a rate of three to five drops per minute when the pump is operating. 6. Sufficient coil length was allowed by the factory to permit several gasket installations before a new coil is required. If necessary, replacement gaskets can be installed on the cooling coils as follows: a. Cut off tip end of coil immediately above brass ferrules. b. Remove the coil at the open cylinder end. Install replacement gaskets. Use new ferrules at tip ends. Bend copper tubes connecting to the ends of the shorter coil.

14 3-2 SECTION 3 MAINTENANCE SECTION 2-2 SECTION 2 OPERATIION Maintenance Schedule Component Each Test Monthly 3 Months 6 Months Annual Cylinder Check Calibration Check Plug Seal Surface Test By Qual. Factory Tech. Temp Controller Piping Check For Leaks Molds Check Surfaces For Nicks Pump Clean Check Valves Pressure Gauge Check Calibration Cal. By Qualified Factory Tech. Thermocouple Circuit Calibrate Lubrication Lubricate Plug Thds. Relief Valve Replace Seat Pump Lubricator Replace Oil In Lubricator Heaters Test By Qual. Factory Tech. High Pressure Filter Clean Low Pressure Filter Replace Filter

15 Section 4 Troubleshooting Guide SECTION 4 TROUBLESHOOTING GUIDE 4-1 PROBLEM CHECK THIS DO THIS No Power Fuses Or Breakers Reset Or Replace Will Not Heat Won t Hold Pressure *Can t Release Pressure Heater Switch Heater Fuse Temp. Controller Pressure Bleed Valve External Leak Pressure Release Valve High Pressure Filter Turn On Replace Check Program Close Tighten Connections Replace Clean Or Replace High Pressure Bad Relief Valve Replace Shut-Down Failure Rupture Disc Replace Erratic Temperature Will Not Pump Won t Cool Cylinder Plug Leaking Thermocouple Socket or Plug Temperature Controller Air Supply Valve Regulator Pump Switch Water Supply Cool Water Valve Plug Loose Seal Dirty Clean Setup Open Turn Clockwise Turn On Connect Open Tighten Clean And Inspect *Special instructions for releasing pressure if high-pressure filter is plugged: disconnect the low-pressure tubing from the air-to-cylinder valve, slowly open the air-to-cylinder valve to release pressure.

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17 Section 5 - Replacement Parts Part Number Description Valve, Relief Filter, Porolloy 7050 Controller, Microprocessor Temperature C08112 Contactor C08262 SSR, 220V C09111 Valve, High Pressure P-0255 Nipple, Pipe 1/4" MPT x 3"L P-0269 Bushing, Reducer 3/8" x 1/8"NPT P-0284 Regulator, Air P-0308 Valve, Inlet and Cooling P-0405 Switch, Flush Tumbler P-0407 Switch, Pump P-0452 Lamp, Pilot P-0458 Pilot Light Assembly P-0518 Lubricator P-0665 Fuse, 40 A P-0674 Muffler, Pump P-0735 Adapter, 1/8" MPT x 1/4" T P-0741 Snubber, 1/4" MPT x 1/4" FPT P-0853 Check Valve Assembly P-0866 Bushing, 3/8" x 1/4"NPT P-1075 Filter Assembly P-1130 Fuse, 1 A P-1206 Safety Head Assembly P-1244 Connector, 1/4"T x 1/8" MPT P-1246 Elbow, Tube 1/4"T x 1/8" MPT P-1255 Elbow, Tube 1/4"T x 1/4" MPT P-1265 Tee, Tube 1/4" P-1285 Elbow, Street 1/4"NPT P-1292 Caster P-1462 Pump, Hydraulic P-1582 Disc, Rupture P-1662 Fuse, 2A, 250V, 3AG, Fast Blow P-1840 Gauge,100 psi,2.5",1/4 NPT P-2043 Gauge, 30 kpsi P-2265 Fuse Holder, 3AG,250V, Panel Mount P-2380 Socket, Thermocouple P-2610 Fuse,0.250A,250V,3AG,Time Delay P-3107 Valve, Solenoid, 220V SECTION 5 REPLACEMENT PARTS 5-1 To ensure correct part replacement, always specify Model and Serial Number of instrument when ordering or corresponding REPL_PARTS REV A

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19 Section 6 - Drawings and Schematics SECTION 6 DRAWINGS AND SCHEMATICS 6-1 Drawing Number Description Model 1910 Curing Chamber Cylinder Assembly Schematic, Piping Schematic, Wiring Modified Bridgman Seal Control Panel Identification DWGS REV A

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29 PRESSURIZED CURING CHAMBERS A Critical Tool for Compressive Strength Testing Chandler Engineering offers several pressurized curing chambers that are specifi cally designed to cure standard two-inch cement cube samples for compressive strength testing in accordance with API and ISO standards for oilfi eld cements. The curing chambers cover a wide range of operational temperatures and pressures to simulate a wide variety of downhole conditions during the curing process. Selection of the best instrument for your application is based on the number of cubes needed for testing, the size and features of each curing chambers. Each of the curing chambers has been designed for safe operation and have pressure relief and over-temperature protection. The curing chambers are an important part of any oilfi eld cement laboratory and are part of a complete line of cement testing instruments nts offered by Chandler Engineering. The Chandler Engineering Model 4207D Compressive Strength Tester is also an essential instrument nt used in conjunction with determining the compressive strength of the cube after curing in the curing chamber. The Chandler Engineering Pressurized Curing Chambers have been used in hundreds of laboratories and have application in research centers, product development laboratories and fi eld laboratories. Operational Simplicity The curing chambers are simple to operate. All of the operational onal controls are conveniently located on the front panel. The temperature and pressure are easily read on the panel gauges and digital indicators. A programmable temperature controller is capable of controlling multi-slope temperature gradients during a test. In addition, the temperature controller will control the cooling rate at the end of the test in conjunction with the application of cooling water. Pressure is generated with an air-operated highpressure pump, and control is maintained with a pressure relief valve. FEATURES Single or Dual Cell Instruments Capacity up to 16 standard cubes Temperature control with multi-slope gradient capability External chiller connections 2001 North Indianwood Avenue, Broken Arrow, OK Phone: Fax: , by AMETEK, Inc. All rights reserved. chandler.sales@ametek.com AEROSPACE & DEFENSE

30 Model Number Number of Cubes Maximum Input Power Weight Shipping Dimensions Temp Press kva Net Ship F C psi MPa lb Kg lb kg W x D x H , V 16 4 or BP settling tube test * 16 (8/cyl.) *Note: The Model 7375 is dual cell unit x 38 x 79 in. 104 x 96 x 200 cm 41 x 38 x 79 in. 104 x 96 x 200 cm 20 x 22 x 19 in. 50 x 55 x 48 cm 36 x 38 x 66 in. 91 x 97 x 167 cm 53 x 38 x 66 in. 134 x 97 x 167 cm Specifications Operating Temperature 32 to 120ºF / 0 to 50ºC Compliance API Spec. 10A / ISO Utilities Cooling Water psi / kpa; nominal flow 2 Lpm Compressed Air psi / kpa Power Supply 220 VAC ±15% 50/60 Hz 7.5 kva Manufacturer s specifications subject to change without notice R North Indianwood Avenue, Broken Arrow, OK Tel: Fax: chandler.sales@ametek.com Houston Sales and Services 4903 W. Sam Houston Parkway, N., Suite A-400, Houston, TX Tel: Fax: Printed in the U.S.A. 2008, by AMETEK, Inc. All rights reserved. XM808PDF (360000)

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